Project: 2ZZ-GE Swap Into AE92

Good day everyone!

New project on progress...this is the project i have been waiting for, as it is my dream to have this engine in previous car (AE111 Corolla), but i could'nt find resources at that time and furthermore i was hooked on a Subaru STi back then. So...thank god for giving me the chance to work on this engine. It's a 2ZZ-GE from a Celica  (ZZT231).

Donor engine (halfcut)

Slight knock on the intake manifold but it is repairable.

This engine is a 1.8 liter with VVTL-i, which stands for Variable Valve Timing and Lift - Intelligent. It works on same princple as i-VTEC, in fact this 2ZZ-GE is introduced way before i-VTEC goes into production. Stock HP is 190PS, which is about 180 hp. It has low-cam and high-cam which is switchable at around 6000~6200rpm, giving it the change in exhaust note, as like the VTEC. In addition, 2ZZ also incorparate VVT-i on the intake cam, which varies the intake cam angle across the rpm range.

As you can see in the photo above,the wiring have been removed for me to work on grafting it with the AE92 wiring. The owner decided to maintain the stock AE92 dashboard for a sleeper look. This engine have hundreds of wires and it challanges me and my wiring skills to graft this engine wiring with the stock AE92 wiring. I love challanges :-)

There is so many differences on how both systems run, i have to check what differences between the AE92 and this Celica on the wiring routing and how things are run. The speed sensor and water temp sensor comes directly from respective sensors on the AE92 but on the 2ZZ, signal comes from the ECU..! There a few things like the returnless fuel rail and reversed exhaust location. Well, i leave the mechanicals to Garage Daz and it's time to crack my head on the wirings...

Stay tuned for updates!

Project AE86 20Valve swap + Freedom ECU Update #2

Completed wiring

Completed wiring (AE86 body loom + 20 valve 4AG ecu loom),all connector and mounting point follow stock factory location

The wiring have been installed in the car,i uploaded new map into the Freedom ECU and it fires at first crank.Will take some photos and maybe some videos soon. It is not yet tuned as there is a few bits and pieces on the mechanical side to be finished.

Stay tuned for next update!

Subaru ECU Re-Flash

I am currently doing Subaru ECU Re-Flash using 'open source' for Subaru vehicles (OBD2 equipped WRX and STI,year 2000 and above).The Re-Flash will be done using Tactrix Open-Port 2.0 as shown below. A brief introduction to ecu reflash is written below, i only write some basics just to give an insight on this process.

What is a ECU Reflash?

ECU reflash is a way of tuning our stock factory ecu using a dedicated software to read and re-write (this process called reflash) certain parameters and maps inside the ECU. ECU reflash is the most cost effective way of tuning our ECU as there is no need to pay for expensive standalone ECU and installation charges. There downtime on your car, just connect the device to your OBD2 port and start tuning.

Which Subaru model can be Reflashed?

Basically all Subaru with HC16 or SH2 processor can be reflashed.

What is the ECU Flash software?

ECU Flash is a software used to read and write 'maps' to your factory ecu. It also allows user to edit parameters and maps as a process of tuning. The parameters and maps read from the ecu is called ROM image or simply,ROM.

Ecuflash software

Shown here is the fuel and ignition timing map,this map can be adjusted just like any other stand alone ecu. Beside this,there are a lot of other parameters and maps can be accessed for tuning such as AVCS (valve timing),MAF scaling,injectors,idle,compensations etc.

The advantages of tuning the factory ecu is we will not sacrifice drivability and tuning is quick as most parameters is already set from factory, factory ecu also have safety features that the manufacturer have develop to safe guard our engine such as knock control and limp home mode if sensors fail. Our Subaru factory ECU is very intelligent and can adapt with new changes quickly and learns the changes over time.

What are the tools needed?

Basically, for open-source reflash, we need a Tactrix Open-Port cable,a reflash connector and the EcuFlash software. One more software can be used to make changes and the most popular for Subaru Open-Source tuning is Romraider. Other tuning tools is Wideband O2 sensor and a dynamometer (where accessible).

What is Romraider?

Romraider is a software developed to tune our subaru ROM after being read using the EcuFlash software. It will allow user to change the parameters and maps and also to log the ecu data while driving the vehicle. ECU data logging is  very very important in tuning our vehicle. Through ecu logging, we can verify whether the tune that have been made is good or safe to our engine. We also can check our engine health through logging and check for problems by viewing various data.

On the next installment i will talk about some parameters inside the Subaru ecu.

Project AE86 20V swap + Freedom ECU has started!

The AE86 20V swap project have started! Just Received both of the AE86 wiring and 20V Blacktop wiring to be combined.This will allow stock wiring look on the car and less mess on the wiring. All will follow factory routing and will look like factory.

The original AE86 4AGE 16 valve wiring.All will be stripped out to take whatever necessary to be combine with the 4AGE 20 valve wiring. 

Shown here is the 4AG 20 valve wiring,also being stripped out,remove the unnecessary and combined with the factory AE86 wiring.

Will post up some more so stay tuned....

Toyota Members Dyno Day

Last Sunday a few members of Toyotarians around Klang Valley gathered up for a dyno day challange at my friend workshop (CARWORX@ USJ1)

The early birds...

Stock looking LE but *powderfull*

SEG with 20v Blacktop

SEG with 4AGZE Supercharged..

Another SEG with 20V Blacktop

The most modded car of the day...20V Blacktop with some goodies..Horsepower? Secret,haha

All cars have good readings,making well over 140hp on wheel...The purpose of dynoing our car is not to brag about how many horsepower you have but to know how your engine performs and also to monitor whether the engine is in good condition or not. We can see the AFR (Air-fuel ratio) vs RPM and determine whether it is safe or not on your engine,monitor knocks during engine load,torque produced and many more. Dyno tune is the way to go,although it is a bit expensive but only on dyno we can extract every 0.1 horse power from your engine, and fine tune it up with a road tune, definitely it is the best way to tune your car.Every car is different thats why we need to custom tune your engine management to suit your modification.

For further info on tuning package and engine management theory, please don't hesitate to call me 012 359 8616 (Rahmat), we can have a chat and see what sort of management and tuning suits best.

Perdana Eterna + E-manage Tune

Finished tuned a Perdana V6 Eterna Twin Turbo,its on the road tune and owner happy with the performance,previously it is very rich on boost,so a leaner mixture is adjusted to give a little bit of response.

My friend plugging the E-manage

This is the most wired car i have ever worked on,so many wires under the dash,it is very-very hard to install the E-manage.It took me almost 1hour and a half..phiewww...at last,hope i will never see this kind of wiring again..haha

AE101 4AGZE + Microtech MT-8 Tuning Update#2

Went to tune the car last night after a few problems with the fuel delivery systems.The fuel pump hose inside the tank keeps disintegrating and the fuel regulator goes crazy. The pump hose wont last long inside the petrol tank,so the owner bought an original factory fuel hose for the pump and now its looking good,still holding up. The car knocks badly when the supercharger is triggered,i reconfirm the static timing and lock it at 0 degrees.

After static timing is checked,then plug in the LM-2 WBO2 in and off we go. A few test pull done,the engine seems like doesnt want to rev above 6500 rpm, its like cutting on fuel. Quick check on the Microtech Handset and find out the revlim is at 7000,stock supercharge is 7500 so raise it to 7500rpm.

Next,browse through the ignition timing settings,wasnt quite happy with it so i map it again.First thing is to eliminate the knock when the supercharger kicks in.

The owner is using RON95 so thats why it knocks badly,so the tune have to suit RON95. A series of pulls and few adjustments later to the fuel and ignition map, the engine rev cleanly to rev limiter, without any serious knocking, i have to pull a lot of timing from this motor to eliminate the knock,but pulling too much timing will hurt performance,hence a compromise and balance is needed, also to save the motor from destruction.

After 2 hours,we call it a quit and continue another day. Next session is to tune the cruising AFR and a little fine tuning on the throttle pump function. Hope the owner is more happy with his car now,went to 200kmh with ease...almost as fast as my Scooby...

Update #2

Very busy and not enough time....but i will try to keep my promises to all my customers.

Few projects on progress:-

1. AE86 + Haltech Platinum Sport 1000 (Install and Tune) - In progress,wiring
2. AE86 + 20v Blacktop + Freedom ECU with DLI (waste spark ignition) = (Install and tune) - In progress,wiring completed
3. Eterna V6 TT + Emanage (Tuning)- Done!
4. AE101 + 4AGZE + Microtech MT8 (Tuning) - Done!



*Updated on 27th May 2011

Mitsubishi Eterna V6TT + E-manage

Just finished doing E-manage installation for a Mitsubishi Eterna V6 TT..will snap some photos.Car is not yet tuned. Been busy with few more projects to come.

Silvertop to Blacktop (conversion no.17)

Another Silvertop to blacktop conversion,it was out of the blue so i forgot to bring my camera along,it was an SEG AE101 with silvertop engine,having problems with idling and such, a quick check discovered that the ECU is leaking a capacitor. Owner takes this opportunity to remove the airflow meter and convert to blacktop system.Conversion done in 2 days due to my day job constraint (1 day if on public holidays)..