1991 Toyota MR2 Service & Repair Manual (P/N RM179U1, RM179U2)

• Covers the 1991 Toyota MR2 SW20/SW21 in a 1,584-page PDF scan combining Toyota factory Repair Manual Volume 1 (RM179U1) and Volume 2 (RM179U2) — 644 PDF pages for Volume 1 and 940 for Volume 2.
• Engine repair coverage separates the 2.0L 3S-GTE turbo and 2.2L 5S-FE, with tune-up, compression testing, valve-clearance shim selection, timing-belt service, cylinder-head work, cylinder-block overhaul, engine removal, turbocharger, EFI, cooling, lubrication, ignition, starting, and charging procedures.
• Powertrain chapters cover clutch diagnosis and bleeding, the S54 manual transaxle for 5S-FE applications, the E153 manual transaxle for 3S-GTE applications, and the A241E automatic transaxle, including removal/installation, internal inspection, disassembly, reassembly, adjustment, and operational checks.
• Chassis sections include wheel alignment, front and rear suspension, axle hubs and drive shafts, ABS diagnosis and actuator/speed-sensor service, manual and power steering, and electronic power-steering control-system checks.
• Electrical, body, and safety coverage includes SRS airbag diagnosis and component replacement, body-electrical circuits and connectors, lighting, wipers, power windows/locks/mirrors, cruise control, theft deterrent, body panels and glass, T-bar roof, interior trim, seat belts, and R-12 air-conditioning system service.
• Factory reference material includes service-specification tables, standard bolt-torque tables, illustrated SST/SSM part-number matrices, exploded assembly views, sectional views, troubleshooting charts, and system-specific circuit/connector diagrams.

Two-Volume Factory Scope

This is the Toyota factory repair-manual set for the 1991 MR2 SW20/21, not an engine-only publication. Volume 1 concentrates on maintenance and engine systems, while Volume 2 carries the repair coverage into the clutch, transaxles, suspension, brakes, steering, SRS, body electrical, body hardware, and air conditioning. The procedure format is best suited to experienced technicians and advanced DIY mechanics already comfortable with workshop practice, because Toyota presents compact task steps, illustrations, SST references, specifications, cautions, and cross-references rather than beginner-level mechanical instruction.

Engine and Powertrain Repair

The engine mechanical section is split around the two U.S.-market powerplants. For the 3S-GTE, the manual covers T-VIS operation, turbocharger on-vehicle inspection and troubleshooting, timing-belt removal/installation and valve-timing checks, cylinder-head disassembly and inspection, cylinder-block work, and complete engine removal. The 5S-FE receives its own timing-belt, cylinder-head, camshaft, cylinder-block, and engine-removal procedures rather than being treated as a generic variation.

EFI coverage goes well beyond basic tune-up data. It includes the diagnosis system, volt/ohmmeter troubleshooting, fuel-pressure testing, injectors, cold-start injector circuits, throttle body and idle-speed control, ECU-related inputs, oxygen sensing, EGR temperature sensing, and engine-specific sensor/actuator checks. Separate chapters handle PCV, EVAP, EGR, three-way catalyst systems, coolant circulation, oil-pressure checks, oil pumps/coolers, ignition, starter, and alternator service.

Volume 2 adds internal driveline repair. The S54 and E153 manual transaxles have separate component-removal, inspection, reassembly, and installation coverage, while the A241E chapter includes electronic-control diagnosis, mechanical system tests, road tests, shift-schedule checks, torque-converter work, planetary gear units, clutches, brakes, valve body, differential, and final installation.

Chassis, Electrical, Body, and A/C

The chassis material includes front/rear alignment, struts, ball joints, stabilizers, rear axle carriers and drive shafts, plus brake-system diagnosis and ABS troubleshooting. The steering chapter distinguishes manual steering from power steering and includes the electronic control system and diagnosis checks. SRS coverage is unusually detailed for a general repair manual, with inspection/replacement requirements, front airbag sensors, center airbag sensor assembly, spiral cable, steering-wheel pad, repair-wire procedures, troubleshooting, and disposal information.

Representative technical illustrations include the 3S-GTE and 5S-FE timing-belt component exploded views, the 3S-GTE turbocharger cutaway and boost-control schematic, EFI system schematics, S54/E153 and A241E sectional views, and body-electrical connector and circuit diagrams. Appendix C also cross-references Toyota special service tools and materials by section; examples include SST 09082-00700 for SRS airbag deployment and SST 09213-31021 for crankshaft-pulley removal.

The manual also calls out repair traps that matter during teardown. It warns that incorrect cylinder-head bolt loosening can warp or crack the head, and the 5S-FE camshaft section cautions that forcing a cocked camshaft can damage the camshaft or cylinder head.

Toyota references the separate 1991 MR2 Electrical Wiring Diagram Manual (EWD083U) and 1991 MR2 New Car Features (NCF062U) as companion publications. They are not part of this PDF; the repair set itself still contains extensive body-electrical circuit, connector, and diagnostic material. For SRS, fuel-pressure, brake, steering, rotating-engine, and R-12 refrigerant work, follow the factory precautions and battery-isolation instructions in the applicable section before beginning repair.