[Supras] MR2 100amp Alternator in 92T --- NOT a drop-in

[B A]

Each fix I implement seems to result in a new issue cropping up.  Fun times!

First thing I do is to re-do the PCV hose with a shorter length.
Unfortunately, this proved to be not possible without *seriously* crimping
the hose itself. This is standard 3/4" rubber hosing --- in order to make it
go down towards the bottom of the engine WITHOUT hitting the alternator, it
required such a sharp 90-degree turn downward immediately after the metal
opening by the oil cap that the hose was crimped to the point of not being
functional. Giving the hose just a tad more slack resulted in it getting
absolutely jammed between the back of the alternator and the intake plenum.

So.... I did the exact opposite. I took the remainder of the 5-ft hose,
attached one end to the bottom part of the engine, and just left the rest of
the 5-ft dangling. Will route that PCV hose and determine appropriate length
AFTER the alternator is in place, to ensure no crimping.

So I put the alternator on, semi-tightened the pivot bolt, swung the
alternator down and put the belt on it (fit like a champ since the
alternator now has the original stock 92T pulley), popped in the tensioner
bolt into the alternator, then moved the 10mm tensioner nut upwards until
the belt was at appropriate tension. So far so good....

.... until it came time to plug in that connector on the back of the new MR2
alternator! The MR2 alternator is sufficiently wider/deeper than the stock
one, that this time it wasn't the PCV hose in the way, it was the *intake
plenum itself*   There was no way I could plug in the connector at all --
there just wasn't enough space between the alternator's backside and the
intake plenum.

So.... undid all of the above progress so that the belt was off and the
alternator was just pivoting around on the pivot bolt.  Swung the alternator
high up so that the back receptacle was up and no longer behind the intake
plenum. Plugged in that connector into the back receptacle, then lowered the
alternator back down again.

With the back connector in place, I repeated the process of putting the belt
back on and tightening the pivot and tensioner bolts. Finally making
progress......

..... until I tried to put the connector from the battery onto that long
positive terminal on the alternator. The postive terminal bolt on the MR2
alternator is larger diameter than the stocker.... so that little connector
from the battery simply won't fit over the threaded bolt. **Bummer**    I
vaguely recall reading about someone dealing with this as well --- iirc,
they had to bore out the hole in the connector to achieve a larger diameter
so it would fit over the positive terminal bolt on the alternator.

But it's now 11:15pm and I've been at this WAY longer than this should ever
have taken me.

I am going to go search the forums now for how to do this, but if someone
knows/remembers how to get that cable connector from the battery to fit over
the larger-diameter alternator terminal, please let me know. How do you make
the hole in the connector bigger? Is there some sort of portable machine
that will bore that hole bigger?

Bummed out but soldiering on....