1991 Toyota MR2 Turbo Revival: From Rough to Ready

Engine Diagnosis and Rebuild

• 💡 The 1991 Toyota MR2 Turbo, powered by the 3S GTE engine, was found to have significant issues including a blown head gasket, interior destruction, and rust.
• 🛠️ Initial diagnosis revealed not just a blown head gasket, but also worn piston rings (6-7% leak) and severely burned valves in cylinder 4, necessitating a full engine rebuild.
• 🔬 After a complete teardown, the engine block and crank were sent for inspection and machining, while the cylinder head received a full valve job with new valves.
• ⚙️ The engine rebuild included upgraded internals such as ARP main and head studs, and ACL race bearings, while retaining the factory piston, rod, and crank.
• 💨 The turbocharger was inspected and found to be undamaged, with no bent or damaged turbine blades, allowing it to be reinstalled.

Bodywork and Paint Preparation

• ✨ The MR2's body was stripped down and prepped for paint, with significant rust issues addressed.
• 🎨 The car was sent to Torrey Pines Collision Center for bodywork and paint, transforming its appearance.
• 🌟 Upon return, the bodywork was completed, with the car looking straight and having a uniform color.

Fuel System and Electrical Troubleshooting

• ⛽ A major issue preventing the car from starting was a seized fuel pump, which caused the IGN fuse to repeatedly blow during cranking.
• 🔌 After extensive troubleshooting, including checking relays, fuses, and wiring harnesses, the seized fuel pump was identified as the primary culprit.
• 🔧 The fuel tank was removed, cleaned, and a new fuel pump and filter were installed, resolving the fuel delivery problem.
• ⚡ Other electrical issues addressed included a melted clutch switch and a ground wire that was not properly connected to the chassis.

Cooling System and Suspension Upgrades

• 🌡️ The original radiator, with 280,000 miles, was replaced with a thicker Mishimoto Xline aluminum radiator and upgraded fans for better heat management.
• 💨 New silicone hoses were installed to replace the aging rubber ones, ensuring a reliable cooling system.
• 🔧 The suspension and brakes were upgraded with new shocks, pads, and rotors, and the OEM wheels were refinished and fitted with Falcon Aenus RT 615K Plus tires.

Interior and Exterior Restoration

• 🛋️ The interior received a refresh with new seat cover replacements, a polished instrument cluster glass, a new steering wheel shell, and a new shift boot and knob.
• 💎 JDM-style tail lights were installed, and the exterior trim was polished, giving the MR2 a refreshed '90s aesthetic.
• 💨 A new windshield was installed, completing the exterior restoration.
• 🚗 The final steps included addressing a bent tie rod that affected alignment and installing wiper arms with new blades and the Toyota badge.

First Drive and Completion

• 🚀 The MR2 Turbo underwent its first drive after the extensive rebuild, with careful attention to engine break-in procedures, including monitoring coolant temperatures and oil pressure.
• 🕹️ The long-throw shifter and smooth clutch engagement were noted, and the engine performed well, with the turbo audible.
• ✅ The MR2 Turbo revival project was completed, resulting in a car that looks and drives like new, ready to join the throtl fleet.