From: Mike King (mfk@comlab.gtri.gatech.edu)

Hi,

	I have received many E-Mails concerning an engine swap that I recently did.  
I thought this might be interesting for others as well.  Feel free to use this info 
however you like.  Let me know if you would like me to expand upon any certain aspect 
of the job.  Take it easy...

Mike King

1991 or 92 Toyota MR2 Engine Upgrade Information

To completely replace the Normally Aspirated 2.2 liter 5S-FE with the Turbo Charged 2.0 liter 3S-GTE you will need the following components:

*Major Items:

• ***Repair Manual***
• 3S-GTE Engine w/ drive shaft support bracket (***Ensure that all sensors are intact and engine wiring harness( a small wiring harness only a couple of feet long) is intact with ECU connectors...basically, a sloppy CHOP job engine will be more hastle than it's worth)
• E153 Manual Transaxle
• 3S-GTE Clutch assembly including disk, cover, release bearing, and release fork (note: the two clutches are completely different for the different engines even though the repair manual does not distinguish them.)
• 3S-GTE Exhaust system (Cat. Back)
• 3S-GTE Drive Shafts
• 3S-GTE ECU including Engine cooling fan control unit
• Intercooler and Engine Compartment cooling fan

Option 1: If you don't already have ABS then you will need the new rear Hubs and speed sensor wire clamps which make room for the ABS speed sensors on the new Drive Shafts.

Option 2: If you are not EXTREMELY electrically gifted then I would recommend obtaining the engine wiring harness that runs from the ECU in the driver's side rear of the car(luggage compartment) all the way to the driver's side left foot(Relay Block Number 1.) (this wiring harness will allow you to make the engine swap without any electrical signal tracing or splicing...everything will snap into place perfectly (we hope.) Relay Block Number 2 (in the engine compartment) is essentially the wiring harness we are concerned about. This harness includes connections to the brake lights, power antenna , luggage compartment light, ECU, Engine, Left Rear ABS sensor, compartment temperature sensor, center stop light, left rear speaker, grounds, and Relay Block Number 1) You can complete the swap without this harness, but you would have to be very systematic and careful. (Side Note: I am an Electrical Engineer so by nature I am usually up to any electrical challenge, but I opted not to risk burning up my car's electrical system because of a slight oversight...which almost certainly will occur.)

*Additional Items:

• 3S-GTE Intake Air Cleaner assembly (don't need the bladder)
• 3S-GTE Ignition coil and Igniter
• 3S-GTE The transaxle control cables (A MUST or you will not be able to get past second gear.)

Option 3: Engine compartment lid...The 3S-GTE has raised vents

Option 4: Luggage compartment lid...has the TURBO label

*Items NOT needed (common between the two engine types):

• Rear suspension components
• Alternator
• A/C compressor and associated electrical stuff
• Clutch release cylinder
• Speed sensor cable
• fuel pump and lines
• Cruise control system
• Brake system

Author's Comments:

I performed the engine swap over a week period in a friend's house garage. I actually purchased a wrecked MR2 Turbo which was only damaged in the front. I did all of the work myself except for some help dropping down the engine with a hoist. I am not a mechanic nor have I had any training. It is easy to do if you are careful and follow the instructions in the repair manual...pages EM-(134-143) and EM-(169-180). Everyone I talked to about the swap told me to just sell my car and buy a turbo car. If you love your car as much as I do then you can appreciate my apprehension. Anyway, it was worth every minute of my time and every drop of sweat from my brow (did the swap in Hotlanta, GA). The improvement in performance is staggering. However, one never remains satisfied for long...I am already in the process of modifying it further!

Some Warnings:

Exhaust system components tend to deteriorate quickly...try not to break off any of the 3S-GTE's exhaust bolts like I did. It is sometimes hard to locate various components and their associated bolts and nuts. Consequently, I put everything that was practical into it's own ziplock bag and labeled it for easy retrieval later. When it comes time for the first turn of the key...Expect for it not to start. Odds are, you will have to troubleshoot a connection that you forgot to make:) .

Good Luck!

Mike King
USNA '95
mfk@comlab.gtri.gatech.edu
404-816-1022