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Fitting the TRD 3SGTE muffler to the OEM B pipe is easy as it's made to fit properly. New bolts and crush washer gasket. The muffler is made by SANGO who also made the OEM mufflers so it just fits properly. Spoke too soon it would seem....
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This bolt on the muffler is not playing ball. The bolt will thread into the captive nut when the muffler isn't on the hanger but when it is the alignment isn't quite right so it meets the nut thread but won't thread in. I had issues last time I fitted the muffler so I know I can get it to work. Just frustrating having a bolt fighting me that has already taken 30mins and I still haven't got it in.
I beat it!!! The TRD 3SGTE muffler is bolted to the MR2!
What a mission!
I decided to fully unbolt it again, then get the troubled bolt into the captive nut on the left hanger first. Then bolt the right hanger in, then bolt the B pipe to the muffler. I'll need to get some bolts to hold the B pipe to the muffler body but that can wait.
Get in my belly!! (Insert Austin Powers character)
Finally got the TRD muffler back on. One problem bolt required the whole thing to come off then go back on a different sequence.
The list of things to do is getting smaller! Here I'm tightening up the fuel feed hose. It's loose in the photo but the gap on the left should be about 1mm or less but not fully tightened.
Radiator hoses all replaced too. Only 3 heater hoses in the frunk for the cooling system are still original from 1990.
Painted the top side of the turbo engine lid rain guard. The sun has damaged the paint beyond repair so a new coat went down. It was visible through the lid louvres. The other side was good so as shown previously I polished it and has all the OEM stickers intact.
I realised I hadn't replaced the sump plug washer on the bolt. A new one comes with the large seal kit so why not. 40Nm tight which is a fair amount but not too crazy. Essentially enough to create a seal.
This is a crazy idea I've been working with for a while. The OEM airbox has a sealed chamber with a very small hole leading back to the filter area. So, I've taken that concept and expanded on it. The large pipes are for the BOV (blow off valve) and the theory is to muffle that sound using a muffler arrangement in the side of the airbox. The smaller pipe is for the IACV (idle air control valve) at cold idle it can make quite a loud sucking noise. I want to remove that noise.
My BOV is a GFB Respons so it has venting and recirculation bias adjustment. So for a MAP sensor engine I can either go full venting or full recirculation and when in recirculation mode it will hopefully remove the BOV sound too. Not that I'm against it but maybe making the car more neighbour/wife friendly. But then when I want it to be the car I've always wanted it to be, I can just rotate the BOV dial on top and there we go!
Trimming the tubes down with a drop saw I borrowed to make them straight. The hacksaw is no good for doing that. Now they are all the correct length after I made them 10mm longer on purpose so I could trim them properly.
Then cleaning up the ends with sandpaper so they aren't sharp.
I drew up a CAD template for drilling holes in the muffler pipes. Then used a centre punch and a small hammer to mark the 196 holes to be drilled in the 4 pipes.
