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K Series Engine Swap Research

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6.8M views 2.3K replies 159 participants last post by  mcmcmc  
#1 · (Edited by Moderator)
Last Update: 3/12/2014

"Getting closer and closer, Thanks to all who are helping make this a more manageable task for others"
Mounts: Solved
Shifting Mechanism: Solved
Axles: Solved, Updated 3/12/2014
Wiring: Researching, Updated 3/12/2014
Radiator Hoses: Solved
Heater Hoses: Solved
A/C: Pending Updated 3/12/2014
Throttle Cable: Pending Updated 3/12/2014
Fuel System: Solved
Exhaust System: Solved, Updated 3/12/2014
Anti-Lock Brakes: Solved
Power Steering: Solved


General Info: Always Read First...!
Well, I have been gone for a long time and will try to keep this updated. Sorry about the delay as I am in a transition period and can't work on the swap.
Also some really big information the innovative mounts put the engine so far forward that only the PRB intake manifold off of an RSX type S will fit.

BottledFedMR2 has confirmed this and it's been verified. So anything else will require the firewall to be cut or the manifold to be shortened. This sucks but at the same time it's nice to have the engine weight as far forward as possible as it puts it more centered.

I will have CONFIRMED next to everything I know for 100% is correct information.

Mounts: CONFIRMED
Recommends 75 was told by innovative that it's the same as a 65a poly used by
other companies. Theirs is pure poly so 65a could sag over time.
http://www.innovativemounts.com/ProductDetails.asp?ProductCode=90551

Shifting Mechanism: CONFIRMED
Use the Factory MR2 cables and this bracket will make them interface with no other mods.
http://www.innovativemounts.com/ProductDetails.asp?ProductCode=50507
**Note: 2006+ Civic SI transmission will require the shift "Arms" off of an RSX type S transmission. You will then be able to
hook up the innovative shift Mechanism as it would be on a normal RSX-type s Transmission.


Axles: CONFIRMED
Axles can be ordered through Drive Shaft Shop they now have part numbers on file though they are not on their website.
Part Number: RA9040x2 and RA9041X2

Wiring:
There is much debate about the wiring so far it's every man for himself. I haven't actually started the physical wiring so I can't confirm anything or have a proven design. There are a few that have completed their swaps and have them running and driving but they all sort of do wiring differently. Monkeywrench racing is working on a full swap kit and will be selling the parts all separately. I talked to them and they will be offering a wiring solution. Right now this is known for a fact!

If you want the car to fully function like a stock spyder you will need to shotgun the ECUs (Factory Toyota ECU and Honda ECU) if you don't care and want to replace your cluster then you can run a straight Honda ECU but don't expect it to be very easy and you will need to know wiring to do it. You will also find it a lot harder to get the A/C running correctly without redesigning the whole A/C wiring system.

Now if you just run the Honda ECU by itself and keep your factory cluster you will lose your TEMP gauge and a few other idiot lights.


Old Info 3/12/2014

ABS:

I have found in theory that the ABS is almost completely independent of the engine control unit there is one wire going to the ECU and from talks with people its a input to tell ecu that ABS is active.

P/S:
The P/S system isn't too much of an issue in my eyes as it will keep running if you don't give it any signal from ECU. So at the basic level, you have P/S no matter what. Now if you want to operate factory style then you need to configure Kpro to see the signal from the pump to IDLE UP on the current draw which is PIN E3-25.

There is also a pin on the ECU for turning the pump on and off while the engine is running/off. This pin is E3-19 on the ECU. From what I understand if the Power Steering ECU doesn't see any input on this pin it will just stay on all the time with the car in ACC/ON position. As for any speed variance to Pump pressure adjustments, this is all done between the P/S ECU and the ABS ECU (as the ABS ECU supplies the speed signal).

A/C:
I am working with innovative and when I start my swap will be using a prototype A/C adapter plate. You will want to keep your 1zz compressor as it will be the easiest by far to adapt to work. The K-series compressors are bigger and right now the 1zz one will barely fit.

I will be running wiring straight to the HVAC controls so that I can bypass the Toyota multiplex system and in essence just hard wiring the functions like Honda has in its cars all the way up to 2002. I will be recreating the same system they used in the earlier model civics that did not require any type of digital electronics.

At the back of the Toyota Hvac controls the A/C switch comes out as an analog +12 or Grounded signal that goes to the combo meter where it is processed and sent to the ECU on a multiplex. I will just be wiring straight to this output on the HVAC control and cutting the meter and associated multiplex functions out of the circuit. I will then create a patch harness for the A/C compressor that contains the High/Low switch relays to cut the clutch and also figure out a way to wire a freeze-out switch into this same harness.


Unless I am missing something and by all means correct me. I see that if you completely remove the factory Toyota ECU the only things that will not work are the A/C, Temp gauge, and Some idiot lights and that is it. Everything else can be wired/jumped to function like normal.

The Temp gauge is on multiplex along with some of the idiot lights and A/C. You could make these work using the factory ECU as a multiplex conversion box and feed it the K-swaps sensor signals and hope they are in the same range as factory Toyota's or hook up factory Toyota sensors in addition to the Honda ones on the engine. IE: two oil pressure switches, two temp sensors ETC...

My goal is to make it as streamlined and simple as possible (Wiring/Electronics). That is why I want the Toyota ECU to be completely gone and all functions controlled by the Honda ECU.

Overall I am getting more and more done day by day and hope to start buying parts soon. I wanted to figure out most of the wiring before I even took the first bolt off the car. I'm hoping to have some of the conversion harness already made before I even start working on the car. "


Throttle Cable:
Was informed that if you buy a Cruise Control delete it will allow the factory cable to bolt in no major mods are needed. Getting verification but should be for a 00-04 RSX.

Radiator Hoses: CONFIRMED
He also said that the K-series and the 2zz are very similar in where all the hoses route. Since this is true He has confirmed the fact that in the swap in the lotus all the hoses fit up 99% perfectly.

He said cutting one hose 2 inches is all that is required on the lotus. Since the engine is what determines the placement of hoses then the spyder should be no different than what's required for a 2zz swap.

Heater Hoses: CONFIRMED
Read Radiator Hoses Same applies.

A/C System:
Again BottledFedMR2 is the guy to see, he is working on bringing an A/C bracket to production. He is close to having it ready and I myself will be buying one.
It will use the 1zz compressor, he says it will be a little lower than he would like but it doesn't seem to be a big issue.

Tim said they are in the works to make a bracket for the Lotus with Kswap. So He says he doesn't see why the spyder wouldn't be able to use it. Again like the throttle cable he would need someone to test fit it and confirm or send it back to have it modified till they get it right. But it is doable and not a big issue.

The Lotus has issues with A/C line clearance and he said that is one of the problems they are working on. When I asked him if the Lotus and spyder have very similar bay layouts I didn't know for sure but he said the way the firewalls are the spyder might actually have more room for the lines. Like everything though he can't say for sure.

Exhaust System: CONFIRMED
PPE makes a Header now for MR-2 Spyder with Kswap and is also available through MWR.
The collector size is 2.5" and the overall header is longer than the stock one so will stick out further than the factory.
Still waiting to get info on if you can use a downpipe to make it line up with the rest of the factory system.

Fuel System: CONFIRMED
You will need to run a return of some sort. You will need to also get a fuel regulator. I am still a little iffy on this from a basic swap standpoint because Honda uses a returnless system factory so you might not need to do this if you're just going to OEM performance.

Extra Notes:
I will update this a little more in a few days. I wanted to get something new on here as I have been away from the forums for a while and people might like to see a summary of the events going on with the Kswap. The main thing that is missing is the wiring. Once there is an agreed-upon design that everyone thinks works and is simple as it can be will the swap gets easy enough for everyone.
 
#1,952 ·
Do any of you have guys have dyno sheets of your various setups.
And mod lists in one thread?

Just something I saw that has been done on other forums to see what the power curve looks like between the different setups as well as the power the cars are making.

I have read through the posts regarding headers as well and wanted to find out which header most of the guys are using.

Just and update on the dss shafts with the kseries outers and n source hubs . They have been holding up this far no issues to report. I will test it at the track on the 16th December with a set of 24.5 13s Hoosier drag slicks. Hopefully they hold up. :)
 
#1,954 ·
Do any of you have guys have dyno sheets of your various setups.
And mod lists in one thread?

Just something I saw that has been done on other forums to see what the power curve looks like between the different setups as well as the power the cars are making.

I have read through the posts regarding headers as well and wanted to find out which header most of the guys are using.

Just and update on the dss shafts with the kseries outers and n source hubs . They have been holding up this far no issues to report. I will test it at the track on the 16th December with a set of 24.5 13s Hoosier drag slicks. Hopefully they hold up. :)
Here's my dyno sheet from the summer. K24A2, PPE header, Type S oil pump & RDX injectors, otherwise stock. Tuner recommended upgrading the intake manifold and cam gear.

Final numbers were 199/169. I need to redo the intake to reduce intake temps, it's on the list of things to do this winter. Tuner was Pure Tuning in Toledo if anyone is wondering.
79835
 
#1,953 ·
Morning Guys,

I did the test and tune one the 16th unprepped track.
Managed a 1.8 60ft and 12.3 @181.
The shafts held up great and took all the abuse i threw at it. I managed a total of 8 runs :cool: and on the 9th i stripped second gear :( this is when the track heated up and the first time second gear gripped.The previous runs
i had bad wheel spin going to second and third.

Need todo some research now on how to resolve the latest issue.

The hubs and kesries outers work and should never give any issues for most of the guys unless you going to make huge power which majority of us wont be doing.

(y)
 
#1,955 ·
Those numbers are pretty low. You don't mention what year k24a2. It's on the engine vin tag. The 10th digit will correspond to the year: 4=2004, 5=2005, etc.

04-05 k24a2's came with some of the smallest cams. 06-08 have the biggest exhaust cams. 09+ are bigger, but the cam is 5mm shorter and has to be used with 09+ vtc to compensate for the length. For stock cams it's common to mix and match with k20a/a2/z3 cams. Nobody runs 04-05 stock cams if given a choice.

If you're running an RBB (takes some massaging but mine fits fine) I would keep it for the torque. You can also increase the plenum volume so that it keeps making power to 8500, though stock i wouldn't spin above 7500 for street engine.

Pick up a 50° VTC gear. Same one used on k20a2 and k20a3. K24A2 is really limited by its 25° VTC.
 
#1,956 ·
Those numbers are pretty low. You don't mention what year k24a2. It's on the engine vin tag. The 10th digit will correspond to the year: 4=2004, 5=2005, etc.

04-05 k24a2's came with some of the smallest cams. 06-08 have the biggest exhaust cams. 09+ are bigger, but the cam is 5mm shorter and has to be used with 09+ vtc to compensate for the length. For stock cams it's common to mix and match with k20a/a2/z3 cams. Nobody runs 04-05 stock cams if given a choice.

If you're running an RBB (takes some massaging but mine fits fine) I would keep it for the torque. You can also increase the plenum volume so that it keeps making power to 8500, though stock i wouldn't spin above 7500 for street engine.

Pick up a 50° VTC gear. Same one used on k20a2 and k20a3. K24A2 is really limited by its 25° VTC.
It's an 08. From what I've seen those numbers are more or less in line with what I should expect with what I have. It was a hot day and I was seeing very high intake temps, so I'm sure I was losing a bit there as well. I'd like more power of course, but it's more money and not high on the priority list.
 
#1,957 ·
I agree. Stock TSX will dyno ~185/150. The 25° VTC is severely limiting. Even a stock K20a2 tune is almost always 30°+ VTC cruising.

For reference, I've logged IAT's at idle and cruise. Even on hot summer day, IAT's drop quickly as soon as you start moving. But, on an 80° day at a stop light IAT's will creep up to 100-110° if you have a short ram and the filter isn't sealed off from engine bay. On a dyno it's going to be much worse. Can get some heat removed with a fan at the back as well.
 
#1,963 ·
I'm researching k swap options and this thread is fantastic. I haven't read all 99 pages... but is there a strong reason to use an 02-04 vs 05-06 RSX Type S trans? I know the gearing is quite different (k-series Transmission Gear Ratio Table), and I think the 02-04 gearing would work better for me, but does either one easier to swap in? I would guess the 02-04, but just double checking. Thanks!
 
#1,964 ·
I'm researching k swap options and this thread is fantastic. I haven't read all 99 pages... but is there a strong reason to use an 02-04 vs 05-06 RSX Type S trans? I know the gearing is quite different (k-series Transmission Gear Ratio Table), and I think the 02-04 gearing would work better for me, but does either one easier to swap in? I would guess the 02-04, but just double checking. Thanks!
Well, this question is now moot, as I ended up grabbing an 07 Civic SI trans with an LSD. Looks like Mitch's has a kit that will work with it, so hopefully not a bad buy haha.
 
#1,969 ·
Is anyone using a PLM header modified with success? I imagine they are the same as the k-tuned swap headers? Which PLM headers easily clear the rear subframe? I just threw a k24 into my EP3 track car and picked up an MR-S for a fun street car.

View attachment 82309 View attachment 82308
It's doesn't just tried this weekend

Sent from my SM-G975U1 using Tapatalk
 
#1,978 ·
I added it to the ecu side, and then just tapped it into the other brown/yellow wires on the A plug.

before you do that, do you have 12v at the ecu pin E1? If you do, then the ecu is not providing ground to turn on the fuel pump relay. Youre heading down the right path in that you now know what’s not happening, next would be to find out why.
All that the MAP wiring change (cut and tap) does is change voltage from one side to the other on the EFI relay control circuit. The ground to trigger the relay comes when e1 drops to ground.
 
#1,979 ·
The controll circuit for fuel pump command comes from battery, through AM2 fuse (15A) , through ignition Switch IG2, now on red/white wire to C/OPN (fuel pump) relay, out on green/red wire to A3, this is all on the Toyota harness. A3 need to see ground to turn on fuel pump. A3 should run to ecu E1.

power to the pump is on a black wire at A16 on Toyota harness, passes through relay, through pump to ground. BLACK WIRE IS NOT GROUND ..learned that the hard way

for the efi relay, the white/black wire, which went to ground, now has 12v from efi1 (15a fuse)(yellow wire) The grey wire going to B21 on Toyota harness need to see ground when key Is on.
 
#1,982 ·
Hey Guys,

I am just researching the MR2/K swap info and wanted to know how are the quality of the MAP swap kit parts. Has anyone used it for a prolonged period of time? How has the mounts and shifter linkages held up to tracking abuse? I love the idea of K swapping a MR2 but only if swap package is robust enough to handle track work. I appreciate any comments/feedbacks.

Thanks.
 
#1,983 ·
I've done a few track days on mine with a K24. No issues so far in that regard. There were fitment issues with the mounts with the initial install, and I received the wrong oil pump chain. Overall, I would still recommend MAP. Brandon over there is super-helpful, and overall quality was pretty good.

A big disclaimer though- I used the Civic SI transmission with seems to have a more stout adapter on the transmission side. I don't believe that adapter is available anymore.
 
#1,985 ·
Not the person you are replying to, but in my case I had issues with the motor mounts not all lining up. Could just be my car, but I needed to modify the front mount and add a spacer to make it fit.

Also, not sure if it's the case for a K20, but if you run a K24 you will need an oil cooler for track use. Pre oil cooler I'd hit 280° on track within 15 minutes, even with cooler ambient tenps. With the cooler installed my steady state temperature seems to be around 240°. I didn't do any ductwork or add fans, so I'm sure I could get it lower if I tried.
 
#1,986 ·
Again, thanks for the insight, How long have you had the swap and how many track events? I don't own a spyder yet but l will only be buying the car to drop a K24 in it . If the parts are not robust, I will scrap the entire idea.

And regarding oil temps, it isn't oil temps that will kill your engine, it's oil pressure. Did you measure what were the pressures at 280F? The S2000 guys can be tracking their F20s @ 280F for 80+ events without issues. For a dedicated race car, I agree 100% to go with an oil cooler but for the causal HDPE car, I am not completely sold on it given that it does introduced more potential failure points (leaks) and in some cases, causes over cooling for street use.
 
#1,987 ·
The swap parts are not refined, however if you are handy everything can be made to work. I had a couple fitment issues also with the mounts, grinder, dremel, drill etc. can handle it. the shifting mechanism is probably the worst, it needs some bracing, as shifting through the gears causes the cable bracket to bend and ends up in missed gears... there were some issues with the shifter mechanisms and brackets breaking because of lack of welds, which supposedly has now been remedied, but as far as I know the bracing has not been added to the cable bracket, which helps shifter feel tremendously.

It's a pretty easy swap for someone with some mechanical knowledge as far as swapping an engine from a different manufacturer goes
 
#1,991 ·
The swap parts are not refined, however if you are handy everything can be made to work. I had a couple fitment issues also with the mounts, grinder, dremel, drill etc. can handle it. the shifting mechanism is probably the worst, it needs some bracing, as shifting through the gears causes the cable bracket to bend and ends up in missed gears... there were some issues with the shifter mechanisms and brackets breaking because of lack of welds, which supposedly has now been remedied, but as far as I know the bracing has not been added to the cable bracket, which helps shifter feel tremendously.

It's a pretty easy swap for someone with some mechanical knowledge as far as swapping an engine from a different manufacturer goes
Are you referring to the RSX shifter or the later (Civic) type shifter? As far as I know, using the later transmission yields Honda factory-like shifter quality. I am using the Innovative shifter adapter on a RSX gearbox and the result is great, but I spent a lot of time shimming all of the link connections to minimize fee-play.

Dave
 
#1,995 ·
doing the streetable track car or trackable street car thing is a balancing act. I do however think an oil cooler is a worthwhile addition on the k24. As long as you aren't running the oil cooler in the front, you won't notice a pressure drop. It's not something that you need to do right away, but I would add one before a track day.
 
#2,000 ·
the map mounts retain the oem toyota passenger side engine mount, driver side transmission mount, and rear engine mount. I have added a poly insert to the rear engine mount and a 75a innovative rsx front mount. I have no vibration, and my engine does not rock enough to make the ac compressor contact the firewall without massaging
 
#2,003 ·
You can use an 02-04 rsx type s harness, 02-04 rsx base harness or an 02-05 Ep3 engine harness. I am using an Ep3 harness. No modifications are necessary to the base or Ep3 harness they are only missing the plug for reverse lock out. I have a write up for adding reverse lock out to 5 speed harnesses and 5 speed ecu’s if you go that route
 
#2,004 ·
I believe you rewire the secondary intake runner of the intake manifold plug (found on the RSX base harness) for the reverse lockout, is this correct? Can you please send me the write up? Thank you very much.

However, if i pursue this swap, i will be using a 5 speed, PDN ecu as those are far more plentiful on the market. But i think aside from getting a KPro installed, nothing else is required for the EC.
 
#2,006 ·
you can do it that way with the base rsx harness. The Ep3 harness does not have that plug. I am using e21 evap vsv pin to control it.
I am also using an Ep3 ecu. There is nothing wrong with the 5spd ecu’s just need to use a different output for reverse lock.

I’ll send the write up tomorrow it’s on the work computer
 
#2,008 ·
If you are using the k24 you will either need to de pin the crank sensor connector from the k24 engine and repin the connector onto the rsx harness with the wires in the same orientation as they were the k24, and you will need to do the same with the knock sensor. Or you can replace the sensors with rsx units

on the charge harness, if you are using a k24 starter, you will need to use the k24 starter signal connector on the rsx charge harness

the engine harness has 1 plug that goes to the conversion harness, the conversion harness has 1 plug that goes to the ecu, the rest are body harness connections.

The mim is totally separate and gets hard wired into the necessary connections


there are currently 3 axle options stateside that I know of. Drive shaft shop, insane shaft, or N1 source adapter hubs to use honda axles
 
#2,009 ·
If you are using the k24 you will either need to de pin the crank sensor connector from the k24 engine and repin the connector onto the rsx harness with the wires in the same orientation as they were the k24, and you will need to do the same with the knock sensor. Or you can replace the sensors with rsx units

on the charge harness, if you are using a k24 starter, you will need to use the k24 starter signal connector on the rsx charge harness

the engine harness has 1 plug that goes to the conversion harness, the conversion harness has 1 plug that goes to the ecu, the rest are body harness connections.

The mim is totally separate and gets hard wired into the necessary connections


there are currently 3 axle options stateside that I know of. Drive shaft shop, insane shaft, or N1 source adapter hubs to use honda axles
Thanks. Yes K24 will be the engine choice as K20s are too expensive and makes less power for the same money. I was aware that I needed to rewire the crank sensor but I didn't know I can also rewire the knock sensor. Was told that I needed to buy a K20 knock sensor. This is good info.

Regarding the starter connector, where would you be able to get a K24 starter connector? Or, can I use a K20 starter instead? I think I will need a K20 alternator for the same reason. In addition, I think I will need a K20 water pump housing and a EP idler pulley.

Sounds like the MAP wiring harness, ECU, engine harness and chassis harness are all PnP. The only other work is hardwiring the MIM.

Ah, that is what DDS stands for and from my reading, they are not very good. Insane shafts is what MAP offers but seems quite pricey. I am also aware of the N1 source adapter hubs but I didn't think they were plug and play? Sounds like there was some machining that was required?

 
#2,010 ·
Regarding the axles, passenger side stock rsx-s and driver's side 06+ civic si are the correct lengths to use stock Honda axles.

The outer hubs would need to be turned down to clear the spindle and to mount a (70mm ID / 80mm OD I believe?) tone ring. This would allow you to use the N1 Source adapter hubs, stock Honda axles, and still have ABS (the spacer would not be needed).

I haven't had time to do this yet.
 
#2,022 · (Edited)
So from my understanding, DDS and Insane shafts are both PnP. However, after seeing the prices of the DDS, it's kind of "Insane". :) And I have read reports that some people are snapping them. But will i be able to retain full ABS functions if using these shafts? The 3rd option is the use of the N1 hubs along with some combo of OE Honda shafts. It sounds like there are a couple of Honda OE driveshaft options as outlines by Bi Doe and TeeMS.

Regarding the axles, passenger side stock rsx-s and driver's side 06+ civic si are the correct lengths to use stock Honda axles.

The outer hubs would need to be turned down to clear the spindle and to mount a (70mm ID / 80mm OD I believe?) tone ring. This would allow you to use the N1 Source adapter hubs, stock Honda axles, and still have ABS (the spacer would not be needed).

I haven't had time to do this yet.
Can you clear up what axles can be used? Do i need:

  • 2 x passenger side stock rsx-s or
  • 2 x driver's side 06+ civic si or
  • I need one of each? If so, which model axle for which side on the MR2 chassis?

And what do you mean by "The outer hubs would need to be turned down to clear the spindle and to mount a (70mm ID / 80mm OD I believe?) tone ring". Are you modifying the N1 hub or the knuckle/spindle?


I used 2 right side TSX axles, and swapped the inner join to a male for the driver side. No grinding, no spacers. Then I tapped my rear abs sensor wires into the fronts. In theory this should defeat the dreaded "ice mode" that I have heard about, Haven't been in the situation yet.
If i understand this correctly, you purchased three 04-08 TSX passenger side axels, used one as is and completed surgery on the other two to make 1 axle. Is this correct? Can you elaborate how you combined 2 axles into 1? If so, which side on the MR2 chassis was used as is and which side required the 2 to 1 axle? And i think this solution doesn't offer a "tone ring" which is required for ABS hence so you just rewired the rear ABS sensors to read from the front. But i think technically, this is really tricking the computer and you will not actually have rear wheel abs function, is this correct?

BTW, thank you both for providing your insight to my questions. Again, sorry for all the questions, just need to get a good understanding to see what i am getting myself into. Thanks.