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

[B A]

Right.  Wasn't sure using a drill bit might not just crack/break the
connector rendering it useless.  "Zach" in the forums wasn't shy about
stating that it is an obvious solution that evidently won't damage the
connector.

I'll get the swap wrapped up tomorrow.   Thanks again for everyone's
assistance.

bca


On 22/12/2007, Jim Jobe <jjobe2 at supratech.org> wrote:
>
>
> It's called a drill?
>
> On Fri, Dec 21, 2007 at 11:25:19PM -0600, B A wrote:
> > 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....
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