Toyota MR2 1988 Operating instructions

TOYOTA
MR2
1988 Repair Manual
•Engine
·Chassis
·Body
• Electrical
·Specifications
FOR USA 8l CANADA

FOREWORD
This manual contains maintenance and repair procedures for
the 1 988 MR 2.
Applicable model: AW11 series
The manual is divided into 21 sections and 5 appendixes with a
thumb index
for each section at the edge of the pages.
Please note that the publications below have also been pre-
pared
as relevant service manuals to the components and
systems in this vehicle.
Manual Name Pub. No.
• 1 988 MR 2 Electrical Wiring Diagram EWD035U
Manual
• TCCS (4A-GE) Diagnosis Manual 36903A
• ECT (A240E) Diagnosis Manual DM010U
• MR 2 Collision Damaged Body Repair
36440A
Manual
• 1 988 model New Car Features NCF024U
All information
in this manual is based on the latest product
information at the time
of publication. However, specifications
and procedures are subject
to change without notice.
TOYOTA MOTOR CORPORATION

1988 TOYOTA MR 2
REPAIR MANUAL
INTRODUCTION
MAINTENANCE ...._..
ENGINE MECHANICAL 14®1
SUPERCHARGER SYSTEM
EMISSION CONTROL SYSTEMS 1!£1
EFI SYSTEM
COOLING SYSTEM
LUBRICATION SYSTEM I!!J
IGNITION SYSTEM
STARTING SYSTEM EiJI
CHARGING SYSTEM :
CLUTCH
EJI
MANUAL TRANSAXLE 1®11
AUTOMATIC TRANSAXLE l!jl
FRONT AXLE AND SUSPENSION I:D
REAR AXLE AND SUSPENSION
BRAKE SYSTEM l:mJI
STEERING
BODY ELECTRICAL
SYSTEM llnJI
BODY
AIR CONDITIONING SYSTEM litll
SERVICE SPECIFICATIONS ..
STANDARD BOLTTORQUE SPECIFICATIONS --
SSTANDSSM-
AUTOMATIC TRANSMISSION ~
HYDRAULIC CIRCUIT ~
ELECTRICAL WIRING DIAGRAMS -

IN-1
INTRODUCTION
Page
HOW TO USE THIS MANUAL .. •. . . .. . .. . • .. . •. . IN-2
IDENTIFICATION INFORMATION . . . . . . •. •. •••. . . IN-4
GENERAL REPAIR INSTRUCTIONS . . . .. .. . . •. •. • IN-4
PRECAUTIONS FOR VEHICLES EQUIPPED WITH
A CATALYTIC CONVERTER •. . . . . . • . .. • .. • .. . IN-6
VEHICLE LIFT AND SUPPORT LOCATIONS . . . . .. IN-7
ABBREVIATIONS USED IN THIS MANUAL ••. . . . . IN-8

IN-2
650 (47, 64)
i
I 650 (47. 64) I
1 310 122. 30) 1
INTRODUCTION -How to Use This Manual
HOW TO USE THIS MANUAL
To assist you in finding your way through the manual, the Sec-
tion Title and major heading are given at the top of every page.
An INDEX is provided on the
first page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain
to all repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair
for each possible cause is referenced in the remedy col-
umn
to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together.
Example:
+I 5oo (36, 49) I
I 36o (26. 35) I Suspension
Support----(~ 'lr'
Dust Seal----:::i:""'~
Spring Seat
1,450 (105, 42)
.,._ ___ Steering Knuckle
with Axle Hub
Ikg-em (ft-lb, N~ : Specified torque
+Non-reusable part FA1563

INTRODUCTION -How to Use This Manual
IN-3
Illustration:
what to
do and where
The procedures are presented in a step-by-step format:
• Illustration shows what to do and where to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such
as specifications and warnings.
Example:
/Task heading: what to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive
brake piston
as shown in the figure.
SST 09350-30020 (09350-061 20)
/ ""
Set part No. Component part No.
/Detail text: how to do it
(b) Measure the stroke applying and releasing the com-
pressed air (4 - 8 kg/cm2, 57 - 114 psi or 392 -
785 kPa) as shown in the figure.
Piston stroke: 1 .40 -1. 70 mm (0.0551 - 0.0669 in.)
----
-------Specification
This format provides the experienced technician with a FAST
TRACK
to the information needeq. The upper case task heading
can be read at a glance and only when necessary, the text
below
it provides detailed information. Important specifications
and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page
to go to.
SPECIFICATIONS
Specifications are presented in bold type throughout the text in
the applicable step. You never have to leave the procedure to
look up your specs. All specifications are also found in Appen-
dix A, Specifications, for quick reference.
WARNINGS, CAUTIONS, NOTES:
• WARNINGS are presented in bold type, and indicate there is
a possibility of injury to you or other people.
• CAUTIONS are also presented in bold type, and indicate the
possibility
of damage to the components being repaired.
• NOTES are separated from the text but do not appear in
bold. They provide additional information
to help you effi-
ciently perform the repair.

IN-4
INTRODUCTION -Identification Information, General Repair Instructions
4A-GE & 4A-GZE Engine
~
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the front lug-
gage end panel of the front luggage compartment.
This number is also stamped on
top of the instrument panel and
the driver's door.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the cylinder block, as
shown.
GENERAL REPAIR INSTRUCTIONS
1. Use fender seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts
in order to facilitate
reassembly.
3. Observe the following:
(a) Before performing electrical work, disconnect the
negative cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative
(-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen theterminal
nut and raise the cable straight up
without twisting it or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the
nut after installation. Do
not use a hammer or such to tap the terminal onto
the post.
(f) Be sure the cover for the positive (+)terminal is pro-
perly in place.
4. Check hose and wiring connectors
to make sure that they
are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins, gaskets, 0-rings and oil
seals etc.
with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the ... " symbol.

WRONG
p -
INTRODUCTION -General Repair Instructions
IN-5
IN0036
CORRECT
? IN0001
6. Precoated parts
Precoated parts are the bolts and nuts,
which have been
coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.
(b)
(c)
Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut or
installation part threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
bolt or nut threads.
Precoated parts are indicated in the
component
illustrations by the "*" symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening tor-
ques. Always use a torque wrench.
9. Use of special service tools {SST) and special service
materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and
follow the proper work procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the fuse amp rating
or use one of a lower rating.
11. Care
must be taken when jacking up and supporting the
vehicle.
Be sure to lift and support the vehicle at the
proper locations
(See page IN- 7).
{a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands.
It is extremely dangerous to do any work on
the vehicle raised on jack alone, even
for a small job
that can be finished quickly.
12. Observe the
following precautions to avoid damage to
parts:
(a) Do not open the cover or the case of the ECU
unless absolutely necessary. (If the IC terminals
are touched, the IC may be destroyed by static
electricity.)
(b)
(c)
(d)
To disconnect vacuum hoses, pull on the end, not the
middle
of the hose.
To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.

General Repair Instructions,
IN-6 INTRODUCTION -Precautions for Vehicles Equipped with a Catalytic Converter
(e) When steam cleaning an engine, protect the distribu-
tor, coil and air filter from water.
(f) Never use an impact wrench to remove or install ther-
mo switches or thermo sensors.
(g) When checking continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
(h) When using a vacuum gauge, never force the hose
onto a connector
that is too large. Use a step-down
adapter instead. Once the hose has been stretched,
it
may leak.
Exampl~
VTVftt.1F
I Si111
13. Tag hoses before disconnecting them:
(a) When disconnecting vacuum hoses, use tags to iden-
tify how they should be reconnected.
(b) After completing a job, double check that the
vacuum hoses are properly connected. A label under
the hood shows the proper layout.
~
IN0002
PRECAUTIONS FOR VEHICLES EQUIPPED WITH A
CAT AL VTIC CONVERTER
WARNING: If large amounts of unburned gasoline flow
into the converter, it may overheat and create a fire hazard.
To
prevent this, observe the following precautions and
explain them to your customer.
1. Use only unleaded gasoline.
2. Avoid prolonged idling.
Avoid running the engine at idle speed for n'lore than 20
minutes.
3.
Avoid spark jump test.
(a) Spark jump test only when absolutely necessary. Per-
form this test as quickly as possible.
(b) While testing, never race the engine.
4. Avoid prolonged engine compression measurement.
Engine compression tests must be made as quickly as
possible.
5. Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra
load on the converter.
6.
Avoid coasting with ignition turned off and prolonged
braking.
7. Do
not dispose of a used catalyst along with parts con-
taminated with gasoline or oil.

Front
INTRODUCTION -Vehicle lift and Support locations
VEHICLE LIFT AND SUPPORT LOCATIONS
Seam Notches Seam Notches
JACK POSITION ------------~···
--®
Front . . . . . . . . . . Jack up support of front luggage pan
Rear . . . . . . . . . . . Rear engine mounting
PANTOGRAPH
JACK POSITION----------~ 0
SUPPORT POSITION
Safety stand
NOTE: If the arms of the swing arm lift cannot be positioned as
shown by the rectangles above. position them under the floor pan rein-
forcements shown by the hexagons.
IN0047
IN0034