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

[B A]

As promised, posting to let everyone know that the alt swap is now complete.
Car is running nice and strong once again with the new 100amp MR2
alternator. The last steps that had to be done:

1. I did purchase, at Chris (88T)'s suggestion, a pre-formed hose with a
built-in 90degree angle, to prevent the crimping i mentioned below. But the
MR2 alternator is still so big that there's just no room for the hose. So i
scrapped that and continued with the plan of routing the PCV line underneath
the alternator and then have it come up and go around the outside of the
alternator up towards the oil cap.

2. Connected the plug into the alternator's back receptacle *before*
installing the alternator, so the intake plenum wouldn't get in the way.

3. Widening the hole in the connector from the battery: Instead of drilling,
I just purchased this 6"-long round metal file for 4 bucks:

http://images.lowes.com/product/037103/037103218469.jpg

Spent about 3-4 minutes filing away at the inside of that round hole and got
it large enough to go around the MR2 positive terminal bolt.  Bob's
suggestion of soldering in an additional connector would probably have been
wise, re: keeping the ability to go back to stock 80A.....   in a perfect
world with a bit more time on my hands, I probably would have gone that
route.

4. Had to hit up Lowe's and snare an M8-1.25 hex nut to secure the connector
from the battery, as the MR2 alt did not come with one.

Belt tension was a bit loose, so tightened it up a bit with the 10mm nut
until there was about 0.5 - 0.75" freeplay in the belt. Fired up the car,
and presto. The battery/headlights/ebrake warning lights were all gone, and
car was running strong once again -- all ready for the Infinity
amp/subwoofer and Polk speakers install now.

For someone who's done plenty of other Supra mods (AVC-R, TDSE install, TRD
boost gauge, Gentex chromatic mirror with digital temp/compass, HKS TT,
etc.)... I clearly was not expecting this MR2 alternator to present a
challenge, and it showed. With the appropriate mindset adjustment and good
advice from several people here (esp Steve/Dan), the job is done and the car
is running great.

Took plenty of pics, so I will put together an illustrated How-To/Tech-Tip
on supraforums so any other 89-92t owners who want to do the 100A alternator
upgrade won't run into the same issues I did.

Thanks again for the helpful responses, and cheers from Austin, TX
Brian


On 22/12/2007, Bob Shapton <bshap at tonedeaf.com> wrote:
>
> Another possible solution is to get 2 terminals - one with the correct
> diameter hole for the old wiring and the other with the correct diameter
> hole
> for the alternator post. Connect the 2 new terminals together by soldering
> or by usinfg a short piece of wire of the appropriate guage, Then bolt in
> the
> 'adapter' mini-harness. This way you can revert to the original small
> alternator if desired in the future.
>
> Bob