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

IN-8 INTRODUCTION -Abbreviations Used in This Manual
ABBREVIATIONS USED IN THIS MANUAL
ABV
A/C
A/T, ATM
Bl
B2
B3
B4
BTDC
BVSV
cl
c2
Ca
Calif.
C/B
DP
ECT
ECU
EFI
EGR
ELR
ESA
EVAP
EX
Ex.
Fl
F2
F3
FIPG
FL
FPU
IG
IN
ISC
LH
Max.
Min.
MP
M/T, MTM
N
0/D
0/S
PCV
PS
RH
SSM
SST
STD
S/W
TCCS
TDC
TWC
UD
U/S
vsv
VTV
w/
w/o
Air By-pass Valve
Air Conditioner
Automatic Transaxle
Second Coast Brake
Second Brake
First and Reverse Brake
Underdrive Brake
Before Top Dead Center
Bimetal Vacuum Switching Valve
Forward Clutch
Direct Clutch
Underdrive Clutch
Vehicles Sold in California
Circuit Breaker
Dash Pot
Electronic Controlled Transaxle
Electronic Controlled Unit
Electronic Fuel Injection
Exhaust Gas Recirculation
Emergency Locking Retractor
Electronic Spark Advance
Evaporative (Emission Control)
Exhaust (Manifold, Valve)
Except
No. 1 One-way Clutch
No. 2 One-way Clutch
Underdrive One-way Clutch
Formed in Place Gasket
Fusible Link
Fuel Pressure Up
Ignition
Intake (Manifold, Valve)
Idle Speed Control
Left-hand
Maximum
Minimum
Multipurpose
Manual Transaxle
Neutral
Overdrive
Oversize
Positive Crankcase Ventilation
Power Steering
Right-hand
Special Service Materials
Special Service Tools
Standard
Switch
TOYOTA Computer Controlled System
Top Dead Center
Three-way Catalyst
Underdrive
Undersize
Vacuum Switching Valve
Vacuum Transmitting Valve
With
Without

MA-1
MAINTENANCE
Page
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . MA-2
MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . MA-4
GENERAL MAINTENANCE . . . .. . . . . . . . . . . . . . . . MA-12·~,_,
GENERAL NOTES:
• Every service item in the periodic maintenance list must be
performed.
• Failure to do even one item can cause the engine to run poor-
ly and increase exhaust emissions.

MA-2 MAINTENANCE -Maintenance Schedule
MAINTENANCE SCHEDULE
Maintenance operations: A =Check and adjust if necessary;
R =Replace, change
or lubricate;
=Inspect and correct or replace if
necessary
NORMAL CONDITION SCHEDULE
Maintenance services beyond 60,000 miles
\ SeN;ce ;nteNal (Odome-
(96,000 km) should be performed at the same
ter reading or months, intervals shown in each maintenance schedule.
System whichever comes first) Miles x 1 ,000 10 20 30
40
50 60
See page
(item No.)
\
Km x 1,000 16 32 48 64 80
96
Maintenance items Months
12 24
36
48
60 72
ENGINE Valve clearance A MA-7
(item 13)
Drive belts(1l I !
MA-4
(item 2)
I
Engine oil and oil filter * R R R ! R R R MA-5
(item 6)
Supercharger oil * 4A-GZE I I
MA-5
(item 7)
Engine coolant(2l R
MA-6
(item 8)
Exhaust pipes and mountings I I '
MA-7
(item 12)
i
FUEL
Idle speed (3) I 4A-GE i A A A
MA-7
(item 14)
Air filter*
R R MA-5
(item 5)
Fuel line and connections I ! I
MA-7
(item 11)
Fuel tank cap gasket i R
MA-6 (item 1
IGNITIO Spark plugs R
MA-4
(item 3)
EVAP Charcoal canister I
MA-6
(item 9)
BRAKES Brake pads and discs I I I i
MA-8
(item 16)
Brake line pipes and hoses I I I
MA-8
(item 15)
CHASSIS Steering linkage l I I l
MA-8 (item 1 7)
Ball joints I I I
MA-9
(item 19)
Automatic transaxle, manual transaxle, I I I
MA-9
(item 20)
differential and steering gearhousing oil(4l MA-9
(item 18)
Bolts and nuts on chassis and body I I I MA-11 (item 23)
For vehicles sold
in California. maintenance services indicated by a star (*) is required underthe terms of the Emission
Control Systems Warranty. See Owner's Guide
or Warranty Booklet for complete warranty information.
NOTE:
(1) After 60,000 miles (96,000 km) or 72 months, inspect every 1 0,000 miles (16,000 km) or 12 months.
(2) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(3) After 60,000 miles (96,000 km) or 72 months, adjust every 30,000 miles (48,000 km) or 36 months.
(4) Inspect the steering gear housing
for oil leakage only.

MAINTENANCE -Maintenance Schedule
MA-3
Follow the severe condition schedule if vehicle is operated mainly under one or more of the following severe conditions:
• Towing a trailer, using a camper or car top carrier.
• Repeat short trips less than 5 miles (8 km) and outside temperatures remain below freezing.
• Extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use.
• Operating on dusty, rough, muddy or salt spread roads.
SEVERE CONDITION SCHEDULE
Maintenance services beyond 60,000 miles
Service interval (Odome-
(96,000 km) should be performed at the same
ter reading
or months, intervals shown
in each maintenance schedule.
System whichever comes first) See page
\ Miles x 1
,000
5
10
15 20
25 30
35
40
45 50
55 60
(item No.)
Maintenance items \
Km x 1,000
8 16 24
32 40
48 56
64 72
80 88
96
Months 6
12 18
24
30 36 42 48 54 60
66 72
ENGINE
Timing belt R
(1)
MA-4
(item 1)
Valve clearance A
MA-7
(item 13)
Drive belts
121
I MA-4
(item 2)
Engine oil and oil filter * R R R R R R R R R R R R
MA-5
(item 6)
Supercharger oil * 4A-GZE I I
MA-5
(item 7)
Engine coolantl31 R
MA-6
(item 8)
Exhaust pipes and mountings I I I I
MA-7
(item 12)
FUEL
Idle speed 1
41 4A-GE A A A
MA-7
(item 14)
Air filter* 151
I I I I I R I I I I I R MA-5
(item 4, 5)
Fuel line and connections I I
MA-7
(item 11)
Fuel tank cap gasket R
MA-6
(item 10)
IGNITION Spark plugs R
MA-4
(item 3)
EVAP Charcoal canister I
MA-6
(item 9)
BRAKES Brake pads and discs I I I I I I
MA-8
(item 16)
Brake line pipes and hoses I I I MA-8
(item 15)
CHASSIS Steering linkage I I I I I I MA-8
(item 17)
Ball joints I I I I I I
MA-9
(item 19)
Automatic transaxle, manual transaxle, R R R
MA- 9, 10 (item 21 or 22)
differential
and steering gear housing oill71
MA-9
(item 18)
Bolts and nuts on chassis and
bodyl61
I I I I I I
MA-11
(item 23)
For vehicles sold in California, maintenance services indicated by a star (*) is required under the terms of the Emission
Control Systems Warranty. See Owner's Guide for complete warranty information.
NOTE:
(1) For the vehicles frequently idled
for extensive periods and/or driven for long distance at low speeds such as taxi,
police and door-to-door delivery, it is recommended to change at 60,000 miles (96,000 km).
(2)
After 60,000 miles (96,000 km) or 72 months, inspect every 1 0,000 miles (1 6,000 km) or 12 months.
(3) After 60,000 miles (96,000 km) or 72 months, replace every 30,000 miles (48,000 km) or 36 months.
(4)
After 60,000 miles (96,000 km) or 72 months, adjust every 30,000 miles (48,000 km) or 36 months.
(5) Applicable when operating mainly on dusty roads. If not, follow the normal condition schedule.
(6) Applicable when operating mainly on rough and/or muddy roads. If not, follow the normal condition schedule.
(7) Inspect the steering gear housing for oil leakage only.

MA-4
Nippondenso
CORRECT
MAINTENANCE -Maintenance Operations
CHOQ04 CH0146
Borroughs
EC0003 EC0004 EC0001
WRONG WRONG
CH0086
~FI0087
MAINTENANCE OPERATIONS
ENGINE
Cold Engine Operations
1. REPLACE TIMING BELT
(a) Remove the timing belt.
(See pages EM-1 5 to 1 7)
(b) Install the timing belt.
(See pages EM-22 to 25)
2. INSPECT DRIVE BELTS
(a) Visually check the belt for separation of the adhesive
rubber above and below the core, core separation
from the belt side, severed core, separation of the rib
from the adhesive rubber, cracking or separation of
the ribs, torn or worn ribs or cracks in the inner ridges
of the ribs.
If necessary, replace the drive belt.
(b) Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge:
Nippondenso
Borroughs
BTG-20 (95506-00020) or
No. BT-33-73F
Drive belt tension:
4A-GE
Alternator New belt
Used belt
Air con.
New belt
Used belt
4A-GZE
Alternator
w/
Air con. New belt
Used belt
w/o
Air con. New belt
Used belt
Supercharger New belt
Used belt
If necessary, adjust the drive belt tension.
NOTE:
175 ± 5
lb
115 ± 20 lb
160 ± 20 lb
105 + 10 lb
165 ± 10 lb
85 ± 15 lb
175 ±
Sib
115 ± 20 lb
175 ±
51b
115 ± 20 lb
• "New belt" refers to a belt which has been used less
than 5 minutes on a running engine.
• "Used belt" refers to a belt which has been used on a
running engine
for 5 minutes or more.
• After replacing the drive belt, check that it fits properly
in the ribbed grooves, especially in the places
difficult
to see.
• After installing a new belt, run the engine for about 5
minutes and then recheck
the tension.
3. REPLACE SPARK PLUGS
(a) Disconnect the spark plug cords at the boot.
DO NOT pull on the cords.

MAINTENANCE -Maintenance Operations
MA-5
(b) Using plug wrench (16 mm), remove the spark plugs.
(c) Check the electrode gap of new spark plugs.
Correct electrode gap: 1.1 mm (0.043 in.)
Recommended
spark plugs:
4A-GE NO PQ16R
NGK BCPR5EP11
4A-GZE NO PQ20R
NGK BCPR6EP11
NOTE: If adjusting the gap of a new plug, bend only the
base
of the ground electrode. Do not touch the tip. Never
....._ ____________ __;.IGo.;;..;o-'-'71 attempt to adjust the gap on a used plug.
EM0873
4. INSPECT AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
(b) Clean the element with compressed air.
First blow from back side thoroughly. Then blow off
the front side of the element.
5. REPLACE AIR FILTER
Replace the air cleaner element with a new one.
6. REPLACE ENGINE OIL
AND FILTER
(See page LU-4)
Oil grade: API grade SF or SF/CC, multigrade
viscosity and fuel-efficient oil
Engine oil capacity:
Drain and refill with oil filter change
w/o Oil cooler
3.3 liters (3.5 US qts, 2.9 Imp. qts)
w/ Oil cooler
3.4 liters (3.6 US qts, 3.0 Imp. qts)
7. INSPECT SUPERCHARGER OIL LEVEL
(See page SC-3)
Supercharger oil: Part No. 08885-801 08 or
equivalent

MA-6 MAINTENANCE -Maintenance Operations
Pipe Drain Plug Air Bleed Plug
MA0330
~
c
Air should flow through freely and no
charcoal should come out.
EC1121
MA0379
8. REPLACE ENGINE COOLANT
(See page
C0-3)
(a) Open the air bleed plugs.
(b) Drain the coolant from the radiator, engine and pipe
drain plugs.
(Engine drain is on the left next to the oil filter.)
(c) Close the drain plugs.
(d) Fill system with coolant.
(e) Close the air bleed plugs.
Coolant capacity:
M/T
With heater
12.2 liters (12.9 US qts, 10.7 Imp. qts)
Others
12.4 liters (13.1 US qts, 10.9 Imp. qts)
AIT
12.9 liters (13.6 US qts, 11.4 Imp. qts)
Use a good brand of ethylene-glycol base coolant, mixed
according to the manufacturer's instructions.
9. INSPECT CHARCOAL CANISTER
(a) Disconnect the hoses to the charcoal canister located
below the air intake chamber. Label the hoses for
correct installation.
(b) Plug pipe A with your finger and blow compressed air
(3 kg/cm
2,
43 psi or 294 kPal through pipe B (fuel
tank side).
• Check that air comes out of the bottom pipe C
without resistance.
• Check that no activated charcoal comes out.
If necessary, replace the charcoal canister.
NOTE: Do not attempt to wash the charcoal.
(c) Connect the hoses to the charcoal canister.
10. REPLACE GASKET IN FUEL TANK CAP
(a) Remove the old gasket (0-ring) from the fuel tank
cap. Do not damage the cap.
(b) Install the new gasket by hand.
(c) Inspect the cap for damage or cracks.
(d) Install the cap and check the torque limiter.

MAINTENANCE -Maintenance Operations
MA-7
IG0300
11. INSPECT FUEL LINES AND CONNECTIONS
Visually inspect the fuel lines for cracks, leakage, loose
connections, deformation or tank band looseness.
12. INSPECT EXHAUST PIPE AND MOUNTINGS
Visually inspect the pipes, hangers and connections for
severe corrosion, leaks or damage.
13. ADJUST VALVE CLEARANCE
NOTE: Check and adjust the valve clearance while the
engine is cold.
(a) Remove the valve covers.
(b) Measure and adjust valve clearance.
(See step 3 on page EM- 7)
Valve clearance (cold):
Intake 0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust 0.20 - 0.30 mm (0.008 - 0.012 in.)
(c) Reinstall the valve covers.
Hot Engine Operations
14. 4A-GE ENGINE ONLY:
ADJUST IDLE SPEED
(a) Preparation
• Air cleaner installed
• All pipes and hoses of air intake system connected
• All vacuum lines connected (i.e., EVAP, EGR
systems, etc.)
• EFI system wiring connectors fully plugged
• Engine at normal operating temperature
• Accessories switched off
• Transmission in "N" range
(b) Connect a tachometer to the engine.
(See page IG-2)
CAUTION:
• NEVER allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.
• As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before using.
(c) Race the engine at 2,500 rpm for about 2 minutes.
(d) Set the idle speed by turning the IDLE SPEED
ADJUSTING SCREW.
Idle speed: 800 rpm
(e) Remove the tachometer.
NOTE: Make adjustments with the engine cooling fan
off.

MA-8
MAINTENANCE -Maintenance Operations
MA0356
MA0132 MA0317
MA0332
Freeplay
MA0415
BRAKES
15. INSPECT BRAKE LINE PIPES AND HOSES
NOTE: Inspect in a well lighted area. Inspect the entire
circumference and length
of the brake hoses using a mir-
ror as required. Turn the front wheels fully right or left
before inspecting the front brake.
(a) Check all brake lines and hoses for:
• Damage • Corrosion
• Wear • leaks
• Deformation • Bends
• Cracks • Twists
(b) Check all clamps for tightness and connections for
leakage.
(c) Check that the hoses and lines are clear of sharp
edges, moving parts
and the exhaust system.
(d) Check that the lines installed in grommets, pass
through the center
of the grommets.
16. INSPECT FRONT
AND REAR BRAKE PADS AND DISCS
(Front: See page BR-23, Rear: See page BR-33)
(a) Check the thickness of the disc brake pads and
check
for irregular wear.
Minimum pad thickness:
Front 3.0 mm (0.118 in.)
Rear
1.0 mm (0.039 in.)
NOTE: If a squealing or scraping noise occurs from the
front or rear brakes during driving, check the pad wear
indicator.
If there are traces of the indicator contacting the
disc rotor, the disc pad should
be replaced.
(b) Check the disc for wear or runout.
Minimum disc thickness:
Front 21.0 mm (0.827 in.)
Rear
g,o mm (0.354 in.)
Maximum disc runout:
Front 0.13 mm (0.0051 in.)
Rear 0.1 5
mm (0.0059 in.)
CHASSIS
17. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay.
Maximum steering wheel freeplay: 30 mm (1.18 in.)
With the vehicle stopped and pointed straight ahead,
rock the steering wheel gently back and
forth with
light finger pressure.

MAINTENANCE -Maintenance Operations
MA-9
Front
MA0335
Manual Transaxle Automatic Transaxle
{b) Check the steering linkage for looseness and
damage.
Check that:
• Tie rod ends do not have excessive play.
• Dust seals and boots are
not damaged.
• Boot clamps are not loose.
18. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing
for oil leakage.
19. INSPECT BALL JOINTS AND DUST COVERS
{a) Inspect the ball joints for excessive looseness.
{Front: See page FA-20, Rear: See pages RA-35)
Maximum ball joint vertical play: 0 mm (0 in.}
If excessive play is found, replace the ball joints.
{b) Inspect the dust cover for damage.
20. CHECK TRANSAXLE (A/TOR M/T) AND
DIFFERENTIAL OIL
Visually check the transaxle {A/T
or M/Tl and differential
for oil leakage.
If leakage
is found, check for the cause and repair.
21. REPLACE
MANUAL TRANSAXLE (TRANSMISSION
'------------~M~Ao:;;;.;n::.:::e..:::M~A04=2o AND DIFFERENTIAL) OIL
{a) Remove the drain plug and drain the oil.
{b) Reinstall drain plug securely.
{c) Add new oil until it begins to run out of the filler hole.
Transaxle oil (M/T and differential):
Oil grade API GL-4 or 5
Viscosity SAE 75W-90 or SOW-90
Capacity
C52/4A-GE 2.6 liters
(2.7 US qts, 2.3 Imp. qts)
E51 /4A-GZE
4.2 liters
~....... ____________ ...;;:M:::::Ao::::3::.:.J37 (4.4 US qts, 3.7 Imp. qts)