Toyota MR2 Mk2
Discussion
After two and a half years of driving my much loved first car (a 1.4 SEAT Ibiza), I felt it was time for something a bit different. Something...faster. 
I'd wanted an MR2 for a while and a few weeks ago, after discovering insurance was cheaper than I was expecting, I found one in budget. So I am now the proud new owner of a 1999 UK-spec Revision 5:
Cosmetically it's in really good nick; the interior's pretty tidy and the bodywork's in excellent condition for an eighteen year old car. I haven't driven it too hard yet, partly because it has a ten year old timing belt and partly because jumping from a small, ordinary hatchback to a mid-engined, rear wheel drive sports car with twice the power has the potential to end very, very badly. Even being reasonably cautious though, it's still huge fun! It's got a decent turn of pace, it barely rolls at all in the corners, and the induction kit fitted by a previous owner sounds fantastic.
It isn't perfect: it won't idle properly, there's some surface rust in places, one of the driveshaft seals is leaking gearbox oil and the sills are in need of some welding. I'm happy for it to be an ongoing project though, over the next few months I plan to get all the big jobs done and then sort out all the little details to make it as good as it can be. I'm also hoping to do some skidpan training at some point, which will hopefully reduce the risk of an unplanned reverse entry into a field!
Sometimes the list of things to sort out seems quite long, but every now and then I find myself on a nice road, with good weather and barely any traffic, and I don't really care!
I'd wanted an MR2 for a while and a few weeks ago, after discovering insurance was cheaper than I was expecting, I found one in budget. So I am now the proud new owner of a 1999 UK-spec Revision 5:
Cosmetically it's in really good nick; the interior's pretty tidy and the bodywork's in excellent condition for an eighteen year old car. I haven't driven it too hard yet, partly because it has a ten year old timing belt and partly because jumping from a small, ordinary hatchback to a mid-engined, rear wheel drive sports car with twice the power has the potential to end very, very badly. Even being reasonably cautious though, it's still huge fun! It's got a decent turn of pace, it barely rolls at all in the corners, and the induction kit fitted by a previous owner sounds fantastic.
It isn't perfect: it won't idle properly, there's some surface rust in places, one of the driveshaft seals is leaking gearbox oil and the sills are in need of some welding. I'm happy for it to be an ongoing project though, over the next few months I plan to get all the big jobs done and then sort out all the little details to make it as good as it can be. I'm also hoping to do some skidpan training at some point, which will hopefully reduce the risk of an unplanned reverse entry into a field!
Sometimes the list of things to sort out seems quite long, but every now and then I find myself on a nice road, with good weather and barely any traffic, and I don't really care!
Thanks chaps! I'm being very careful not to upset the balance of the car in the corners, I'm aware of the reputation these cars have!
The timing belt and water pump are being replaced early next week. I'm going to have both sills cut out and replaced at some point as well. After that, I plan to spend a weekend with some sand paper, some rust remedy and some spray paint sorting the remaining rust out. Then I'll get on with the little jobs like replacing the corroded headlamps. I'll keep this thread up to date as I go.
The timing belt and water pump are being replaced early next week. I'm going to have both sills cut out and replaced at some point as well. After that, I plan to spend a weekend with some sand paper, some rust remedy and some spray paint sorting the remaining rust out. Then I'll get on with the little jobs like replacing the corroded headlamps. I'll keep this thread up to date as I go.
Sorry for the lack of updates, it's been a bit of a roller coaster ride over the last few weeks as it's all taken a turn for the worse. I left the car with a local MR2 specialist a couple of weeks ago for them to change the timing belt and sort out the idling problems. A few days later they discovered the reason why it won't idle properly: slightly low compression on cylinders 1, 2 & 4, and very low compression on cylinder 3. 
Various tests were carried out and there's clearly a problem with the piston rings or the cylinder bore itself. We agreed not to carry out any more work until I'd decided what to do, so at the moment I'm back where I started: it's still rusty, it still has an ancient timing belt and it still won't idle. At least I now know why it never felt quite as fast as I was expecting, it's obviously way down on power!
For the time being, my old Ibiza has been taken out of hibernation on my parents' driveway and put back into daily use (I'm very glad I chose not to sell it now!). What happens next all depends on whether or not I can find somewhere to keep the MR2, as I don't really have room for both cars at my house. If I can find somewhere to store it, then it'll become a long-term project. I'll replace the engine, either with another standard 3SGE (albeit one in rather better condition than the one it has currently) or maybe with a 3 litre V6 as that's supposed to be fairly simple as engine swaps go. If I can't find anywhere for it then I'll have to sell it as spares or repair, probably at a pretty noticeable loss.
So that brings this thread up to date, sorry for the rather depressing update. I'll try and post updates more often as everything progresses.
Various tests were carried out and there's clearly a problem with the piston rings or the cylinder bore itself. We agreed not to carry out any more work until I'd decided what to do, so at the moment I'm back where I started: it's still rusty, it still has an ancient timing belt and it still won't idle. At least I now know why it never felt quite as fast as I was expecting, it's obviously way down on power!For the time being, my old Ibiza has been taken out of hibernation on my parents' driveway and put back into daily use (I'm very glad I chose not to sell it now!). What happens next all depends on whether or not I can find somewhere to keep the MR2, as I don't really have room for both cars at my house. If I can find somewhere to store it, then it'll become a long-term project. I'll replace the engine, either with another standard 3SGE (albeit one in rather better condition than the one it has currently) or maybe with a 3 litre V6 as that's supposed to be fairly simple as engine swaps go. If I can't find anywhere for it then I'll have to sell it as spares or repair, probably at a pretty noticeable loss.
So that brings this thread up to date, sorry for the rather depressing update. I'll try and post updates more often as everything progresses.
Thanks for all the comments guys, I feel I should add a bit more detail:
Although I had arranged for a specialist to carry out all the work, if the engine was to be replaced I would do that myself, so labour costs aren't an issue. I would also change the timing belt on the new engine as suggested. I've decided that as tempting as a V6 or a BEAMS engine is, a standard 3SGE is probably the way to go. As a bit of background info, I'm only 20, and while I like to think I know my way round an engine, the most complex job I've ever done on a car was changing the Ibiza's clutch. That took me about 30 hours on my driveway with the help of a friend, so I think a complete engine conversion would be a step too far. A simple engine replacement will be a big enough learning experience!
As I said, this all hinges on me finding somewhere to keep it, which needs to happen in the next week or so ideally. Rest assured, the decision to fix or sell will be made soon.
sc0tt - if I do end up having to sell it, I'll be in touch.
Although I had arranged for a specialist to carry out all the work, if the engine was to be replaced I would do that myself, so labour costs aren't an issue. I would also change the timing belt on the new engine as suggested. I've decided that as tempting as a V6 or a BEAMS engine is, a standard 3SGE is probably the way to go. As a bit of background info, I'm only 20, and while I like to think I know my way round an engine, the most complex job I've ever done on a car was changing the Ibiza's clutch. That took me about 30 hours on my driveway with the help of a friend, so I think a complete engine conversion would be a step too far. A simple engine replacement will be a big enough learning experience!
As I said, this all hinges on me finding somewhere to keep it, which needs to happen in the next week or so ideally. Rest assured, the decision to fix or sell will be made soon.
sc0tt - if I do end up having to sell it, I'll be in touch.
Quick update, just as I was about to give up and sell the damn thing, I've finally found somewhere to keep it. Over the next few months I'll be spending most weekends working on it, I'm going to have the sills replaced soon and then I can make a start on replacing the engine and generally tidying it up. I've always wanted a project car, so I'm actually really looking forward to it; I just hope it doesn't throw any more nasty surprises at me, I've had enough of those already!
Wish me luck!
Wish me luck!
kellys hero said:
This is like the UK version of Roadkill.
Unfortunately I'm nowhere near as skilled as those guys, although I hope the MR2 will be more reliable than some of the stuff they've got! 
Thanks for the advice about the fuel pump. I'm not spending any more than I have to at the moment but I'll add it to the list of future jobs.
There's been a bit of progress over the weekend. I haven't got the car back yet but I have seen it and all that's left to be done is the painting and sealing of the new sills, I'm hoping to collect the car and start on the engine next weekend. I've taken the old clutch off the new engine, just to save time next weekend, and spent part of this afternoon cleaning up the throttle body.
I've been told the engine I've bought doesn't idle too well, so I've taken the idle air control valve off the throttle body and cleaned it up as best I can. That way if the engine does idle badly, I'll know the valve isn't the cause.
I've already got most of the stuff I'll need for the engine change, I collected the new oil, oil filter, fuel filter, clutch and water pump yesterday. Now I just need to order the timing belt kit, driveshaft seals and coolant and I think I'll be ready!
Some good progress this weekend. I picked the car up on Friday, with the sills now made of actual metal, which is nice!
A couple of friends came to help, and the work began. A few sheared bolts (and quite a lot of swearing) later, the subframe was out:
Followed by the exhaust:
And finally, twelve hours after we started:
A small bit of welding will be done in the engine bay this week, while I buy some bolts to replace the ones that broke and a new front engine mount, which was so perished it wasn't actually supporting the engine at all. On Friday I'll be painting the welded part of the engine bay and preparing the new engine to be installed (new clutch, water pump, timing belt etc.), then on Saturday it should all go back together. I must be mad!
A couple of friends came to help, and the work began. A few sheared bolts (and quite a lot of swearing) later, the subframe was out:
Followed by the exhaust:
And finally, twelve hours after we started:
A small bit of welding will be done in the engine bay this week, while I buy some bolts to replace the ones that broke and a new front engine mount, which was so perished it wasn't actually supporting the engine at all. On Friday I'll be painting the welded part of the engine bay and preparing the new engine to be installed (new clutch, water pump, timing belt etc.), then on Saturday it should all go back together. I must be mad!
Sorry for the lack of updates, I've been spending all my free time working on the car recently. The new engine was given a new timing belt, water pump, clutch, oil filter and distributor cap the weekend before last. Once the gearbox had been bolted on, it was ready to go back in.
On Monday evening everything was reconnected and we tried to start it for the first time. Initially I just turned it over on the starter motor with the coil disconnected to check everything sounded OK, which it did. I then reconnected the coil and...it started first time!
I didn't run it for long but noticed a slight rattle from the top of the engine. I should have looked into it but it was getting late by then so we packed up and went home. I spent the majority of last week worrying that I'd somehow messed up the timing belt and bent all the valves. On Friday afternoon I went back and started it again and thankfully it sounded fine. I guess the top of the engine was just a bit dry from being sat for a while. We spent a few hours putting the exhaust and subframe back on and reassembling the suspension, then another few hours trying to bleed the f
king stupid clutch! 
Eventually it was done and I had a quick test drive up and down the farm track outside the workshop.
I sorted out the insurance yesterday and took it on its maiden voyage, which just so happened to be a 200 mile journey down to Cornwall on holiday. I've not been that nervous about a car journey in a long time! After stopping several times just to check everything over, I made it without incident. So, the good points: it drives really nicely, I'd forgotten how much fun it is and how good it sounds! Everyone seems to like it, I've already had positive comments and it's only been back on the road for a day! The bad points: it still doesn't idle very well. Whatever it is that's causing it to idle at about 500RPM sometimes is obviously still there, the difference is that this engine can cope with that (just) rather than cutting out like the old one did. Also the gearbox is still leaking, despite us replacing both driveshaft seals. We obviously damaged one when we fitted it. There's also a screeching noise above 4.5k revs that rises with engine speed. The old engine did the same thing, so it must be the alternator (either a bearing or the drive belt) as that's the only component I moved from the old engine to the new one.
I'll keep the updates coming as I tidy it up over the coming months.
On Monday evening everything was reconnected and we tried to start it for the first time. Initially I just turned it over on the starter motor with the coil disconnected to check everything sounded OK, which it did. I then reconnected the coil and...it started first time!
I didn't run it for long but noticed a slight rattle from the top of the engine. I should have looked into it but it was getting late by then so we packed up and went home. I spent the majority of last week worrying that I'd somehow messed up the timing belt and bent all the valves. On Friday afternoon I went back and started it again and thankfully it sounded fine. I guess the top of the engine was just a bit dry from being sat for a while. We spent a few hours putting the exhaust and subframe back on and reassembling the suspension, then another few hours trying to bleed the fking stupid clutch! Eventually it was done and I had a quick test drive up and down the farm track outside the workshop.I sorted out the insurance yesterday and took it on its maiden voyage, which just so happened to be a 200 mile journey down to Cornwall on holiday. I've not been that nervous about a car journey in a long time! After stopping several times just to check everything over, I made it without incident. So, the good points: it drives really nicely, I'd forgotten how much fun it is and how good it sounds! Everyone seems to like it, I've already had positive comments and it's only been back on the road for a day! The bad points: it still doesn't idle very well. Whatever it is that's causing it to idle at about 500RPM sometimes is obviously still there, the difference is that this engine can cope with that (just) rather than cutting out like the old one did. Also the gearbox is still leaking, despite us replacing both driveshaft seals. We obviously damaged one when we fitted it.
There's also a screeching noise above 4.5k revs that rises with engine speed. The old engine did the same thing, so it must be the alternator (either a bearing or the drive belt) as that's the only component I moved from the old engine to the new one.I'll keep the updates coming as I tidy it up over the coming months.
Alex C2 said:
Likely seized alternator, just had the same on the good lady's car.
MR2 Ben good source of bits if you don't have a go-to place already.
MR2-Ben's been very useful recently! In fact I should have another delivery from them in the next few days. I do as much work as I can on my cars but after trying and failing to remove the driveshaft earlier this week (I don't have access to the workshop at the moment) I gave in and took it to the garage. The driveshaft seal has been replaced and the alternator looked at. Apparently the bearings are fine but I hadn't put enough tension on the belt. Now it's been tightened and the screeching's gone away, so that was a pleasant surprise.MR2 Ben good source of bits if you don't have a go-to place already.
I've been slowly working through my list of jobs this week, starting with the rust on the engine lid. I didn't think to take a picture of the rust patch but I sanded it down to bare metal and repainted it:
Next up was the rust inside the doors. I'd noticed the rust when I changed the speakers and wanted to stop it before it rotted all the way through to the outside. First up was some rust treatment, followed by some white primer and then some top coat:
Someone's clearly been in there before. I'm not quite sure what the previous rust repair is, it looks like a gel that's hardened and then had tin foil put over the top. It's keeping water off the rust though, so it can stay there for now!
The grill below the rear bumper was looking a little worse for wear; a quick coat of Hammerite smartened it up quite well I think:
Finally, I was going to sort this out, which is under the bonnet:
I was going to take the front wing off so I could see just how bad it was, but some of the nuts and bolts are so rusted it was just never going to happen. All I succeeded in doing was taking the wheel arch liner off and finding this:
Oh good, more rust!
Brilliant...
J4CKO said:
Credit to you for sticking with it!
These things can realltry your patience and seem never ending, but one day you will realise it is mostly done (never 100 percent done) and you are enjoying it, you know it inside out and it's your car with all the time you have put into it.
Oh it's certainly tried my patience at times, so far it's put up a fight pretty much every step of the way. I agree that it well never really be finished (I'm sure that's the same for all project cars!) but it's getting there now. It's slowly feeling more like it's "mine" now as well, even though I am the thirteenth owner! These things can realltry your patience and seem never ending, but one day you will realise it is mostly done (never 100 percent done) and you are enjoying it, you know it inside out and it's your car with all the time you have put into it.
Since returning from Cornwall a few weeks ago, the MR2 has been put on to daily commuting duties. It's hardly the best motorway cruiser in the world but realising that I average just over 40 MPG was a pleasant surprise, although I suspect this is mostly due to the "smart" speed limits on the M6. As ever, I'm continually doing little jobs here and there. I've adjusted the throttle position sensor and replaced the lambda sensor but to no avail, it's still refusing to idle nicely. I've got a few more ideas though, so I'll get there one day! At least I had some success with some T-Cut and the tail lights, makes the back of the car look a lot better.
Some friends and I drove down to Rockingham on Thursday night for the last Summer Social meet of the year. I've not been to one before but it sounded good and made for a nice trip out. And of course, as soon as I arrived I was persuaded by said friends to have a go at the sprint course, which is the first chance I've had to really chuck this car around. I'm pretty rubbish at competitive driving but I was certainly impressed by the handling. Although it has now got me thinking about limited slip diffs...
Some friends and I drove down to Rockingham on Thursday night for the last Summer Social meet of the year. I've not been to one before but it sounded good and made for a nice trip out. And of course, as soon as I arrived I was persuaded by said friends to have a go at the sprint course, which is the first chance I've had to really chuck this car around. I'm pretty rubbish at competitive driving but I was certainly impressed by the handling. Although it has now got me thinking about limited slip diffs...
gofasterrosssco said:
Good effort getting her back on the road! Had a few of these, and they are brilliant. My Rev 5 BEAMS was the best version overall.
If you're looking for an LSD, you can rob the TorSen diff from a UK Mk3 MR2 gearbox - fits straight in and works well on the road.
Cheers! I'll keep this in mind, especially as I might need to sort out the gearbox soon. It's always whined a bit but I'm sure it's slowly getting louder. If you're looking for an LSD, you can rob the TorSen diff from a UK Mk3 MR2 gearbox - fits straight in and works well on the road.
I spent most of the weekend sorting out various bits and pieces. I treated and painted the passenger side front inner wheel arch (after discovering I can easily poke a screwdriver right through it in a couple of places), before quickly putting the arch liner back in so I can pretend the rust isn't there!
I also undersealed the inside of the doors. I know that sounds strange, but I wanted a bit more rust prevention than just the treatment and spray paint I applied before. Finally, a bit of decoration added to the front end:
I'm sure it's not to everyone's taste but it should come in handy if (when) I stuff it into the gravel when I eventually get round to doing a track day.
I'm heading down to Goodwood on Sunday morning, where the car will be on display as part of the Japanese themed Breakfast Club. I just hope the weather turns out to be better than the forecast.
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