Club Racer project : TWO IS200s(LHD) with 3S-GE swap w/goodies - Page 2 - Lexus IS Forum
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post #16 of 279 (permalink) Old 02-12-2012, 08:02 PM Thread Starter
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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.







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





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











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



























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









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.













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







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









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



-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
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post #17 of 279 (permalink) Old 02-23-2012, 11:38 PM Thread Starter
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Part 8 : Removing stock engine(1G-FE)!!





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

Disconnect batt.




Remove ECU harness






Remove all the under panels.








Drain all the lubricants & coolants.





Remove stock exhaust.




Remove A/T propeller shaft




Stock TB.




Notice the brake ducting on the front under cover!




Engine coming off along with subframe.















Bye-bye 1G-FE!!!







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



-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
MotorKlasse is offline  
post #18 of 279 (permalink) Old 02-24-2012, 04:34 PM
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forgive me for asking but what does "club racer" mean?
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post #19 of 279 (permalink) Old 02-24-2012, 05:02 PM
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Garage
Thats alot of red X's..fix please

ISR220 Build
http://my.is/forums/f219/isr220-neo-...2011-a-391109/
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post #20 of 279 (permalink) Old 02-24-2012, 08:48 PM
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Damn that was a good update. +rep, keep it up man!
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post #21 of 279 (permalink) Old 02-24-2012, 10:47 PM Thread Starter
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Quote:
Originally Posted by sanctfy View Post
forgive me for asking but what does "club racer" mean?


Meaning it's for those driver who enjoys the track often and participate amateur league.

Quote:
Originally Posted by Adam P View Post
Thats alot of red X's..fix please


All fixed.

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread

Last edited by JohnnyChimpo; 03-03-2012 at 12:35 AM.
MotorKlasse is offline  
post #22 of 279 (permalink) Old 03-03-2012, 12:07 AM Thread Starter
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Part 9 : Putting 3S-GE !!!


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.





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




Stock bushing...




Hardrace(stiffened rubber) bushing installed!






Bye-bye 1G-FE & 4AT





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




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.





Installed Hardrace reinforced engine mount.





Engine has been placed on the subframe.




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




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









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




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





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)











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!!!




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

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
MotorKlasse is offline  
post #23 of 279 (permalink) Old 03-03-2012, 12:15 PM
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^awesome update man! lots of great work has been done so far.

I'm not sure if I would have gone with Hardrace bushings though....

Updated - Hardrace bushings in Action and OEM
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post #24 of 279 (permalink) Old 03-03-2012, 08:54 PM
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Looks really good! I don't know if it's just me but some of the pictures aren't working. Can't wait to see it finished!

`01 MSM
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post #25 of 279 (permalink) Old 03-04-2012, 07:01 PM Thread Starter
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Quote:
Originally Posted by Jerm__ View Post
^awesome update man! lots of great work has been done so far.

I'm not sure if I would have gone with Hardrace bushings though....

Updated - Hardrace bushings in Action and OEM


Wow, I appreciate your opinion on Hardrace bushing.
We will keep our eye on the bushing and let you know how it goes.

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread

Last edited by MotorKlasse; 03-16-2012 at 04:08 AM.
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post #26 of 279 (permalink) Old 03-04-2012, 07:07 PM Thread Starter
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Quote:
Originally Posted by jazilla View Post
Looks really good! I don't know if it's just me but some of the pictures aren't working. Can't wait to see it finished!
If you refresh, it should show up all the pictures.
The media server is also located in Korea, which causes some delay.

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
MotorKlasse is offline  
post #27 of 279 (permalink) Old 03-04-2012, 08:22 PM
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crazy build!

JDM TRD NEO WIDEBODY
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post #28 of 279 (permalink) Old 03-05-2012, 12:19 PM
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This is sick! this makes me have the strange urge to play forza and make a track Altezza.......keep up the good work!

2002 MSM Sportcross
TEIN//Gita//Blitz//Pioneer//FIGS//Work

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post #29 of 279 (permalink) Old 03-23-2012, 01:37 AM Thread Starter
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Part 10 : Firing up the 3S-GE!


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

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.



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.




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








We put Personal shift knob and boots.




Installed power steering cooler.




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

















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






Seats and harness are installed




Now waiting for the wheels.




Enkei RPF1 17x9 ET35, have arrived!






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.

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
MotorKlasse is offline  
post #30 of 279 (permalink) Old 03-23-2012, 01:38 AM Thread Starter
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Part 10 continues...


Quickly we also re-made the GT wing lower bracket.










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






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










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






I will post up the detail shots of the complete car soon!

-. 2011 MB C63 : Daily beater
-. 1992 MB 190E 2.3-16V : Sunny weekend 1
-. 1984 MB 300D : Sunny weekend 2
-. 2001 Lexus IS200(w/ITB 3S-GE) : TRACK ONLY, 270hp 2,500lb RWD
-. 2014 Toyota FJ Cruiser : For towing race car.

IS200 w/3S-GE swap RACE CAR build thread
MotorKlasse is offline  
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