1991 Toyota MR2 Service & Repair Manual (P/N EWD083U/NCF062U)
1584 Pages • 133.50 MB • Instant, Printable PDF
Toyota Models Covered & Key Technical Specifications
Models: Toyota MR2 (SW20 series), Toyota MR2 (SW21 series)
Sub-models / Variants: 3S-GTE Engine, 5S-FE Engine
Model Years: 1991
Technical Data:
- Engine Displacement (3S-GTE): 2.0 liters
- Engine Displacement (5S-FE): 2.2 liters
- Configuration: In-line 4-cylinder, DOHC, 16-valve
- Firing Order: 1–3–4–2
- Spark Plug Gap (3S-GTE): 0.8 mm (0.031 in.)
- Spark Plug Gap (5S-FE): 1.1 mm (0.043 in.)
- Compression Pressure (3S-GTE): 11.5 kg/cm² (164 psi) or more
- Compression Pressure (5S-FE): 12.5 kg/cm² (178 psi) or more
- Intake Valve Clearance (3S-GTE): 0.15–0.25 mm (0.006–0.010 in.)
- Exhaust Valve Clearance (3S-GTE): 0.20–0.30 mm (0.008–0.012 in.)
- Intake Valve Clearance (5S-FE): 0.19–0.29 mm (0.007–0.011 in.)
- Exhaust Valve Clearance (5S-FE): 0.28–0.38 mm (0.011–0.015 in.)
- Idle Speed (USA M/T): 750 ± 50 rpm
Toyota Manual Features & Content Preview
- Covers 1991 Toyota MR2 (SW20/SW21) engine mechanical systems for both the 3S-GTE and 5S-FE powerplants
- Official 1584-page Toyota OEM publication (Volume 1) detailing engine maintenance and overhaul procedures
- Contains 47 exploded-view diagrams of engine components and timing belt systems
- Serves as the primary technical reference for the SW20 series debut, featuring unique cross-referenced specifications for both engine variants
Engine Coverage and Systems
The engine mechanical manual details the architecture and service requirements for the 2.0-liter 3S-GTE and 2.2-liter 5S-FE engines. Sections define cylinder head assembly, engine block tolerances, and turbocharger system integration for the 3S-GTE. Lubrication systems, cooling, and ignition timing data are provided alongside maintenance schedules for drive belts, spark plugs, and air filtration.
The documentation outlines factory procedures for timing belt replacement, valve clearance adjustments via shim selection charts, and compression testing. Because engine maintenance involves high-pressure fuel lines and sensitive electronics, always review the included safety protocols and battery isolation steps before initiating a teardown. Torque specifications are provided for critical assembly components, including camshaft bearing caps, engine mounting brackets, and intake manifold fasteners. Electrical system troubleshooting notes focus on sensor diagnostic thresholds and battery maintenance protocols for the Supplemental Restraint System (SRS).
Technical Specifications Preview
Engine cooling capacity is documented at 13.6 liters for the 3S-GTE and 13.0 liters for the 5S-FE. Valve clearance for the 3S-GTE intake is listed at 0.15 to 0.25 mm in the cylinder head specification table. Compression pressure for the 5S-FE is specified at a minimum of 10.0 kg/cm² in the engine mechanical data section.
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