Image Please bare with us while we are carrying out some much needed maintenance to the forum. New look coming soon!

Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Once you've introduced yourself why not throw up a few pictures of your car or a project thread?
User avatar
mlcoolj
Altezza Guru
Posts: 1740
Joined: Tue Oct 20, 2009 8:14 pm

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Tue Mar 27, 2012 8:55 am

ah ok, I get it now... keep the pics coming!
Image

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Tue Mar 27, 2012 9:49 am

mlcoolj wrote:ah ok, I get it now... keep the pics coming!


Will do! :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

User avatar
Robin H
Southern England Rep
Posts: 2356
Joined: Sun Mar 18, 2007 10:23 pm
Location: Dorset
Contact:

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby Robin H » Tue Mar 27, 2012 9:32 pm

really good stuff

keep the pictures coming
Deals on Anodised Altezza parts.... cooling panels and battery bars..
Image

If you are a UK member and interested in club meets please sign up here:
viewtopic.php?f=6&t=7729


Please Support TezzaWorld
viewtopic.php?f=2&t=8309


Club stickers
viewtopic.php?f=16&t=8724

Blitz Turbo Altezza RS220
Image
I wish I had more time.....

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Wed Mar 28, 2012 2:42 am

Robin H wrote:really good stuff

keep the pictures coming



Here is! :)


Part 7 : Interior painting!


Because new roof from Lexus Korea was EXTREMELY expansive($1,000+), we had to seal off the roof cutout.

Pictures of the roof before painting.
Image

Image




Results came out very GOOD!! Don't have good pictures at this moment.
Image




Roll cages/roof were painted by bodyshop.
Here are few pictures. ;)
Image

Image

Image

Image




Time to trim the dash and fit into the car. :)
Requires patient to make it fit like glove.
Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image

Image






Whoa!! dash does make huge difference.
Now it feels like "a car" now. :hello:
Image

Image

Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Wed Mar 28, 2012 2:43 am

Part 7 : Interior painting! (Continues...)




Now we cleaned the floor and paint it to the body color.
White car was harder to make it clean because the paint was very light. :crycry:
Image

Image

Image

Image

Image




Here is the grey car after painting the floor.
The grey car(mine) came out much cleaner. :)
Image

Image








Also cleaned and re-sealed with under-coating where burn marks from the roll-cage welding.
Image

Image

Image




It's snowing outside when we leave the shop.
It was loooong day. Now time for dropping stock engine. :cool:
Image



Friend's S2000 resting outside of the shop.
Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Thu Mar 29, 2012 2:36 am

Part 8 : Removing stock engine(1G-FE)!!

Image



3S-GE is already at the port, going thru the customs.
Now, it's time to remove stock engine and auto transmission. :thumbup:

Disconnect batt.
Image



Remove ECU harness
Image

Image



Remove all the under panels.
Image

Image





Drain all the lubricants & coolants.
Image

Image


Remove stock exhaust.
Image



Remove A/T propeller shaft
Image



Stock TB.
Image



Notice the brake ducting on the front under cover! :)
Image



Engine coming off along with subframe.
Image

Image

Image

Image

Image

Image




Bye-bye 1G-FE!!!
Image

Image




Empty engine bay! :thumbup: Easy part is done. Now time to put 3S-GE!
Image

Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

User avatar
lakers
Tezza Fanatic!
Posts: 209
Joined: Mon Feb 14, 2011 6:42 pm

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby lakers » Thu Mar 29, 2012 10:36 am

you guys are not making any jokes, :D build looks great cant wait to see the 3sge in there 8) 8)
To find yourself, think for yourself © Socrates 469 BC

User avatar
mlcoolj
Altezza Guru
Posts: 1740
Joined: Tue Oct 20, 2009 8:14 pm

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Thu Mar 29, 2012 10:57 am

looking good!
Image

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Fri Mar 30, 2012 3:32 am

mlcoolj wrote:looking good!



Thank you! :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Fri Mar 30, 2012 3:33 am

lakers wrote:you guys are not making any jokes, :D build looks great cant wait to see the 3sge in there 8) 8)



It's almost there. :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Fri Mar 30, 2012 3:34 am

Part 9 : Putting 3S-GE !!!


Image



Now it's time to put 3S-GE engine in. :)
The propeller shaft is different, so make sure you get the right shaft for the 6MT.
One on the top is one for the 6MT, which is longer than 4AT version.
Image




While we are installing Hardrace new bushings on all the lower arm, we also reinforced the rear lower arm.
Below is pre-weld picture.
Image



Stock bushing...
Image



Hardrace(stiffened rubber) bushing installed! :)
Image





Bye-bye 1G-FE & 4AT
Image




Hello 3S-GE & 6MT!!!!
Image



I Also got the all the used Altezza suspension/subframe.
Altezza DID had thicker sway bars compared to IS200s.
Also there are extra differential mounting point on the rear subframe.
Image




Installed Hardrace reinforced engine mount.
Image




Engine has been placed on the subframe.
Image



While we are at it, we also drilled few holes on the thermostat. :)
Image



Now time to install the clutch pedal!!
Requires cutting/drilling/welding and etc.
Image

Image

Image




New Exedy clutch has been installed before putting tranny on the engine.
Image



Had to pull the shifter and rotate because it was leaning towards RHD side.
Image




Modified stock Altezza LSD to create some initial torque.
Left one is from IS200(4 bolts end caps), right one is from Altezza(6 bolts end caps)
Image

Image

Image

Image




The exhaust manifold interferes with steering gearbox input shaft, so we had to fabricate the custom exhaust manifold(2-1 section, no pictures yet)
Relocate the coolant line, power steering line, fuel line, clutch line and etc, then here is...Whoohoo!!!
Image



Now time to work on re-wiring chassis harness to accept 3S-GE ECU.
Image






Just a random shot before we leave the shop. My friend's S2k!
Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

User avatar
mlcoolj
Altezza Guru
Posts: 1740
Joined: Tue Oct 20, 2009 8:14 pm

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby mlcoolj » Fri Mar 30, 2012 8:32 am

you have some friends with some badass rides! alos some badass rides in that garage! :shock: Why did you drill some holes in the thermostat? and what did you modify in the LSD?

EDIT: Also nice to see that you point out the differences between the IS200/Altezza drivetrain...
Image

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Sat Mar 31, 2012 6:04 am

mlcoolj wrote:you have some friends with some badass rides! alos some badass rides in that garage! :shock: Why did you drill some holes in the thermostat? and what did you modify in the LSD?

EDIT: Also nice to see that you point out the differences between the IS200/Altezza drivetrain...



We drill the wholes on the thermostat to allow some water flow at lower water temp to keep the water temp down at track.
We modified the stock Altezza LSD to have some initial lock-up torque. :)
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Sat Mar 31, 2012 6:05 am

Part 10 : Firing up the 3S-GE!


Hello guys.
It has been awhile since the last update.


Let start up with the customer who visited our shop with his ITB S2000. :)
Image



The re-wiring the chassis harness to accept 3S-GE was PITA!!
The problem was I was not be able to get the chassis wiring of SXE10(JDM Altezza).
The SXE10 service manual is only avail in Japanese and it IS very hard to get.

Image

After spending DAYS and DAYS with 3S-GE Engine wiring diagram and 1F-GE Engine & Chassis wiring diagram, I finally figured out everything. :)
We did had issue with engine stalling, TRC and etc but very glad that everything worked out after many trial.

Altezza ECU does NOT support OBD, but it DOES uses VSC which IS200/300 only sports traditional traction control(TRC).
So we had to disable ETCS(Toyota's electrical throttle body), and use direct cable link to control throttle body.
Image



Used stock S2000 resonator to use on the rear muffler. Now welding time for the exhaust!
Image

Image

Image



We put Personal shift knob and boots. :)
Image



Installed power steering cooler. :)
Image



We used Recaro Pole Position for front seats, Willans 6-pt harness, Challenge FULL-Aluminium coilovers with Hyperco springs(800lb/550lb)

Image

Image

Image

Image

Image

Image

Image



Also had to cut the transmission tunnel little wider since 6-SP manual transmission didn't fit the opening.
Image

Image



Seats and harness are installed :)
Image


Now waiting for the wheels. :)
Image



Enkei RPF1 17x9 ET35, have arrived!
Image

Image



The white car will be running first race day with stock engine(1G-FE, 155hp) with 4-sp auto since we spent too much time with the grey car.
ECU problems and power steering pressure issue took too long to fix.
Since the driver of the white is the beginner, we thought it would not be a bad idea to run the track with under powered engine for his first race day.

But we still installed the suspension and wheels.
Excuse the front fender since it will be re-done by bodyshop once it is all done.

RPF1 17x9 ET35 with 255/40/17 all around!!
Using Hankook RS-3 tires due to race regulation.
Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.

motorklasse
Trc Off
Posts: 109
Joined: Sat Mar 03, 2012 7:34 am
Location: Seoul, Korea

Re: Club Racer project : TWO IS200s(LHD) with 3S-GE swap!!!

Postby motorklasse » Sat Mar 31, 2012 6:06 am

Part 10 continues...


Quickly we also re-made the GT wing lower bracket from our wings for S2000
Image

Image

Image




We also installed S2000 fuel pump since stock one can not support extra 60hp.
Image





Now time to fit some nice Personal steering wheel with WorksBell GTCs on white car!! :)
Image

Image

Image

Image



Also swapped out the old riced out LED taillight with stock ones on white car.
Image

Image



I will post up the detail shots of the complete car soon! :)
Image
For weekend : 2011 MB C63(Euro-spec)
For daily : 2003 BMW 320i(Euro-spec), 2.2L I-6 w/5-sp manual.
For track : 2001 Lexus IS200 w/3S-GE, 6-sp manual swap.


Return to “Member's Cars / Projects”

Who is online

Users browsing this forum: No registered users and 3 guests