Suspension Up-Grade 1991 to 1995 stock
From: Kostas Chryssos (sv1bt@athena.compulink.gr)
To: uunet!validgh.com!mr2-interest@uunet.uu.net
Subject: Suspension Up-Grade 1991 to 1995 stock
Date: Fri, 22 Sep 1995 19:04:03 +0200
I will be glad to reply to any individual question.
Please e-mail directly
bibi
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Suspension Upgrade USA MODEL MR2 MKII TURBO
1991 stock ====> to 1993/95 stock
++ GENERAL ++
= Up-grade is easy, all parts fit as obtained without any modifications
required.
= Lifting of the car and working safely under it is a must.
= Standard tools required, torque wrench and a support tripod or lift to
secure engine from the bottom or the top.
= It is recommended to use the 1995 Service Manual for torque specs,
instructions and general assistance. Pages mentioned here-in are 1995 edition.
= Every effort has been taken to confirm part no etc. Errors and omitions
accepted. No responsibility undertaken. This document is prepared for my own
personal use.
= Parts marked (*) are not required to change due to this upgrade. It is
though recommended that they be changed given the opportunity.
++ PARTS ++
1. (*) 48830-17040 (x2) Link assy rear stabilizer
2. (*) 90201-10005 (x4) Washers
3. (*) 90179-10054 (x4) Nuts
4. 48780-17040 (x2) Rod assy strut rear
5. (*) 90119-12146 (x2) Bolt for strut rod
6. (*) 48787-17020 (x2) Cushion strut bar FR
7. (*) 48787-17030 (x2) Cushion strut bar RR
8. (*) 90387-18018 (x2) Coller for strut bar
9. (*) 90948-02138 (x4) Retainer cushion
10. (*) 90179-12094 (x2) Nut body side
11. (*) 90179-18014 (x2) Nut carrier side
12. 48703-17030 (x1) Arm assy rear susp No.1 RH
13. 48707-17020 (x1) Arm assy rear susp No.1 LH
14. (*) 90101-12169 (x4) Bolt rear susp arm
15. (*) 90101-14043 (x2) Bolt rear susp arm
16. 90201-14026 (x2) Spacer
17. 90201-20019 (x2) Spacer
18. 90105-12059 (x4) Bolts
19. 43330-39345 (x2) Joint assy lower ball rear
20. 48730-17040 (x1) Arm assy rear susp No.2 RH
21. 48730-17040 (x1) Arm assy rear susp No.2 LH
22. 90201-12066 (x2) Spacer
23. 90179-12093 (x2) Nut
24. 51206-17020 (x1) Member sub-assy rear susp (bridge)
Note: Item 24 should be painted with black hard epoxy based paint prior to
installation. Try spray paint to cover inside as much as possible to prevent
future corrosion.
++ PROCEDURE ++
= Follow instructions in Service Manual 1995 edition pages SA58 to SA65.
Make sure you have an extra pair of hands available. Some work requires two.
= Lift car
= Remove rear wheels
= Remove stabilizer link
= (W ABS) Remove ABS speed sensor bracket
= Remove lower susp arm
= Remove rear axle carrier from susp arm
= Loosen (do NOT remove yet) the 4 screws holding the "bridge", use a tripod
to support the engine properly, remove the 3 bolts and the engine rear
mount, the 2 bolts and the exhaust pipe mount,
= With the engine secured remove the 4 bolts holding the "bridge"
= Lower the bridge carefully
= Remove the stabilizer bar from the "bridge:
= Install the stabilizer bar to the new "bridge"
= Reverse install items using new parts where applicable.
= Take care to properly torque all bolts and nuts.
= The susp arms and the strut bars come pre-adjested for proper length.
Please re-check the length prior to mounting.
= At the end allign wheels in accordance to the 1995 manual.
++ ADDITIONAL OPTIONAL 1995 UPDATE ITEMS (RECOMMENDED) ++
1. 48609-17040 (x2) Support subassy front suspension
2. 48820-17030 (x2) Link assy front stabilizer (strongly rec.)
3. 48753-17020 (x1) cover rear susp support No. 1 RH
4. 48753-17030 (x1) cover rear susp support No. 1 LH
5. 48750-17040 (x2) Support assy rear susp
6. 90179-14015 (x2) Nuts
7. 48811-17130 (x1) Bar stabilizer front
8. 48815-17110 (x2) Bush stabilizer front
9. 48824-17021 (x2) bracket stabilizer front
10. 48812-17110 (x1) Bar stabilizer rear
11. 48818-17111 (x2) Bush stabilizer rear
++ OPTIONAL SPRINGS AND ABSORBER 1995 UPDATE ++
1. 48131-17600 (x1) Spring front coil RH
2. 48131-17600 (x1) Spring front coil LH
3. 48510-19335 (x1) (OPT 66) Absorber assy FRH
4. 48520-19055 (x1) (OPT 66) Absorber assy FLH
5. 48331-17030 (x2) Bumper front spring
6. 48231-1R290 (x2) Spring coil rear
7. 48530-19535 (x1) Absorber assy RRH
8. 48540-19045 (x1) Absorber assy RLH
9. 48341-17020 (x2) Bumper rear spring
The above conclude the total suspension UpDate EXCLUDING part 48660-17040 and
48670-17040 RH and LH front bar assy as those require dif anchorage. The new
part is fixed size while the old is adjustable. Personally I prefer the old
part.
++ In addition to the above here is a list of the NEW CAR FEATURES ++
++ for 1993, 1994 and 1995 Models ++
1993==> 1. S54 Manual transaxle change (internal)
2. Seat belt warning light change of operatrion
1994==> 1. Models discontinued: SW20L-ACMZZA, AJMZZK AND SW21L-AJMZKK
2. Exterior equipment:
a. Rear design of combination lights
b. Rear spoiler change to one piece
3. Interior equipment:
a. Steering wheel design change decreased diameter old:
380mm, new: 370mm
b. Auto transaxle lock button added
4. 3SGTE Engine:
a. Recommended oil grade change
b. Engine control system changed to conform to OBD-I
requirements
5. 3SFE Engine
a. As above 3SGTE
6. Wheel alignment and suspension component modified to further
enhance driving stability and confort.
7. Electrohydraulic power steering. Two system controls added
to assist driving characteristics.
8. Cruise control system improved
9. SRS airbag changed to include passenger side
10. Air conditioning system up-grade to R134a
1995==> A carry over from 1994. No changes.
+++++++====> CODES
Code: SW20L-AJMZZA
1. SW20 ==> 3SGTE engine
(SW21) ==> 3SFE engine
2. L ==> Left hand steering
3. A ==> MR2
4. J ==> 2 door coupe with T-bar roof
(C) ==> 2 door coupe
5. M ==> 5 speed manual
(P) ==> 4 speed automatic
6. Z ==> Base grade
7. Z ==> DOHC and MFI (EFI) with TC
(K) ==> DOHC and MFI (EFI)
8. A ==> Destination USA
Kostas Chryssos