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

The volumes cross-reference maintenance and engine procedures with chassis, body and electrical repairs, including the related work involved in engine and transaxle removal.

Electrical coverage: Appendix D (Electrical Wiring Diagrams), listed in Volume 2's contents, is absent from this PDF. The separate EWD083U wiring manual and NCF062U New Car Features publication are also excluded; system-specific circuit and connector diagrams are included within the repair chapters.

Two Volumes in One Printable PDF

Search, bookmarks and small labels: PDF text search is unavailable. Embedded bookmarks cover both volumes, but several 3S-GTE emissions entries lead to 5S-FE sections. Dense wiring and connector diagrams require zooming to read small labels.

Both volumes are combined in one printable, English-language, 1,584-page PDF. This total includes two forewords, two contents pages and two memo pages.

Engine, Driveline and Chassis Repair

The following selected topics outline the repair coverage. Other examples include audio-system troubleshooting and body-dimension drawings.

• Engine mechanical: Step-by-step engine removal, timing-belt service, compression testing, valve-clearance adjustment, and cylinder-head and cylinder-block overhaul for the 3S-GTE and 5S-FE.

• Fuel and engine systems: EFI diagnosis, turbocharger inspection, emissions testing, cooling and lubrication service, ignition timing, starter repair and alternator overhaul.

• Clutch and transaxles: Clutch diagnosis and bleeding, S54/E153 internal repair, and A241E electronic-control diagnosis, mechanical tests and overhaul.

• Suspension, brakes and steering: Wheel alignment, axle hubs and drive shafts, brake repair, ABS actuator and speed-sensor checks, and manual and power steering service.

• Body electrical and SRS: Wiring and connector diagrams, airbag fault tracing, sensor replacement, spiral-cable service and front airbag sensor repair-wire procedures.

• Body and air conditioning: Panel and glass work, roof mechanisms, interior trim, seat belts, and R-12 refrigeration diagnosis and compressor service.

Toyota's procedure format is written for experienced technicians, with workshop measuring equipment and the specified special service tools needed for the relevant tasks.

Engine Mechanical and EFI Diagnosis

Engine-specific detail: Separate timing-belt, camshaft, cylinder-head and block procedures are supported by exploded views and valve-clearance shim-selection charts. The 3S-GTE material adds T-VIS operation, a turbocharger cutaway and boost-control schematics alongside on-vehicle inspection and troubleshooting.

EFI schematics accompany fault charts for starting, stalling and drivability problems, with volt/ohmmeter checks, fuel-pressure tests and ECU-input diagnosis. Engine-specific checks cover cold-start injectors, throttle bodies, idle-speed control, oxygen sensors and EGR gas-temperature sensing.

PCV, EVAP, EGR and three-way catalyst systems have separate inspection procedures. Cooling and lubrication chapters cover coolant replacement and air removal, oil-pressure checks, oil pumps and oil coolers.

The cylinder-head instructions warn that an incorrect bolt-loosening order can warp or crack the head. The 5S-FE camshaft procedure also warns of cylinder-head damage and camshaft seizure or breakage if the shaft is not kept level.

Transaxle Tests and Internal Repair

Separate S54 and E153 sections detail input and output shafts, synchronizers and differentials, with sectional views and assembly adjustments. A241E coverage includes a sectional view, torque-converter work and overhaul of planetary units, clutches, brakes, the valve body and differential. Road tests and shift-schedule checks accompany the mechanical and electronic diagnosis.

The A241E troubleshooting flowchart separates engine, electronic-control and internal transaxle faults. This gives the technician a diagnostic path for deciding which system needs investigation before internal repair.

Suspension, ABS and Power Steering

Front and rear chassis procedures cover struts, ball joints, stabilizers and rear axle carriers, with separate drive-shaft procedures for each engine. ABS diagnostic charts include circuit checks and oscilloscope inspection of speed-sensor signals.

Steering coverage distinguishes manual steering from EHPS (Electro-Hydraulic Power Steering), including pump-pressure testing and electronic-control diagnosis.

SRS, Body Electrical and Air Conditioning

Airbag service: Collision-specific inspection and replacement requirements accompany front and center sensor assembly work. Steering-wheel pad and center airbag sensor disposal procedures are included.

Electrical fault tracing: Lighting, wipers, power windows, locks and mirrors have system-specific circuit and connector information. Cruise-control and theft-deterrent sections provide symptom-based troubleshooting.

Roof and refrigeration work: Body procedures include T-bar roof adjustment and removable-roof disassembly. A/C coverage extends to manifold-gauge diagnosis, compressor and magnetic-clutch disassembly, shaft-seal replacement and control-system checks.

Workshop References and Precautions

Service-specification and standard bolt-torque tables accompany Appendix C's illustrated SST/SSM matrices. Tool references include SST 09213-31021 for crankshaft-pulley removal and SST 09082-00700 for airbag deployment.

Follow the section-specific precautions for SRS, pressurized fuel, brakes, steering, rotating components and R-12 service, including the applicable battery-isolation requirements.

Cooling Capacity and Thermostat Test Examples

The coolant-replacement section lists capacities with the heater circuit included: 13.6 liters for the 3S-GTE and 13.0 liters for the 5S-FE. These figures accompany the coolant-filling and air-removal procedures.

For both engines, thermostat inspection specifies a valve-opening range of 80–84°C (176–183°F), alongside a separate valve-lift check.