MR2 Roadster Owners Club

The Common Room => Reader's Rides => Topic started by: Trebordoody on August 1, 2021, 12:15

Title: Black '03 Projects
Post by: Trebordoody on August 1, 2021, 12:15
Hi all,

This seems like a good place to start a journal of work done on my new hobbie/project car, my '03 MR2.

The car is in really good condition and has obviously been well looked after, with a fairly new hood and recently refurbed alloys making it a compelling buy from a friend of my Dad's.

I finally managed to get some top-down driving over the last couple of weeks, and I'm instantly in love with the car. Its great to drive, involving and not likely to lose my license (as previous hot hatches I've owned have threatened on a few occasions!). Driving it reminds me a bit of an X reg Celica we bought new many years ago and had great fun in, before the kids arrived and we needed to get a more sensible car!

After a good clean, here's the list of stuff I'm planning to do over the next few weeks, largely based on MOT advisories:
 

I'm hoping to get some track driving tuition in before the end of the year, then who knows where things will head!

So to begin, a few pics of the car as bought...

(https://i.ibb.co/kx6YvH4/20210621-183228.jpg) (https://ibb.co/kx6YvH4) (https://i.ibb.co/RQHYLxV/20210621-183241.jpg) (https://ibb.co/RQHYLxV) (https://i.ibb.co/xm1x3Yx/20210621-183257.jpg) (https://ibb.co/xm1x3Yx)
Title: Re: Black '03 Projects
Post by: Trebordoody on August 1, 2021, 12:37
I've already done the headlight polishing using the Autoglym Headlight Restoration Kit (was on offer for £17 on Amazon), and I'm really amazed at the results! As you can see from the before and after pics, I think it takes years off the car!!

This is the kit that uses successively finer sanding and polishing pads with an electric drill attachment. It took a couple of hours - and both drill batteries - but was pretty straight forward if you follow the instructions. I finished with Surface Sealant Easy Clean Coating (£12 on eBay) to hopefully keep them from fading back for a while.

First job down, and feeling very happy that I've got a new hobbie! ;D

(https://i.ibb.co/ngyzFXC/20210728-182245.jpg) (https://ibb.co/ngyzFXC) (https://i.ibb.co/0YxB53n/20210728-203407.jpg) (https://ibb.co/0YxB53n) (https://i.ibb.co/6BnY7FF/20210728-182217.jpg) (https://ibb.co/6BnY7FF) (https://i.ibb.co/7KdxL9M/20210728-203402.jpg) (https://ibb.co/7KdxL9M)
Title: Re: Black '03 Projects
Post by: Joesson on August 1, 2021, 12:56
That's the first one done from your list!
Title: Re: Black '03 Projects
Post by: puma2 on August 1, 2021, 14:32
 :) that is a good clear job keep going and let us no how you get on with the rest ;D  ;D
Title: Re: Black '03 Projects
Post by: 1979scotte on August 1, 2021, 17:42
What's it like underneath?
Title: Re: Black '03 Projects
Post by: Trebordoody on August 5, 2021, 20:29
Quote from: 1979scotte on August  1, 2021, 17:42What's it like underneath?


I haven't had it up on a ramp or anything, but it looks pretty decent for 85K miles.
I checked the rear subframe when purchasing and it seems solid enough. I've read on here that they rot from inside out, but it doesn't show any obvious issues and the seller was keen to let me know it was solid too.
Once I've done a service, I need to do a proper check on everything and see what else is inevitably lurking under there! I'll be back on the forum gathering checklists for that and will upload pics of concerns ;)



Title: Re: Black '03 Projects
Post by: The Other Stu on August 6, 2021, 08:58
Have a really good look underneath - nappy off and up on stands. Unfortunately, the hole in the subframe is often where you can't see it - near where the welds are, hidden.

My first one had a hole the size of a tuppence. The second one, was about twice the size. Both on the right hand side as you look from the rear.
Title: Re: Black '03 Projects
Post by: Trebordoody on August 6, 2021, 17:50
Quote from: The Other Stu on August  6, 2021, 08:58Have a really good look underneath - nappy off and up on stands. Unfortunately, the hole in the subframe is often where you can't see it - near where the welds are, hidden.

My first one had a hole the size of a tuppence. The second one, was about twice the size. Both on the right hand side as you look from the rear.

OK thanks for the advice! Hopefully there are no surprises under there. I'm recovering from surgery which means it won't be for a while, but I have the axle stands and ready to investigate.

I should have pointed out in my intro that one of the reasons to buy the MR2 was to get into mechanics as a hobbyist - I'm in the electronics industry, but have never played with engines and bodywork. So with the money I've already saved getting shut of my Audi, I've bought a load of basic mechanic's tools (sockets, spanners etc), jack, stands, polishers etc and keen to start learning!

With this forum's support I'm sure I'm in safe hands.
Title: Re: Black '03 Projects
Post by: Chilli Girl on August 6, 2021, 17:59
You certainly are. I've learnt a hell of alot, you never stop learning. Well done for getting the first of the tools. ;D  These are awesome cars so much so I'm on my third in 16 years! Can't live without one!
Title: Re: Black '03 Projects
Post by: 1979scotte on August 6, 2021, 21:56
Quote from: Chilli Girl on August  6, 2021, 17:59These are awesome cars so much so I'm on my third in 16 years! Can't live without one!

I shall quote this post every time you even think about selling.
Title: Re: Black '03 Projects
Post by: Trebordoody on October 5, 2021, 17:05
Its been a while (recovering from a hernia and weather got in the way!), so time for an update...

Our office opened up again, so I went to work with the top down. I could hear a knocking/ringing on the passenger-side as I was travelling along. After reading notes on the forum, I was already aware of brake dust shields just being taken off due to rust. I checked mine and, sure enough, it was barely attached. In the bin it went when I got home, and I plan on removing the others soon.

More of a priority occurred in-between: the EML came on on the way home! I bought an ODB reader of Amazon and it threw out the (apparently dreaded) code P1349 - VVTi issue!
Back to the forum and other searches showed that this can just be caused by contaminant in the oil system so to flush the system first. My first major job was to have a go at servicing the car (remember, I'm completely new to mechanics!) so my fingers were firmly crossed that this would resolve things!

I managed to follow Carolyn's excellent service instructions (thanks for a very easy to follow guide Carolyn!):
https://www.mr2roc.org/forum/index.php?topic=67536.msg799515#msg799515 (https://www.mr2roc.org/forum/index.php?topic=67536.msg799515#msg799515)
The only change was I needed to take the brace off to get the air box opened.
I'm also glad that I put lots of cardboard around the oil pan - a slight breeze caused havoc!
But everything else went according to plan. 
I decided to flush the system with Forte - which claims to also target VVTi so no harm doing this now.
30 min idle and oil refill, followed by new oil filter, new sparks and new air filter.
I reset the ODB code and fired her up, and the engine didn't explode! PHEW!!
And after 5 more trips this week, the EML has stayed off! Fingers still crossed as I know it can come back any time, but so far so good!

While the nappy was off, I took a better look around the subframe cross member following The Other Stu's advice. Pics are attached. There is quite a bit of rust obviously and a couple of worrying areas. I tapped around and seems solid everywhere, but other than keeping an eye on it not sure what to do. If Stu or anyone can cast their eye over them and share opinion, that would be great! Hopefully there's still some life left in it - I'm not sure that would be a good second job for the inexperienced me!!

The suspension arms didn't look particularly good either - one to add to the list perhaps?

If the cross member is OK for now, my next priority at the moment is getting MOT advisories sorted.
- Brake pads and discs replaced all round.
- Suspension rubber boots are worn - I might leave this a while and replace the whole lot with the arms in the spring.

On a different (and less concerning) note, I'm disappointed that the headlight misting has returned already. The Autoglym polish/refurb did a great job, but I think the UV sealant didn't perform. Its not as bad as it was, but I hoped for a longer term fix. I'll try again and put another couple of coats of UV on just to see how that goes. Maybe a spray or something else is required.

That's all for now - I'm really chuffed I've got my hands dirty and the car is still running. Hopefully the brake replacement will mean it can stop afterwards!!!

(https://i.ibb.co/SvQ69my/20211003-160514.jpg) (https://ibb.co/SvQ69my) (https://i.ibb.co/D4SqcHV/20211003-160506.jpg) (https://ibb.co/D4SqcHV) (https://i.ibb.co/0BKwBq7/20211003-160343.jpg) (https://ibb.co/0BKwBq7) (https://i.ibb.co/wpZ3ksk/20211003-160339.jpg) (https://ibb.co/wpZ3ksk) (https://i.ibb.co/HGc9xmn/20211003-160422.jpg) (https://ibb.co/HGc9xmn) (https://i.ibb.co/K7dJSQ2/20211003-160452.jpg) (https://ibb.co/K7dJSQ2) (https://i.ibb.co/w0vBTtW/20211003-160327.jpg) (https://ibb.co/w0vBTtW) (https://i.ibb.co/ZKhV1Tx/20211003-160325.jpg) (https://ibb.co/ZKhV1Tx)
Title: Re: Black '03 Projects
Post by: Topdownman on October 5, 2021, 17:41
That fifth picture does look like you need some welding on the subframe.

The first step for me would be to wire brush all the rust, de-rust it and then prime/paint with a suitable product (everything under the car, not just the subframe). Its the kind of job you will probably need to do every few years but will look so much better for being done, stop the rampant spread of rust and will help to pass the MOT as the car looks like it is being maintained.

The front shock boots in particular fall apart but I wouldnt do that job on is own but replace them when you decide what you want to do about your suspension. There are lots of threads about suspension refresh/upgrade etc. to confuse you!
Title: Re: Black '03 Projects
Post by: Roj on October 5, 2021, 18:35
As Topdownman says, the fifth pic looks like the most worrying. If it's still solid underneath that surface rust, it won't stay that way for long. I'd second the advice above re: rubbing down, treating and keeping an eye on things.

Don't get too worried about the suspension arms, they're almost all corroded on the surface but rarely rot through unless badly damaged. Bushes don't look too clever though.
Title: Re: Black '03 Projects
Post by: Trebordoody on October 6, 2021, 08:35
Thanks Topdownman and Roj, really useful feedback.

I won't be able to weld anything, but can definitely rub down, treat and paint. Hopefully that patch remains solid for a while!

And I'm glad the suspension can wait. I do want to do it, but not just yet. I'll probably do the whole thing and replace the bushes at the same time in the spring.

Thanks again both of you.
Cheers, Rob


Title: Re: Black '03 Projects
Post by: Roj on October 6, 2021, 11:39
Quote from: Trebordoody on October  6, 2021, 08:35Thanks Topdownman and Roj, really useful feedback.

I won't be able to weld anything, but can definitely rub down, treat and paint. Hopefully that patch remains solid for a while!

And I'm glad the suspension can wait. I do want to do it, but not just yet. I'll probably do the whole thing and replace the bushes at the same time in the spring.

Thanks again both of you.
Cheers, Rob



Top tip for the future if/when you take things apart to replace or refurbish them. Buy yourself an impact gun, specifically one with a decent break out torque rating. Life changing piece of kit!
Title: Re: Black '03 Projects
Post by: Trebordoody on October 6, 2021, 12:02
Quote from: Roj on October  6, 2021, 11:39Top tip for the future if/when you take things apart to replace or refurbish them. Buy yourself an impact gun, specifically one with a decent break out torque rating. Life changing piece of kit!

Thanks Roj, good advice - I'll ask Father Christmas and see what happens! ;)
Title: Re: Black '03 Projects
Post by: AJRFulton on October 9, 2021, 17:18
A 3/8" electric ratchet is a fucking great thing as well - after the impact gun, the next life changing bit of kit! Particularly on a cold day, when reaching in a place with barely any purchase.
Title: Re: Black '03 Projects
Post by: Trebordoody on February 12, 2022, 15:30
Well, its been a while and with plenty going on in life and work, plus miserable weather, I haven't had much time to work on things.

However, some updates:

Just after Christmas, the battery died and couldn't start up. I jumped started it fine, but within a week it had died again. I think the cold weather exposed the weakness in the battery, and I suspect that it was dead for a while before I bought the car - I know it was SORNED for a few months. And apparently once they die, they never fully recover!

I therefore bought a new battery and its been absolutely fine since!

The big job that had highest priority was sorting the subframe and underside rust. Thanks to previous responses, I rubbed down the subframe and suspension arms etc, rust treated, zinc primed and Hammerite smooth sprayed it, and I think that the underside looks much more respectable now. The rust spot behind the cat seemed pretty solid, but I'll keep an eye on it.

I've now received new pads and discs so that's my next job.

I've also receieved a new InPhase USW10 for under the dash, and new JVC head unit is on the way, so upgrading the audio will be next month's work (and adjusting the handbrake travel while I'm there!)

(https://i.ibb.co/9TdVqst/20211028-153129.jpg) (https://ibb.co/9TdVqst) (https://i.ibb.co/5rR0znZ/20220212-114304.jpg) (https://ibb.co/5rR0znZ) (https://i.ibb.co/0B9FX2z/20211211-120829.jpg) (https://ibb.co/0B9FX2z) (https://i.ibb.co/WHbd0NK/20220212-114242.jpg) (https://ibb.co/WHbd0NK) (https://i.ibb.co/1vWx6WM/20211211-120824.jpg) (https://ibb.co/1vWx6WM) (https://i.ibb.co/cDRfZ8p/20220212-114229.jpg) (https://ibb.co/cDRfZ8p) (https://i.ibb.co/9WhxKQT/20220212-114409.jpg) (https://ibb.co/9WhxKQT)
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 19:33
Yay! A week off work with some decent weather means
a) I can get the top down and have a blast around the local B roads
b) I can do some work on the toy!  ;D

Main job to complete this week is brakes. I've had a set of Pagid disks and pads for a while, particularly as the scoring was an advisory on the last MOT but also because they look a mess, so finally summoned up the courage to give it a go!

I also wanted to get rid of the blue paint on the calipers and mid-section of the disc which was done by the previous owner. Whilst its not too offensive on a black car, its pretty tired and needs redoing. I thought of going red, but I've had 3 black cars with red calipers and although I like the combination, I fancied a change and something more low key. So have decided to go black with some white TRD decals off eBay.

Hopefully the How To (https://www.mr2roc.org/forum/index.php?topic=11550.0) will see me through this...!

(https://i.ibb.co/gDd0RLt/IMG-0029.jpg) (https://ibb.co/gDd0RLt) (https://i.ibb.co/zRWYrV0/IMG-0028.jpg) (https://ibb.co/zRWYrV0)
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 20:19
Thankfully the calipers and discs all came off fine. Whilst they were off I tidied up the hub with wire brushing etc, and removed the remnants of the brake dust shields.

I sanded the calipers down and gave them a few coats of Hammerite smooth black spray and they came up really well. I applied the TRD decal sticker, then thought I should put some clear laquer over them to protect them.

What a mistake....!!!!  :-[  :-[

I don't know if it was because the laquer has been around in the garage for a while, or it shouldn't be used with the Hammerite, but it orange peeled straight away. And then softened the Hammerite which started to come away!! Lesson learned - don't mix Hycote laquer and Hammerite!!!

So basically started again - peeled, scraped, sanded and resprayed, stuck on the decal and left it at that. I've read that some on the forum have just put decals and they've lasted a while, so we'll see how it goes!

(https://i.ibb.co/BnLJm2Z/IMG-0033.jpg) (https://ibb.co/BnLJm2Z) (https://i.ibb.co/Yt4LTPN/IMG-0034.jpg) (https://ibb.co/Yt4LTPN)
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 20:21
With the new pads and discs installed, the whole set-up looks waaay better now and I'm happy with the choice of black calipers on the car.

Still the rears to do, but hopefully they'll go quicker!

(https://i.ibb.co/K0MtVC2/IMG-0036.jpg) (https://ibb.co/K0MtVC2) (https://i.ibb.co/k9qsQBT/IMG-0037.jpg) (https://ibb.co/k9qsQBT)
Title: Re: Black '03 Projects
Post by: Alex Knight on March 15, 2022, 21:38
Quote from: Trebordoody on March 15, 2022, 20:21Still the rears to do, but hopefully they'll go quicker!

LOL - enjoy resetting the handbrake 🤪
Title: Re: Black '03 Projects
Post by: shnazzle on March 15, 2022, 22:04
The only big difference on the rear is that the pistons need winding in with the correct tools (easily available at your local) and that the handbrake cable gets in the way of swinging the caliper off the carrier.

Some people undo the actual cable. I just undo the bracket held on with the 12mm bolt.

Handbrake OFF
Wind the piston in,mount it all up. 
Get in the car, pump the brake a good few times. Press and hold in, then pull the handbrake. Over 4 mr2s and 10+ years this never failed me
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 22:46
Quote from: shnazzle on March 15, 2022, 22:04The only big difference on the rear is that the pistons need winding in with the correct tools (easily available at your local) and that the handbrake cable gets in the way of swinging the caliper off the carrier.

Some people undo the actual cable. I just undo the bracket held on with the 12mm bolt.

Handbrake OFF
Wind the piston in,mount it all up.
Get in the car, pump the brake a good few times. Press and hold in, then pull the handbrake. Over 4 mr2s and 10+ ; ;) )  years this never failed me

Thanks for the advice shnazzle!

The handbrake is "near the end of travel" according to another MOT advisory, so I was just going to adjust the cable nut under the centre console like some others have.

However, sounds like your method also adjusts things. Will the handbrake go back to where it was before (near end of travel) or will it correct things and go back to a few clicks?

I guess I'll find out either way!!  ;)
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 22:49
Quote from: AlexKnight on March 15, 2022, 21:38LOL - enjoy resetting the handbrake 🤪

Oh great!  :o Sounds like I'll need another week off work...
Title: Re: Black '03 Projects
Post by: shnazzle on March 15, 2022, 22:50
Quote from: Trebordoody on March 15, 2022, 22:46Thanks for the advice shnazzle!

The handbrake is "near the end of travel" according to another MOT advisory, so I was just going to adjust the cable nut under the centre console like some others have.

However, sounds like your method also adjusts things. Will the handbrake go back to where it was before (near end of travel) or will it correct things and go back to a few clicks?

I guess I'll find out either way!!  ;)
Depends on whether the person that did your brakes last time set them properly. If not, it'll tighten it up. If thye did, then sadly there is another issue. Either on the caliper side or cable.
The adjustment in the center console is the final step of adjustment. Last resort kind of thing. But, if the cable is stretched then it's definitely the way forward
Title: Re: Black '03 Projects
Post by: Trebordoody on March 15, 2022, 23:00
Quote from: shnazzle on March 15, 2022, 22:50Depends on whether the person that did your brakes last time set them properly. If not, it'll tighten it up. If thye did, then sadly there is another issue. Either on the caliper side or cable.
The adjustment in the center console is the final step of adjustment. Last resort kind of thing. But, if the cable is stretched then it's definitely the way forward

OK thanks! I guess I'll find out soon enough!!
Title: Re: Black '03 Projects
Post by: Trebordoody on May 6, 2022, 17:24
Update time as its been a while...!

Finally got the brakes sorted out - I think!
First of all I figured out that the caliper had seized on the rear left, so got a replacement from MR2Ben, painted it up to match the others and it seems to have helped.

However, I fought with the Eezibleed kit on the brake reservoir!! >:(
This is the one that uses the pressure from the spare tyre to help you do the bleed on your own. The caps they provide as standard don't fit the '2, and the universal adapter you can buy separately just doesn't form a good enough seal on the reservoir, so brake fluid started p*ing out everywhere!!  :-[
I asked my daughter to help and reverted to the old-fashioned bleed method and got there in the end. 

However, the handbrake travel was still way too much (10+ clicks) despite the adjustment guidance, so after checking the cables, I decided to take the last resort and adjust the cable. Now its a few clicks and seems to be holding the car just fine!

My first attempt at brake changes (pads and disks all round, and now a caliper change) and I'm finally there and still alive after a few drives! Its been nerve-wracking, but this forum and its guidance are inspiring!

MOT is booked for a couple of weeks so my fingers are crossed!!! I'm hoping there'll just be an advisory for the front suspension boots degrading and that's it!
Title: Re: Black '03 Projects
Post by: Trebordoody on May 6, 2022, 17:38
I should add, that in-between all this, I did manage to take the car on its first weekend away!

We stayed in Hungerford so not far, but nice to drive over the back roads through Berkshire.
Finally use the "Midship Runabout" luggage set we bought before Christmas (when it was on offer!). The thinking is that if it fits in the bags, it will fit in the car! And it turned out to be true! :)

One issue I'm having at the moment is getting the missus and daughters to travel with the roof down (hair etc)!! I get it, but I've already warned my better half that we can't pull up at the Shinding South event with the roof up - we probably won't be allowed in!! We'll see how it goes...  ;D

(https://i.ibb.co/B4ctvkx/IMG-0089.jpg) (https://ibb.co/B4ctvkx)
Title: Re: Black '03 Projects
Post by: Topdownman on May 7, 2022, 11:16
Good work with the brakes.

Isnt the smaller 3rd bag supposed to go in the middle?

If your passengers are struggling with their hair, there is always the Bjorn Borg approach...
Title: Re: Black '03 Projects
Post by: Trebordoody on May 7, 2022, 13:20
Quote from: Topdownman on May  7, 2022, 11:16Good work with the brakes.

Isnt the smaller 3rd bag supposed to go in the middle?

If your passengers are struggling with their hair, there is always the Bjorn Borg approach...

Yeah, the bags in the pic are actually empty and moved around so I could get the jack out. But I don't think it made much difference which way the bags went in.

And I suggested Kathryn Hepburn headscarves, but they're all having none of it!!  ;D  ;D
Title: Re: Black '03 Projects
Post by: Trebordoody on June 6, 2022, 22:35
Decided to take a quick look at the rear light cluster as it had an MOT advisory about condensation.

Following the simple guide put together by @Fatbloater, I was able to strip it down quite easily, but did break a tab (as seems expected!)

While there, I noticed the paint had lifted (see pic) - I guess as a result of moisture ingress - so what was supposed to be a quick job, ended up with a trip to Halfords for some silver paint! Couple of hours later and a couple of paint coats after priming, and I think that's another job off the MOT to-do list!

(https://i.ibb.co/7S2h7bJ/IMG-0222.jpg) (https://ibb.co/7S2h7bJ)
Title: Re: Black '03 Projects
Post by: Trebordoody on June 6, 2022, 22:41
This week decided to change the worn front Bridgestone tyres to match the rears, so now have Falken Ziex all round. I think it's improved the handling slightly, but still feels a little vague sometimes and I'm guessing down to worn bushes and suspension components. The tyre pressures are fine, so I'm hoping a suspension overhaul later this year will help!

Also managed to use some metal polish and Autoglym vinyl and rubber care to clean up all the rubber window seals.
I forgot to take pics but they look waaay better!!!  :D

I would never have thought to use metal polish, but more good advice found on the forum!
Title: Re: Black '03 Projects
Post by: Trebordoody on June 6, 2022, 22:57
Thanks to meeting the MR2 guru @Carolyn at ShinDing South (thanks again Carolyn!), my next jobs are replacing the o-ring on the chain tensioner to stop a small oil leak there, and while I'm in that part of the engine bay, put a new aux belt in.

I know if I follow the instructions in each How To properly and methodically I should be fine, but I have to admit, I'm pretty terrified as a newbie mechanic!!

Won't learn if I don't try...!!! :-\
Title: Re: Black '03 Projects
Post by: J88TEO on June 7, 2022, 09:02
Quote from: Trebordoody on June  6, 2022, 22:57Won't learn if I don't try...!!! :-\
A few swear words and you will get the hand of it. Quite therapeutic when you dig in more... ;D
Title: Re: Black '03 Projects
Post by: Joesson on June 7, 2022, 09:24
@Trebordoody

You may or may not be aware and I'm pretty sure @Carolyn will have mentioned it, but others have been caught out, there are two belt sizes for our cars, one for those Without Air Con and another for those With Air Con.
I'm also sure C will have mentioned a sketch, or these days I suppose a foto of the belt in situ to remind you of the route when reinstalling. Google Maps won't help with that.
Title: Re: Black '03 Projects
Post by: Trebordoody on June 7, 2022, 09:36
Thanks @Joesson, Carolyn did indeed mention both belt types (I have a non-AC one on the way) and taking a route photo, so fingers crossed I won't blow anything up!  :o
Title: Re: Black '03 Projects
Post by: Joesson on June 7, 2022, 19:39
Quote from: Trebordoody on June  7, 2022, 09:36Thanks @Joesson, Carolyn did indeed mention both belt types (I have a non-AC one on the way) and taking a route photo, so fingers crossed I won't blow anything up!  :o

I believe I am correct in saying that as this is an auxiliary belt, driven by  a pulley on the end of the crank shaft, it drives by friction of the belt the alternator, air con pump if fitted, and the water pump.
This means that there is nothing to "blow up", unlike a toothed cam belt that if incorrectly fitted can cause some damage!
Title: Re: Black '03 Projects
Post by: Trebordoody on June 24, 2022, 18:03
Still not able to find time to change the aux belt, but did manage a 5-minute upgrade on the HVAC controls this week (seeing as pretty much everyone else I saw at Shinding South had replaced the old knobs!)

"X3 FOR TOYOTA YARIS 1998-2005 VITZ ECHO SWITCH KNOB A/C HEATER BUTTON DIALS HEAT" on eBay for less than a tenner.

Vast improvement to the looks and very happy with them!

(https://i.ibb.co/cD3Y8P1/IMG-0235.jpg) (https://ibb.co/cD3Y8P1)
Title: Re: Black '03 Projects
Post by: Trebordoody on August 8, 2022, 09:59
Finally got another day to work on the '2. I wish I had more time...!

This weekend I managed to change the aux belt using the great How To (https://www.mr2roc.org/forum/index.php?topic=59515.0) from @shnazzle (thank you!). After a lot of faffing around and scratching my arm to pieces on the bodywork, I found that doing the top/forward- most pulley last was easiest, but the instructions are great!  ;)

Next was finally installing the chain tensioner o-ring that I got from @Carolyn at the Oxford meet. Followed another great How To (https://www.mr2roc.org/forum/index.php?topic=56959.0) and it went really. I only managed to rip my thumbnail off slightly trying to compress the oily tensioner, but the instructions are great! Thanks Carolyn!  ;)

I found I have a partially seized front caliper (slighting binding was an MOT advisory) so I checked it and struggled to push the piston back in. So I think I need a set of refurbs soon. I've already done the back one that had completely seized so I'm wondering whether just to replace all the rest at the same time and be done with them. No injuries this time!

Finally, I gave my headlights another sand and polish. I think the UV clear coat I used last time wasn't up to the job, so have tried the 3M wipes this time. Let's see how it goes!

And of course, took it for a fantastic blast through the sunny countryside to make sure everything was OK :)

Still didn't get around to upgrading the stereo and speakers for which I've had replacements lying in the garage for nearly a year now! But best to focus on the mechanical stuff that needs doing first.

In the meantime, I got some new H7 Nightbreaker headlight bulbs and an Autoglym roof cleaner kit, so they will hopefully get done at the weekend along with a full DA polish - will be fun to try out machine polishing for the first time!!

Loving this car!! ;D ;D ;D

Title: Re: Black '03 Projects
Post by: Trebordoody on August 8, 2022, 10:02
Quote from: Joesson on June  7, 2022, 19:39I believe I am correct in saying that as this is an auxiliary belt, driven by  a pulley on the end of the crank shaft, it drives by friction of the belt the alternator, air con pump if fitted, and the water pump.
This means that there is nothing to "blow up", unlike a toothed cam belt that if incorrectly fitted can cause some damage!

And it didn't blow up @Joesson !  ;)
Title: Re: Black '03 Projects
Post by: Joesson on August 8, 2022, 13:43
Quote from: Trebordoody on August  8, 2022, 10:02And it didn't blow up @Joesson !  ;)

And I 'm very pleased to hear (or not hear) that.
I note you've replaced your rear brake calipers and are now pondering what to do with the fronts.
Having recently worked on my brakes , (slightly binding MOT advisory) and suspension I can say that my rears were quite well stuck and with all the parts and tools needed to refurb them I also opted for new.
The fronts were less stuck but did take some time and effort to clean up, repaint and fit new pistons and seals. There was a cost saving but only because I had the brake cleaner (I did buy a bottle of methylated spirit to give the components an initial clean) zinc and high temp silver paints for painting in stock and, importantly, I didn't charge myself for my labour!
Remember though you will have the OE pad carriers that would look out of place with new calipers unless you clean and paint them.
I also took the opportunity to replace the flexible hoses.
Enjoy.


Title: Re: Black '03 Projects
Post by: thetyrant on August 8, 2022, 14:07
Quote from: Trebordoody on August  8, 2022, 09:59I found I have a partially seized front caliper (slighting binding was an MOT advisory) so I checked it and struggled to push the piston back in. So I think I need a set of refurbs soon. I've already done the back one that had completely seized so I'm wondering whether just to replace all the rest at the same time and be done with them. No injuries this time!

Ive got a pair of good recent refurbed front calipers in my garage somewhere, they were refurbed for the guy i got them off but he never used them, i put one on for a quick test for couple of miles as suspected one of mine wasnt working correctly, turned out it was fine and another issue so took the refurbed one back off for when it was really needed, never happened and car has been gone awhile now so if your interested i will dig them out and think on a price, but will be sensible :D 
Title: Re: Black '03 Projects
Post by: Trebordoody on August 10, 2022, 17:38
Quote from: Joesson on August  8, 2022, 13:43And I 'm very pleased to hear (or not hear) that.
I note you've replaced your rear brake calipers and are now pondering what to do with the fronts.
Having recently worked on my brakes , (slightly binding MOT advisory) and suspension I can say that my rears were quite well stuck and with all the parts and tools needed to refurb them I also opted for new.
The fronts were less stuck but did take some time and effort to clean up, repaint and fit new pistons and seals. There was a cost saving but only because I had the brake cleaner (I did buy a bottle of methylated spirit to give the components an initial clean) zinc and high temp silver paints for painting in stock and, importantly, I didn't charge myself for my labour!
Remember though you will have the OE pad carriers that would look out of place with new calipers unless you clean and paint them.
I also took the opportunity to replace the flexible hoses.
Enjoy.



Thanks @Joesson, I might give this a go. I already cleaned and painted the calipers a while back and the piston on this one was a little stiff when I changed the pads and discs, but its obviously got worse over the last few months.
I have brake cleaner too, and I see a replacement piston and seals are available if needed and only ~£35, but I seem to recall that you needed some specific tools to remove the pistons etc - is that not the case? Or is that only for the rears. I can't seem to find a good "How To" on the forum for piston refurbs...!
Title: Re: Black '03 Projects
Post by: Trebordoody on August 10, 2022, 17:40
Quote from: thetyrant on August  8, 2022, 14:07Ive got a pair of good recent refurbed front calipers in my garage somewhere, they were refurbed for the guy i got them off but he never used them, i put one on for a quick test for couple of miles as suspected one of mine wasnt working correctly, turned out it was fine and another issue so took the refurbed one back off for when it was really needed, never happened and car has been gone awhile now so if your interested i will dig them out and think on a price, but will be sensible :D

Thanks for the offer @thetyrant, much appreciated. I still may well take you up on this depending on how easy (or not) it is to do a piston rebuild as @Joesson suggests, so I'll PM you to get the price if needed ;)
Title: Re: Black '03 Projects
Post by: Joesson on August 10, 2022, 20:03
Quote from: Trebordoody on August 10, 2022, 17:38Thanks @Joesson, I might give this a go. I already cleaned and painted the calipers a while back and the piston on this one was a little stiff when I changed the pads and discs, but its obviously got worse over the last few months.
I have brake cleaner too, and I see a replacement piston and seals are available if needed and only ~£35, but I seem to recall that you needed some specific tools to remove the pistons etc - is that not the case? Or is that only for the rears. I can't seem to find a good "How To" on the forum for piston refurbs...!

Special tools are only needed for the rear calipers.
You will find that that either the brake bleed or the banjo nut holes are in line with the back of the piston and I encouraged mine out with a suitably sized rod and perhaps a light tap with a hammer.
If the piston is to be replaced there is no problem with any likely damage but both of mine came out easy enough. The rear pistons were a different story.
If I ever needed to do the job again I would remove the pistons with the caliper in situ by removing the pads and pushing the piston out with the brake pedal. Clamp off that hose and move on to the next caliper.
I read and watched several How To's on line, and they suggested using compressed air, no compressor. A foot pump, I tried an electric pump but couldn't get a good enough seal.
The How To's are OK to show you how to fit the seals.
Make sure the inner square section seal is not twisted wrong way around. The big cup seal I put into the piston groove and then partially insert the piston and ease the seal into the groove in the caliper. Sounds easy enough but the difficulty increases marginally because you have lubricated it  all with special grease.
While I replaced drum brake cylinder seals many years ago and in more recent years some largish industrial hydraulic cylinder seals, I have never worked  on brake calipers before.
But, basic engineering principals apply and once you've watched a couple of you tube videos and done the first caliper you will be as good as the next man, well good enough for sure.
Title: Re: Black '03 Projects
Post by: Trebordoody on August 12, 2022, 18:55
Quote from: Joesson on August 10, 2022, 20:03Special tools are only needed for the rear calipers...

OK thanks @Joesson , you've inspired me! Just ordered replacement piston and rings etc from Brake Parts so I'll give it a go! Won't learn if I don't try!! Appreciate the pointers and hope its as straight forward as you describe.
Title: Re: Black '03 Projects
Post by: Trebordoody on September 30, 2022, 12:37
So, I received the caliper piston kit and intend to do that next when I next get a break, but in the meantime I finally got around to installing the new headunit and speakers (which I've had for about a year, but other priority jobs needed to get done)

I managed to get a JVC KD-X272DBT mechless headunit for <£100 on Amazon, and chose it because it was BT handsfree and DAB...and cheap!

For the speakers I ordered the Pioneer TS-A1600C as it had good reviews and also came with the adapter rings to fit the woofers to the MR2 doors! Saved butchering the existing speaker mounts with a Dremel that many seem to have done!

I also got some Kilmat sound deadening - there was some already on the door it turned out, but only a few patches so now it's got better coverage.

(https://i.ibb.co/prLSs3h/IMG-0027.jpg) (https://ibb.co/prLSs3h) (https://i.ibb.co/nfDMz9k/IMG-0564.jpg) (https://ibb.co/nfDMz9k) (https://i.ibb.co/DQ48bmk/IMG-0565.jpg) (https://ibb.co/DQ48bmk)

Everything's in but still some work to do as the right woofer isn't connected up properly yet and I ran out of time, but the headunit works fine and I think a big improvement on the Fisher Price!

(https://i.ibb.co/Qv55MFc/IMG-0561.jpg) (https://ibb.co/Qv55MFc) (https://i.ibb.co/nnqt0rX/IMG-0562.jpg) (https://ibb.co/nnqt0rX) (https://i.ibb.co/85Yqz2c/IMG-0563.jpg) (https://ibb.co/85Yqz2c) (https://i.ibb.co/g4Zkg2K/IMG-0566.jpg) (https://ibb.co/g4Zkg2K)

Once I get all this done, I'll add the under-dash sub I've got (InPhase USW10) as a future job!
But I think the brake caliper rebuild is the next step!
Title: Re: Black '03 Projects
Post by: Trebordoody on March 5, 2023, 21:13
Its been far too long (bad weather and life getting in the way), but finally got around to changing out the seized front caliper. Thanks @Joesson for the confidence boost and instruction, it really wasn't as bad as I thought!

Now the wheel turns freely when jacked up, so I'm well chuffed that another job (and MOT advisory) is sorted!

(https://i.ibb.co/HXhLMYH/Front-Caliper-Breakdown.jpg) (https://ibb.co/HXhLMYH) (https://i.ibb.co/zZ7bCVk/New-Caliper-Kit.jpg) (https://ibb.co/zZ7bCVk)

Next job is to get the under-dash sub installed!
Title: Re: Black '03 Projects
Post by: Trebordoody on March 13, 2023, 18:23
Wow! The effort needed to change a headlight bulb...!!

(https://i.ibb.co/0n161DN/16-C269-BB-7632-4120-9-F7-B-293-D54-B3-F336.jpg) (https://ibb.co/0n161DN)

I knew this would be tricky based on other comments here, especially the passenger side, but I spent two hours last night trying to get that bloody clip on to hold the main H7 bulb in and gave up before I took a hammer to it!

So this morning, I took my time and took the bumper off - I think this is a much easier way to do it in hindsight. It also meant I could give the lamp edges a good clean underneath, as green moss had got in over the winter. I could also check the frame for rust and thankfully all looks really solid behind the bumper.

So now I have some nice bright Nightbreakers in and one more job ticked off!
Title: Re: Black '03 Projects
Post by: Chilli Girl on March 13, 2023, 18:26
Well done ;D
Title: Re: Black '03 Projects
Post by: Trebordoody on March 13, 2023, 18:27
Also added a battery cut-off switch today - 5 minute job! :)

Hopefully won't need it much, but I think it will be useful over winter months when the car often sits for a week or two.

(https://i.ibb.co/f85fm27/11060-F86-3-C62-4412-A86-A-ADD710-EE1774.jpg) (https://ibb.co/f85fm27)
Title: Re: Black '03 Projects
Post by: J88TEO on March 14, 2023, 07:58
Had one installed a few years back and never had to charge the battery again...even after leaving not starting it for up to 4 weeks!
Title: Re: Black '03 Projects
Post by: Trebordoody on April 3, 2023, 08:38
Made the most of the good weather this weekend to finally install the under-dash sub. Like others, I went with the InPhase USW10, and I'm really happy with the sound now!

This is not a straight forward job at all! After figuring out the wiring path from the battery to the sub, it meant taking the storage bin plastics out (and the driver's seat) so I could get to the battery side grommet. I ran the wire (yellow in the pic) across to the driver's side an d under the seatbelt and door plastics to the front.

(https://i.ibb.co/LvFV5Q6/97-D99948-E01-A-4-F87-802-F-48-A1-FC14-CC2-F.jpg) (https://ibb.co/LvFV5Q6)

Then the hard part! Lying on my back in the footwell with legs over the back of the car for a couple of hours, I managed to install the metal brackets to hold the sub and then the sub itself. So fiddly, so frustrating, I think my shoulders dislocated a number of times. My wife asked what all the scratches were on my shoulders...  :o

There aren't many places to mount the sub to, but I followed the @shnazzle method with the brackets (and even the sponge), but also added a strip of builders tape for a bit of extra insurance and to spread the weight.

(https://i.ibb.co/mJc3kXL/F08-B0-FD3-7-E85-4-D85-9754-9-ED38-F5-B005-F.jpg) (https://ibb.co/mJc3kXL)

But it's in there and sounds great! Especially driving with the top down in the evening sun last night - just magic!!

Another job off the list!  ;D
Title: Re: Black '03 Projects
Post by: shnazzle on April 3, 2023, 09:00
Where did you mount the other end? It looks quite upright compared to how mine used to be.
Did you use another bracket? 
Title: Re: Black '03 Projects
Post by: Topdownman on April 3, 2023, 10:10
Are you sure you havent just mounted a frying pan under there?!
Title: Re: Black '03 Projects
Post by: Trebordoody on April 3, 2023, 23:04
Quote from: shnazzle on April  3, 2023, 09:00Where did you mount the other end? It looks quite upright compared to how mine used to be.
Did you use another bracket?

No, I used one of the existing bolt points on the cross member under the dash - I think it might even be the one that you originally had a bracket on which snapped and then decided to connect directly instead? I managed to get it on the bolt directly anyway, and there's room for my feet which is the main thing.
Title: Re: Black '03 Projects
Post by: Trebordoody on April 3, 2023, 23:05
Quote from: Trebordoody on April  3, 2023, 23:04No, I used one of the existing bolt points on the cross member under the dash - I think it might even be the one that you originally had a bracket on which snapped and then decided to connect directly instead? I managed to get it on the bolt directly anyway, and there's room for my feet which is the main thing.

And it might just be the photo angle tbh! It looks quite close to the pedals in the photo and it really isn't.
Title: Re: Black '03 Projects
Post by: Trebordoody on July 4, 2023, 17:53
Decided to give the soft top some care and attention on an overcast day, so used some Autoglym cleaner, applied Renovo roof dye (plenty of others on the forum seem to use this) and Autoglym waterproofer/protector.

Very pleased with the results! ;D (The photos don't really do it justice tbh)

Before:
(https://i.ibb.co/CV8zJwc/Roof-Before.jpg) (https://ibb.co/CV8zJwc)

After:
(https://i.ibb.co/C6c12Yp/Roof-After.jpg) (https://ibb.co/C6c12Yp)

And if you're wondering about the messy paintwork, it was being clayed between roof coat drying times ;)
I finished off the detailing with DA polish and even new reg plates to tidy things up.

(https://i.ibb.co/Wkp4pJj/Clean.jpg) (https://ibb.co/Wkp4pJj)

Ready for the next evening sunshine drive!


Title: Re: Black '03 Projects
Post by: Trebordoody on July 4, 2023, 18:10
Next (long overdue) job on the list is suspension refresh this summer.

I've just received my new KYB shocks:

(https://i.ibb.co/vsvRB00/KYB-Shocks.jpg) (https://ibb.co/vsvRB00)

But I'm still undecided on lowering springs - Tein seem popular and affordable, but others claim that H&R and Eibachs are less harsh and maybe more like OEM, but seem way more expensive. I'm thinking I might try Teins and see how I get on, and I can always change them later.

The other more tricky job is bush replacements. I'm not sure I can manage that as well on ramps and stands on the driveway, so tempted to get a local garage involved - they'll need to align it all anyway.

The aim is for a firmer, more direct ride (not bone shattering, but it feels a bit vague at the moment), so OEM feel would be fine, hence KYBs, but I prefer a lower stance. I'm also planning to get track day tuition later this year, so want to do some newbie track work but not looking for a pro racer set-up with coilovers etc at this stage!!

I've scoured the forum and still none the wiser on these things to be honest, so any recommendations (or maybe just pointers to good threads) appreciated!