Bargain-bucket MR2

[The Arch Bishop]

Bank holidays are for;

1. Eating chocolate
2. Spending time with family and friends
3. Locking yourself away in the garage with a variety of paints and brushes

Currently I'm waiting for the weather to get a bit less mank so I can roll the bucket out of the garage and have a bit more space to investigate the sticking rear brake and tidy up the front of the chassis, so in the meantime I've been busy getting some of the less important jobs done, including getting the last of the more pressing surface rust off the rear of the chassis and making good with paint.

Not the best photo, but you get the idea;



This was the trailing edge of the chassis box section with was looking crusty on both sides. It's had the full Hydrate/zinc primer/Gravitex/Hamerite combo. I've also finished the rear of the sills so I've now got sound jacking points to get the car higher for further work.

The off-side rear caliper has also had a lick of paint (just on the bits you can see with the wheels on - one day I'll get them refurbed properly) as well as the disc hub;



The rear ARB was really crusty looking;



So it got wire-brushed, wet 'n dried, Hydrate'd and then a coat of Hamerite;





I've also done some fairly gentle cleaning of the engine bay which is now a little more presentable;





I wouldn't eat my dinner off it, but I'd now happily rest my pint on it. Not sure that works as an analogy really...

[1979scotte]

Good analogy.
Carry on.

[The Arch Bishop]

Good analogy.
Carry on.

It was between that or;

"I wouldn't take it home to meet my Mum, but I'd possibly take it out for a Nando's"...

[1979scotte]

Good analogy.
Carry on.

It was between that or;

"I wouldn't take it home to meet my Mum, but I'd possibly take it out for a Nando's"...

Like that one too.
Hate nandos though.

[The Arch Bishop]

Well who's this cheeky upstart in prime parking spot on the drive? Yes, the bucket has been let out of hibernation at last! Let the good times, if not exactly roll, then at least turn up and spend the party in the kitchen...

Look! It's even got some honest-to-goodness dirt on it!





So a little more fettling was done on the other rear brake insomuch that I took the caliper off, wound it back in then reinstalled as per the other side. The result was that I could turn it by hand again, but I've still noticed that, compared to the other side, it's a lot warmer after a run. I'm starting to suspect a sticky piston there.

Otherwise it's still running pretty well for an old nail and I enjoyed ragging back from work in it. I just wish I could pin-point the wobbly handling without replacing everything and hoping for the best. My latest suspicion is to the front tyres - Kumho's of Jan 2012 vintage still with most of their tread left on. Again, it shows that the car has done so little in that time that they look a bit past their best;



Now with many years of driving mk1 MR2s as everyday transport, I know that tyres are crucial to how these handle. The wrong tyre or even old ones can throw up some very odd characteristics on the road. Kumhos are not bad tyres, but I'm not aware of anyone who has run these on an MR2 and with them being hard and cracked, it seems the best place to start in my quest for a more predictable car.

It's got Avon ZV5s (dated week 45 2011) on the back, but these still look perfect and feel softer than the fronts. Bank balance will determine whether I replace them all. Such a shame as there's a tonne of tread still on all of them and they've all worn in a uniform way.

Then we get into the age old chestnut - which tyres....

[1979scotte]

Dirt I think not.

Tyres.
Falken ze 914
Uniroyal rainsport
Yokohama AD08R
Toyo R888

Cheapest first.
Best last.

[The Arch Bishop]

Dirt I think not.

Tyres.
Falken ze 914
Uniroyal rainsport
Yokohama AD08R
Toyo R888

Cheapest first.
Best last.

Hey for one of my project cars, that's almost dirty!

Falkens - I've had these (and the 912's) on previous cars and they've been very good - only downside is that they have very hard sidewall - great for direction changes, but not as good for ride comfort.
Rainsports - Had these on my wife's car - great in the wet but by Christ they wear quickly and when they go off, they really go off.
AD08R - My dad's gone for these on his MR2, but the price is a bit beyond my budget.
Toyo's - Bit too track focused and pricey for me.

I'm ideally looking for a balance of grip and ride comfort rather than all out on one or other. My usual work roads are almost sub-B and pretty much destroyed (like everywhere I suppose). Price for the Avon ZV7's is pretty good for a quality tyre (slightly cheaper than the Falkens) but I don't have experience of them to be sure. If I can get Falkens for the right price, then I'd be tempted. I had them on my Puma and Forester and they worked well on both.

[smarty72]

I've had ZV7's since Autumn last year, they came in just under £250 total (bargain!).

I don't have experience of the other tyres mentioned above so can't compare like for like, but I have no complaints and the ride (on standard suspension) is very good (IMO).

This is my second roadster with a four year gap in-between.  My first roadster had some unheard of cheap (Chinese?) rubber at one end and Nankang's at the other (which Carolyn swears by) and I had no complaint about those either - maybe I'm not picky enough?

The guy that bought that roadster off me (he'd had a few Porche's and did track days etc)  joined the forum briefly, and fitted Toyo's as the majority of members swore by them (at that time).  He reckoned they 'destroyed' the handling - not sure how that story helps you though?

I believe 'OldRedCelica' has ZV7's fitted too around the same time if you want a second opinion.

They seem to grip nicely and are predictable, have a good wet grip rating, don't know that you need much else for the road really.

[J03]

I'm ideally looking for a balance of grip and ride comfort rather than all out on one or other

The Kumho Ecsta Le Sport KU39 always used to fit that description rather well. They were fantastic tyres wet & dry, but with a slightly softer sidewall for the comfort factor.

[The Arch Bishop]

I've had ZV7's since Autumn last year, they came in just under £250 total (bargain!).

I don't have experience of the other tyres mentioned above so can't compare like for like, but I have no complaints and the ride (on standard suspension) is very good (IMO).

This is my second roadster with a four year gap in-between.  My first roadster had some unheard of cheap (Chinese?) rubber at one end and Nankang's at the other (which Carolyn swears by) and I had no complaint about those either - maybe I'm not picky enough?

The guy that bought that roadster off me (he'd had a few Porche's and did track days etc)  joined the forum briefly, and fitted Toyo's as the majority of members swore by them (at that time).  He reckoned they 'destroyed' the handling - not sure how that story helps you though?

I believe 'OldRedCelica' has ZV7's fitted too around the same time if you want a second opinion.

They seem to grip nicely and are predictable, have a good wet grip rating, don't know that you need much else for the road really.

For me that sounds perfect to be honest.

Short and possibly boring story, but when I were a lad, I bought my first MR2 mk1 and it came with a matching set of Goodyear Eagle NCT2s. They were superb and I had a good few years wear from them. They'd grip, slide and do whatever you like. Eventually, they ended up near-slicks and I had to replace them. I went to my local high quality tyre seller and requested a set of Eagle NCT5s (3 better surely). I drove home on them and the car felt very odd indeed but I put it down to them needing a bit of scrubbing in. As the week wore on I found it was actually a challenge to keep up with general traffic. Then one day I turned right into a junction in slightly damp conditions at a very sensible speed. The car speared straight on up and over a thankfully low kerb and across the grass. I drove very gingerly back to the tyre depot and explained that the tyres were terrible, but being a young lad, it was suggested that I was driving beyond my limits, but they did say that they'd send me out with one of their fitters so he could try it. The grumpy sod they sent me out with barely communicated above a grunt and after a drive around some local roads, returned to the depot. He walked up to his manager and rumbled "It's flipping lethal on those..." With me vindicated, they replaced them for a full set of Yokos and the car was fab again.

So that's why I'm deliberating over tyres, although I've never had a similar experience since - it just seemed that those tyres were really bad for that car. I've run ditchfinders on other cars when money has been tight and never really had a problem. Mid engined cars can be funny beasts though!

I'm ideally looking for a balance of grip and ride comfort rather than all out on one or other

The Kumho Ecsta Le Sport KU39 always used to fit that description rather well. They were fantastic tyres wet & dry, but with a slightly softer sidewall for the comfort factor.

I think that's what's on there at the moment - or a generation of those anyway.

[The Arch Bishop]

Well I've had a spiffing week commuting in the Bucket while my Suzuki Swift sits dejectedly down the bottom of the drive.

In all honesty, it's been faultless and in some areas, it's improved a great deal from just being used. The sticky caliper seems to have unstuck itself - no more hot hub there and the front end feels a lot better - possibly due to having scrubbed in a little (I have been attacking the bends a fair bit) or possibly me just getting used to it. Who knows...

Another few hundred miles under its belt and I thought I'd check the oil again. It's a fairly high-mile PFL engine so I'm expecting it to drink Castrol like an RX8, but it still doesn't appear to have used a drop since I did the oil change, so it seems that I've been lucky and got a good 'un or it's had the engine replaced at some point. The new chain tensioner seal is doing it's thing and there's no fresh oil leaking down there either.

So all in all, it's happy dayz for the bucket! A rough tot up suggests that it owes me about £1,300 or thereabouts with the majority of that (ignoring the initial £500 purchase price) being the brand new cross member. For a car in this condition (my wife commented that it only looks a fraction of its age - she's even been driving it now and then), that is stupidly good value.

What I really like about it is that, unlike the majority of my project cars, everything still feels so well screwed together. My Puma felt like it'd done ever single one of its 105k miles and more on top. The MGF had only done 75k miles, but the odd bit of trim would drop off as a reminder of the shoestring budget it was developed on (still an amazing achievement considering what the Rover engineers had to work with - it's a better car than people give it credit for). But the MR2 feels like it's made of sterner stuff. Everything works. Every switch still clicks like new, every dial feels well oiled, every control feels tight. It had clearly been engineered very carefully with expertise.

So great car. I'm now starting the slippery slope of wanting to buy it trinkets... Quick shift? Nice new gear knob? Uprated speakers..... As I said, slippery slope... 

[The Arch Bishop]

Slippery slippery slope indeed....

Service swag;



As there's another bank holiday coming up and as the engine has proven itself to be solid, I've decided to do some more in-depth servicing. I changed the oil and filter when I changed the sump last year, but other than that (and because I wasn't sure if it'd be a smoker or not), I didn't bother with anything else.

So a visit to MR2-Ben's website for some basics - gearbox oil as I doubt it's ever been changed (and a really good price at the moment), some fresh plugs and an air filt.....ooooo....Blitz panel filter... oooo it's a lot cheaper than the same on eBay.... oh what the hell. Slippery slope...

I've also been using the considerable knowledge of this forum to try and diagnose my wide open throttle power loss - https://www.mr2roc.org/forum/index.php?topic=65086.0

It's not a massive problem, but if the car has an issue, I'm keen to investigate. I've also learnt a lot from that thread!

What a top bunch you all are!  :notworthy:

[The Arch Bishop]

Lovely outside today, so time to get on and do a bit of servicing with my shiny new bits!

First thing's first, out with the old plugs and in with the new. Nothing too challenging there and the old plugs looked, well, old but fairly good in terms of colour.



Next was the rather lovely Blitz filter. I have to say the job of getting the airbox top off is a fiddle, but the old filter came out in the end - a bit mucky but better than expected;



And the new one in;



Next up - gearbox oil change. First I lifted the car slightly at the back as my driveway slopes upwards;



Then because I reckon you have to be quite accurate with the car being level, I used another jack at the side just to tweak it up a cm or two;



Yes, I'm sad enough to use a spirit level;



Then some grovelling about on the floor to remove the filler bolt and then the drain bolt;



The oil that came out was a little dirty, but actually better than I expected. No grittiness to it either so the chances are that the 'box is in pretty good shape.



While that was all draining off, I lashed together a filler from some clear tube and a funnel. I've used this tubing on other cars too as it's clear (so you can see it draining through) and also a touch slimmer than garden hose (so it fits through the filler hole without any hassle. Behold this beauty;



Tubing was juuuuuust long enough with the battery removed;



After that, it was just a case of filling with Redline gearbox oil and making sure it drained to the correct level. All done and pleased! Other than the obligatory dropping the drain plug washer into the drained oil, it all went smoothly. None of my shiny new bits are in any way visible now they're done which is a shame!

I also checked the oil while it was on the perfect flat - nope, still hasn't used a drop sitting 3/4 of the way up the dipstick! I'm starting to think I've been very lucky with this PFL....which means it'll probably throw a conrod out of the block the next time I start it..... 

Well, no time to test drive as a BBQ and tonne of lovely beer beckons. Livin' the dream!

[shnazzle]

Good job done that is. And all looks good
Enjoy the BBQ!

[Joesson]

The Archbishop said:

"Then some grovelling about on the floor to remove the filler bolt and then the drain bolt";

This sequence of removal is so important.
Why is that? one wonders.

Please don't find out the hard way.

[paulj]

I know advice the day after is no use at all, but i used this syringe in place of the hose...

[The Arch Bishop]

Be jeezus, it's been a while since I updated this...

But for very good reason. Basically, the Bucket hsa sat on the driveway in disgrace for the last 2 months. Why? It's a very long story which some of you may have read in this thread - https://www.mr2roc.org/forum/index.php?topic=65086.0

Basically, the hesitation at full throttle suddenly resolved itself through the rev range. It had no torque or go and the throttle would kangaroo the car at mid throttle or sudden openings. Basically, it was dog slow and undrivable. I've had a tremendous amount of help from this superb forum but even swapping out a multitude of parts (Kindly donated by Schnazzle) failed to find the cause.

I also hooked up via the social mediaz with the local MR2 gang (mostly Mk1's and a smattering of mk3's) and one of their number who seems to spend his time converting 1zz's to 2zz's came over to take a look.

First thing checked was the timing which, although the chain was a little loose (maybe it does need a new tensioner), was bang on. Then he had a listen and declared that the inlet manifold was breaking down internally. Now removing one of these without removing the engine is pretty much impossible, although some have managed it. I spent a great many evenings taking apart more and more in the engine bay trying to get the inlet off, but it just wasn't happening. Coolant was drained (and spilt), knuckles were carved of by stubborn throttle housings and still no luck. At this point, I chucked the towel in and left the car looking more and more sorry for itself down the end of the drive.

I had checked the inlet as best I could with an endoscope and a pair of grabbers (to see if I could find any evidence of the inlet runners splintering) and nothing,

So, I'm faced with now trying to reassemble the inlet to the block (it was near impossible to get the bolts out - it'll be harder still to get them back in) with the nagging doubt that that could still be the problem and that, if not, I'm no further to finding what the problem is. Oh and the MOT is up in a few days.

You may have noticed, but I'm at a total low.

One bit of good news was that while checking the timing, it was noted that the top end of the engine looked, in wear terms, like it'd done no mileage. I guess it's had a new or very low mileage engine put in not long ago - possibly why it doesn't use any oil at 120,000 miles.



Seriously, the cams look like they are brand new. Very strange!

But yeah, waited for the summer, summer came, car broke down, much depressing.

Any motivation anyone can spare to bung my way would be appreciated, coz I can't find any of the bastard stuff.

[jonbill]

That's a sorry tale. I've not heard of inlet manifolds breaking down  internally although I'm sure it can happen, they being plastic. And it would sort of fit the symptoms. You may find biting the bullet and taking the engine out to sort it is the easier path.

[The Arch Bishop]

It's certainly starting to look that way, but then comes the bigger problem of while the engine is out, new clutch, new this new that or maybe a 2zz... none of which I really have the disposable income for at the minute.

It's just all a bit bleak at the moment. Add to that that I am not convinced the inlet is the problem. I know it could happen, but scouring the internet, I can find no other mentions of this happening with an MR2.

[The Arch Bishop]

Well, slight update. Local chap turned up today and ripped the inlet out of the bay, thus removing any last vestige of my manliness. 

We've booked a date to put it back together (we couldn't find anything wrong with the inlet) so further testing can take place. The future is at least looking a little less bleak!

[delhusband]

Sorry to hear about your troubles, hope you're up and running soon

[The Arch Bishop]

Cheers delhusband - I just needed a right kick up the bum to get going again which is why I posted on the forum. Usually you can find the support to get up and moving again.

We did also discuss a 2ZZ swap, but the cleanliness of the existing engine means it's a bit of a shame to rip it out. Ultimately it's a known quantity and donor engines are not unless you know the history of them. Would also require a loan.

[jonbill]

Still leaves you with a disassembled engine and no idea what the problem is though!
With the bits shnazzle sent you, have you tried swapping ecu and harness?

[The Arch Bishop]

the guy coming to help me put it back together has a full compliment of spares (even a new engine if required). There's a spare harness as well. The idea is to get it back into a movable state so we can investigate it further.

If we really can't work it out, then it may be time for the engine to come out and a 2ZZ swap.

Whatever, it's a step in the right direction!

[K T M Rider]

I would speculate that quite a few of us on here have followed your excellent RR with great interest, so it is nice to hear from you, even if - sadly - the news itself is currently a bit shite.

FWIW your RR helped inspire me to make the effort to change my gearbox oil the other week, so you can be assured that even if you are not yourself currently benefitting from all the hours you have sweated over your 2 - there are other members of this forum who are doing.

Great that you have found someone to help with the motivation and diagnostics.

Looking forward to the next installment (fingers crossed it's some better news).