2zzge to AE82 conversion

[JP]

This is a few pics of a conversion I've been wanting to do for a while. Throwing a 2zzge with C60 6-speed combo from a ZZE123 into an AE82 CS sedan, using the EFI/Powersteering etc from a junk AE82 twincam hatch and running the show with a Vipec V44 ecu.

Original 4ac before it was removed:


Made a small jig to locate the crank centerline for when the 2zz's in the bay so the correct mount can be fabricated:


Gave the bay a degrease and pressure clean:


Made some small modifications to the top AE82 gearbox mount base plate and bolted up the other AE82 brackets, then threw the box in the bay to check fitment. Plate mods involved slotting holes and using an end-mill to make a flat surface for the bolt heads.


Found out that the webbing on the 2zz sump fouls on the AE82 crossmember, so sectioned the crossmember. This pic shows the sectioned area ready to be plated up:


With that done I bolted the engine in to check the rest of the fitment. Found that the head fouls on the brake master cylinder, so had to retrofit an AE112 Master/Booster/Lines and external bias valve to get clearance:

[JP]

For the timing belt engine mount, I decided to use part of the original ZZE123 mount and a carby AE82 insulator.

First off I milled the bottom of the 2zz mount flat:



I cut the metal part off the AE82 insulator that held the studs and tacked on a bit of 20mm square bar.
Then milled some recesses for the bolt heads in the zze123 alloy bracket, drilled some 10mm holes and turned up a locating sleeve that allowed me to accurately drill the required 8.5mm holes for the M10x1.25 tap:



Holes were then tapped and the mount is basically done. A quick trim of the excess bar and weld in webbing to reinforce it, then a sandblast and coat of paint will have it finished.

Pics of engine as it sat with the mount:

[JP]

Timing cover mount finished off, sandblasted etc. AE112 Master and booster fitted and now has a ton of clearance to the head:



Crossmember plated up and given a coat of black:



Stripped the bay out and gave it a coat of toyota "JC" red:



Fitted up the booster, bias valve and sorted the lines to fit:


Pulled the cam cover off the engine to see how gummed up the engine is, I'd bought a complete gasket set and ARP head studs in anticipation of the top end being in poor condition... to my suprise it's very clean, so I'll be leaving the head alone for the moment.

[JP]

After sorting out all the suspension arms/bushes/brakes etc the car was back on it's wheels again and the engine went back in for the final time.

The shift setup needed a bit of work.... With the ZZE gearbox bracket/linkages, AE82 cables and AE82 shifter, it was impossible to select 1st/2nd/reverse etc. Compared the shift cable bracket between the C52 and ZZ C60 and found some significant differences. I chopped up the two and tacked together a hybrid bracket which can now select all 6 gears and reverse with the stock AE82 shifter unmodified.

I'll probably mod the bracket some more so the up/down selector cable sits flatter and further away from the turbo manifold runners.

3 of the 4 mounts now have 70 duro polyurethane inserts now, they were a pain to turn on the lathe and the torque mounts will probably need some slots milled in to reduce the vibration they'll transmit to the cabin. To do that I'll need to borrow an indexing head for the mill.

Next on the list is the driveshafts, using ae92 passenger shaft with 1zz inner CV, 2zz half-shaft with AE111 outer and CV. For the moment I've got two outer CV stubs bolted into the hubs so it doesn't wreck the new bearings rolling around with no shafts in.

pics...

Original ZZE bracket with AE82 cables, you can see the rearmost cable is at it's limit in neutral:


Comparison of ZZE and AE shift cable brackets:



Hybrid Bracket tacked together:


Overview of the back of the bay:


Mounts:




Overall shot of bay showing room between engine and firewall for turbo:


Front of engine, can see the clearance to the AE112 master etc:

[JP]

This is the turbo that's going on...

TD05-18G with T25 rear, 0.5bar actuator and 3" inlet cover.






I really didn't want to run a cable speedo with the turbo next to the firewall, so bit the bullet and bought a full set of gauges for the car. Fitting speedo, tach, oil temp, oil pressure, coolant temp and fuel level gauges into an old stock cluster, along with the warning light symbols from the original AE82 cluster.

Gauges are from Speedhut in the US, their "Revolution" line, all came packaged nicely in one box, the different looms/sensors all bagged and labelled individually for each gauge..






Will look just like this but with black bezels on the gauges:


2 1/16" outer gauges and 3 3/8" speedo and tach, boost gauge will go on the pillar


Next up is making a start on the turbo manifold and modding the rail to return-style.

[BiGbEn]

loooking goood

[JP]

Return setup for the fuel system is done, welded a -6 fitting to the rail for the inlet and made up a NPT bung which I welded to the other end of the rail and screwed in a -6 elbow. Mounted a turbosmart FPR800 to a custom bracket on the end of the cam cover and then bent up some alloy 3/8 hardline and flared the ends to suit -6 tube nuts.

Also put some red wrinkle finish paint on the cam cover but I'll be stripping that off tomorrow and refinishing it in black wrinkle instead

Rail:


Regulator:


Hardline:

[turbo ke20]

great conversion mate! looking forward to seeing more progress pics

[JP]

stripped the covers, took ages to get the paint out of all the crevises, also pressure tested the fuel rail and found a pinhole leak in the weld for the -6 fitting so sorted that out, refinished the covers and put some satin black on the fuel rail

[mattysshop]

i've been keeping an eye on this, very nice mate, very nice!!

[toyo-al]

Amazing work mate!

Coming together real well

[J0RD0]

THIS THING IS AWSOME! will piss some people off on the street for sure!

[tomvale13]

I was lolling at the craziness BEFORE I saw the turbo.

[fixeruperer]

sweet as those motors are pretty nice, i been waiting for some one to use them for a conversion. should be a lil monster !

[JP]

have lots of stuff on the way from the US for this... Bosch 525cc injectors, NGK AFX wideband with NTK sensor, genuine waterpump, Bosch combo 3bar map/IAT sensor, earls thermostatic oil sandwitch plate, earls oil cooler, setrab PS cooler and 15ft lengths of black aeroquip push-lock hose in all sizes they make.

Also placed an order with Kilners Engineering in Brisbane for a whole bunch of flanges to be laser cut. Should be quick progress once everything arrives