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4AGE 20V Blacktop

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Diary of Swap
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85/6 4AGE -> 4AGZE

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Air Intake Filter
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Exhaust Manifold
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Ignition Timing
Oil Cooler Hoses
Oil Filter Adapter O-Rings
Oil Pan Gasket
Oxygen Sensor
Radiator Removal
Starter
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87+ Brake Upgrade
Caliper Rebuild-Front
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Dust Shield Removal
Parking Brake Cable
SS Braided Brake Line

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Ball Joint Replacement
Bushings Install - Front
Bushings Install - Rear
Steering Knuckle Removal
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87+ Antenna Replacement
Clear Turn Signals - Front
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Door Hinges
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Power Window Regulator
Rekeying Trunk Lock
Rust PM - Battery Bracket

Rust PM - Front Wheel Wells
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Shift Boot

SideMarker Mod

Sunroof Rattle
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2006 Austin
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2005 Topeka NA2005
2004 Galveston
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Suspension Setup Pics
My MR2 Diary
Latest Pics of My MR2



20V Blacktop Swap - Cooling System

 

Another one of the main fabrication hurdles with the swap (but one of the easiest and funnest!) is routing the coolant system lines. Luckily, the input & output of the water system is on the exhaust side of the engine.

Instead of trying to find rubber hose of the exact shape, I purchased some 1-1/4" 0D 6061 Aluminum pipe from a local supplier for the straight runs. It was cheap and very easy to work with.

The engine-radiator line was easy to fabricate. If you notice closely I reused a line from the 16V engine as well as one from the 20V clip.

The radiator-engine line was more complicated since I needed to incorporate the filler neck. Also, I am not using the stock MR2 oil cooler, so I don't need to route the line over the exhaust manifold. (if you do use the oil cooler, just mount the filler neck over the manifold.) I ran the line over to the driver's side of the car, straight up to near the fuse box and then back over into the thermostat housing. For the elbows I just purchased 2 proper sized hoses that each had two 90 degree bends. Then just made up some brackets to hold the pipe to the firewall. I attached the filler neck to the firewall as well.

 

The heater core lines are a lot easier since you just use flexible rubber hose. I forget the diameter I used, but it's the same as the 16V lines. I used the same bracket that was on the tranny to hold the lines in place. You can sorta make them out in the below pic:


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Disclaimer: This web page in no way replaces the MR2 repair manual. Follow what it says before me. The purpose of this page is to give you a better pictorial description of what to do. I cannot be held responsible for any mishaps caused by this web page.