The Toyota MR2 is very fun and cool convertible that offers great performance combined with the ability to drop the top. However, from the factory, the MR2 does not come with a rollbar, which many people consider a must-have safety feature in a convertible sports car like this one. An aftermarket rollbar can be installed in an MR2, though it is not the easiest task and takes some special tools and skills.
- Skill level:
- Moderately Challenging
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Things you need
- Socket set and ratchet
- Rotary cutting tool
Put the top down. Disconnect the negative battery terminal on the battery. With a socket, remove the seats, seat belt reels and shoulder harness guide bolts. Remove the evaporative emissions canister cover that is bolted onto the car on the driver's side. Remove the fuel pump cover, which is held on with silicone. Disconnect the wires and hoses that go on the fuel pump and fuel gauge sender on the passenger side. Unplug the evaporative line. Loosen the bolts for the computer bracket on the firewall behind the driver's side and turn the bracket around.
Remove some of the carpeting and firewall insulation to allow the rear brace plates to be installed. Remove the battery air box from the engine bay. Disconnect the fuel filler valve and vent hose under the car. Unbolt and remove the gas tank with the help of an assistant.
Set the rollbar in place, being careful not to damage the convertible top. Align the upper rollbar brackets on the main hoop with the shoulder harness guide attachment points. Install the bolts that hold the bar in place on the shoulder guides and hand-tighten them.
Make sure that the bar is sitting all the way down in the car. Mark where you are going to drill holes by using the holes in the rollbar mounting plate brackets as a guide. Drill the proper-size holes with a power drill.
Move under the car to the fuel tank cavity where the tank was removed. Use a rotary cutting tool to open a slot on either side of the fuel tank cavity so that you can install the front lower backup plates. Make sure you don't cut through the chassis cross-brace.
Slide the backup plates through the slots and have an assistant thread the bolts on hand tight. Install the rear lower hoop backup plates and hand-tighten them. Use a long screwdriver to slide the back up plates with the nuts attached so that the align with the bolt holes that were drilled in Step 4. Hand-tighten the bolts.
Move back to the engine bay and use the rotary cutting tool to cut off the nut bracket that is welded onto the driver's side of the firewall. This should be smooth to allow the backup plate to be properly installed. Install the rearward brace mounting bolts through the firewall and into the backup plates with the original bolts and washers.
Check all the bolts for tightness. Seal all of the openings that were cut with expanding foam and then spray the exposed metal with undercoating to prevent rust. Reinstall the fuel tank. Attach all of the wire, fuel lines and evaporative emissions lines that were disconnected. Reinstall the computer, air box and battery. Trim the evaporative canister cover and reinstall it. Glue the fuel pump cover back on. Install the seat belt reels and the fasten the shoulder harness guide to the rollbar instead of the car. Trim the rear carpet and luggage compartment boxes to fit around the rollbar. Reinstall the seats.
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