First thing i would like to know is how effective is the intercooling system compared to a front mount? im not completely sure where the intercooler would be stored but it seems to me as though it wouldnt be getting a lot of cool air rushing through it like a front mount does, this is one off my main concerns because when i purchase the mr2 i would like to push it 18-20psi and hopefully achieve ~300hp more or less.
Q1
Front mounts are useless on an MR2 due to the lag you create having to get the air from the back of the car to front mount, and then back to the engine in the back. Options for intercooling are pretty much as follows:
Minimum if you want ~300hp:
a.) upgrade side mount to an HKS/Greddy/ARC or equivalent
b.) add ducting/fans to the intercooler to improve flow of air through it
c.) Add water/Methanol injection to the system to eliminate knock/regulate intake temps
Better option, top mount intercooler:
a.) upgrade to a Full-Race or Border or equivalent top mount intercooler
b.) add ducting/fans to the intercooler to improve flow of air through it
c.) Add water/Methanol injection to the system to eliminate knock/regulate intake temps
Best option, W2A intercooler:
a.) upgrade to a water to air intercooler
Q2.
I find I spend more time under the car more than over the side. It can get tight in there, so I generally try not to spend too much time on it myself lol.
Q3.
BOV may make it run rich due to that additional air that's vented, but the AFM has accounted for as staying in the system. You could change the system to a MAP sensor system, but that's a lot of effort just for a BOV. The real question is, what are you using the BOV for?
Q4.
Depends on your car. If its been well maintained in its previous life, and you're not modding it too much, it should be fine. I drove mine everyday for 50,000kms back in the day when it only had bolt ons, and it was fine. the moment i started changing turbos/ecu etc, the motor blew.