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	<title>Midship Runabout &#187; strut</title>
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	<link>http://www.midshiprunabout.org</link>
	<description>The Toyota MR2 Internet Archive</description>
	<lastBuildDate>Fri, 02 Apr 2010 06:50:19 +0000</lastBuildDate>
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		<title>Ball Joint Removal</title>
		<link>http://www.midshiprunabout.org/mk2/ball-joint-removal/</link>
		<comments>http://www.midshiprunabout.org/mk2/ball-joint-removal/#comments</comments>
		<pubDate>Sat, 12 Mar 2005 00:01:45 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[International MR2 Owners Club]]></category>
		<category><![CDATA[MK2]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=310</guid>
		<description><![CDATA[I thought I would share my experience with removing my front ball joints on my &#8217;93 T. I have never done this before on any car so it was all new to me. I knew several methods of removing them and didn&#8217;t think it would be difficult at all. Overall it was not difficult but [...]]]></description>
			<content:encoded><![CDATA[<div id="post_message_5237">I thought I would share my experience with removing my front ball joints on my &#8217;93 T.</div>
<p>I have never done this before on any car so it was all new to me. I knew several methods of removing them and didn&#8217;t think it would be difficult at all. Overall it was not difficult but I had some issues.</p>
<p>I have my complete control arm and strut rod off the car in one piece with the ball joint still attached.</p>
<p>I first attempted to use the hammer method. I removed the cotter pin and loosened the castle nut up to the top. I then placed a washer on top of the nut and started smacking it with a medium sized ball-pein hammer&#8230; didn&#8217;t come out.</p>
<p>So I figured I would try it on my newly purchased press. The press is more than enough to push it out but getting the item in there properly so it sits level and is resting on the area between the boot and control arm was not easy. I ended up getting some metal that was laying around and I had it all setup so it should push it straight out. After beginning to apply pressure the angle iron I had (1/4&#8243; thick) started to bend&#8230; ball joint still not out.</p>
<p>After this I figured I would look for a price on the SST to do this. Partznet showed nothing so I searched on Google a bit to find it or others similar and didn&#8217;t come across anything except a pivot type separator.</p>
<p>I went back into the garage and figured I would try the pickle fork. I am not a fan of these because they can easily tear the boots and my ball joints were not showing signs of needing to be replaced. Infact they were showing signs of being replaced recently.</p>
<p>I got the pickle fork out, and then I thought about using a 2 jaw puller instead. Put the pickle fork back and found the 2 jaw puller.</p>
<p>I set it up so the two jaws of the puller were inbetween the boot of the ball joint and the control arm. The push rod of the puller was then directly on top of the ball joint stud. I started to tighten it down and before you knew it the ball joint was out.</p>
<p>Here is a picture of how I setup the puller on the second control arm. Once in this position all you do is crank the puller down with a wrench and in seconds the ball joint is out.</p>
<p><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ffba98bcde58ce3509febf6cf9681880.jpg" border="0" alt="" /></p>
<p>I will be calling Toyota one of these days to price the SST for this, if it is too expensive for me I will just continune to do it in this manner.</p>
]]></content:encoded>
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		<title>Replacing the Struts</title>
		<link>http://www.midshiprunabout.org/mk2/replacing-the-struts/</link>
		<comments>http://www.midshiprunabout.org/mk2/replacing-the-struts/#comments</comments>
		<pubDate>Tue, 09 Nov 2004 17:19:50 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[Lovehorsepower.com]]></category>
		<category><![CDATA[MK2]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[adjust]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=1187</guid>
		<description><![CDATA[Here I am replacing a very used set of Tokico Illuminas with KYB AGX struts.  The old struts were shot due to a poor choice of boots.  These are just notes and pictures and not all the information you need to safely remove and replace the struts.  It should help though. New struts and boots [...]]]></description>
			<content:encoded><![CDATA[<p align="left">Here I am replacing a very used set of Tokico Illuminas with KYB AGX struts.  The old struts were shot due to a poor choice of boots.  These are just notes and pictures and not all the information you need to safely remove and replace the struts.  It should help though.<br />
New struts and boots<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/struts_and_boots.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/8a7247f945fb9d4801af13455161d020.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">You <strong>may want</strong> to attempt to loosen the top strut bolt before jacking up the car.  This is the bolt located under the strut tower cover and is a 19mm bolt.  If the assembly moves when you turn the bolt, it can be removed later.  <strong>Only loosen this bolt</strong> a small amount, under no circumstances should you remove this bolt at this time.  Jack up the car, and remove the wheel. </p>
<p align="left"><strong>Rear Struts:<br />
</strong>Rear strut assembly (spring, housing and strut) before removing:<br />
<strong><a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_old_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/10551cc69e51deeb25de17dd0190e6e2.jpg" border="0" alt="" width="160" height="120" /><br />
</a><br />
</strong>Start by removing the anti-roll bar that connects to the strut housing.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_anti_roll_remove.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/daf2f0298edfa406cc2680e3a32d2cb2.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Then remove the brake line &#8216;C&#8217; clip, and brake line from the caliper.  Hang the brake line out of the way.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_brake_line_clamp.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/fe7d62798b437bc6a93b57712b7d4a1e.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Remove the speed sensor cable, but do not remove the speed sensor.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_speed_sensor_cable_undo.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6dd829781c8df10dd34541c0a56f0e35.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Loosen the top four bolts that hold the strut in place, and then remove the large lower bolts.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_housing_remove1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7f1aa8eeae00b4f570cedcbe5fc053b3.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_housing_remove2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/627817216d5d976648318a74df98be2a.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The assembly can now be removed after removing the top four bolts.  You will have to push down on the rotor/hub to get enough clearance to remove the strut housing assembly.  It&#8217;s a good idea to put some sort of rag (underwear) to protect the CVT boot.<br />
 <a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_assembly_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/3f984646b0b3e84e12c865e04bcfe4b1.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_assembly_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0d3e1526dc1d05eeb063f05c8cadbb5d.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">If you loosened the top strut bolt (19mm) before, it will make the next step easier.  If you are removing stock springs, you will need a <strong>spring compressor</strong>.  Please be careful as there can be a large amount of energy stored in the spring!  With the spring compressor installed, remove the top 19mm bolt and spring.  <br />
Removing the gland nut can be difficult.  Soaking it in WD40 or other penetrating lubricant can help.  Then a pipe wrench and vice can be used to remove the nut.  I choose to paint the old components, and then install the new strut.<br />
Pour a small amount of oil into the housing, and install the new strut.  The oil should take up the space between the strut and the housing.  Make sure not to over-fill it since you will need some space to tighten down the gland nut.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_new_strut1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/27accc942c391ae26b9581de65e7fbe4.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Then install a new boot.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_new_strut_with_boot.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d133c3c51fc23d23fe15165270483d52.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Next the spring.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_new_strut_with_spring.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1cb9d2da591e2456f0f9dfadafc5834c.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Lubricate the top piece.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_top_lubricated.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9456d42b73bbe05f271969ff6ef8fd34.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install the top using the 19mm bolt and spring compressor (if necessary).  Make sure to point the top mount piece toward the large bolt holes on the strut housing.  Tighten the bolt using a torque wrench and vice to hold the top.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_top_installed1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ddae7d2706224c78e76e5d0980dc8d22.jpg" border="0" alt="" width="160" height="213" /></a> <a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_top_installed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/2304e04290dc654c46529613b01c8386.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_housing_top_installed3.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4f4f309f0d6d19cc69bab50999c860e4.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install the rear strut by pushing down on the hub/rotor and move the assembly into place.  Hand tighten the top four bolts.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_installed1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e81715e3a3a4eae4a1749a1bdfa1f8bb.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install the anti-roll bar to the strut housing.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_installed2a.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9ebfbc57f4c4210bdd987e236b6620ec.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install the brake line and speed sensor line.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_installed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/09006d5431e46cf8f5ef510f78d8ed76.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Don&#8217;t forget the &#8216;C&#8217; clamp on the brake line.  Tighten the large bottom two bolts to 180ft-lb.  Tighten the top four strut assembly bolts to specification.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/rear_strut_installed3.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/48773f248bee5622a82d19a63edc762f.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left"><strong>Front Struts:<br />
</strong>Here is the old assembly in place.<br />
 <a href="http://www.lovehorsepower.com/images/MR2_Struts/old_strut_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/98aafe7a8e5ab3fc1d50641d1c0872e3.jpg" border="0" alt="" width="160" height="120" /></a><strong><br />
</strong>The first step is to remove the anti-roll bar hook up to the strut housing.  This can be done in two places.  I found it easier to reach the bottom location.  You will most likely need a hex driver and 14mm wrench to remove this bolt.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/anti_roll_bar.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e2dae57ff1c30edd821718e789e0acaf.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Next remove the brake line.  You must remove the &#8216;C&#8217; clip on the strut housing and the bolt on the caliper.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/brake_line_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9249132f8a6bb7033e4168cb9759594f.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Then hang the brake line up with a string or wire so that it is out of the way and not dripping.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/brake_line_hang.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/12547bc4cad0c5e7027cadd9ae5d79d4.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Next remove the speed sensor bolt.  You do not need to remove the sensor itself, there is plenty of slack in the speed sensor cable.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/speed_sensor_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7bec36592f62246f353daa782107549b.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The four top strut bolts can now be loosened.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/top_strut_bolts.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e16391773b791603727b6c7651daf9b7.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The large bottom bolts can now be removed.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/bottom_strut_bolts.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/880e318f89f7551fcdf71817c4a059fd.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Now the hub can move out of the way.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/hub_loose.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/2b99a09740c5c8ae5f9a7112e81737ac.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The top strut bolts can now be removed, and the whole spring/strut/strut housing assembly can come out.  <br />
If there are stock springs installed, you will need to use a spring compressor to compress the spring so that it doesn&#8217;t fly off when you remove the strut bolt (19mm) at the top of the strut bar.  If you have loosened this bolt earlier on, great!  Otherwise you will have to hold the assembly in a vice while removing this bolt.  I&#8217;ve found that the Eibach springs I had installed didn&#8217;t need to be compressed.  Please be careful as there can be a large amount of energy stored in the springs.<br />
Now comes the hard part.  Removing the gland nut can be somewhat difficult.  I recommended soaking it in WD40, or some other penetrating lubricant.  Then remove it with a pipe wrench.  If this doesn&#8217;t work, you can try to put the assembly in a vice, with the vice holding the gland nut.  Then use some extensions to twist the assembly.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/strut_housing.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9682d412f3df5a6d7a99158267b9f322.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Pour a small amount of oil into the housing, and install the new strut.  The oil should take up the space between the strut and the housing.  Make sure not to over-fill it since you will need some space to tighten down the gland nut.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/gland_nut_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/fcf287ef9cde326f4cc6ae761fe57686.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install a new boot.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/strut_boot_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/934bc4e95007fdc40a0a1441a44bc6ba.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Install the spring.  Line up the &#8216;larger end&#8217; with the bottom.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/spring_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/369d9bf2a62f33cbd0743d74f8b74438.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Clean out the bearing and re-lubricate them.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/strut_top.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/afc12a4e3ff6a27a1dbb67f11c858a5d.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_Struts/strut_top2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a90336b35a7f003994c0effa3a4495be.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Line up the top strut mount so that the &#8216;OUT&#8217; faces the part of the strut housing that points toward the outside of the car (the part of the strut housing with the large bolts).  It also must be lined up with the top of the strut bar as shown.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/strut_top3.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1f5f918b2d364e3035afb734faebf5b2.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">You may need to use a spring compressor in order to tighten the 19mm bolt.  If you cannot tighten the 19mm bolt to the torque specifications, you can install the assembly, lower the car down, and then tighten the bolt.  Point the top piece (four studs) with cut-out toward the back of the car.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/assembly_front.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ed425049e47194c7c355e770b09af4bc.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Install the assembly and just hand tighten the top four bolts.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/top_bolts.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/3f86dc4c0af7a441236cca506f98c4a6.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left"><a href="http://www.lovehorsepower.com/images/MR2_Struts/new_front_install1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0eb06eb7f920b344272ca31deeeeab6c.jpg" border="0" alt="" width="160" height="213" /></a></p>
<p align="left">Tighten the lower two bolts to 180ft-lbs.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/new_front_install3.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/946c8b819cc4e9182711f89e772580dc.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Re-install the brake line, C-clip, and bolt for the speed sensor line.  Tighten the top four strut assembly bolts to specification.<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/new_front_assembly_installed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/3ea61de8511dda82292e8832d4313238.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Adjustable KYB AGXs:<br />
<a href="http://www.lovehorsepower.com/images/MR2_Struts/kyb_agx_top.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/574f08c3c71ae906502cb38c98ae6997.jpg" border="0" alt="" width="160" height="120" /></a></p>
]]></content:encoded>
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		</item>
		<item>
		<title>MR2 Turbocharger Removal</title>
		<link>http://www.midshiprunabout.org/mk2/mr2-turbocharger-removal/</link>
		<comments>http://www.midshiprunabout.org/mk2/mr2-turbocharger-removal/#comments</comments>
		<pubDate>Thu, 15 Apr 2004 16:31:02 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[3S-GTE]]></category>
		<category><![CDATA[Forced Induction]]></category>
		<category><![CDATA[Lovehorsepower.com]]></category>
		<category><![CDATA[MK2]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[bleed]]></category>
		<category><![CDATA[drain]]></category>
		<category><![CDATA[engine]]></category>
		<category><![CDATA[filter]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=1170</guid>
		<description><![CDATA[Here is a brief document describing how to remove (or rather how I remove) the turbocharger from the MKII MR2.  The reason for removing the turbo here is because a couple of the exhaust manifold studs have come loose and are stripped.  I plan on repairing them with time inserts.  If you have to stock [...]]]></description>
			<content:encoded><![CDATA[<p>Here is a brief document describing how to remove (or rather how I remove) the turbocharger from the MKII MR2.  The reason for removing the turbo here is because a couple of the exhaust manifold studs have come loose and are stripped.  I plan on repairing them with time inserts.  If you have to stock exhaust system on your car, I can&#8217;t really help you out, as I had it removed by a shop.  The shop charged me $50.00 to remove the exhaust.  I then installed an aftermarket exhaust which is significantly easier to remove.<br />
I start off by going in from the top and removing the X strut brass (2 bolts, 2 nuts), and piping going from the turbocharger to the intercooler.  Here is a picture of the exhaust (that I use) once it has been removed:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/Exhaust_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c4055aa87a6028245d7a117746c3600b.jpg" border="0" alt="" width="160" height="120" /><br />
</a>I then remove the heat shield from the turbocharger &#8211; EGT probes can be seen in the following photo:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/heat_shield_removed_top.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1b920398f34c48876de9fb9e3688f82c.jpg" border="0" alt="" width="160" height="120" /></a><br />
Next up, is to remove the primary catalytic converter.  I feel this is one of the more difficult steps in the process, as some of the bolts are difficult to get at &#8211; particularly the bolts on the brackets holding the converter in place.  Here is a photo from underneath before the converter is removed:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/cat_from_below.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d2eea4d4856117d4ff91d96fb9ea9eb7.jpg" border="0" alt="" width="160" height="120" /><br />
</a>At this point, I remove the oil filter, the heat shield attached to the pipe going from the exhaust side of the turbocharger to the converter, and the O2 sensor.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/top_heat_shield_o2_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c46198b8a282f3456e4bfc60d3c9f9df.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Next, I go back underneath the car and remove the engine mount shown in the following picture.  The bolt to the left of the engine mount is the driver&#8217;s side converter bracket bolt.  There are 3 bolts to this bracket, one to the converter as can be seen in the picture and two that bolt to the block.  Only one of those that go to the block needs to be removed.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/under_engine_mount_cat.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/96542a1961cdc6acc5df8647b6e24d0b.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Once the engine mount is removed by removing the through bolt, 4 bolts for one side of the bracket, and 2 for the other, the driver&#8217;s side converter bracket can be loosened.  The turbocharger is now clearly visible from underneath.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/under_cat_driver_bracket_no_mount.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5c288be3261106550d6bb085960ab6e7.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_from_under.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/2b0a57ccaeb856529cbdfffaab319e2d.jpg" border="0" alt="" width="160" height="120" /><br />
</a>After removing the 2 bolts (on the passenger side) that go from the passenger side bracket to the converter, I go back up top to loosen the bracket.  There are 2 bolts that hold this bracket to the engine block.  I remove one, and loosen the other so as to be able to move the bracket aside.  They can be seen in the following picture:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/pass_side_cat_bracket_from_top.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f06fb684e4ad520deead37eb60b0a7fb.jpg" border="0" alt="" width="160" height="120" /><br />
</a>I use a universal join and an extension to remove one of these 12mm bolts and loosen the other.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/universal_joint.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/aa33059292beb2e2a6742d9957c29ec1.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/tool_universal_joint.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/106a73b9fb74d4a7184d568efe9bcff4.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Underneath the two brackets holding the converter to the block can now be moved aside and the 3 bolts and 2 nuts that hold the converter to the pipe coming from the turbo exhaust to the converter can now be removed.  The converter is somewhat heavy, but can be held with one hand while removing the last bolt.  The converter is now removed:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/no_converter_underneath.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/693390163ce74c3d11d44f1c6300d57d.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Back up top, I remove the intake pipe to the turbo:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/intake_pipes_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1c31a99a7358c87144df49aa4fe0ae41.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/intake_pipes_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a3826e45d7c4e919b9d5693d178a6da5.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Next is to remove the water pipe leading to the turbo.  I do not find it necessary to drain the coolant, but some will spill out on this step.  When the turbo is put back in, I just re-bleed/burp the coolant system.  The metal coolant lines are shown in this picture:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_coolant_line.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/557ee3d7499c3cdb3dd842fe00501489.jpg" border="0" alt="" width="160" height="120" /><br />
</a>First &#8211; the coolant pipe bolt must be removed &#8211; it is shown in this picture &#8211; 12mm:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_coolant_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/32ba38b42a32a40143b94f9662312eee.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The two nuts that hold the turbo coolant pipe to the turbo are then removed.  I had to use a universal joint here to remove the bottom bolt  The rubber air hose to the turbo is also removed..<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_coolant_pipe_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/79362364d65f54ee942a9a3edf056374.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_coolant_pipe.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/b58227a07377f073bf41b305bfccd224.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The air hoses to wastegate actuator are then removed.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/wastegate_air_hose_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/27137a475bdadcbd4d3c109413a4534a.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Next up is the 27mm oil bolt.  It can be seen in this picture:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/oil_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/564dca4ee62f44a5b71f251f7dcbdb5f.jpg" border="0" alt="" width="160" height="120" /><br />
</a>I use the tool in this picture to remove it (the bolt is in the socket).  It can be very tight.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/oil_bolt_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7613e01871c912e4375438023c0fd213.jpg" border="0" alt="" width="160" height="120" /><br />
</a>It is now possible to loosen the bolts holding the pipe that goes from the turbine side (exhaust) to the converter.  Some of the bolts are hard to get at.  If so, just wait until you can loosen the turbo and manifold in a later step.  The nuts for this pipe are shown in this picture:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_exhaust.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f8aad754f692b7d610613e081636afbe.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Next is underneath the car again where the oil pipe to the turbo is loosened &#8211; it is attached to the turbo via two bolts on studs and the pipe is also attached to the block with one bolt shown in the following picture.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/oil_pipe_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f1d7f85e2437092f07beb40e443881d4.jpg" border="0" alt="" width="160" height="120" /><br />
</a>After that bolt is removed the two nuts (12mm) that hold the oil pipe to the turbo can be removed.  One can be gotten to via a straight extension, and the other with a universal joint.  One of the bolts can be seen in the following picture &#8211; the other is pointed to by an arrow.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/oil_pipe_bolts_turbo.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f026e18af104c6a1f0b580c14e64bc39.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The next two bolts to remove are on the turbo bracket.  These 12mm bolts can be very tight.  I used a 12mm wrench and another 13mm wrench connected together to make a longer lever arm.  It&#8217;s also possible to use a large socket and extension on the open end of the 12mm wrench.  Once the lower bolt is removed the upper one can be removed.  It is not necessary to remove the entire bracket from the turbo.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_bolts.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/95add5301d61c7d23025608c5642a105.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Again it is not necessary to remove the bracket, but if done, this is what it looks like &#8211; the oil pipe is now free.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_backet_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/21bfbd0d6aeda9982eb81cf938d6ad52.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Now the exhaust manifold nuts can be loosened (do not remove yet), and the pipe leading from the turbine side (exhaust) of the turbo to the converter (that has already removed) can be removed.  This is not necessary but significantly reduces the weight of the turbo assembly when lifting it out of the engine compartment.  One of the studs is very close to the oil cooler (where the oil filter attaches), but with the manifold loosened, it can be removed by moving the turbo assembly, and pulling the pipe out.  The pipe removed:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/downpipe_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a83806bbcd16cb6e8afd7c10fd0bc1dc.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/downpipe.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/14cd4fc1ce40c3fd3f87d13c348c7470.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The turbocharger can now be removed by loosening the 4 nuts that hold the turbocharger to the exhaust manifold.  I needed to remove the rubber hose connection from the high pressure side of the turbo to get enough clearance for the 12mm wrench.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/removing_turbo.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/aad886da4086efb8150937268de0786c.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The turbocharger can now be removed from the engine compartment.<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_removed_manifold.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/aa851cd7910e1c49e084c7b90a9ac865.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4c47acc0c905cc1f767eb63c84232ef2.jpg" border="0" alt="" width="160" height="120" /></a> Close up of compressor side (TO4E-50 trim): <a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_close_compressor_side.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ec1976484ef2ea042a4c9a25584096e2.jpg" border="0" alt="" width="160" height="120" /></a> Close up of turbine side: <a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_close_turbine_side.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a0d1b6488a931a2f036917b90471fe92.jpg" border="0" alt="" width="160" height="120" /><br />
</a>Turbo and turbo oil pipe:<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/turbo_removed_and_oil_pipe.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f9b92588449c6e32dca36175d7be078b.jpg" border="0" alt="" width="160" height="120" /><br />
</a>The exhaust manifold can now be removed (exhaust gasket still in place):<br />
<a href="http://www.lovehorsepower.com/images/TurboRemoval/manifold_removed_gasket.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/284c867bfaf8637d0ea29486d3e69f20.jpg" border="0" alt="" width="160" height="120" /></a> Gasket removed: <a href="http://www.lovehorsepower.com/images/TurboRemoval/manifold_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5d1556ca4e481a6709b6a69b9860e0cb.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/manfold_removed_close_up.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0ecfdfaf59001257f5c1b894831ee2d6.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/manifold.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/8d9b1ca3d9313936040daeae31a20082.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/TurboRemoval/manfold_removed_closeup2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1ee7013009a6b053593cf30e6276e53f.jpg" border="0" alt="" width="160" height="120" /></a></p>
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		<title>20V Blacktop Swap &#8211; Miscellaneous Info</title>
		<link>http://www.midshiprunabout.org/mk1/20v-blacktop-swap-miscellaneous-info/</link>
		<comments>http://www.midshiprunabout.org/mk1/20v-blacktop-swap-miscellaneous-info/#comments</comments>
		<pubDate>Thu, 28 Aug 2003 18:00:36 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[20V 4A-GE]]></category>
		<category><![CDATA[Engines]]></category>
		<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[adjust]]></category>
		<category><![CDATA[air filter]]></category>
		<category><![CDATA[belt]]></category>
		<category><![CDATA[CEL]]></category>
		<category><![CDATA[Clutch]]></category>
		<category><![CDATA[ECU]]></category>
		<category><![CDATA[engine]]></category>
		<category><![CDATA[filter]]></category>
		<category><![CDATA[pedal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[swap]]></category>
		<category><![CDATA[tensioner]]></category>
		<category><![CDATA[transmission]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=772</guid>
		<description><![CDATA[Here&#8217;s a summary of the smaller things that you will need to do that aren&#8217;t big enough for their own page: Fuel line Contrary to what was previously on this page, the 16V fuel line fits fine with no modifications (both SC &#38; NA). I mistakenly used the 20V line which needed to be extended. [...]]]></description>
			<content:encoded><![CDATA[<p>Here&#8217;s a summary of the smaller things that you will need to do that aren&#8217;t big enough for their own page:</p>
<p><span style="font-size: small;"><strong>Fuel line</strong></span></p>
<p>Contrary to what was previously on this page, the 16V fuel line fits fine with no modifications (both SC &amp; NA). I mistakenly used the 20V line which needed to be extended. Sorry about that.<a href="javascript:newwin('../day24/fuel1.jpg')"><br />
</a> </p>
<p><span style="font-size: small;"><strong>Throttle Cable</strong></span></p>
<p>For neatness this needs to be extended a couple feet. If not, the cable will have to drape over the engine. I combined the MR2 cable with that of the 20V.</p>
<p>Here&#8217;s the steps and pics:</p>
<p>- Cut the ends of each off with pliers, being careful not to cut the actual cable.<br />
- Strip the protective rubber about 1/2&#8243; back exposing the metal structure of the cable housing.<br />
- Measure/mark the length of cable needed for when your foot is off the gas pedal &amp; when it&#8217;s all the way down. Do the same on the extension end, this time using the actual throttle assembly. If you need to expose more cable on either side, cut off more of the housing.<br />
- Once you get the lengths right, using a 1/16&#8243; ferrule (you may need to enlarge the hole to allow both cables to fit), crimp the 2 cables together.<br />
- Using some 5/16&#8243; ID fuel hose I had sitting around, that acts as a protective covering for the exposed cable/ferrule. Make sure the crimped ferrule can slide through it easy enough.<br />
- Use some heat shrink tubing on the ends of the joint to keep moisture &amp; dirt out.<br />
- Then some clamps to hold the hose onto the metal housing</p>
<p><a href="javascript:newwin('../day24/throttle1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4725be1d462eeea661b890aa1521812f.jpg" border="0" alt="" width="200" height="73" /></a> <a href="javascript:newwin('../day24/throttle2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/df3776f51532ed7b6834ffe83bb0086c.jpg" border="0" alt="" width="200" height="301" /></a> <a href="javascript:newwin('../day24/throttle3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c26bfc074980ac7d067232997ce52bd8.jpg" border="0" alt="" width="200" height="132" /></a></p>
<p><span style="font-size: small;"><strong>Alternator Bracket</strong></span></p>
<p>The 20V has a huge alternator bracket with an idler pulley so that the belt doesn&#8217;t interfere with the chassis. You can reuse the 16V NA bracket on the 20V block. However, on the blacktop you will need to cut away some material to clear the hydraulic timing belt tensioner.</p>
<p>Before:</p>
<p><a href="javascript:newwin('../day14/altbracket2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/faa75351b2f0fd29bfcc3b8ccc525c9c.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p>After:</p>
<p><a href="javascript:newwin('../day14/altbracketmod1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ef49263f6fef341dc13b64fa11d40082.jpg" border="0" alt="" width="200" height="264" /></a> <a href="javascript:newwin('../day14/altbracketmod2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/26e6b0a82852e02def731ee58a99ae63.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p><strong><span style="font-size: small;">Oil Pressure Sender</span></strong></p>
<p>Use the 16V oil pressure sensor, as the Trueno/Levins just have an idiot light instead of a gauge.</p>
<p><span style="font-size: small;"><strong>Clutch/Flywheel Info</strong></span></p>
<p>If you are replacing the clutch or flywheel make sure to get one for a C series transmission. The MR2 SC clutch/flywheel will NOT fit. The shaft on the C series trannies are smaller than the E series.</p>
<p><strong><span style="font-size: small;">Mounting (ECU, MAP, Ignitor/Coil, Coolant Overflow Bottle)</span></strong></p>
<p>Fab mounts for the ECU in the new driver&#8217;s side location.</p>
<p>For the blacktop, mount the MAP sensor at a convenient location near the #1 intake side. I used an existing welded nut on the chassis.</p>
<p>Same goes with the ignitor &amp; coil, but this time near #4. I chose a place on the strut tower. 2 bolts fit perfectly in existing holes. A third hole was drilled and tapped.</p>
<p>Since the filler neck was on the opposite side of the engine bay, I had to use a different location for the overflow bottle. I decided to use a different bottle altogether since mine was weathered pretty bad. Just using a cheapo from Autozone at the moment.</p>
<p><strong><span style="font-size: small;">Vaccuum Lines</span></strong></p>
<p>The 20V has 2 brake booster lines coming off the TBs. Luckily both are on the #1 side of the engine, making it easy to route the hose to the MR2&#8242;s single booster line. I used the one that comes of the #4 TB, since the #1&#8242;s fitting can be easily removed and a bolt inserted to block it off.</p>
<p>You can also block of a line that was used for the power steering system in the Levin/Trueno. Near the fuel rail by #4 cylinder there should be 3 hoses, each of distinct sizes. It&#8217;s the middle sized hose that can be capped.</p>
<p><span style="font-size: small;"><strong>Crank Pulley</strong></span></p>
<p>If you have the Silvertop, make sure to use the 16V crank pulley and timing marker. This helps with adjusting the ignition timing. On the blacktop, you can&#8217;t use the 16V timing marker since it uses a different tensioner. However, make sure to paint marks along the crank pulley, on all edges. The belt gets in the way of the inside mark making it hard to see.</p>
<p><strong><span style="font-size: small;">Decklid Latch</span></strong></p>
<p>The intake box on the Blacktop interferes with the engine latch. So grind away at the latch until there&#8217;s room. I had to bend one side of the latch slightly, as well as remove the bottom bolt hole to make room for the coupling to the air filter.</p>
<p><span style="font-size: small;"><strong>Axles &amp; Tranny Stiffener</strong></span></p>
<p>The Levins and Truenos have equal length drive shafts. Unfortunately these shafts are an inch or 2 too long to use in the MR2. The MR2 axles fit fine of course, so it may be possible to Frankenstein something together. The cup of the 20V extension shaft on the passenger side is too large for the MR2&#8242;s tulip joints. You may be able to remove the tulip joint from the 20V axle and refit it to the MR2&#8242;s axle. I&#8217;m not sure. This is something I may try later, as I have a spare driver&#8217;s side MR2 axle.</p>
<p>Also, if you use the MR2 axles, the 20V tranny stiffener will not fit. You can either grind away some of the material to make the stiffener fit, or just run without it. To make it fit I believe you need to chop 1 corner off, using one less bolt holding it in place.</p>
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		<title>Removal of MR2 Fuel Injectors</title>
		<link>http://www.midshiprunabout.org/mk2/removal-of-mr2-fuel-injectors/</link>
		<comments>http://www.midshiprunabout.org/mk2/removal-of-mr2-fuel-injectors/#comments</comments>
		<pubDate>Sat, 09 Aug 2003 17:09:48 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[3S-GTE]]></category>
		<category><![CDATA[Lovehorsepower.com]]></category>
		<category><![CDATA[MK2]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[fuel injector]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=1183</guid>
		<description><![CDATA[Notes and pictures on how to removal the fuel injectors from a 1991 MR2 Turbo.  Start off my removing the X strut tower brace and intake tube connecting the intercooler with the throttle body.  Shown is the intake pipe prior to removal (Greddy IC).  Clicks pictures to enlarge. Intake pipe removed. Remove the throttle body [...]]]></description>
			<content:encoded><![CDATA[<p align="left">Notes and pictures on how to removal the fuel injectors from a 1991 MR2 Turbo.  Start off my removing the X strut tower brace and intake tube connecting the intercooler with the throttle body.  Shown is the intake pipe prior to removal (Greddy IC).  Clicks pictures to enlarge.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/intake_pipe.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a0f44102befed72bb7c36b2803a22608.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Intake pipe removed.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/intake_pipe_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4d5f29a35a879acf57086403945e640a.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Remove the throttle body pipe (Four 12mm bolts) and throttle body stay.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/throttle_pipe_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e39a8ef718a5e4151bfb7ffdea643a4e.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/throttle_pipe_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9f5e7c0f0e70b5d63bed5c158d2df837.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Remove the throttle body air tube and disconnect the throttle position sensor.  The air tube is located on the bottom side of the throttle body and is a fairly large diameter air tube.  It can be seen in the following picture under the throttle body.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/throttle_body_air_tube_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/49c3a48e1020816efb564f548d946893.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Remove the throttle cable &#8211; two 12mm bolts.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/throttle_cable_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/281c1cf5cef2238b7ac655c875ff71ba.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The cold start injector pipe needs to be removed by unbolting the two union bolts.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/cold_start_pipe.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c546bfce00a02ee77e9b2aa742547ff4.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Cold start fuel pipe removed.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/cold_start_pipe_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/21a17b2a0a272e6f71dbf9ac1dbe76c9.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The EGR components need to be removed next.  There are two Allen bolts to be removed.  These can be tight, so I used a set of pliers to twist the Allen wrench.  Then remove the other bolts holding on the EGR components.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/egr1.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f09f34d6001e87698b87c709f17687ef.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">EGR removed.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/egr_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ce7d58973519e1ed357bdcc1214602af.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/egr_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/79ff650d7138209dde6d77451f815713.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">The fuel union bolt is removed next.  This one has been tapped for fuel pressure readings.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/union_bolt.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f5ae2094d1e2a8879c20bd45e1675484.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/union_bolt2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d81124ce5c31e423b9a036ab46b33148.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Injectors can now be unplugged.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/injectors_unplugged.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a3f150ee07cc34ede69d02b799ad12ac.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/injectors_unplugged2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5a038b959b9cee600b3a854ae2d119e3.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">After un-bolting the two bolts that hold the wiring harness cover, the fuel rail can be coaxed out.  The wiring harness must be pulled up some before the rail will come out.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/fuel_rail_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7fd4206305f3d8d5b1a3a683c288997f.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/fuel_rail_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7cb527f8ad87c51f1b211426e22fde05.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Supra Twin Turbo fuel injectors.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/supra_injectors.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/17fecb37586e471aae13cffad34dd641.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">Fuel rail without injectors.<br />
<a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/injectors_removed.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/da1aca070d4a1bfbe7bb3a869892dec7.jpg" border="0" alt="" width="160" height="120" /></a> <a href="http://www.lovehorsepower.com/images/MR2_RemovalOfInjectors/injectors_removed2.jpg"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6ea26b23398f7e5f7fd5582a6baba918.jpg" border="0" alt="" width="160" height="120" /></a></p>
<p align="left">When <strong>installing</strong> different injectors, it&#8217;s a good idea to replace the various gaskets.  There are 4 small insulators that go on top of each injectors and the same insulator goes on the bottom of each injector on the inside of the rail.  There are 4 large insulators that go on the bottom of each injector port on the outside of the fuel rail.  The O-rings on each injector (there are two &#8211; a large and small) should also be replaced.  When installing the rail, be sure that the large rubber insulators that go on the fuel rail do not fall off!  This has happened to be numerous times &#8211; just check the garage floor before bolting the rail down.  It is not necessary, but probably a good idea to replace the copper crush washers on the union bolts for the cold start pipe and the fuel rail.  Leaks in the fuel system are generally a very bad thing!  There are also the two metal gaskets for the throttle body and the short throttle body inlet pipe that may or may not need to be replaced.  If you start the car and it barely runs, or runs very poorly, chances are the rail did not seal.</p>
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		<title>Front Bushing Install</title>
		<link>http://www.midshiprunabout.org/mk1/front-bushing-install/</link>
		<comments>http://www.midshiprunabout.org/mk1/front-bushing-install/#comments</comments>
		<pubDate>Sun, 13 Jul 2003 18:00:44 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[bushings]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>
		<category><![CDATA[TRD]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=688</guid>
		<description><![CDATA[Going to be replacing all the bushings with the TRD bushing set, while I have my suspension apart. I&#8217;ll try to show the removal of the various suspension pieces. Things may be a little different if you are not replacing everything like I am though. *Procedure of pressing the bushings out with just 2/3 jaw [...]]]></description>
			<content:encoded><![CDATA[<p align="left">Going to be replacing all the bushings with the TRD bushing set, while I have my suspension apart. I&#8217;ll try to show the removal of the various suspension pieces. Things may be a little different if you are not replacing everything like I am though.</p>
<p align="left"><strong>*Procedure of pressing the bushings out with just 2/3 jaw pullers courtesy of Dale Conner &amp; Bill Merton from MR2 forum </strong></p>
<p align="left"><em>Front Removal</em></p>
<p align="left">1) Here&#8217;s a picture of what all is replaced in the TRD bushing set: strut top (green), control arm (purple), &amp; strut arm (red). So, you need to remove the strut assembly &amp; the two arms. The steering knuckle will be close to being removed, as it will still be attached to the tie rod end. If you don&#8217;t believe you need to replace the tie rod end bushing (which you need to purchase the entire end, not just bushing if you do), you can skip that step.</p>
<p align="left"><a href="javascript:newwin('../../../bushings/frontsuspension.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/b7bc3f5995ccf8699102a1e6aa89f6cc.jpg" border="0" alt="" width="200" height="248" /></a></p>
<p align="left">2) I would suggest loosening the strut bar nut first. If you have a deep well 22mm socket, you can use a ratchet. Else, a 22mm wrench will work.</p>
<p align="left"><a href="javascript:newwin('../../7strutarm1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9ebfc90e77d29c5f1cc8b3c0b32823dd.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">3) Loosen lugnuts. Raise and support the front of the vehicle. Remove wheels.</p>
<p align="left">4) Just for sake of simplicity for this page, I&#8217;m going to point you to other pages where I go over the strut assembly and steering knuckle removal. If you do not want to replace the strut top, or have the Fensport bushing set (which does not include a new strut top) then you do not need to remove the strut assembly.</p>
<ul>
<li><a href="http://www.padandwheels.com/mr2/struts/fronts/struts.html">Strut Assembly Removal</a></li>
<li><a href="http://www.padandwheels.com/mr2/suspensionbits/hub.html">Steering Knuckle Removal</a></li>
</ul>
<p>5) Measure the length of &#8216;A&#8217; below, so that caster can be put back to the correct spot.</p>
<p><a href="javascript:newwin('../../measure.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c02dd48744792a43619b3ebe4b2587bd.jpg" border="0" alt="" width="200" height="135" /></a></p>
<p>6) Remove the strut arm from the control arm, by removing the two 17mm nuts.</p>
<p><a href="javascript:newwin('../../7strutarm2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/45751cbab73b15bc61c0c87abb63599d.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>5) Remove the bolt that you loosened in step 1. You should then be able to remove the strut bar. Here&#8217;s some pics of it.</p>
<p><a href="javascript:newwin('../../strutbar1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a5ec6e26e7bc307a7139a1a72863a21f.jpg" border="0" alt="" width="200" height="53" /></a></p>
<p>And disassembled. The 2 bushings (green arrows) are to be replaced by TRD ones. And the collar (red arrow) needs to be replaced with a new one from the dealer.</p>
<p><a href="javascript:newwin('../../strutbar2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c9f56b0b50fec847119d9191018b1bb8.jpg" border="0" alt="" width="200" height="41" /></a></p>
<p> </p>
<p>6) If you aren&#8217;t replacing the ball joints, skip this step.</p>
<blockquote><p>I&#8217;d suggest removing the ball joint from the control arm at this point. Unless you have a vice handy. I placed a jack under the control arm to raise it up and then use a 2 or 3 jaw puller to pop it out. Beware, the ball joint will literally POP up once it is loose. So keep away from inside the fenderwell while you tighten the puller. (The below picture was taken before I actually got the ball joint off. That&#8217;s what the strut arm is there, and the jack isn&#8217;t.)</p>
<p><a href="javascript:newwin('../../6balljointpuller.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/614e24dd12279e1fd44b2dfa47eb319a.jpg" border="0" alt="" width="200" height="156" /></a></p>
<p> </p></blockquote>
<p>7) Remove the 17mm bolt holding the control arm to the frame of the car.</p>
<p><a href="javascript:newwin('../../8controlarm2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d26584a927811701eb7f963e3cd55958.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p>Here&#8217;s a pic of the control arm out of the car (ball joint is still in place):</p>
<p><a href="javascript:newwin('../../controlarm.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f27fe3b1c02257d7c322fbd0b36a6153.jpg" border="0" alt="" width="200" height="302" /></a></p>
<p> </p>
<p> <img src='http://www.midshiprunabout.org/wp-includes/images/smilies/icon_cool.gif' alt='8)' class='wp-smiley' /> If you&#8217;ve noticed, there&#8217;s only one bushing per side that needs pressed out in the front, the one in the end of the control arm. Here&#8217;s some pics of how I went about doing it. The &#8220;pusher&#8221; part of the puller I used was big enough that it didn&#8217;t fit inside the bushing, so I was able to just use it, instead of using a stack of washers. It would probably be easier to put the control arm in a vice, but since I didn&#8217;t have one at the time, I tried it without. It was surprisingly easy, just have the cheater bar handy. Here&#8217;s some pics of the different steps as I was pushing it out with a 2 jaw puller.</p>
<p><a href="javascript:newwin('../../cabushing1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/8a83accaa5f99d4dfb4abf4ce982effb.jpg" border="0" alt="" width="200" height="133" /></a> <a href="javascript:newwin('../../cabushing2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/2187a6128f150a299964a7868e0aa270.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p><a href="javascript:newwin('../../cabushing3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e88b37a5a0b13b09162543013ae0f5fe.jpg" border="0" alt="" width="200" height="133" /></a> <a href="javascript:newwin('../../cabushing4.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6c0d83ab1b807d833daac1fb3b850dcb.jpg" border="0" alt="" width="200" height="134" /></a></p>
<p><em>Front Control Arm Bushing Install</em></p>
<p>1) Here&#8217;s a pic of the new TRD bushing beside the control arm. Notice the tapered end, you will need to press that end in first.</p>
<p><a href="javascript:newwin('0newbushing.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ab7c2f7b6a5274a8f0c1134270dffb18.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>2) Lube up the bushing with some grease. I just used some white lithium grease, since that&#8217;s all I had around. Silicone grease would probably work better.</p>
<p><a href="javascript:newwin('1grease.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/fe10aa697b17615a1536a27e49ecacee.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>3) Carefully position the 2 parts in a table vise and start squeezing the bushing in. Make sure everything is going in straight. It may help to have an extra pair of hands to help hold and turn the vise handle.</p>
<p><a href="javascript:newwin('2vise1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4a66f5745ed6ceda9754e877659d3a64.jpg" border="0" alt="" width="200" height="133" /></a> <a href="javascript:newwin('2vise2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e96986dfc8de1ec30df1525d7e784d32.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>4) After a while, you will not be able to push the bushing in any further without damaging your vise. Trust me on this&#8230;my brand new vise now has a slightly bent handle.</p>
<p><a href="javascript:newwin('3visedone.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/19ed91aee6c1bfda0a39196a6d604cad.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>5) Quickly reposition the control arm in the vise, and place your 2 jaw puller over the bushing. Use a few fender washers to disperse the force so that the entire bushing is pushed in instead of just the middle piece. Don&#8217;t just use one or 2 washers either, use at least 3 or 4. The bushing laughs at using just 2 washers, as they will just bend and be destroyed like crazy. Use some tape or super glue to hold the washers in place while you position the puller. An assistant is nice here as well.</p>
<p><a href="javascript:newwin('4puller1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7995fc99599f1f3d0f6535ac08261f63.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p><a href="javascript:newwin('4puller2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/749f8d096286ac987b6a84c3d11e1dde.jpg" border="0" alt="" width="200" height="302" /></a></p>
<p> </p>
<p>6) Eventually after applying much force onto the bushing (you may need to use a cheater bar to turn the puller), You can see the other end popping out and locking the bushing into place.</p>
<p><a href="javascript:newwin('5pullerdone1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/2dc64cd694e2cf6c6e04e42121390795.jpg" border="0" alt="" width="200" height="301" /></a><a href="javascript:newwin('5pullerdone2.jpg')"> <img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ebd791d77dd447fc12db466baebb016a.jpg" border="0" alt="" width="200" height="301" /></a></p>
<p> </p>
<p>7) Remove the puller once you are certain the bushing is all the way in. And clean up the excess grease.</p>
<p><a href="javascript:newwin('6bushingin1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0e8c47eebc5fcbf7a344d157b3f473d2.jpg" border="0" alt="" width="200" height="133" /></a> <a href="javascript:newwin('6bushingin2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/cec3d7cd384a0e5496928037a602705f.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p> <img src='http://www.midshiprunabout.org/wp-includes/images/smilies/icon_cool.gif' alt='8)' class='wp-smiley' /> Install the control arm back onto the car. Do not tighten al the way to spec yet.</p>
<p><a href="javascript:newwin('controlrodin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/bc0293e5dbeab8f30e52e55fba3152ae.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p><em>Front Stut Bar Bushing Install</em></p>
<p>This should be fairly straightforward.</p>
<p>1) Here&#8217;s the pieces how they go back onto the strut bar:</p>
<p><a href="javascript:newwin('strutbar.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/254f5f711b08f77e16af0f3b085aabb0.jpg" border="0" alt="" width="200" height="47" /></a></p>
<p> </p>
<p>2) Place one of the nuts to the original position. Remember the measurement you took back in step 1? Then place one of the retainers, a new collar, and a bushing. Notice the smaller end of the bushing is toward the end of the strut bar.</p>
<p><a href="javascript:newwin('strutbar2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a72a4cc2f1f6aa0b392d2a4c9ff3d39e.jpg" border="0" alt="" width="200" height="74" /></a></p>
<p> </p>
<p>3) Then place the strut bar back on the car. Add the other bushing, retainer, lock washer and the other nut. Start tightening the nut down. Insert the 2 bolts at the end of the strut bar to the control arm, once the nut pulls the bushings tight enough.</p>
<p><a href="javascript:newwin('strutbar3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/72eeba1dc21eced2d176ca1247a43990.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>4) Here&#8217;s the strut bar and control arm in place with their new bushings.</p>
<p><a href="javascript:newwin('sbcrin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/47260a752dc8c110b8f43e6cbdca55a1.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>5) Reinstall the various other pieces you removed to get to the suspension arms.</p>
<p>6) Before attaching the wheel, jack up the corner of the car via the control arm. Raise it up until it gets into it&#8217;s normal position, as if the car was lowered onto the ground. Tighten the suspension arms&#8217; nuts and bolts to spec. This is so the bushings aren&#8217;t twisted when the wheels are installed &amp; the car is lowered to the ground.</p>
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		<title>Ball Joint Replacement</title>
		<link>http://www.midshiprunabout.org/mk1/ball-joint-replacement/</link>
		<comments>http://www.midshiprunabout.org/mk1/ball-joint-replacement/#comments</comments>
		<pubDate>Sat, 12 Jul 2003 18:00:05 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[guide]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=685</guid>
		<description><![CDATA[Here&#8217;s a step-by-step guide to replacing the lower ball joints. The pictures below are with the strut assembly removed as I am doing the entire suspension work at the same time &#38; had just removed the struts. Tools Needed: Various sockets, wrenches, &#38; ratchet 2 or 3 jaw puller Jack &#38; stands   1) Loosen [...]]]></description>
			<content:encoded><![CDATA[<p align="left">Here&#8217;s a step-by-step guide to replacing the lower ball joints. The pictures below are with the strut assembly removed as I am doing the entire suspension work at the same time &amp; had just removed the struts.</p>
<p align="left">Tools Needed:</p>
<ul>
<li>Various sockets, wrenches, &amp; ratchet</li>
<li>2 or 3 jaw puller</li>
<li>Jack &amp; stands</li>
</ul>
<p> </p>
<p>1) Loosen wheel lugnuts. Raise and support front of car, and remove wheel.</p>
<p><a href="javascript:newwin('0rotor.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/197b188b931c265ba0bf43c744d4dd0d.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>2) There&#8217;s 2 different ways you could go about doing this. First, here&#8217;s probably the &#8216;proper&#8217; way. I&#8217;ll let you decide which will be easier.</p>
<p>1-3) Remove the two 14mm bolts that hold the knuckle to the ball joint. Ignore the strut assembly, rotor, and caliper being off&#8230;</p>
<p><a href="javascript:newwin('4balljoint2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/31a7efcde1b78a129a6d64fb71d08ddb.jpg" border="0" alt="" width="200" height="166" /></a> <a href="javascript:newwin('4balljoint3a.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6aac2100a1b8e8c8a6e7c0df338af074.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p>1-4) Remove the 2 nuts holding the strut arm to the control arm. The control arm should then fall down toward the ground. If not, you may need to loosen the bolt holding the arm to the chassis.</p>
<p><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/45751cbab73b15bc61c0c87abb63599d.jpg" alt="" width="200" height="133" /></p>
<p>1-5) Remove the cotter pin &amp; castle nut from the ball joint, and attach your 2 or 3 jaw puller. Beware, the ball joint will literally POP out of the control arm, so keep away from inside the fenderwell while you tighten it down.</p>
<p><a href="javascript:newwin('6balljointpuller.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/614e24dd12279e1fd44b2dfa47eb319a.jpg" border="0" alt="" width="200" height="156" /></a></p>
<p> </p>
<p>Now here&#8217;s another way&#8230;i haven&#8217;t tried it this way so it may not work as well as I envision it to.</p>
<p>2-3) Remove the 2 nuts holding the strut arm to the control arm.</p>
<p><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/45751cbab73b15bc61c0c87abb63599d.jpg" alt="" width="200" height="133" /></p>
<p>2-4) Remove the cotter pin and castle nut from the ball joint. Hit the top of the control arm near the hub with a mallet. Give it a good whack. That should loosen the ball joint from the control arm. This way you don&#8217;t have to bother with a 2 or 3 jaw puller. The control arm should fall to the ground once it is loose.</p>
<p>2-5) Remove the ball joint from the hub by removing the two 14mm bolts.</p>
<p><a href="javascript:newwin('4balljoint2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/31a7efcde1b78a129a6d64fb71d08ddb.jpg" border="0" alt="" width="200" height="166" /></a> <a href="javascript:newwin('4balljoint3a.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6aac2100a1b8e8c8a6e7c0df338af074.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>6) Here&#8217;s the new ball joint:</p>
<p><a href="javascript:newwin('newbj.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0aaff5d86a3f922185972f6603e2b413.jpg" border="0" alt="" width="200" height="127" /></a></p>
<p> </p>
<p>11) Bolt it onto the steering knuckle.</p>
<p><a href="javascript:newwin('newbj1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/74c5d7aaffb2fd70ecf2ab82f0ffef9d.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>12) Now, place the steering knuckle onto the control arm and tighten down the castle nut. Insert new cotter pin.</p>
<p><a href="javascript:newwin('newbj2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/63266524b1c0ff43e1ffbbc9f3366b06.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>13) The rest of the assembly is opposite the removal.</p>
]]></content:encoded>
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		<item>
		<title>Steering Knuckle Removal</title>
		<link>http://www.midshiprunabout.org/mk1/steering-knuckle-removal/</link>
		<comments>http://www.midshiprunabout.org/mk1/steering-knuckle-removal/#comments</comments>
		<pubDate>Tue, 06 May 2003 18:00:56 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[guide]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[steering knuckle]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=696</guid>
		<description><![CDATA[Here&#8217;s a step-by-step guide to removing the steering knuckle, in case you need to replace your wheel bearings. The pictures below are with the strut assembly removed as I am doing the entire suspension work at the same time &#38; had just removed the struts. Tools Needed: Various sockets, wrenches, &#38; ratchet 2 or 3 [...]]]></description>
			<content:encoded><![CDATA[<p align="left">Here&#8217;s a step-by-step guide to removing the steering knuckle, in case you need to replace your wheel bearings. The pictures below are with the strut assembly removed as I am doing the entire suspension work at the same time &amp; had just removed the struts.</p>
<p align="left">Tools Needed:</p>
<ul>
<li>Various sockets, wrenches, &amp; ratchet</li>
<li>2 or 3 jaw puller (don&#8217;t get them from Harbor Freight! they stink!)</li>
<li>Jack &amp; stands</li>
</ul>
<p> </p>
<p>1) Loosen wheel lugnuts. Raise and support front of car, and remove wheel.</p>
<p><a href="javascript:newwin('0rotor.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/197b188b931c265ba0bf43c744d4dd0d.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>2) Remove caliper by the two 12mm bolts. Then remove the two 17mm bolts that attach the mounting brackets to the steering knuckle, indicated below. Remove the mounting bracket and brake pads from the rotor.</p>
<p><a href="javascript:newwin('1caliperoff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c6f1305bbdca910a1e3da3ef4b35f148.jpg" border="0" alt="" width="200" height="194" /></a></p>
<p> </p>
<p>3) The rotor should then pull off.</p>
<p><a href="javascript:newwin('2rotoroff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/3d319129426b147b027b6c5d452edf79.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>4) Hang the caliper from the strut assembly, or if you removed the assembly like me, then hang it from the strut top bolt holes in the frame. This is so you don&#8217;t put any tension on the brake lines.</p>
<p><a href="javascript:newwin('3hangcaliper.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/f978d698d275412844f104738dc62981.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>5) At this point, I would remove the tie rod end from the steering knuckle. If you have the strut assembly in place, the hub is solidly in place. (I probably should have done this before removing the strut assembly to make it alot easier&#8230;) Anyway, remove the cotter pin and 17mm bolt from the bottom of the tie rod end. Attach a 2 or 3 jaw puller to pop the tie rod out of the steering knuckle.</p>
<p><a href="javascript:newwin('5tierodpuller.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4e81e235c58aa825ad2ab21009ab7982.jpg" border="0" alt="" width="200" height="195" /></a></p>
<p> </p>
<p>6) Scribe a mark in the strut bracket to indicate the current camber position. (Ignore the loose bolt and the brake line&#8230;)</p>
<p><a href="javascript:newwin('../struts/fronts/4hub3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0957666c39a092a70447b4102ade1137.jpg" border="0" alt="" width="200" height="99" /></a></p>
<p> </p>
<p>7) Remove the steeering knuckle from the strut assembly, two 17mm nuts/bults. (Ignore the brake line.)</p>
<p><a href="javascript:newwin('../struts/fronts/4hub1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/1d59450f8a557edde7139f3b2f37b07f.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p> <img src='http://www.midshiprunabout.org/wp-includes/images/smilies/icon_cool.gif' alt='8)' class='wp-smiley' /> Remove the two 14mm bolts that hold the knuckle to the ball joint.</p>
<p><a href="javascript:newwin('4balljoint2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/31a7efcde1b78a129a6d64fb71d08ddb.jpg" border="0" alt="" width="200" height="166" /></a> <a href="javascript:newwin('4balljoint3a.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6aac2100a1b8e8c8a6e7c0df338af074.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p>The steering knuckle should then fall in your lap and you are ready to take it to a machine shop to have them press out/in the wheel bearings. Or if you have the proper tools, you can do it yourself. I just took it to a shop, $25 for one hub.</p>
<p><a href="javascript:newwin('knuckle.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/192019aff69a9eda8ccceb1d9bc8a1b9.jpg" border="0" alt="" width="200" height="218" /></a><a href="javascript:newwin('knuckle2.jpg')"> <img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/b36c877121cd3eb25c090cfced6e1c64.jpg" border="0" alt="" width="200" height="203" /></a></p>
<p> </p>
<p>9) Now would be a good time to change the ball joint and tie rod end if you haven&#8217;t in a long while.</p>
<p>10) The installation is opposite the removal.</p>
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		<title>Rear Bushings Install</title>
		<link>http://www.midshiprunabout.org/mk1/rear-bushings-install/</link>
		<comments>http://www.midshiprunabout.org/mk1/rear-bushings-install/#comments</comments>
		<pubDate>Tue, 06 May 2003 18:00:08 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[Suspension & Bracing]]></category>
		<category><![CDATA[bushings]]></category>
		<category><![CDATA[install]]></category>
		<category><![CDATA[removal]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>
		<category><![CDATA[TRD]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=693</guid>
		<description><![CDATA[The pics below are during my full suspension/brake system rebuild. So they will be a little different than yours since I was removing everything. *Procedure of pressing the bushings out with just 2/3 jaw pullers courtesy of Dale Conner &#38; Bill Merton from MR2 forum   Rear Removal 1) Here&#8217;s a pic of what the [...]]]></description>
			<content:encoded><![CDATA[<p align="left">The pics below are during my full suspension/brake system rebuild. So they will be a little different than yours since I was removing everything.</p>
<p align="left"><strong>*Procedure of pressing the bushings out with just 2/3 jaw pullers courtesy of Dale Conner &amp; Bill Merton from MR2 forum </strong></p>
<p align="left"> </p>
<p align="left"><em>Rear Removal</em></p>
<p align="left">1) Here&#8217;s a pic of what the rear TRD bushing set replaces: strut top (blue), control arm (purple), &amp; strut arm (yellow &amp; red). So you will need to remove the strut assembly and the 2 arms. The inner tie rod bushing is not included with the kit. The only way to order it from Toyota is to purchase the actual inner tie rod which runs about $50 from the dealer. The axle carrier does not need to be removed completely. It will still be attached to the drive shaft and the tie rod end.</p>
<p align="left"><a href="javascript:newwin('../../../bushings/rearsuspension.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d4ac575ce1af7d268e3075f8ba1c509b.jpg" border="0" alt="" width="200" height="274" /></a></p>
<p align="left"> </p>
<p align="left">2) Loosen lug nuts, raise &amp; support the rear of vehicle with jack stands. Remove wheel. (Ignore that the caliper is removed below.)</p>
<p align="left"><a href="javascript:newwin('../../rear/caliperoff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/8dbd59727f66e83c25bc448c90a94f91.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">3) If you have new TRD strut tops you need to remove the strut assemblies. If you have the set from Fensport, or don&#8217;t feel like removing the strut assemblies, goto step 4.</p>
<blockquote><p>To save space on this page, goto my <a href="http://www.padandwheels.com/mr2/struts/rears/rears.html">Rear Strut Removal page</a>.</p></blockquote>
<p align="left">4) Remove the two 14mm bolts holding the bottom of the axle carrier to the lower control arm&#8217;s balljoint. Then remove the control arm from the body of the car, 17mm bolt.</p>
<p align="left"><a href="javascript:newwin('controlarmin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5b5e1d5317fe5c0bf7e142d762e7d2b2.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">5) Remove the 17mm bolt and nut holding the strut arm to the body of the car. May need to remove one bolt of the underbody cover to get to the bolt.</p>
<p align="left"><a href="javascript:newwin('strutarmin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/397ce19d6112a4efd507eb4e4747342a.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">6) The strut arm and control arm should come out of the car together. You can then separate them by removing the 22mm bolt &amp; the various other parts holding them together. (The below pic is with the ball joint removed)</p>
<p align="left"><a href="javascript:newwin('strutcontrol2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/225bf278d69f8a1d5dfbfa760c0f4634.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">7) Here&#8217;s pics of the removal of the control arm &amp; strut rod bushings.</p>
<p align="left"><a href="javascript:newwin('../front/controlarm.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/abeef29b5647d4004a383efd2583cb8e.jpg" border="0" alt="" width="200" height="239" /></a> <a href="javascript:newwin('../front/strutarm.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4f23cb9231db028b9f5a20670afb152e.jpg" border="0" alt="" width="200" height="186" /></a></p>
<p><em>Rear Strut Arm Bushing Install</em></p>
<p>1) Take the new bushing and lube it up with some grease. Notice that one end of the bushing is tapered, while the other is not.</p>
<p>2) Position the bushing and strut arm in the vice and start pushing the bushing in. Make sure everything goes straight.</p>
<p><a href="javascript:newwin('bbushing2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c8ad77467d28a3ae766fb11804e3ab48.jpg" border="0" alt="" width="200" height="301" /></a></p>
<p> </p>
<p>This is about as far as you can get with the vice.</p>
<p><a href="javascript:newwin('bbushing3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7a86ea71ae04c09fd671be350d37d19f.jpg" border="0" alt="" width="200" height="152" /></a></p>
<p> </p>
<p>3) Now, reposition the strut arm in your vice, and attach your 2/3 jaw puller.</p>
<p><a href="javascript:newwin('bbushing3a.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e21853af2c78083c62097469589ae68c.jpg" border="0" alt="" width="200" height="172" /></a></p>
<p> </p>
<p>Use a few fender washers to apply the pressure evenly across the bushing.</p>
<p><a href="javascript:newwin('bbushing4.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/ebbea011f0d0e2abcafd623c498ea8f9.jpg" border="0" alt="" width="200" height="301" /></a></p>
<p> </p>
<p>4) The other end of the bushing should pop out once it&#8217;s completely in place. Wipe off the excess grease.</p>
<p><a href="javascript:newwin('bbushing5.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/9983969637cb88489cb7e55506e56a89.jpg" border="0" alt="" width="200" height="150" /></a><a href="javascript:newwin('bbushing6.jpg')"> <img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/46cf2d801dd2e3f50b41b0862278610a.jpg" border="0" alt="" width="200" height="198" /></a></p>
<p> </p>
<p><em>Rear Control Arm Bushing Install</em></p>
<p>Do the same for the control arm bushing.</p>
<p><a href="javascript:newwin('abushing1a.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/7abee82350a8bbb804483af95baaba89.jpg" border="0" alt="" width="200" height="148" /></a></p>
<p><a href="javascript:newwin('abushing5.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/4b0852d39d63b6d6102ef7faddca5d5a.jpg" border="0" alt="" width="200" height="301" /></a> <a href="javascript:newwin('abushing2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/e6fae0d6f2c78b04878d8a63c8aefbd8.jpg" border="0" alt="" width="200" height="208" /></a><a href="javascript:newwin('abushing3.jpg')"> <img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/67d58565be45395b8328987541619b68.jpg" border="0" alt="" width="200" height="147" /></a></p>
<p> </p>
<p><em>Rear Strut/Control Arm Bushings Install</em></p>
<p>This needs to be done when putting the arms back onto the car.</p>
<p>1) Install the strut arm back onto the car.</p>
<p><a href="javascript:newwin('strutarmin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/397ce19d6112a4efd507eb4e4747342a.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>2) Place the retainer, new collar, new bushing, and then the control arm&#8230;.</p>
<p><a href="javascript:newwin('strutcontrol.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/3a330aaf7ad903441bd8d73dc7a470b0.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>3) Another new bushing, retainer, and the nut. Just tighten the nut by hand.</p>
<p><a href="javascript:newwin('strutcontrol2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/225bf278d69f8a1d5dfbfa760c0f4634.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>4) And then install the control arm onto the body of the car</p>
<p><a href="javascript:newwin('controlarmin.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5b5e1d5317fe5c0bf7e142d762e7d2b2.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>5) Tighten down the strut/control arm bushing 22mm nut.</p>
<p><a href="javascript:newwin('strutcontrol3.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/b4396a283e13bbfd1b322a53bdf4c06f.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p> </p>
<p>6) Reinstall the rest of the parts you removed to get to the suspension arms.</p>
<p>7) Before attaching the wheel, jack up the corner of the car via the control arm. Raise it up until it gets into it&#8217;s normal position, as if the car was lowered onto the ground. Tighten the suspension arms&#8217; nuts and bolts to spec. This is so the bushings aren&#8217;t twisted when the wheels are installed &amp; the car is lowered to the ground.</p>
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		<title>&#8217;87+ Brake Upgrade</title>
		<link>http://www.midshiprunabout.org/mk1/87-brake-upgrade/</link>
		<comments>http://www.midshiprunabout.org/mk1/87-brake-upgrade/#comments</comments>
		<pubDate>Sat, 12 Oct 2002 18:00:38 +0000</pubDate>
		<dc:creator>Darkday</dc:creator>
				<category><![CDATA[Brakes]]></category>
		<category><![CDATA[MK1]]></category>
		<category><![CDATA[MK1 MR2 Write-ups]]></category>
		<category><![CDATA[Sources]]></category>
		<category><![CDATA[conversion]]></category>
		<category><![CDATA[ECU]]></category>
		<category><![CDATA[engine]]></category>
		<category><![CDATA[remove]]></category>
		<category><![CDATA[spring]]></category>
		<category><![CDATA[strut]]></category>
		<category><![CDATA[struts]]></category>
		<category><![CDATA[swap]]></category>

		<guid isPermaLink="false">http://www.midshiprunabout.org/?p=671</guid>
		<description><![CDATA[All you need to upgrade your 85/86 to the bigger 87+ rotors are the rotors themselves and the caliper mounting brackets. If you want to go all out for this upgrade, you will need the dust shields from the 87+. You&#8217;ll need new brake pads too, since you are using new rotors. Any year brake [...]]]></description>
			<content:encoded><![CDATA[<div>
<p align="left">All you need to upgrade your 85/86 to the bigger 87+ rotors are the rotors themselves and the caliper mounting brackets. If you want to go all out for this upgrade, you will need the dust shields from the 87+. You&#8217;ll need new brake pads too, since you are using new rotors. Any year brake pads will work, they are all the same.</p>
<p align="left"><span>*Note: You will probably notice that I mixmatched front and rear pics throughout this writeup. I&#8217;m not trying to confuse you, it&#8217;s just the best pics I had when I threw this page together.</span></p>
<p align="left">1) First off, put the car on jackstands, and remove the wheel.</p>
<p align="left"><a href="javascript:newwin('0wheeloff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0b349ad9ca9a2ce921aa0f4d7403d1b9.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left"> </p>
<p align="left">2) Remove the two 12mm bolts holding the caliper to it&#8217;s mounting bracket. Slide the caliper out of the way and secure it in place so as not to bind or put pressure on the brake line.</p>
<p align="left">3) Remove the two 17mm bolts circled below holding the mounting bracket to the hub. (Ignore the fact that the strut assembly is removed from the hub, you don&#8217;t have to do that.) Remove the mounting bracket and brake pads off from the rotor.</p>
<p align="left"><a href="javascript:newwin('1caliperoff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c6f1305bbdca910a1e3da3ef4b35f148.jpg" border="0" alt="" width="200" height="194" /></a></p>
<p align="left">4) Remove the rotor from the hub. It should just wiggle right off, but it could be stuck on there good. You may need to get two bolts the proper size to push the rotor off the hub.</p>
<p align="left">5) Now you need to decide what to do with the dust shield. There&#8217;s 3 possibilities, each involve snipping off part of the shield:</p>
</div>
<ul>
<li>Replace it with the larger 87+ dust shield</li>
<li>Cut/Trim it to fit the rotor</li>
<li>Remove it completely</li>
</ul>
<div>
<p align="left">Notice one of the options isn&#8217;t to replace the axle carrier (hub) with the 87+. Here&#8217;s why you can&#8217;t courtesy of Bill Merton as he tried going this route:</p>
</div>
<blockquote>
<div>
<p><span>&#8220;Can&#8217;t be done. The tabs where the axle carrier (hub) mount to the struts on 85-86 are too thin to accommodate the wider 87+ hub assy. And larger bolts are used on the 87+, as well. You&#8217;d have to shave down the edge of the hub and drill the holes in the strut to do this. Ah&#8230;so I&#8217;ll just change the entire strut assembly&#8230;solves that problem, right?</span></p>
<p><span>&#8220;Next problem&#8230;the big metal pieces that the strut arm and control arm bolt to (that are bolted on right behind the engine compartment) are different. No problem&#8230;I&#8217;ll just shorten the control arm by using the 87+ arm and thereby account for the fact that the 87+ axle assembly&#8217;s control arm mounting point sticks out farther. Wrong. The angle is too steep and you end up with an amazing amount of rear wheel toe-in. )&#8230;</span></div>
<div>
<p><span>&#8220;Okay&#8230;so those damn mounting blocks need to be swapped, too. Wrong. The mounting holes on the frame are in different spots between 86 and 87+. Only one really lines up and without significant modification, those 87+ blocks simply won&#8217;t bolt on. Even IF you managed to do all this, remember to swap your ball joints while you&#8217;re at it. The mounting bolts for the 87+ are much larger and the 86 ball joints won&#8217;t bolt up. &#8220;</span></div>
</blockquote>
<div>Here&#8217;s how you can use the larger 87+ dust shields, courtesy of Bill again:</div>
<ul>
<li>
<div>Remove the three bolts holding the dust shield on the 87+ assy.</div>
</li>
<li>
<div>Cut a wedge out of the bottom of the dust shield wide enough that you can wiggle it free of the hub assy.</div>
</li>
<li>
<div>Remove the 85-86 hub the same way.</div>
</li>
<li>
<div>Slide the 87+ shield on the 85-86 hub.</div>
</li>
<li>
<div>Note points of interference, especially where the strut arm mounts up.</div>
</li>
<li>
<div>Cut away material or bend as necessary to make the shield work.</div>
</li>
</ul>
<div>
<p align="left">I just went ahead and remove the shields completely. I haven&#8217;t had any problems for the year it&#8217;s been done (2500 miles). Here&#8217;s how you do that:</p>
</div>
<blockquote>
<div>Remove the 3 torx bolts. Just use a 10mm socket to remove them. Here&#8217;s a pic of the bolts, there&#8217;s a third one on the opposite side as well. You have to go at these at an angle, becuase the hub is in the way. It also took a pair of pliers on the nut driver to get these loose.</div>
<div><a href="javascript:newwin('5dustshield1.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/c03b6cb41112b167a810757648ceffeb.jpg" border="0" alt="" width="200" height="133" /></a></div>
<div>Now the dust shield should be loose. However, you can&#8217;t just pull it off over the hub. So you need to cut a slot in it so you can. Do that in the spot below with a dremel or rotozip type tool.</div>
<div><a href="javascript:newwin('6dustshield2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/d0c469c2919d45192214077e68222bcb.jpg" border="0" alt="" width="200" height="133" /></a></div>
<div>I ended up having to cut off more than indicated above, since the metal was not as flexible as I thought. Used the side-cutting bit on a Rotozip. Here&#8217;s the dust shields off, to show you how much you need to cut off.</div>
<div><a href="javascript:newwin('6shieldsoff.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/18a3297f0aaee2fe55c247b2bc804d75.jpg" border="0" alt="" width="200" height="86" /></a></div>
</blockquote>
<div>
<p align="left"> </p>
<p align="left">6) Now that the new bigger rotors will fit (no matter which method you picked above), slide those bad boys on.</p>
<p align="left"><a href="javascript:newwin('7newrotor.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/eab71dee7fc9c91404103500cc220547.jpg" border="0" alt="" width="200" height="160" /></a></p>
<p align="left"> </p>
<p align="left"> <img src='http://www.midshiprunabout.org/wp-includes/images/smilies/icon_cool.gif' alt='8)' class='wp-smiley' /> Here&#8217;s some pics of the mounting brackets. These are the heart of the conversion; what you&#8217;ll have to find from a fellow MR2 owner or the junkyard. I believe the Toyota dealer will only sell these with new calipers, never asked them though.</p>
<p align="left"><em>Front:</em></p>
<p align="left"><a href="javascript:newwin('8frontmb.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5f95f510da818e649f5533fc9df5a0f1.jpg" border="0" alt="" width="200" height="216" /></a> <a href="javascript:newwin('8frontmb2.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/0e6eeead58da5ce9034d1636df9d4ec5.jpg" border="0" alt="" width="200" height="163" /></a></p>
<p align="left"><em>Rear:</em></p>
<p align="left"><a href="javascript:newwin('8rearmb.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/a39e9f50838e1d69034918c31d19848e.jpg" border="0" alt="" width="200" height="488" /></a></p>
<p align="left"> </p>
<p align="left"> <img src='http://www.midshiprunabout.org/wp-includes/images/smilies/icon_cool.gif' alt='8)' class='wp-smiley' /> Move the various spring clips that hold the brake pads in place over to the larger mounting brackets. If you get lost doing this look in the BGB or Haynes manual for a diagram to help. It&#8217;s not that great of a diagram, but it works. It may be better to do this after you get the bracket on the hub. You decide&#8230;</p>
<p align="left">9) Place the larger 87+ mounting brackets onto the hub with the two 17mm bolts.</p>
<p align="left">10) Insert the new brake pads.</p>
<p align="left"><a href="javascript:newwin('10pads.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/5bde94fbe995d07aa6c0217de84edbe6.jpg" border="0" alt="" width="200" height="133" /></a></p>
<p align="left">11) And finally, slide the caliper over the pads and attach it to the mounting bracket by the two 12mm bolts.</p>
<p align="left"><a href="javascript:newwin('11caliperon.jpg')"><img src="http://www.midshiprunabout.org/wp-content/uploads/HLIC/6856a9f21ed97871bf3b882209157a13.jpg" border="0" alt="" width="200" height="301" /></a></p>
<p align="left"> </p>
<p align="left">12) Replace wheel and lower from jackstands. Repeat for the other 3 wheels.</p>
</div>
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