Toyota Starlet K Swap.. But why?

In my mind this was always the destination, it’s just that 2024 wouldn’t be the year I’d set off on that journey.

Toyota Starlet GT at Blyton Park

You’re not here to read about the work I’d put into the original 4EFTE engine Toyota had intended for this car, but it’s important I set the scene for what’s to come.

With a trailer acquired, and the last few jobs buttoned up. It was finally time to see if 3? 4? 5? 6?! years of tinkering had been worthwhile.

Toyota Starlet GT Turbo 4EFTE Engine

The engine had been rebuilt, re-wired, re-plumbed, re-imagined. Nervous, but hopeful that the things I’d done would work just fine a day was put in the diary for mapping, what could possibly go wrong?

The day started well, with the car behaving, the temperatures all fine, no silly little leaks, no issues with the wiring, the ECU or PMU configuration.

As the day wore on however, it was clear there was an issue with boost control. The car would either sit happily at wastegate pressure, or overshoot and rattle off an elevated boost cut safety. Over and over the engine would be loaded up on the hub dyno, throttle would be pinned only for the run to cut dramatically short with a rush of air, and a high pitched whistle.

As night fell, our struggles with what was deemed a faulty, or fake MAC solenoid continued. Until eventually, the engine cried uncle. Spitting rod number four through the block and sump. I was devastated.

4EFTE bent / snapped rod and damaged piston

We’ll never truly know the cause, part of the game some might say. The solenoid bench tested just fine, and having gone through the data with colleagues and friends, we have our theories. But airing them out on the internet? Not really my style.. we live and learn.

So what next?

My immediate thought was a K20 from a Honda Civic Type R, but was that a knee jerk reaction? I’d poured so much into the 4E platform it almost felt like I had unfinished business with it. I knew an engine swap would set me back a year, was the juice really worth the squeeze?

I applied some man maths. To source and build a 4EFTE would cost about the same as the parts required to make a really good start with the swap. Once I’d added up the value of the 4E parts I could sell? It was a no brainer.

With a decision made it was time to source parts: Engine, gearbox, driveshafts, engine mounts, exhaust manifold, wiring, plumbing, brakes, gear shifter, shifter cables, intake manifold, throttle body, radiator.. not much then.

Honda K20A2 engine on dolly

But more on that next time.


about the author

Tim explores his passion for design, manufacture and engineering through the build of his unique 1993 Toyota Starlet GT Turbo.

about the author

Tim explores his passion for design, manufacture and engineering through the build of his unique 1993 Toyota Starlet GT Turbo.