Toyota MR2 Models Repair Service Manual 1984-2007
Complete service repair manual with Electrical Wiring Diagrams for Toyota MR2 Models 1984-2007, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Toyota MR2 Models 1984-2007 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Toyota MR002 (AW11 Series) Repair Manual 1989.pdf
Toyota MR002 (AW11 Series) Service Manual 1988.pdf
Toyota MR002 Repair Manual MK2002.pdf
Toyota MR002 Service Repair Manual 1991.pdf
Toyota MR002 Spyder Roadster MR-S MK3 (Model ZZW30 Series) Service Manual 1999-2007.pdf
Toyota MR002 (SW20_21 Series) Repair Manual 1991.pdf
Toyota MR002_Turbo Service Manual 1993 (bonus material).pdf
PRODUCT DETAILS:
Total Pages: 13,022 pages
File Format: PDF
Language: English
MAIN SECTIONS
Toyota MR002 (AW11 Series) Repair Manual 1989......1
Introduction......3
How to use this manual......4
Identification information......6
General repair instructions......6
Precautions for vehicles w/ catalytic converter......8
Precautions for vehicles w/ an audio system w/ built-in anti-theft......9
Vehicle lift and support locations......10
Abbreviations used in this manual......11
Maintenance......13
Maintenance schedule......14
Maintenance operations......16
General maintenance......24
Engine Mechanical......27
Troubleshooting......28
Engine tune-up......32
Compression check......40
Timing belt......41
Cylinder head (4A-GE)......52
Cylinder head (4A-GZE)......81
Cylinder block......92
Supercharger System......139
Troubleshooting......140
Supercharger......141
Supercharger relay......157
Emission Control Systems......159
System purpose......160
Component layout and schematic drawing (4A-GE)......161
Component layout and schematic drawing (4A-GZE)......162
Positive crankcase ventilation system......163
Fuel evaporative emission control system......164
Dash pot system......166
Exhaust gas recirculation system (4A-GE)......168
Exhaust gas recirculation system (4A-GZE)......174
Three-way catalyst system......179
Troubleshooting (see page EM-2)......28
EFI System......181
Description......182
Precautions......185
Inspection precautions......185
Troubleshooting......189
Diagnosis system......201
Troubleshooting with volt/ohmmeter (4A-GE)......209
Troubleshooting with volt/ohmmeter (4A-GZE)......211
Troubleshooting EFI circuit with volt/ohmmeter (4A-GE)......213
Troubleshooting EFI circuit with volt/ohmmeter (4A-GZE)......228
Fuel system......244
Fuel pump......244
Cold start injector......253
Pressure regulator (4A-GE)......258
Pressure regulator (4A-GZE)......259
Injector......260
Fuel tank and line......273
Air induction system......274
Air flow meter......274
Throttle body......277
Idle speed control valve (4A-GZE)......286
Auxiliary air valve (4A-GE)......288
Electronic control system......289
Location of electronic control parts......289
EFI main relay......290
Circuit opening relay......291
Solenoid resistor (4A-GZE) and injector relay......293
Start injector time switch......295
Water temperature sensor......296
EGR gas temperature sensor (California)......297
High temperature line pressure up system......298
Idle-up system......299
Oxygen sensor......300
Electronic controlled unit (ECU)......303
Fuel cut RPM......308
Cooling System......309
Troubleshooting......310
Check of engine coolant......310
Replacement of engine coolant......311
Water pump......314
Thermostat......318
Radiator......319
Electric cooling fan (radiator)......321
Electric cooling fan (engine compartment)......325
Lubrication System......331
Troubleshooting......332
Oil pressure check......332
Replacement of engine oil and oil filter......333
Oil pump......335
Oil cooler and pressure regulator......343
Ignition System......349
Precautions......350
Troubleshooting......350
Electronic spark advance......351
On-vehicle inspection......352
Distributor......357
Starting System......361
Troubleshooting......362
Starter......363
Clutch starter relay......372
Clutch start switch (see page CL-4)......392
Charging System......373
Precautions......374
Troubleshooting......374
On-vehicle inspection......375
Alternator......378
Engine main relay......388
Clutch......389
Troubleshooting......390
Check and adjustment of clutch pedal......391
Bleeding of clutch system......391
Inspection of clutch start system......392
Clutch master cylinder......393
Clutch release cylinder......397
Clutch unit......400
Manual Transaxle......405
Precautions......406
Troubleshooting......406
Removal of transaxle......407
C52 transaxle......411
Transmission components......411
Disassembly of transmission......414
Inspection of transmission components......422
Assembly of transmission......428
Differential......441
E51 transaxle......442
Components......442
Removal of component parts......445
Inspection of component parts......453
Input shaft assembly......457
Output shaft assembly......463
Oil pump assembly......469
Shift and slect lever assembly......474
Differential......478
Installation of component parts......488
Installation of transaxle......500
Shift lever and control cable......504
Automatic Transaxle......507
System description......508
Troubleshooting......508
Basic troubleshooting......508
General troubleshooting......509
Preliminary check......511
Manual shift test......513
Stall test......514
Time lag test......515
Hydraulic test......516
Road test......517
Electronic control system......521
Operating mechanism for each gear......536
Automatic shift schedule (A240E/4A-GE)......537
Automatic shift schedule (A240E/4A-GZE)......538
On-vehicle repair......539
Removal of transaxle......546
Torque converter......550
Oil pump......550
Disassembly of transmission......552
Component group disassembly, inspection and assembly......572
Oil pump......573
Direct clutch......576
Forward clutch......579
No.1 one-way clutch and sun gear......582
No.2 one-way clutch and rear planetary gear......584
First and reverse brake piston......586
Intermediate shaft......588
Counter shaft......590
Valve body......598
Front Axle and Suspension......651
Troubleshooting......652
Front wheel alignment......653
Front axle hub......657
Front shock absorber......665
Front suspension......670
Ball joint......670
Lower arm......671
Stabilizer bar and link......673
Strut bar......675
Rear Axle and Suspension......677
Troubleshooting......678
Rear wheel alignment......679
Rear axle hub and carrier......682
Rear drive shaft......690
Rear suspension......711
Rear shock absorber......712
Ball joint......716
Lower arm......717
Strut rod......719
Suspension arm......720
Stabilizer bar and link......722
Brake System......725
Precautions......726
Troubleshooting......726
Checks and adjustments......729
Master cylinder......732
Brake booster......739
Front brake......742
Rear brake......750
Brake hoses and tubes......764
Steering......765
Precautions......766
Troubleshooting......766
On-vehicle inspection......767
Steering column assembly......767
Steering gear housing......778
Body Electrical System......791
General information......792
Location of switches and relays......796
Ignition switch......800
Lighting......801
Wiper and washer......809
Instruments, gauges and wiring lights......813
Rear window defogger......821
Heater......823
Cruise control system......829
Power window......853
Door lock control system......856
Remote control mirror......858
Audio system......859
Clock......868
Body......871
General information......872
Front hood......873
Engine hood......873
Headlight......874
Front door......875
Luggage compartment lid......885
Moulding......886
Windshield......901
Quarter window glass......907
Rear window glass......909
T-bar roof......913
Sun roof......920
Instrument panel......924
Seat......930
Seat belt......931
Body dimensions......932
Air Conditioning System......937
General information......938
A/C system circuit......940
System components......943
General description......944
Special tools and equipment......946
SSM (special service materials)......946
Troubleshooting......946
Checking of refrigeration system w/ manifold gauge......948
On-vehicle inspection......951
Refrigeration system......952
Checking of refrigeration volume......952
Installation of manifold gauge set......952
Compressor......953
Receiver......967
Condenser......967
Condenser fan motor......969
Relays......970
Pressure switch......971
Water temperature sensor......971
Cooling unit......972
Evaporator......974
Refrigerant lines......975
Thermistor......976
A/C switch......976
A/C amplifier......977
Vacuum switching valve......979
Service Specifications......981
Maintenance......982
Engine mechanical......983
Supercharger system......986
EFI system......987
Cooling system......992
Lubrication system......992
Ignition system......993
Starting system......993
Charging system......993
Clutch......994
Manual transaxle......995
Automatic transaxle......1002
Front axle and suspension......1007
Rear axle and suspension......1008
Brake system......1009
Steering......1010
Body......1011
Lubricant......1012
Standard Bolt Torque Specifications......1013
Standard bolt torque specifications......1014
SST and SSM......1017
Special service tools......1018
Special service materials......1031
Electrical Wiring Diagrams......1033
How to read this section......1033
System index......1034
Toyota MR002 (AW11 Series) Service Manual 1988......1060
Volume 1......1060
Contents......1061
Introduction......1062
How to use this manual......1063
Identification information......1065
General repair instructions......1065
Precautions for vehicles equipped with a catalytic converter......1067
Vehicle lift and support locations......1068
Abreviations used in this manual......1069
Maintenance......1070
Maintenance schedule......1071
Maintenance operations......1073
General maintenance......1081
Engine Mechanical......1083
Troubleshooting......1084
Engine tune-up......1088
Inspection of engine coolant......1384
Inspection of engine oil......1406
Inspection of battery......1447
Inspection of air filter......1074
Inspection of high-tension cords......1425
Inspection of spark plugs......1425
Inspection of alternator drive belt......1447
Adjustment of valve clearance......1089
Compression check......1115
Timing belt......1116
Cylinder head (4A-GZE)......1156
Cylinder head (4A-GE)......1127
Cylinder block......1167
Supercharger System......1214
Troubleshooting......1215
Supercharger......1216
Supercharger relay......1232
Emission Control Systems......1233
System purpose......1234
Component layout and schematic drawing (4A-GE)......1235
Component layout and schematic drawing (4A-GZE)......1236
Positive crankcase ventilation (PVC) system......1237
Fuel evaporative emission control (EVAP) system......1238
Dash pot (DP) system......1240
Exhaust gas recirculation (EGR) system (4A-GE)......1242
Exhaust gas recirculation (EGR) system (4A-GZE)......1248
Three-way catalyst (TWC) system......1253
EFI System......1255
Description......1256
Precautions......1259
Inspection precautions......1259
Troubleshooting......1263
Diagnosis system......1275
Troubleshooting with volt/ohmmeter (4A-GE)......1283
Troubleshooting with volt/ohmmeter (4A-GZE)......1285
Fuel system......1318
Fuel pump......1318
Cold start injector......1327
Pressure regulator (4A-GE)......1332
Pressure regulator (4A-GZE)......1333
Injector......1334
Fuel tank and line......1347
Air induction system......1348
Air flow meter......1348
Throttle body......1351
Idle speed control (ISC) valve (4A-GZE)......1360
Auxiliary air valve (4A-GE)......1362
Electronic control system......1363
Location of electronic control parts......1363
EFI main relay......1364
Circuit opening relay......1365
Solenoid resistor (4A-GZE) and injector relay......1367
Start injector time switch......1369
Water temperature sensor......1370
EGR gas temperature sensor......1371
High temperature line pressure up system......1372
Idle-up system......1373
Oxygen sensor......1374
Fuel cut rpm......1382
Cooling System......1383
Troubleshooting......1384
Check of engine coolant......1384
Replacement of engine coolant......1385
Water pump......1388
Thermostat......1392
Radiator......1393
Electric cooling fan (radiator)......1395
Electric cooling fan (engine compartment)......1399
Lubrication System......1404
Troubleshooting......1405
Oil pressure check......1406
Replacement of engine oil and oil filter......1407
Oil pump......1408
Oil cooler and pressure regulator......1416
Ignition System......1421
Precautions......1422
Troubleshooting......1422
Electronic spark advance (ESA)......1423
On-vehicle inspection......1424
Distributor......1429
Starting System......1433
Trouble shooting......1434
Starter......1435
Clutch starter relay......1444
Clutch start switch......1444
Charging System......1445
Precautions......1446
Troubleshooting......1446
On-vehicle inspection......1447
Alternator......1450
Engine main relay......1460
Clutch......1461
Troubleshooting......1462
Check and adjustment of clutch pedal......1463
Bleeding of clutch system......1463
Inspection of clutch start system......1464
Clutch master cylinder......1465
Clutch release cylinder......1469
Clutch unit......1472
Manual Transaxle......1476
Precautions......1477
Troubleshooting......1477
Removal of transaxle......1478
C52 transaxle......1482
Transmission......1482
Components......1482
Disassembly of transmission......1485
Inspection of transmission components......1493
Assembly of transmission......1499
Differential......1512
E51 transaxle......1513
Components......1513
Removal of component parts......1516
Inspection of component parts......1524
Input shaft assembly......1528
Output shaft assembly......1534
Oil pump assembly......1540
Shift and select lever assembly......1545
Differential......1549
Installation of component parts......1559
Installation of transaxle......1571
Shift level and control cable......1575
Automatic Transaxle......1577
System description......1578
Troubleshooting......1578
Basic troubleshooting......1578
General troubleshooting......1579
Preliminary check......1581
Manual shifting test......1583
Stall test......1584
Time lag test......1585
Hydraulic test......1586
Road test......1587
Electronic control system......1591
Operating mechanism for each gear......1606
Automatic shift diagram (A240E/4A-GE)......1607
Automatic shift diagram (A241E/4A-GZE)......1610
On-vehicle repair......1613
Removal of transaxle......1620
Torque converter......1624
Oil pump......1625
Disassembly of transmission......1626
Component group disassembly, inspection and assembly......1646
Oil pump......1647
Direct clutch......1650
Forward clutch......1653
No.1 One-way clutch and sun gear......1656
No.2 One-way clutch and rear planetary......1658
First and reverse brake piston......1660
Intermediate shaft......1662
Counter shaft......1664
Valve body......1672
Assembly of transmission......1688
Differential......1710
Installation of transaxle......1720
Front Axle and Suspension......1724
Troubleshooting......1725
Front wheel alignment......1726
Front axle hub......1730
Front shock absorber......1738
Front suspension......1743
Ball joint......1743
Lower arm......1744
Stabilizer bar and link......1746
Strut bar......1748
Rear Axle and Suspension......1750
Troubleshooting......1751
Rear axle alignment......1752
Rear axle hub and carrier......1755
Rear drive shaft......1763
Rear suspension......1779
Rear shock absorber......1780
Ball joint......1784
Lower arm......1785
Strut rod......1787
Suspension arm......1788
Brake System......1790
Precautions......1791
Troubleshooting......1791
Checks and adjustments......1794
Master cylinder......1797
Brake booster......1804
Front brake......1807
Rear brake......1815
Brake hoses and tubes......1829
Steering......1830
Precautions......1831
Troubleshooting......1831
On-vehicle inspection......1832
Steering column assembly......1832
Steering gear housing......1843
Body Electrical System......1855
General information......1856
Location of switches and relays......1860
Ignition switch......1864
Lighting......1865
Wiper and washer......1873
Instruments, guages and warning lights......1877
Rear window defogger......1885
Heater......1887
Cruise control system......1893
Power window......1917
Door lock control system......1920
Remote control mirror......1922
Radio, stereo tape player and antenna......1923
Clock......1930
Body......1932
General information......1933
Front hood......1934
Engine hood......1934
Headlight......1935
Front door......1936
Luggage compartment lid......1946
Moulding......1947
Windshield......1962
Quarter window glass......1968
Rear window glass......1970
T-bar roof......1974
Sun roof......1981
Instrument panel......1985
Seat......1991
Seat belt......1992
Body dimensions......1993
Air Conditioning System......1997
General description......1998
Air conditioning system circuit......2000
System components......2003
Precautions......2004
Special tools and equipment......2004
Troubleshooting......2005
Checking of refrigeration system with manifold guage......2006
On-vehicle inspection......2009
Refrigeration system......2010
Checking of refrigerant charge......2010
Installation of manifold guage set......2010
Compressor......2011
Receiver......2026
Condenser......2027
Condenser fan motor......2028
A/C relays......2029
Pressure switch......2030
Water temperature sensor......2030
Cooling unit......2031
Evaporator......2033
Refrigerant lines......2034
Thermistor......2035
A/C switch......2035
Air conditioner amplifier......2036
Vacuum switching valve (VSV)......2038
Service Specifications......2039
Maintenance......2040
Engine mechanical......2041
Supercharger system......2044
EFI system......2045
Cooling system......2050
Lubrication system......2050
Ignition system......2051
Starting system......2051
Charging system......2051
Clutch......2052
Manual transaxle......2053
Automatic transaxle......2060
Front axle and suspension......2065
Rear axle and suspension......2066
Brake system......2067
Steering......2068
Body......2069
Lubricant......2070
Standard Bolt Torque Specifications......2071
SST and SSM......2074
SST (special service tools)......2075
SSM (special service materials)......2087
Automatic Transmission Hydraulic Circuit......2088
Electrical Wiring Diagrams......2098
Toyota MR002 (SW20_21 Series) Repair Manual 1991......2125
Vol. 1_Repair Manual......2125
Volume 1......2125
Contents......2126
Introduction......2127
How to use this manual......2128
Identification information......2130
General repair instructions......2130
Precautions for vehicles with Airbag......2133
Precautions for vehicles with catalytic converter......2137
Precautions for vehicles with audio and anti-theft systems......2137
Vehicle lift and support locations......2138
Abbreviations......2139
Maintenance......2140
Maintenance schedule......2141
Maintenance operations......2143
General maintenance......2153
Engine Mechanical......2155
Descritption (3S-GTE)......2156
Description (5S-FE)......2158
Troubleshooting......2160
Engine tune-up......2164
Toyota-variable induction system......2176
Idle and/or 2,500 RPM HC/CO checking......2177
Compression check......2179
Timing belt (3S-GTE)......2180
Timing belt (5S-FE)......2201
Cylinder head (3S-GTE)......2215
Cylinder head (5S-FE)......2251
Cylinder block (3S-GTE)......2287
Cylinder block (5S-FE)......2335
Exhaust System......2382
Exhaust pipes and heat insulators......2383
Turbocharger System......2384
Description......2385
Precautions......2387
Troubleshooting......2388
Turbocharger......2390
Intercooler......2403
Emission Control Systems......2410
3S-GTE......2411
System purpose......2411
Component layout and schematic drawing......2412
Positive crankcase ventilation system......2413
Fuel evaporative emission control system......2430
Exhaust gas recirculation system......2433
Three-way catalyst system......2437
5S-FE......2427
System purpose......2427
Component layout and schematic drawing......2428
Positive crankcase ventilation system......2429
Fuel evaporative emission control system......2430
Exhaust gas recirculation system......2433
Three-way catalyst system......2437
EFI System......2442
Description......2443
Precautions......2446
Inspection precautions......2446
Troubleshooting......2452
Diagnosis system......2466
Troubleshooting with volt/ohmmeter......2474
Fuel System......2526
Fuel pump......2526
Cold start injector (3S-GTE)......2540
Cold start injector (5S-FE)......2543
Fuel pressure regulator (3S-GTE)......2546
Fuel pressure regulator (5S-FE)......2548
Injectors (3S-GTE)......2551
Injectors (5S-FE)......2561
Fuel tank and lines......2570
Air Induction System......2572
Air flow meter (3S-GTE)......2572
Throttle body (3S-GTE)......2575
Throttle body (5S-FE)......2581
Idle speed control valve (3S-GTE)......2589
Idle speed control valve (5S-FE)......2592
Electronic Control System......2595
Location of electronic control parts......2595
EFI main relay......2597
Circuit opening relay......2598
Cold start injector time switch......2599
Solenoid resistor (3S-GTE)......2600
Fuel pump relay and resistor (3S-GTE)......2601
Fuel pressure VSV (5S-FE)......2602
T-VIS VSV (3S-GTE)......2604
Turbocharging pressure VSV (3S-GTE)......2606
EGR VSV......2608
Water temperature sensor......2609
Intake air temperature sensor (5S-FE)......2610
Vacuum sensor (5S-FE)......2611
Turbocharging pressure sensor (3S-GTE)......2612
EGR gas temperature sensor (3S-GTE & 5S-FE Calif. only)......2613
Oxygen sensor (main)......2614
Sub-oxygen sensor (5S-FE Calif. only)......2616
Electronic controlled unit (ECU)......2617
Fuel cut RPM......2623
Cooling System......2624
Description......2625
Troubleshooting......2627
Engine coolant check......2627
Replacement of engine coolant......2628
Water pump......2633
Thermostat......2637
Radiator......2639
Electric cooling fans......2644
Radiator cooling fans (w/ A/C)......2644
Radiator cooling fan (w/o A/C)......2651
Engine compartment cooling fan (3S-GTE)......2654
Lubrication System......2660
Description......2661
Troubleshooting......2664
Oil pressure check......2665
Replacement of engine oil and oil filter......2666
Oil pump......2668
Oil cooler (3S-GTE)......2677
Oil cooler (5S-FE)......2682
Oil Nozzles (3S-GTE)......2685
Ignition System......2686
Precautions......2687
Troubleshooting......2688
Ignition system circuit......2689
On-vehicle inspection (3S-GTE)......2690
On-vehicle inspection (5S-FE)......2695
Distributor (3S-GTE)......2699
Distributor (5S-FE)......2704
Starting System......2708
Troubleshooting......2709
Starter......2710
Starter relay......2725
Clutch start switch (M/T only)......2725
Charging System......2726
Precautions......2727
Troubleshooting......2727
On-vehicle inspection......2728
Alternator......2731
Ignition main relay......2743
Service Specification......2744
Maintenance......2745
Engine Mechanical (3S-GTE)......2746
Engine mechanical (5S-FE)......2750
Exhaust system......2754
Turbocharger system......2754
EFI system (3S-GTE)......2755
EFI system (5S-FE)......2758
Cooling system......2761
Lubrication system......2762
Ignition system......2763
Starting system......2763
Charging system......2763
Lubricant......2764
Standard Bolt Torque Specifications......2765
Standard Bolt Torque Specifications......2766
Volume 2......2769
Contents......2770
Clutch......2771
Troubleshooting......2772
Check and adjustment of clutch pedal......2773
Bleeding of clutch system......2774
Inspection of clutch start system......2775
Clutch master cylinder......2776
Clutch release cylinder......2779
Clutch unit......2783
Manual Transaxle......2787
Description......2788
Precautions......2790
Troubleshooting......2790
Removal and installation of transaxle......2791
S54 Transaxle / SW21 series......2793
Removal of component parts......2793
Component parts......2807
Input shaft assembly......2807
Output shaft assembly......2813
Shift and select lever assembly......2820
Differential......2823
Installation of component parts......2833
E153 Transaxle / SW20 series......2843
Removal of component parts......2843
Component parts......2859
Input shaft assembly......2859
Output shaft assembly......2865
Oil pump......2871
Shift and select lever shaft......2876
Differential......2880
Installation of component parts......2890
Shift lever and control cable......2902
Automatic Transaxle (A241E)......2904
Description......2905
Operation......2907
Troubleshooting......2912
Basic Troubleshooting......2912
Genaral troubleshooting......2913
Preliminary check......2915
Diagnosis system......2917
Electronic control system......2923
Mechanical system tests......2934
Road test......2938
Automatic shift schedule......2941
On-vehicle repair......2942
Removal and installation of transaxle......2944
Torque converter......2946
Removal of component parts......2947
Component parts......2973
General notes......2973
Second coast brake......2974
Oil pump......2977
Direct clutch......2981
Forward clutch......2985
Front planetary gear......2990
Second brake......2993
Rear planetary gear......2995
First and reverse brake......2998
Intermediate shaft......2999
Counter shaft......3001
Underdrive clutch and one-way clutch no. 3......3009
Underdrive brake and B4 accumulator piston......3014
Valve body......3015
Differential......3027
Installation of component parts......3036
Shift lock system......3066
Suspension and Axle......3069
Troubleshooting......3070
Wheel alignment......3071
Front wheel alignment......3072
Rear wheel alignment......3074
Front axle hub......3077
Front suspension......3086
Front shock absorber......3086
Ball joints, lower arm and stabilizer bar......3092
Rear axle shaft and carrier......3099
Rear drive shaft (5S-FE engine)......3107
Rear drive shaft (3S-GTE engine)......3120
Rear suspension......3137
Rear shock absorber......3138
Ball joint, lower arm and stabilizer bar......3143
Engine lateral control rod......3154
Brake System......3156
Precautions......3157
Troubleshooting......3157
Checks and adjustments......3160
Master cylinder......3164
Brake booster......3170
Front brake......3172
PE36T disc (for 3S-GTE)......3172
PD51 disc (for 5S-FE)......3180
Rear brake......3188
Proportioning and by-pass valve......3202
Anti-lock brake system......3203
Description......3203
Diagnosis system......3206
Troubleshooting......3210
Speed sensor diagnosis system......3216
ABS actuator......3220
Control relays......3224
Front speed sensor......3225
Rear speed sensor......3227
Anti-lock brake system circuit......3229
Steering......3231
Precautions......3232
Troubleshooting......3232
On-vehicle inspection......3233
Steering column......3234
Manual steering gear housing......3245
Power steering......3257
Description......3257
On-vehicle inspection......3260
Power steering pump......3263
Gear housing......3265
Electronic control system......3283
Diagnosis system......3285
Inspection of electronic control components......3288
SRS Airbag......3292
General description......3293
Description......3296
Operation......3298
Inspection items and replacement requirements......3302
Removal and installation of component parts......3306
Steering wheel pad and spiral cable......3306
Front airbag Sensor......3308
Center airbag sensor assembly......3310
Replacement of repair wire for front airbag sensor......3312
Troubleshooting......3315
Disposal of steering wheel pad (with airbag)......3373
Disposal of center airbag sensor assembly......3380
Body Electrical System......3381
General information......3382
Power source......3386
Ignition switch......3390
Lighting system......3393
Wiper and washer system......3423
Combination meter......3428
Defogger system......3443
Power window control system......3447
Power door lock control system......3453
Power mirror control system......3460
Cruise control system......3462
Theft deterrent system......3495
Audio......3512
Clock......3540
Body......3541
General information......3542
Hood......3546
Front Hood......3546
Engine Hood......3547
Headlight......3548
Front door......3549
Luggage compartment door......3562
Mouldings......3564
Windshield moulding......3564
Body outside moulding......3566
Side protection moulding......3569
Back window moulding......3573
Windshield......3575
Quarter window glass......3581
Back window glass......3585
T-bar roof......3588
Moon roof......3597
Instrument panel......3604
Seat......3610
Seat belts......3611
Body dimensions......3613
Air Conditioning System......3622
General information......3623
Description......3625
Preparation......3628
Troubleshooting......3629
Refrigeration system......3631
Drive belt......3635
Refrigeration lines......3636
Compressor......3637
Receiver......3650
Condenser......3651
Cooling unit......3653
Evaporator......3657
Expansion valve......3657
Thermistor......3658
A/C control assembly......3659
Pressure switch......3663
Water temperature sensor......3663
Servomotors......3664
Blower motor......3664
Condenser fan motor......3665
Heater main relay......3665
Magnetic clutch relay......3665
Fan main relays......3666
Vacuum hose circuit......3666
Vacuum switching valve......3667
A/C amplifier......3668
Service Specifications......3669
Clutch......3670
Manual transaxle (S54)......3671
Manual transaxle (E153)......3674
Automatic transaxle (A241E)......3678
Suspension and axle......3682
Brake system......3684
Steering......3685
SRS Airbag......3686
Body......3686
Lubricant......3687
Standard Bolt Torque Specifications......3688
Standard Bolt Torque Specifications......3689
Special Service Tools and Materials......3691
Special service tools......3692
Special service materials......3707
Vol. 2_Electrical Wiring Diagram......3709
Contents......3710
Introduction......3711
How to use this manual......3712
Troubleshooting......3719
Abbreviations......3722
Glossary of terms and symbols......3723
Relay locations......3725
Electrical wiring routing......3729
Power source (current flow chart)......3743
System circuits......3752
ABS......3845
Auto antenna......3863
Back-up light......3805
Charging......3761
Cigarette lighter and clock......3861
Combination meter......3871
Cruise control......3855
Door lock......3811
ECT and A/T indicator light......3850
Electro-hydraulic power steering......3829
Engine control......3763
Engine compartment cooling fan......3781
Fog light (USA)......3789
Heaadlight (USA)......3786
Headlight and fog light (Canada)......3791
Horn......3828
Illumination......3798
Interior light......3801
Light auto turn off......3783
Power source......3753
Power window......3807
Radiator fan and air conditioner......3877
Radio and player......3865
Rear window defogger......3841
Remote control mirror......3833
Shift lock......3843
SRS airbag......3822
Starting and ignition......3757
Stop light......3806
Taillight......3795
Theft deterent......3835
Turn signal and hazard warning light......3803
Unlock and seat belt warning......3816
Wiper and washer......3819
Ground points......3887
Electrical Wiring Diagrams......3893
How to read this section......3893
System index......3895
1......3896
2......3898
3......3900
4......3903
5......3906
6......3909
7......3912
8......3914
9......3916
10......3919
11......3922
12......3924
13......3926
14......3928
15......3930
16......3932
17......3934
18......3936
19......3938
20......3941
21......3944
22......3948
Toyota MR002 Repair Manual MK2002......3952
1996-2004 ENGINE PERFORMANCE Mode 6 - Toyota......3956
2000-13 GENERAL INFORMATION Toyota Engine Code Identification - All Models......3962
2001-02 ACCESSORIES & EQUIPMENT VIP RS3200 Plus - MR2......3963
2001-02 BRAKES Anti-Lock - MR2......4030
2001-02 MANUAL TRANSMISSIONS C56M Diagnosis......4059
2001-02 MANUAL TRANSMISSIONS C56M Overhaul......4143
2001-02 MANUAL TRANSMISSIONS Servicing - MR2......4220
2001-02 STEERING Electro-Hydraulic Power Steering - MR2......4264
2001-03 MANUAL TRANSMISSIONS C56 Overhaul......4312
2001-03 MANUAL TRANSMISSIONS Shift Interlock Systems - MR2 (Sequential Transaxle)......4391
2002 ACCESSORIES & EQUIPMENT Antenna - MR2......4408
2002 ACCESSORIES & EQUIPMENT Audio System - MR2......4414
2002 ACCESSORIES & EQUIPMENT Body Control System - MR2......4450
2002 ACCESSORIES & EQUIPMENT Combination Meter & Clock - MR2......4472
2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - MR-2......4504
2002 ACCESSORIES & EQUIPMENT Defogger System - MR2......4533
2002 ACCESSORIES & EQUIPMENT Engine Immobilizer System - Diagnostics - MR2......4545
2002 ACCESSORIES & EQUIPMENT Engine Immobilizer System - MR2......4569
2002 ACCESSORIES & EQUIPMENT Exterior Lights - MR2......4580
2002 ACCESSORIES & EQUIPMENT Horn System - MR2......4608
2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - MR2......4614
2002 ACCESSORIES & EQUIPMENT Interior Light System - MR2......4621
2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - MR2......4627
2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - MR2......4648
2002 ACCESSORIES & EQUIPMENT Power Window Control System - MR2......4656
2002 ACCESSORIES & EQUIPMENT Wiper & Washer System - MR2......4670
2002 ACCESSORIESSAFETY EQUIPMENT Toyota - Air Bag Restraint Systems......4685
2002 ELECTRICAL Fuses & Circuit Breakers - MR2......4740
2002 ENGINE COOLING Specifications & Drive Belt Routing......4755
2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder......4767
2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder......4848
2002 ENGINE PERFORMANCE Pin Voltage Charts......4929
2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder......4980
2002 ENGINE PERFORMANCE Self-Diagnostics - MR2......5162
2002 ENGINE PERFORMANCE Sensor Operating Range Charts......5241
2002 ENGINE PERFORMANCE Service & Adjustment Specifications......5255
2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder......5303
2002 ENGINE PERFORMANCE Theory & Operation......5539
2002 ENGINE PERFORMANCE Toyota Introduction......5656
2002 ENGINE PERFORMANCE Trouble Shooting - No Codes......5672
2002 ENGINE PERFORMANCE Vacuum Diagrams......5681
2002 ENGINE PERFORMANCE Wiring Diagrams......5737
2002 GENERAL INFORMATION Abbreviations - MR2......5926
2002 GENERAL INFORMATION Computer Relearn Procedures - Import......5935
2002 GENERAL INFORMATION Introduction - MR2......5987
2002 GENERATORS & REGULATORS Charging - MR2......6034
2002 HVAC Manual AC-Heater Systems - MR2......6092
2002 RESTRAINTS Electric Tension Reducer System (Driver) - MR2......6275
2002 STARTING & CHARGING SYSTEMS Starters......6279
2002 STEERING Steering System - MR2......6348
2002 SYSTEM WIRING DIAGRAMS TOYOTA MR2......6480
2002-03 TRANSMISSION Clutches - MR2......6559
2002-04 AXLE SHAFTS RWD Axle Shafts - MR2......6613
2002-04 BRAKES Disc - MR2......6621
2002-04 ENGINE COOLING Electric Cooling Fans - MR2......6653
2002-04 ENGINE Cooling - MR2......6661
2002-04 ENGINE Exhaust System - MR2......6716
2002-04 ENGINE Ignition System - MR2......6718
2002-04 ENGINES Engine Mechanical - MR2......6737
2002-04 ENGINES Lubrication - MR2......7048
2002-04 SUSPENSION Front - MR2......7068
2002-04 SUSPENSION Rear - MR2......7098
CABIN AIR FILTER Cabin Air Filter (Special Applications) - General Information......7121
EMISSION CONTROL ABBREVIATIONS Gasoline & Diesel......7123
EMISSION CONTROL VISUAL INSPECTION PROCEDURES GENERAL INFORMATION Emission Control Visual Inspection Procedures......7183
ENGINE PERFORMANCE Firing Order & Cylinder Identification - Toyota, Lexus & Scion......7203
ENGINE PERFORMANCE O2 Sensor Location & Identification......7205
Electrical Component Locator......7213
GENERAL INFORMATION Air Bag Deactivation Procedures......7224
GENERAL INFORMATION Air BagSRS Component Inspection & Replacement Tables - Asian......7268
GENERAL INFORMATION Commonly Used Abbreviations......7317
GENERAL INFORMATION Diagnostic Connector (DLC) Locations......7344
GENERAL INFORMATION Engine Overhaul Procedures......7378
GENERAL INFORMATION General Cooling System Service......7439
GENERAL INFORMATION Manual Transmission Trouble Shooting......7442
GENERAL INFORMATION Symptom Check List Worksheets......7444
GENERAL INFORMATION TROUBLE SHOOTING......7458
GENERAL INFORMATION Trouble Shooting - Basic Procedures......7462
GENERAL INFORMATION Waveforms - Injector Pattern Tutorial......7523
GENERAL INFORMATION Wheel Alignment Theory & Operation......7531
OBD-II Readiness Monitors LexusToyota - 1996-04......7538
UNIFORM INSPECTION & COMMUNICATION STANDARDS 2010 - 2011 Routine Inspection Reference Guide......7566
UNIFORM INSPECTION & COMMUNICATION STANDARDS 2010 - 2011 Steering & Suspension Systems......7680
Toyota MR002 Service Repair Manual 1991......7794
Volume 1......7794
Contents......7795
Introduction......7796
How to use this manual......7797
Identification information......7799
General repair instructions......7799
Precautions for vehicles with Airbag......7802
Precautions for vehicles with catalytic converter......7806
Precautions for vehicles with audio and anti-theft systems......7806
Vehicle lift and support locations......7807
Abbreviations......7808
Maintenance......7809
Maintenance schedule......7810
Maintenance operations......7812
General maintenance......7822
Engine Mechanical......7824
Descritption (3S-GTE)......7825
Description (5S-FE)......7827
Troubleshooting......7829
Engine tune-up......7833
Toyota-variable induction system......7845
Idle and/or 2,500 RPM HC/CO checking......7846
Compression check......7848
Timing belt (3S-GTE)......7849
Timing belt (5S-FE)......7870
Cylinder head (3S-GTE)......7884
Cylinder head (5S-FE)......7920
Cylinder block (3S-GTE)......7956
Cylinder block (5S-FE)......8004
Exhaust System......8051
Exhaust pipes and heat insulators......8052
Turbocharger System......8053
Description......8054
Precautions......8056
Troubleshooting......8057
Turbocharger......8059
Intercooler......8072
Emission Control Systems......8079
3S-GTE......8080
System purpose......8080
Component layout and schematic drawing......8081
Positive crankcase ventilation system......8082
Fuel evaporative emission control system......8099
Exhaust gas recirculation system......8102
Three-way catalyst system......8106
5S-FE......8096
System purpose......8096
Component layout and schematic drawing......8097
Positive crankcase ventilation system......8098
Fuel evaporative emission control system......8099
Exhaust gas recirculation system......8102
Three-way catalyst system......8106
EFI System......8111
Description......8112
Precautions......8115
Inspection precautions......8115
Troubleshooting......8121
Diagnosis system......8135
Troubleshooting with volt/ohmmeter......8143
Fuel System......8195
Fuel pump......8195
Cold start injector (3S-GTE)......8209
Cold start injector (5S-FE)......8212
Fuel pressure regulator (3S-GTE)......8215
Fuel pressure regulator (5S-FE)......8217
Injectors (3S-GTE)......8220
Injectors (5S-FE)......8230
Fuel tank and lines......8239
Air Induction System......8241
Air flow meter (3S-GTE)......8241
Throttle body (3S-GTE)......8244
Throttle body (5S-FE)......8250
Idle speed control valve (3S-GTE)......8258
Idle speed control valve (5S-FE)......8261
Electronic Control System......8264
Location of electronic control parts......8264
EFI main relay......8266
Circuit opening relay......8267
Cold start injector time switch......8268
Solenoid resistor (3S-GTE)......8269
Fuel pump relay and resistor (3S-GTE)......8270
Fuel pressure VSV (5S-FE)......8271
T-VIS VSV (3S-GTE)......8273
Turbocharging pressure VSV (3S-GTE)......8275
EGR VSV......8277
Water temperature sensor......8278
Intake air temperature sensor (5S-FE)......8279
Vacuum sensor (5S-FE)......8280
Turbocharging pressure sensor (3S-GTE)......8281
EGR gas temperature sensor (3S-GTE & 5S-FE Calif. only)......8282
Oxygen sensor (main)......8283
Sub-oxygen sensor (5S-FE Calif. only)......8285
Electronic controlled unit (ECU)......8286
Fuel cut RPM......8292
Cooling System......8293
Description......8294
Troubleshooting......8296
Engine coolant check......8296
Replacement of engine coolant......8297
Water pump......8302
Thermostat......8306
Radiator......8308
Electric cooling fans......8313
Radiator cooling fans (w/ A/C)......8313
Radiator cooling fan (w/o A/C)......8320
Engine compartment cooling fan (3S-GTE)......8323
Lubrication System......8329
Description......8330
Troubleshooting......8333
Oil pressure check......8334
Replacement of engine oil and oil filter......8335
Oil pump......8337
Oil cooler (3S-GTE)......8346
Oil cooler (5S-FE)......8351
Oil Nozzles (3S-GTE)......8354
Ignition System......8355
Precautions......8356
Troubleshooting......8357
Ignition system circuit......8358
On-vehicle inspection (3S-GTE)......8359
On-vehicle inspection (5S-FE)......8364
Distributor (3S-GTE)......8368
Distributor (5S-FE)......8373
Starting System......8377
Troubleshooting......8378
Starter......8379
Starter relay......8394
Clutch start switch (M/T only)......8394
Charging System......8395
Precautions......8396
Troubleshooting......8396
On-vehicle inspection......8397
Alternator......8400
Ignition main relay......8412
Service Specification......8413
Maintenance......8414
Engine Mechanical (3S-GTE)......8415
Engine mechanical (5S-FE)......8419
Exhaust system......8423
Turbocharger system......8423
EFI system (3S-GTE)......8424
EFI system (5S-FE)......8427
Cooling system......8430
Lubrication system......8431
Ignition system......8432
Starting system......8432
Charging system......8432
Lubricant......8433
Standard Bolt Torque Specifications......8434
Standard Bolt Torque Specifications......8435
Volume 2......8438
Contents......8439
Clutch......8440
Troubleshooting......8441
Check and adjustment of clutch pedal......8442
Bleeding of clutch system......8443
Inspection of clutch start system......8444
Clutch master cylinder......8445
Clutch release cylinder......8448
Clutch unit......8452
Manual Transaxle......8456
Description......8457
Precautions......8459
Troubleshooting......8459
Removal and installation of transaxle......8460
S54 Transaxle / SW21 series......8462
Removal of component parts......8462
Component parts......8476
Input shaft assembly......8476
Output shaft assembly......8482
Shift and select lever assembly......8489
Differential......8492
Installation of component parts......8502
E153 Transaxle / SW20 series......8512
Removal of component parts......8512
Component parts......8528
Input shaft assembly......8528
Output shaft assembly......8534
Oil pump......8540
Shift and select lever shaft......8545
Differential......8549
Installation of component parts......8559
Shift lever and control cable......8571
Automatic Transaxle (A241E)......8573
Description......8574
Operation......8576
Troubleshooting......8581
Basic Troubleshooting......8581
Genaral troubleshooting......8582
Preliminary check......8584
Diagnosis system......8586
Electronic control system......8592
Mechanical system tests......8603
Road test......8607
Automatic shift schedule......8610
On-vehicle repair......8611
Removal and installation of transaxle......8613
Torque converter......8615
Removal of component parts......8616
Component parts......8642
General notes......8642
Second coast brake......8643
Oil pump......8646
Direct clutch......8650
Forward clutch......8654
Front planetary gear......8659
Second brake......8662
Rear planetary gear......8664
First and reverse brake......8667
Intermediate shaft......8668
Counter shaft......8670
Underdrive clutch and one-way clutch no. 3......8678
Underdrive brake and B4 accumulator piston......8683
Valve body......8684
Differential......8696
Installation of component parts......8705
Shift lock system......8735
Suspension and Axle......8738
Troubleshooting......8739
Wheel alignment......8740
Front wheel alignment......8741
Rear wheel alignment......8743
Front axle hub......8746
Front suspension......8755
Front shock absorber......8755
Ball joints, lower arm and stabilizer bar......8761
Rear axle shaft and carrier......8768
Rear drive shaft (5S-FE engine)......8776
Rear drive shaft (3S-GTE engine)......8789
Rear suspension......8806
Rear shock absorber......8807
Ball joint, lower arm and stabilizer bar......8812
Engine lateral control rod......8823
Brake System......8825
Precautions......8826
Troubleshooting......8826
Checks and adjustments......8829
Master cylinder......8833
Brake booster......8839
Front brake......8841
PE36T disc (for 3S-GTE)......8841
PD51 disc (for 5S-FE)......8849
Rear brake......8857
Proportioning and by-pass valve......8871
Anti-lock brake system......8872
Description......8872
Diagnosis system......8875
Troubleshooting......8879
Speed sensor diagnosis system......8885
ABS actuator......8889
Control relays......8893
Front speed sensor......8894
Rear speed sensor......8896
Anti-lock brake system circuit......8898
Steering......8900
Precautions......8901
Troubleshooting......8901
On-vehicle inspection......8902
Steering column......8903
Manual steering gear housing......8914
Power steering......8926
Description......8926
On-vehicle inspection......8929
Power steering pump......8932
Gear housing......8934
Electronic control system......8952
Diagnosis system......8954
Inspection of electronic control components......8957
SRS Airbag......8961
General description......8962
Description......8965
Operation......8967
Inspection items and replacement requirements......8971
Removal and installation of component parts......8975
Steering wheel pad and spiral cable......8975
Front airbag Sensor......8977
Center airbag sensor assembly......8979
Replacement of repair wire for front airbag sensor......8981
Troubleshooting......8984
Disposal of steering wheel pad (with airbag)......9042
Disposal of center airbag sensor assembly......9049
Body Electrical System......9050
General information......9051
Power source......9055
Ignition switch......9059
Lighting system......9062
Wiper and washer system......9092
Combination meter......9097
Defogger system......9112
Power window control system......9116
Power door lock control system......9122
Power mirror control system......9129
Cruise control system......9131
Theft deterrent system......9164
Audio......9181
Clock......9209
Body......9210
General information......9211
Hood......9215
Front Hood......9215
Engine Hood......9216
Headlight......9217
Front door......9218
Luggage compartment door......9231
Mouldings......9233
Windshield moulding......9233
Body outside moulding......9235
Side protection moulding......9238
Back window moulding......9242
Windshield......9244
Quarter window glass......9250
Back window glass......9254
T-bar roof......9257
Moon roof......9266
Instrument panel......9273
Seat......9279
Seat belts......9280
Body dimensions......9282
Air Conditioning System......9291
General information......9292
Description......9294
Preparation......9297
Troubleshooting......9298
Refrigeration system......9300
Drive belt......9304
Refrigeration lines......9305
Compressor......9306
Receiver......9319
Condenser......9320
Cooling unit......9322
Evaporator......9326
Expansion valve......9326
Thermistor......9327
A/C control assembly......9328
Pressure switch......9332
Water temperature sensor......9332
Servomotors......9333
Blower motor......9333
Condenser fan motor......9334
Heater main relay......9334
Magnetic clutch relay......9334
Fan main relays......9335
Vacuum hose circuit......9335
Vacuum switching valve......9336
A/C amplifier......9337
Service Specifications......9338
Clutch......9339
Manual transaxle (S54)......9340
Manual transaxle (E153)......9343
Automatic transaxle (A241E)......9347
Suspension and axle......9351
Brake system......9353
Steering......9354
SRS Airbag......9355
Body......9355
Lubricant......9356
Standard Bolt Torque Specifications......9357
Standard Bolt Torque Specifications......9358
Special Service Tools and Materials......9360
Special service tools......9361
Special service materials......9376
Electrical Wiring Diagrams......9378
Abbreviations......9378
How to read this section......9379
System index......9381
Toyota MR002 Spyder Roadster MR-S MK3 (Model ZZW30 Series) Service Manual 1999-2007......9438
Body Repair Manual......9439
CRIB Bulletins......9440
01 - Urethane Adhesive Sealant for Fixed Glass Installation......9441
02 - Welding High Strength Steel......9444
03 - 2000 paint & Refinish Forumla Codes......9449
04 - Mr2 Spyder Exterior Colours Procedure......9452
05 - SRS Airbag Components Replacement & Disposal Procedures......9453
Collision Repair Manual......9460
01 - Foreword......9462
02 - Views of this text......9463
03 - Introduction - General Repair Instructions......9464
04 - Introduction - How to use this manual......9468
05 - Introduction - Proper and Efficient work procedures......9472
06 - Introduction - Handling Precautions on related components......9477
07 - Introduction - Precautions for repairing body structure panels......9478
08 - Introduction - Abvreviations used in this manual......9480
09 - Body Panel Replacement - Radiator Upper Side Support (assy) - Replacement......9481
10 - Body Panel Replacement - Radiator Upper Side Support (assy) -Replacement 2......9483
11 - Body Panel Replacement - Front side member NO.1 Reinforcement (assy) - Replacement......9486
12 - Body Panel Replacement - Front Crossmember......9489
13 - Body Panel Replacement - Radiator Support......9492
14 - Body Panel Replacement - Front Fender Front Apron......9495
15 - Body Panel Replacement - Front Apron to cowl side upper member......9497
16 - Body Panel Replacement - Front Fender Apron......9500
17 - Body Panel Replacement - Front side member......9503
18 - Body Panel Replacement - Front side member - replacement......9506
19 - Body Panel Replacement - Front Luggage end panel......9510
20 - Body Panel Replacement - steering Gear Box Support Member......9513
21 - Body Panel Replacement - Front Fender Apron Lower Gusset......9516
22 - Body Panel Replacement - Front body Pillar......9518
23 - Body Panel Replacement - Front Door Outer Panel......9523
24 - Body Panel Replacement - Rocker Outer Panel......9526
25 - Body Panel Replacement - Center body outer pillar......9528
26 - Body Panel Replacement - Side Panel No.4 Reinforcement......9531
27 - Body Panel Replacement - Mounting Bracket......9534
28 - Body Panel Replacement - Lower Back Side Panel......9536
29 - Body Panel Replacement - Body Lower Back Upper Pannel......9538
30 - Body Panel Replacement - Body Lower Back Panel......9540
31 - Body Panel Replacement - Frame Rear Upper Crossmember......9542
32 - Body Panel Replacement - Rear Floor Side Rear Member......9545
33 - Body Panel Replacement - Rear Diagonal Member......9548
34 - Body Panel Replacement - Quarter Inner Rear Panel......9551
35 - Body Panel Replacement - Side Panel NO.2 Reinforcement......9554
36 - Body Panel Replacement - Rear Fender Apron Reinforcement......9557
37 - Body Panel Replacement - Wheel Housing Reinforcement......9560
38 - Body Panel Replacement - Rear Seat Back hinge Bracket......9563
39 - Body Panel Replacement - Quarter Wheel Housing Inner Panel......9567
40 - Body Panel Replacement - Rear Floor Side Member......9570
41 - Body Panel Replacement - Roof Pannel......9573
42 - Body Panel Replacement - General Information......9575
43 - Body Panel Replacement - Body Dimension Drawings - Front Luggage Compartment......9577
44 - Body Panel Replacement - Body Opening Areas......9578
45 - Body Panel Replacement - Engine Compartment......9579
46 - Body Panel Replacement - Under Body......9580
47 - Paint - Coating - Body Panel Sealing Areas......9582
48 - Paint - Coating - Body Panel Undercoating Areas......9587
49 - Paint - Coating - Body Panel Anti-Rust Agent (WAX) Application Areas......9588
50 - Paint - Coating - Silencer Sheet Installation Areas......9589
51 - Paint - Coating - Body Panel Anti-Chipping Paint Application Areas......9590
Wire Harness Repair......9591
01 - Foreword......9593
02 - Introduction - General Information......9594
03 - Introduction - How to Perform for System inspection......9598
04 - Introduction - Circuit Protection......9601
05 - Terminal and Connector Repair - Preparatory Items......9603
06 - Terminal and Connector Repair - Connector Repair......9604
07 - Terminal and Connector Repair - Terminal Replacement......9605
08 - Terminal and Connector Repair - Terminal Replacement......9606
09 - Terminal and Connector Repair - Terminal Replacement......9610
10 - Terminal and Connector Repair - Terminal Replacement......9629
11 - Terminal and Connector Repair - Terminal Replacement......9634
12 - Terminal and Connector Repair - How To Install and remove Special connectors......9649
13 - Table of housing cross section......9656
14 - Table of housing shape - Female - Waterproof type......9668
15 - Table of housing shape - Femaile - Non-waterproof type......9693
16 - Table of housing Shape - Male - Waterproff Type......9852
17 - Table of housing Shape - Male - Non-Waterproof Type......9867
18 - Housing part number list......9907
19 - Table of Repairwire, Terminal Packing, Hole plug and press sleeve - Repair Wire (Waterproof ......9971
20 - Table of Repairwire, Terminal Packing, Hole plug and press sleeve - Repair Wire (non-waterpr......9976
21 - Wire Harness Repair Kit with case......9989
22 - Reporting of wire harness problem......9990
23 - Number List......9994
24 - Table of Repair Wire, Terminal Packing, Hole Plug and press sleeve......10003
25 - Table of Repair Wire, Terminal Packing, Hole Plug and press sleeve......10005
26 - Table of Repair Wire, Terminal Packing, Hole Plug and press sleeve......10006
Owners Manual......10007
01 - Air conditioning system......10008
01 - Car audio system......10016
01 - Ignition switch, Transmission and Parking brake......10030
01 - OPERATION OF INSTRUMENTS AND CONTROLS - KEYS......10034
01 - OPERATION OF INSTRUMENTS AND CONTROLS - Lights, Wipers and Defogger......10052
01 - OPERATION OF INSTRUMENTS AND CONTROLS - Seats, Seat belts, Steering wheel and Mirrors......10058
01 - Operation of Instruments and Controls......10092
01 - Other equipment......10098
02 - MR2 U......10106
03 - Quick Index......10108
04 - Forward......10109
CORROSION PREVENTION - 01......10110
ELECTRICAL COMPONENTS - 01......10118
EMERENGENCY - 01......10132
GAUGES, METERS, SERVICE REMINDERS......10150
SCHEDULED MAINTENANCE......10158
SPECIFICATIONS - 01......10216
STEERING AND DRIVING - 01......10224
VEHICLE MAINTENANCE - 01......10230
Repair Manual......10236
Air Conditioning......10237
01 - Air Conditioning System - Precaution......10239
02 - Air Conditioning System - On-Vehicle Inspection......10241
03 - Air Conditioning System - Evacuating......10248
04 - Air Conditioning System - Charging......10249
05 - Air Conditioning System - Location......10251
06 - Troubleshooting - Problem Symptom Table......10252
07 - Drive Belt - On-Vehicle Inspection......10254
08 - Drive Belt - Replacement......10255
09 - Manifold Gauge Set - Set On......10256
10 - Manifold Gauge Set - Set Off......10257
11 - Refrigerant Line - On-Vehicle Inspection......10258
12 - Refrigerant Line - Location......10259
13 - Refrigerant Line - Replacement......10260
14 - Cooling Unit - On-Vehicle Inspection......10261
15 - Cooling Unit - Components......10262
16 - Cooling Unit - Removal......10264
17 - Cooling Unit - Disassembly......10266
18 - Cooling Unit - Inspection......10267
19 - Cooling Unit - Reassembly......10268
20 - Cooling Unit - Installation......10269
21 - Heater Unit - Components......10270
22 - Heater Unit - Removal......10273
23 - Heater Unit - Disassembly......10274
24 - Heater Unit - Inspection......10275
25 - Heater Unit - Reassembly......10276
26 - Heater Unit - Installation......10277
27 - Blower Unit - Components......10278
28 - Blower Unit - Removal......10280
29 - Blower Unit - Disassembly......10281
30 - Blower Unit - Reassembly......10282
31 - Blower Unit - Installation......10283
32 - Compressor and Magnetic Clutch - On-Vehicle Inspection......10284
33 - Compressor and Magnetic Clutch - Components......10285
34 - Compressor and Magnetic Clutch - Removal......10287
35 - Compressor and Magnetic Clutch - Disassembly......10288
36 - Compressor and Magnetic Clutch - Reassembly......10290
37 - Compressor and Magnetic Clutch - Installation......10293
38 - Condenser - On-vehicle Inspection......10294
39 - Condenser - Components......10295
40 - Condenser - Removal......10297
41 - Condenser - Replacement......10299
42 - Condenser - Installation......10300
43 - Blower Motor - Inspection......10302
44 - Blower Resistor - Inspection......10303
45 - Thermistor - Inspection......10304
46 - Pressure Switch - On-Vehicle Inspection......10305
47 - Pressure Switch - Removal......10306
48 - Pressure Switch - Installation......10307
49 - Heater Main Relay - Inspection......10308
50 - Magnetic Clutch Relay - Components......10309
51 - Magnetic Clutch Relay - Inspection......10310
52 - Cooling Fan Relay - Inspection......10311
53 - Condenser Fan - On-Vehicle Inspection......10313
54 - Condenser Fan - Components......10314
55 - Air Conditioning Control System - On-Vehicle Inspection......10316
56 - Heater Control Assembly - On-Vehicle Inspection......10319
57 - Heater Control Assembly - Components......10320
58 - Heater Control Assembly - Removal......10321
59 - Heater Control Assembly - Inspection......10322
60 - Heater Control Assembly - Installation......10324
Body Electrical......10326
01 - Body Electrical System - Precaution......10328
02 - Troubleshooting......10329
03 - Power Source - Location......10336
04 - Ignition Switch and Key Unlock Warning Switch - Location......10342
05 - Ignition Switch and Key Unlock Warning Switch - Inspection......10343
06 - Headlight and Taillight system - location......10344
07 - Headlight and Taillight system - Inspection......10345
08 - Headlight and Taillight system - Adjustment......10348
09 - Turn Signal and Hazard Warning System - Location......10350
10 - Turn Signal and Hazard Warning System - Inspection......10351
11 - Interior Light System - Location......10352
12 - Interior Light System - Inspection......10353
13 - Back-up Light System - Location......10354
14 - Back-up Light System - Inspection......10355
15 - Stop Light System - Location......10356
16 - Stop Light System - Inspection......10357
17 - Wiper and Washer System - Location......10358
18 - Wiper and Washer System - Inspection......10359
19 - Combination Meter - Location......10362
20 - Combination Meter - Circuit......10365
21 - Combination Meter - Inspection......10367
22 - Electric Tension Reducer System (driver) - Location......10372
23 - Electric Tension Reducer System (driver) - Inspection......10373
24 - Defogger System - Location......10374
25 - Defogger System - Inspection......10375
26 - Power window Control System - Location......10378
27 - Power window Control System - Inspection......10379
28 - Power Lock Control System - Location......10382
29 - Power Lock Control System - Inspection......10383
30 - Power Mirror Control System - Location......10387
31 - Power Mirror Control System - Inspection......10388
32 - Audio System - Description......10390
33 - Audio System - Troubleshooting......10398
34 - Audio System - Location......10417
35 - Audio System - Inspection......10418
36 - Antenna - Location......10419
37 - Antenna - Inspection......10420
38 - Clock - Troubleshooting......10421
39 - Engine Immobiliser System - Registration Procedure......10423
40 - Engine Immobiliser System - Location......10431
41 - Horn System - Location......10432
42 - Horn System - Inspection......10433
Body......10434
01 - Clip Replacement......10436
02 - SRS Airbag precaution......10438
03 - Front Bumper - Components......10439
04 - Rear Bumper - Components......10440
05 - Headlight - Components......10441
06 - Headlight - Removal......10442
07 - Headlight - Installation......10443
08 - Hood - Adjustment......10444
09 - Engine Hood - Adjustment......10445
10 - Front Door - Components......10446
11 - Front Door - Disassembly......10447
12 - Front Door - Inspection......10452
13 - Front Door - Adjustment......10453
14 - Front Door - Reassembly......10455
15 - Front Wiper and Washer - Components......10456
16 - Front Wiper and Washer - Removal......10457
17 - Front Wiper and Washer - Inspection......10458
18 - Front Wiper and Washer - Adjustment......10459
19 - Front Wiper and Washer - Installation......10460
20 - Roof Drip Side Moulding - Components......10461
21 - Roof Drip Side Moulding - Removal......10462
22 - Roof Drip Side Moulding - Installation......10463
23 - Windshield - Components......10465
24 - Windshield - Removal......10466
25 - Windshield - Installation......10468
26 - Instrument Panel - Components......10472
27 - Instrument Panel - Removal......10476
28 - Instrument Panel - Disassembly......10480
29 - Instrument Panel - Reassembly......10481
30 - Instrument Panel - Installation......10482
31 - Front Seat - Components......10483
32 - Front Seat - Removal......10484
33 - Front Seat - Disassembly......10485
34 - Front Seat - Inspection......10487
35 - Front Seat - Reassembly......10488
36 - Front Seat - Installation......10490
37 - Seat Belt - Components......10491
38 - Seat Belt - Inspection......10492
39 - Seat Belt Pretentioner - Removal......10494
40 - Seat Belt Pretentioner - Inspection......10496
41 - Seat Belt Pretentioner - Disposal......10497
42 - Seat Belt Pretentioner - Replacement......10502
43 - Seat Belt Pretentioner - Installation......10503
44 - Soft Top - Components......10504
45 - Soft Top - Removal......10507
46 - Soft Top - Disassembly......10512
47 - Soft Top - Inspection......10515
48 - Soft Top - Reassembly......10516
49 - Soft Top - Installation......10521
Brake......10524
01 - Brake System - Precaution......10526
02 - Troubleshooting - Problem Symptoms Table......10527
03 - Brake Fluid - Bleeding......10529
04 - Brake Pedal - On-Vehicle Inspection......10531
05 - Brake Pedal - Components......10532
06 - Brake Pedal - On-Vehicle Inspection......10533
07 - Brake Master Cylinder - Components......10534
08 - Brake Master Cylinder - Removal......10535
09 - Brake Master Cylinder - Disassembly......10536
10 - Brake Master Cylinder - Reassembly......10537
11 - Brake Master Cylinder - Installation......10538
12 - Brake Bsooster Assembly - On-Vehicle Inspection......10539
13 - Brake Bsooster Assembly - Components......10540
14 - Brake Bsooster Assembly - Removal......10541
15 - Brake Bsooster Assembly - Installation......10542
16 - Front Brake Pad - Replacement......10544
17 - Front Brake Caliper - Components......10546
18 - Front Brake Caliper - Removal......10547
19 - Front Brake Caliper - Disassembly......10548
20 - Front Brake Caliper - Inspection......10549
21 - Front Brake Caliper - Reassembly......10550
22 - Front Brake Caliper - Installation......10551
23 - Rear Brake Pad - Components......10552
24 - Rear Brake Pad - Replacement......10553
25 - Rear Brake Caliper - Components......10556
26 - Rear Brake Caliper - Removal......10557
27 - Rear Brake Caliper - Disassembly......10558
28 - Rear Brake Caliper - Inspection......10561
29 - Rear Brake Caliper - Reassembly......10562
30 - Rear Brake Caliper - Installation......10565
31 - ABS Actuator - On-Vehicle Inspection......10566
32 - ABS Actuator - Components......10570
33 - ABS Actuator - Removal......10571
34 - ABS Actuator - Installation......10572
35 - Front Speed Sensor - Components......10574
36 - Front Speed Sensor - Replacement......10575
37 - Rear Speed Sensor - Components......10579
38 - Rear Speed Sensor - Replacement......10580
Charging......10581
01 - Charging System - Precaution......10582
02 - Charging System - On-Vehicle Inspection......10583
03 - Generator - Components......10586
04 - Generator - Removal......10588
05 - Generator - Disassembly......10589
06 - Generator - Inspection......10591
07 - Generator - Replacement......10593
08 - Generator - Reassembly......10595
09 - Generator - Installation......10598
10 - Ignition Relay (No.1) - Inspection......10599
Clutch......10600
01 - Troubleshooting - Problem Symptoms Table......10601
02 - Troubleshooting - Inspection......10602
03 - Clutch Master Cylinder - Components......10604
04 - Clutch Master Cylinder - Removal......10605
05 - Clutch Master Cylinder - Disasembly......10606
06 - Clutch Master Cylinder - Reassembly......10607
07 - Clutch Master Cylinder - Installation......10608
08 - Clutch Release Cylinder - Components......10609
09 - Clutch Release Cylinder - Removal......10610
10 - Clutch Release Cylinder - Disassembly......10611
11 - Clutch Release Cylinder - Reassembly......10612
12 - Clutch Release Cylinder - Installation......10613
13 - Clutch Unit - Components......10614
14 - Clutch Unit - Removal......10615
15 - Clutch Unit - Inspection......10616
16 - Clutch Unit - Instalation......10617
Cooling......10618
01 - Coolant - Inspection......10619
02 - Coolant - Replacement......10620
03 - Water Pump - On-Vehicle Inspection......10623
04 - Water Pump - Components......10624
05 - Water Pump - Removal......10625
06 - Water Pump - Inspection......10626
07 - Water Pump - Installation......10627
08 - Thermostat - Components......10628
09 - Thermostat - Removal......10629
10 - Thermostat - Inspection......10630
11 - Thermostat - Installation......10631
12 - Radiator - On-Vehicle Cleaning......10632
13 - Radiator - On - Vehicle Cleaning......10633
14 - Radiator - Components......10635
15 - Radiator - Removal......10637
16 - Radiator - Disassembly......10638
17 - Radiator - Inspection......10639
18 - Radiator - Reassembly......10640
19 - Radiator - Installation......10642
20 - Electric Cooling Fan - On-Vehicle Inspection......10643
21 - Electric Cooling Fan - Components......10644
22 - Electric Cooling Fan - Removal......10646
23 - Electric Cooling Fan - Disassembly......10647
24 - Electric Cooling Fan - Reassembly......10648
25 - Electric Cooling Fan - Installation......10649
26 - Cooling Fan Relay - Inspection......10650
Diagnostics......10651
001 - Engine - How to proceed with troubleshooting......10658
002 - Engine - Customer Problem Analysis Check......10659
003 - Engine - Pre - Check......10660
004 - Engine - Diagnostic Trouble Code Chart......10671
005 - Engine - Parts Location......10675
006 - Engine - Terminals of ECM......10676
007 - Engine - Problem Symptoms Table......10678
008 - Engine - Circuit Inspection......10680
009 - Engine - Mass Air Flow Circuit Range - Performance Problem......10684
010 - Engine - Intake Air Temp. Circuit Malfunction......10685
011 - Engine - Engine Coolant Temp. Circuit Malfunction......10689
012 - Engine - Engine Collant Temp. Circuit Range - Performance Problem......10693
013 - Engine - Throttle - Pedal Position Sensor - Switch A Circuit Malfunction......10694
014 - Engine - Thottle - Pedal Position - Switch A Sensor Circuit Range - Performance Problem......10698
015 - Engine - Insufficient Coolant Temp. for Closed Loop Fuel Control......10699
016 - Engine - Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)......10704
017 - Engine - Oxygen Sensor Circuit Slow Response (bank 1 sensor1)......10708
018 - Engine - Oxygen Sensor Heater Circuit Malfunction (bank 1 sensor1)......10711
019 - Engine - Oxygen Sensor Circuit Malfunction (bnak 1 sensor 2)......10713
020 - Engine - System too Lean (Fuel Trim) (bank 1)......10715
021 - Engine - Random - Multiple Cylinder Misfire Detected......10720
022 - Engine - Knock Sensor 1 Circuit Malfunction (bank 1)......10725
023 - Engine - Crankshaft Position Sensor A Circuit Malfunction......10728
024 - Engine - Camshaft Position Sensor Circuit Malfunction......10730
025 - Engine - Catalyst System Efficiency Below Threshold (bank 1)......10732
026 - Engine - Evaporative Emission Control System Malfunction......10735
027 - Engine - Evaporative Emission Control System Incorrect Purge Flow......10741
028 - Engine - Evaporative Emission Control System Pressure Sensor Malfunction......10758
029 - Engine - Vehicle Speed Sensor Malfunction......10760
030 - Engine - Idle Control System Malfunction......10763
031 - Engine - Igniter Circuit Malfunction (No. 1)......10766
032 - Engine - Crankshaft Position Sensor Circuit Malfunction (During Engine Running)......10772
033 - Engine - VVT Sensor - Camshaft Position Sensor Circuit Range - Performance Problem (bank 1)......10773
034 - Engine - VVT System Malfunction (bank 1)......10774
035 - Engine - ECM BATT Malfunction......10780
036 - Engine - Body ECU Malfunction......10782
037 - Engine - OCV Circuit Malfunction (Bank 1)......10784
038 - Engine - Stop Light Switch Signal Circuit......10787
039 - Engine - ECM Power Source Circuit......10789
040 - Engine - Starter Signal Circuit......10794
041 - Engine - Fuel Pump Control Circuit......10797
042 - Engine - MIL Circuit Malfunction......10802
043 - Engine - TC Terminal Circuit......10805
044 - Engine - AC Compressor Circuit......10807
045 - Anti-Lock Brake System - How to proceed with trouble shooting......10809
046 - Anti-Lock Brake System - Customer Problem analysis check......10810
047 - Anti-Lock Brake System - pre-check......10811
048 - Anti-Lock Brake System - Diagnostic Trouble code chart......10815
049 - Anti-Lock Brake System - parts location......10817
050 - Anti-Lock Brake System - Terminals of ecu......10818
051 - Anti-Lock Brake System - Problem symptoms Table......10819
052 - Anti-Lock Brake System - Circuit Inspection......10820
053 - Anti-Lock Brake System - ABS Actuator Solenoid Circuit......10827
054 - Anti-Lock Brake System - ABS Motor Relay Circuit......10830
055 - Anti-Lock Brake System - ABS Solenoid Relay Circuit......10835
056 - Anti-Lock Brake System - IG Power Source Circuit......10840
057 - Anti-Lock Brake System - Stop Light Switch Circuit......10843
058 - Anti-Lock Brake System - ABS Pump Motor Lock......10845
059 - Anti-Lock Brake System - ABS ECU Malfunction......10847
060 - Anti-Lock Brake System - ABS Warning Light Circuit......10849
061 - Anti-Lock Brake System - Tc Terminal Circuit......10852
062 - Anti-Lock Brake System - Ts Terminal Circuit......10854
063 - Anti-Lock Brake System - Check for Fluid Leakage......10856
064 - Electro-Hydraulic Power Steering - How to proceed with troubleshooting......10857
065 - Electro-Hydraulic Power Steering - Customer Problem Analysis Check......10858
066 - Electro-Hydraulic Power Steering - Pre-Check......10859
067 - Electro-Hydraulic Power Steering - Diagnostic Trouble Code Chart......10863
068 - Electro-Hydraulic Power Steering - Parts Location......10864
069 - Electro-Hydraulic Power Steering - Terminals of ECU......10865
070 - Electro-Hydraulic Power Steering - Problems Symptoms Table......10866
071 - Electro-Hydraulic Power Steering - Circuit Inspection......10867
072 - Electro-Hydraulic Power Steering - Power Steering ECU Malfunction......10871
073 - Electro-Hydraulic Power Steering - PIG Power Source Drop Voltage......10875
074 - Electro-Hydraulic Power Steering - When resetting voltage, vehicle is being driven......10878
075 - Electro-Hydraulic Power Steering - Speed Sensor Signal Malfunction......10879
076 - Electro-Hydraulic Power Steering - Malfunction in ECU......10881
077 - Electro-Hydraulic Power Steering - PS Warning Light Circuit......10884
078 - Electro-Hydraulic Power Steering - TC Terminal Circuit......10887
079 - Electro-Hydraulic Power Steering - TC Terminal Circuit......10889
080 - Electro-Hydraulic Power Steering - ECM Communication Circuit Malfunction......10891
081 - Supplemental Restraint System - How to proceed with troubleshooting......10892
082 - Supplemental Restraint System - Customer Problem Analysis Check......10893
083 - Supplemental Restraint System - Pre-check......10894
084 - Supplemental Restraint System - Diagnostic Trouble code chart......10900
085 - Supplemental Restraint System - Parts Location......10902
086 - Supplemental Restraint System - Terminals of ecu......10903
087 - Supplemental Restraint System - Problem Symptoms Table......10904
088 - Supplemental Restraint System - Circuit Inspection......10905
089 - Supplemental Restraint System - Open in D Squib Circuit......10910
090 - Supplemental Restraint System - Short in D Squib Circuit (to ground)......10914
091 - Supplemental Restraint System - Short in D Squib Circuit (to B+)......10918
092 - Supplemental Restraint System - Short in P Squib Circuit......10922
093 - Supplemental Restraint System - Open in P Squib Circuit......10926
094 - Supplemental Restraint System - Short in P Squib Circuit (to Ground)......10930
095 - Supplemental Restraint System - Short in P Squib Circuit (to B+)......10934
096 - Supplemental Restraint System - Short in PT Squib (RH) Circuit......10938
097 - Supplemental Restraint System - Open in PT Squib (RH) Circuit......10942
098 - Supplemental Restraint System - Short in PT Squib (RH) Circuit (to ground)......10945
099 - Supplemental Restraint System - Short in PT Squib (RH) Circuit (to B+)......10948
100 - Supplemental Restraint System - Short in PT Squib (LH) Circuit......10951
101 - Supplemental Restraint System - Open in PT Squib (LH) Circuit......10955
102 - Supplemental Restraint System - Short in PT Squib (LH) Circuit (to ground)......10958
103 - Supplemental Restraint System - Short in PT Squib (LH) Circuit (to B+)......10961
104 - Supplemental Restraint System - Airbag Sensor Assembly Malfunction......10964
105 - Supplemental Restraint System - Front Airbag Sensor (RH) Malfunction......10966
106 - Supplemental Restraint System - Front Airbag Sensor (LH) Malfunction......10973
107 - Supplemental Restraint System - Source Voltage Drop......10980
108 - Supplemental Restraint System - SRS Warning Light Circuit Malfunction......10983
109 - Supplemental Restraint System - Tc Terminal Circuit......10988
110 - Engine Immobiliser System - How to proceed with trouble shooting......10992
111 - Engine Immobiliser System - Customer Problem Analysis Check......10993
112 - Engine Immobiliser System - Pre-check......10994
113 - Engine Immobiliser System - Diagnostic Trouble Code Chart......10997
114 - Engine Immobiliser System - Parts location......10998
115 - Engine Immobiliser System - Terminals of ECM......10999
116 - Engine Immobiliser System - Problem Symptoms Table......11000
117 - Engine Immobiliser System - Curcuit Inspection......11001
118 - Engine Immobiliser System - No Communication in Immobiliser System......11002
119 - Engine Immobiliser System - Communication Malfunction No. 1......11004
120 - Engine Immobiliser System - Communication Malfunction No. 2......11005
121 - Engine Immobiliser System - Power Source Circuit......11006
122 - Engine Immobiliser System - Security Indicator Light Circuit......11009
123 - Body Control System - How to proceed with troubleshooting......11011
124 - Body Control System - Customer Problem Analysis Check......11012
125 - Body Control System - Parts Location......11013
126 - Body Control System - Terminals of ECU......11014
127 - Body Control System - Problem Symptoms Table......11016
128 - Body Control System - Circuit Inspection......11018
129 - Body Control System - Ignition Switch Power Source Circuit......11021
130 - Body Control System - Key Unlock Switch Circuit......11024
131 - Body Control System - Poswer Window Control Switch Circuit......11025
132 - Body Control System - Door Lock Motor Circuit......11027
133 - Body Control System - Door Unlock Detection Switch Circuit......11029
134 - Body Control System - Door Key Lock and Unlock Switch Circuit......11031
135 - Body Control System - Door Lock Control Switch......11033
136 - Body Control System - Door Courtesy Switch Circuit......11034
Emission Control......11036
01 - Emission Control System - Purpose......11037
02 - Parts Layout and Schematic Drawing - Location......11038
03 - Parts Layout and Schematic Drawing - Drawing......11039
04 - Positive Crankcase Ventilation (PVC) System - Inspection......11040
05 - Evaporative Emission (EVAP) Control System - Components......11041
06 - Evaporative Emission (EVAP) Control System - Inspection......11042
07 - Three-Way Catalytic Converter (TWC) System - On-Vehicle Inspection......11047
08 - Three-Way Catalytic Converter (TWC) System - Components......11048
Engine - Mechanical......11050
01 - CO HC - Inspection......11051
02 - Compression - Inspection......11053
03 - Valve Clearance - Adjustment......11054
04 - Ignition Timing - Inspection......11059
05 - Idle Speed - Inspection......11060
06 - Timing Chain - Components......11061
07 - Timing Chain - Removal......11063
08 - Timing Chain - Inspection......11067
09 - Timing Chain - Replacement......11068
10 - Timing Chain - Installation......11070
11 - Cylinder Head - Components......11077
12 - Cylinder Head - Removal......11079
13 - Cylinder Head - Disassembly......11082
14 - Cylinder Head - Inspection......11083
15 - Cylinder Head - Replacement......11092
16 - Cylinder Head - Reassembly......11094
17 - Cylinder Head - Installation......11096
18 - Engine Unit - Components......11100
19 - Engine Unit - Removal......11104
20 - Engine Unit - Installation......11109
21 - Cylinder Block - Components......11115
22 - Cylinder Block - Disassembly......11117
23 - Cylinder Block - Inspection......11124
24 - Cylinder Block - Replacement......11130
25 - Cylinder Block - Reassembly......11132
26 - Exhaust System - Components......11139
Introduction......11140
01 - How to use this manual......11141
02 - Identification Information......11143
03 - Repair Instructions - General Information......11144
04 - Repair Instructions - Vehicle Lift and Support Locations......11148
05 - For all of vehicles - Precaution......11150
06 - How to troubleshoot ecu controlled systems - general information......11157
07 - How to troubleshoot ecu controlled systems - how to proceed with trouble shooting......11158
08 - How to troubleshoot ecu controlled systems - how to use the diagnostic chart and inspection ......11168
09 - Terms - Abbreviations used in this manual......11173
10 - Terms - Glossary of sae and toyota terms......11178
Lubrication......11181
01 - Oil and Filter - Inspection......11182
02 - Oil and Filter - Replacement......11184
03 - Oil Pump - Components......11186
04 - Oil Pump - Removal......11189
05 - Oil Pump - Disassembly......11190
06 - Oil Pump - Inspection......11191
07 - Oil Pump - Reassembly......11192
08 - Oil Pump - Installation......11193
Maintenance......11194
01 - Outside Vehicle - General Maintenance......11195
02 - Inside Vehicle - General Maintenance......11196
03 - Under Hood - General Maintenance......11198
04 - Engine - Inspection......11199
05 - Brake - Inspection......11200
06 - Chassis - Inspection......11201
07 - Body - Inspection......11202
Manual Transaxle......11203
01 - Troubleshooting - Problem Symptoms Table......11204
02 - Manual Transaxle Unit - Components......11205
03 - Manual Transaxle Unit - Removal......11207
04 - Manual Transaxle Unit - Installation......11212
05 - Manual Transaxle Assembly - Components......11213
06 - Manual Transaxle Assembly - Disassembly......11216
07 - Manual Transaxle Assembly - Inspection......11225
08 - Manual Transaxle Assembly - Replacement......11226
09 - Manual Transaxle Assembly - Reassembly......11229
10 - Input Shaft - Components......11230
11 - Input Shaft - Disassembly......11231
12 - Input Shaft - Inspection......11233
13 - Input Shaft - Reassembly......11235
14 - Output Shaft - Components......11238
15 - Output Shaft - Disassembly......11239
16 - Output Shaft - Inspection......11242
17 - Output Shaft - Reassembly......11244
18 - Shift and Select Lever Shaft - Components......11248
19 - Differential Case - Components......11249
20 - Differential Case - Disassembly......11250
21 - Differential Case - Replacement......11251
22 - Differential Case - Reassembly......11253
23 - Shift Lever and Control Cable - Components......11257
24 - Shift Lever and Control Cable - Removal......11259
25 - Shift Lever and Control Cable - Installation......11260
Preperation......11261
01 - Maintenance - Equipment......11264
02 - Engine Mechanical - SST......11265
03 - Engine Mechanical - Recommended Tools......11267
04 - Engine Mechanical - Equipment......11268
05 - Engine Mechanical - SSM (Special Service Materials......11269
06 - Emission Control - Equipment......11270
07 - SFI - SST (Special Service Tools)......11271
08 - SFI - Recommended Tools......11272
09 - SFI - Equipment......11273
10 - Cooling - SST......11274
11 - Cooling - Recommended Tools......11275
12 - Cooling - Equipment......11276
13 - Cooling - Coolant......11277
14 - Lubrication - SST......11278
15 - Lubrication - Equipment......11279
16 - Lubrication - Lubricant......11280
17 - Lubrication - SSM......11281
18 - Ignition - Recommended Tools......11282
19 - Ignition - Equipment......11283
20 - Starting - SST......11284
21 - Starting - Recommended Tools......11285
22 - Starting - Equipment......11286
23 - Charging - SST......11287
24 - Charging - Recommended Tools......11288
25 - Charging - Equipment......11289
26 - Clutch - SST......11290
27 - Clutch - Recommended Tools......11291
28 - Clutch - Equipment......11292
29 - Clutch - Lubricant......11293
30 - Manual Transaxle - SST......11294
31 - Manual Transaxle - Recommended Tools......11297
32 - Manual Transaxle - Equipment......11298
33 - Manual Transaxle - Lubricant......11299
34 - Manual Transaxle - SSM......11300
35 - Suspension and Axle - SST......11301
36 - Suspension and Axle - Recommended Tools......11304
37 - Suspension and Axle - Equipment......11305
38 - Suspension and Axle - Lubricant......11306
39 - Brake - SST......11307
40 - Brake - Recommended Tools......11309
41 - Brake - Equipment......11310
42 - Brake - Lubricant......11311
43 - Steering - SST......11312
44 - Steering - Recommended Tools......11316
45 - Steering - Equipment......11317
46 - Steering - Lubricant......11318
47 - Steering - SSM......11319
48 - Supplemental Restraint System - SST......11320
49 - Supplemental Restraint System - Recommended Tools......11321
50 - Supplemental Restraint System - Equipment......11322
51 - Body Electrical - SST......11323
52 - Body Electrical - Recommended Tools......11324
53 - Body Electrical - Equipment......11325
54 - Body Electrical - SSM......11326
55 - Body - SST......11327
56 - Body - Recommended Tools......11328
57 - Body - Equipment......11329
58 - Body - Lubricant......11330
59 - Body - SSM......11331
60 - Air Conditioning - SST......11332
61 - Air Conditioning - Recommended Tools......11334
62 - Air Conditioning - Equipment......11335
63 - Air Conditioning - Lubricant......11336
Service Specifications......11337
01 - Standard Bolt - How to determine Bolt Strength......11339
02 - Standard Bolt - Specified Torque for standard bolts......11340
03 - Standard Bolt - How to Determine Nut Strength......11341
04 - Maintenance - Service Data......11342
05 - Maintenance - Torque Specification......11343
06 - Engine Mechanical - Service Data......11344
07 - Engine Mechanical - Torque Specification......11347
08 - Emission Control - Torque Specification......11349
09 - SFI - Service Data......11350
10 - SFI - Torque Specification......11351
11 - Cooling - Service Data......11352
12 - Cooling - Torque Specification......11353
13 - Lubrication - Service Data......11354
14 - Lubrication - Torque Specification......11355
15 - Ignition - Service Data......11356
16 - Ignition - Torque Specification......11357
17 - Starting - Service Data......11358
18 - Starting - Torque Specifications......11359
19 - Charging - Service Data......11360
20 - Charging - Torque Specification......11361
21 - Clutch - Serive Data......11362
22 - Clutch - Torque Specification......11363
23 - Manual Transaxle - Service Data......11364
24 - Manual Transaxle - Torque Specification......11367
25 - Suspension and Axle - Service Data......11369
26 - Suspension and Axle - Torque Specification......11370
27 - Brake - Service Data......11371
28 - Brake - Torque Specification......11372
29 - Steering - Service Data......11373
30 - Steering - Torque Specification......11374
31 - Supplemental Restraint System - Torque Specification......11375
32 - Body Electrical - Service Data......11376
33 - Body - Torque Specification......11378
34 - Air Conditioning - Service Data......11380
35 - Air Conditioning - Torque Specification......11381
Starting......11382
01 - Starting System - On-Vehicle Inspection......11383
02 - Starter - Components......11384
03 - Starter - Removal......11386
04 - Starter - Disassembly......11387
05 - Starter - Inspection......11389
06 - Starter - Replacement......11392
07 - Starter - Reassembly......11395
08 - Starter - Test......11397
09 - Starter - Installation......11398
10 - Starter Relay - Inspection......11399
Steering......11400
01 - Steering System - Precaution......11401
02 - Troubleshooting - Problem Symptoms Table......11402
03 - Power Steering Fluid - Bleeding......11403
04 - Power Steering Fluid - Inspection......11404
05 - Steering Wheel - Inspection......11407
06 - Tilt Steering Column - Components......11408
07 - Tilt Steering Column - Removal......11410
08 - Tilt Steering Column - Disassembly......11413
09 - Tilt Steering Column - Inspection......11415
10 - Tilt Steering Column - Reassembly......11416
11 - Tilt Steering Column - Installation......11419
12 - Power Steering Vane Pump - Components......11422
13 - Power Steering Vane Pump - Removal......11424
14 - Power Steering Vane Pump - Disassembly......11425
15 - Power Steering Vane Pump - Inspection......11426
16 - Power Steering Vane Pump - Replacement......11428
17 - Power Steering Vane Pump - Reassembly......11429
18 - Power Steering Vane Pump - Installation......11431
19 - Power Steering Gear - Components......11432
20 - Power Steering Gear - Removal......11435
21 - Power Steering Gear - Disassembly......11436
22 - Power Steering Gear - Inspection......11439
23 - Power Steering Gear - Replacement......11440
24 - Power Steering Gear - Reassembly......11444
25 - Power Steering Gear - Installation......11450
26......11452
43......11453
44......11454
45......11459
Supplemental Restraint System......11462
01 - SRS Airbag - Precaution......11463
02 - SRS Airbag - Operation......11464
03 - Steering Wheel Pad and Spiral Cable - Components......11473
04 - Steering Wheel Pad and Spiral Cable - Removal......11474
05 - Steering Wheel Pad and Spiral Cable - Inspection......11475
06 - Steering Wheel Pad and Spiral Cable - Disposal......11477
07 - Steering Wheel Pad and Spiral Cable - Replacement......11485
08 - Steering Wheel Pad and Spiral Cable - Installation......11486
09 - Front Passenger Airbag Assembly - Components......11487
10 - Front Passenger Airbag Assembly - Removal......11488
11 - Front Passenger Airbag Assembly - Inspection......11490
12 - Front Passenger Airbag Assembly - Disposal......11492
13 - Front Passenger Airbag Assembly - Replacement......11499
14 - Front Passenger Airbag Assembly - Installation......11500
15 - Airbag Sensor Assembly - Components......11502
16 - Airbag Sensor Assembly - Removal......11503
17 - Airbag Sensor Assembly - Inspection......11504
18 - Airbag Sensor Assembly - Replacement......11505
19 - Airbag Sensor Assembly - Installation......11506
20 - Front Airbag Sensor - Components......11507
21 - Front Airbag Sensor - Removal......11508
22 - Front Airbag Sensor - Inspection......11509
23 - Front Airbag Sensor - Reassembly......11510
24 - Front Airbag Sensor - Installation......11511
25 - Passenger Airbag Manual On-Off Switch - Inspection......11512
26 - Passenger Airbag Manual On-Off Switch - Location......11514
27 - Passenger Airbag Manual On-Off Switch - Inspection......11515
28 - Passenger Airbag Manual On-Off Switch - Replacement......11516
Ignition......11517
01 - Ignition System - On-Vehicle Inspection......11518
02 - Ignition Coil - Components......11521
03 - Camshaft Position Sensor - Components......11522
04 - Ignition System - Components......11523
05 - Ignition Relay (No.2) - Components......11524
06 - Ignition Relay (No.2) - Inspection......11525
Suspension and Axle......11526
01 - Troubleshooting......11528
02 - Tire and Wheel - Inspection......11529
03 - Front Wheel Alignment - Inspection......11531
04 - Rear Wheel Alignment - Inspection......11534
05 - Front Axel Hub - Components......11535
06 - Front Axel Hub - Removal......11536
07 - Front Axel Hub - Disassembly......11538
08 - Front Axel Hub - Reassembly......11539
09 - Front Axel Hub - Installation......11540
10 - Front Wheel Hub Bolt - Replacement......11541
11 - Front Shock Absorber - Components......11542
12 - Front Shock Absorber - Removal......11543
13 - Front Shock Absorber - Disassembly......11544
14 - Front Shock Absorber - Inspection......11545
15 - Front Shock Absorber - Disposal......11546
16 - Front Shock Absorber - Reassembly......11547
17 - Front Shock Absorber - Installation......11548
18 - Front Lower Suspension Arm - Components......11549
19 - Front Lower Suspension Arm - Removal......11550
20 - Front Lower Suspension Arm - Inspection......11552
21 - Front Lower Suspension Arm - Installation......11553
22 - Front Stabilizer Bar - Components......11555
23 - Front Stabilizer Bar - Removal......11556
24 - Front Stabilizer Bar - Inspection......11557
25 - Front Stabilizer Bar - Installation......11558
26 - Rear Axel Carrier - Components......11559
27 - Rear Axel Carrier - Removal......11560
28 - Rear Axel Carrier - Disassembly......11563
29 - Rear Axel Carrier - Reassembly......11564
30 - Rear Axel Carrier - Installation......11565
31 - Rear Wheel Hub Bolt - Replacement......11566
32 - Rear Drive Shaft - Components......11567
33 - Rear Drive Shaft - Removal......11568
34 - Rear Drive Shaft - Disassembly......11571
35 - Rear Drive Shaft - Reassembly......11573
36 - Rear Drive Shaft - Installation......11576
37 - Rear Shock Absorber - Components......11577
38 - Rear Shock Absorber - Removal......11578
39 - Rear Shock Absorber - Disassembly......11579
40 - Rear Shock Absorber - Inspection......11580
41 - Rear Shock Absorber - Disposal......11581
42 - Rear Shock Absorber - Reassembly......11582
43 - Rear Shock Absorber - Installation......11583
44 - Rear Lower Suspension Arm and Strut rod - Components......11584
45 - Rear Lower Suspension Arm and Strut rod - Removal......11585
46 - Rear Lower Suspension Arm and Strut rod - Installation......11587
47 - Rear Stabilizer Bar - Components......11588
48 - Rear Stabilizer Bar - Removal......11589
49 - Rear Stabilizer Bar - Inspection......11590
50 - Rear Stabilizer Bar - Installation......11591
Wiring Diagrams......11592
01 - Electrical wiring routing......11593
01 - How to use this manual......11599
01 - Introduction......11608
02 - Electrical wiring routing......11609
02 - Introduction......11617
Abbreviations......11618
Connector List......11623
Glossary of terms and symbols......11629
Ground Points......11631
Part number of connectors......11635
Power source......11637
Relay Locations......11643
System Circuits......11653
01 - Power source......11654
02 - STARTING AND IGNITION......11658
03 - CHARGING......11662
04 - ENGINE CONTROL......11664
05 - ENGINE IMMOBILISER SYSTEM......11674
06 - HEADLIGHT......11676
07 - TAILLIGHT......11680
08 - ILLUMINATION......11684
09 - TURN SIGNAL AND HAZARD WARNING LIGHT......11686
10 - STOP LIGHT......11688
11 - BACK%96UP LIGHT......11690
12 - INTERIOR LIGHT......11692
13 - CIGARETTE LIGHTER AND CLOCK......11694
14 - HORN......11696
15 - WIPER AND WASHER......11698
16 - LIGHT REMINDER AND KEY REMINDER BUZZER......11702
17 - SEAT BELT WARNING AND ELECTRIC TENSION REDUCER......11704
18 - POWER WINDOW......11706
19 - DOOR LOCK CONTROL......11708
20 - REMOTE CONTROL MIRROR......11712
21 - RADIO AND PLAYER......11714
22 - AUTO ANTENNA......11716
23 - SRS......11719
24 - EHPS......11724
25 - ABS......11726
26 - REAR WINDOW DEFOGGER......11730
27 - COMBINATION METER......11732
28 - RADIATOR FAN AND CONDENSER FAN......11736
29 - AIR CONDITIONING......11738
Troubleshooting......11742
Toyota MR002_Turbo Service Manual 1993 (bonus material)......11747
Electrical Wiring Diagrams......11748
Repair Manual......11939
Air Conditioning......11940
...
Suspension And Axle......12709
