Photo dump
So, I purchased a 2ZZ-GE donor totally blind online and had it delivered..
I pulled it..
The warning signs were there- the PAS pulley was totally sheared, aux belt shredded (this also drives the water pump.. And there was curse word all compression to be found anywhere)
Previous owner was definitely a complete jeb end, thing was packed with rad weld, bores were distinctly not great and the head was banana'd. Just do the curse word headgasket if it starts going, not this butchery. So the hunt for a new engine was on. In the meantime I had a dummy engine to work with and get things cut, welded etc. So all wasn't lost.
We began doing some wiring, the apprentice was terrible and just wanted to play with the loose wires at any opportunity.
The current plan is to split out the 2zz engine ecu, splice a few wires to the yaris clocks, ignition and fuel pump then let the yaris ecu handle everything else it previously did, minus its engine loom.. We shall see, it feels mighty ambitious to me.
Getting there none the less
Square eyes from staring at this..
Yaris engine be gone (if anyone wants one btw it's now taking up space in my garage..)
Clearly the 6 speed c60 trans isn't going to fit here..
Chopppped. Actually had to remove slightly more from the far side, but this is the bulk of it.
Had to take a chunk from the subframe too to clear the diff
Let some weld into all the holes from drilling spot welded battery trays etc out and blew some primer over, tidy.
Knocked up a plate to house some captive nuts and offer some reinforcement to the chassis leg it'll be sat on.
New captive nut plate in place to take the engine mount.
Knocked up a mount to bolt onto the gearbox, it accepts the standard celica mount.
Fabbed mounts all in place.
Full engine mount assembly
2ZZ-GE sat in the Yaris, doesn't look at all out of place
Space is a little tight for the rad, this is coming to a future video..
Next was driveshafts, this was a headache, there is no combo CVs and shafts that I could find with hours of trawling to mate the c60 to the yaris hubs as all the splining is different both with the CVs and the shafts. I've since been told that using Corolla hubs and an MR2 RH shaft with the Celica LH shaft can be made to work, I may try this at some point, though my solution below should work..
First I was informed (incorrectly) that the mk2 yaris lower arm fits straight in, widens the track and the mk2 hub then accepts the celica CV.. The CV bit is correct, the lower arm bit was not.
So I decided to make some.. Grinder time to make 2 shafts into 4..
This is definitely the best way to remove stubborn CVs..
Turned a hole and taper on one end of the shaft, and a mating dowel and taper on the other, interference fit and pressed together then multi pass on the TIG.
Pressed together
All tigged.
Got some bar..
Turned some sleeves to fit snuggly over the driveshafts for some extra strength, and in the vague hope if the weld fails it'll stop it becoming a flail.
Welded the sleeves on
Sleeve on the shaft, this one I had to split and stick back together again to clear the splines
All finished
In place- I miss-read the measurement on this side and ended up making it 20mm shorter than desired. It's bloody tight but doesn't pop at full droop and lock so should be okay..
That's roughly where we are now
