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Toyota Manuals
Automobile
MR2 1988
Repair manual
Toyota MR2 1988 Repair Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Repair Procedures
How to Use this Manual
Check Piston Stroke of Overdrive Brake
Identification Information
Vehicle Identification Number
Engine Serial Number
General Repair Instructions
Precautions for Vehicles Equipped Witha Catalytic Converter
Vehicle Lift and Support Locations
Abbreviations Used in this Manual
Maintenance
Maintenance Schedule
Normal Condition Schedule
Severe Condition Schedule
Maintenance Operations
Cold Engine Operations
Replace Timing Belt
Inspect Drive Belts
Inspect Air Filter
Replace Air Filter
Replace Engine Oil and Filter
Replace Engine Coolant
Inspect Charcoal Canister
Hot Engine Operations
Inspect Fuel Lines and Connections
Inspect Exhaust Pipe and Mountings
Adjust Valve Clearance
Brakes
Inspect Brake Line Pipes and Hoses
Inspect Front and Rear Brake Pads and Discs
Inspect Steering Linkage
Replace Automatic Transaxle
Tighten Bolts and Nuts on Chassis and Body
Final Inspection
General Maintenance
Outside Vehicle
Inside Vehicle
Under Hood
Engine Mechanical
Troubleshooting
Engine Tune-Up
Adjustment of Valve Clearance
Set N0.1 Cylinder to Tdc/Compression
Adjusting Shim Selection Using Chart
Intake
Exhaust
Inspection and Adjustment of Idle Speed
Idle Hc/Co Concentration Check Method
Further Check Idle Speed
Initial Conditions
Check Oxygen Sensor Operation
Compression Check
Timing Belt Components
Removal of Timing Belt
Remove Spark Plugs
Set No. 1 Cylinder to Tdc/Compression
Remove Rh Engine Mounting Insulator
Remove Crankshaft Pulley
Cylinder Head (4A-Ge
Cylinder Head (4A-Gze
Removal of Cylinder Head
Remove No. 2 Air Outlet Duct
Disconnect No. 3 Fuel Pipe
Remove No. 1 Vacuum Transmitting Pipe
Disconnect No.2 Fuel Hose
Remove Delivery Pipe with Injectors
Lay Wire Harness to One Side
Remove Egr Valve with Pipe
Remove Intake Manifold
Remove Alternator Bracket
Remove Exhaust Manifold
Installation of Cylinder Head
Install Intake Manifold
Install Egr Valve with Pipe
Install Water Outlet with By-Pass Pipe
Clamp Wire Harness
Connect No.2 Fuel Hose
Install No.1 Vacuum Transmitting Pipe
Connect No.3 Fuel Pipe
Install No.2 Air Outlet Duct
Install Water Pump Pulley and Drive Belts
Connect Following Connectors and Wires
Cylinder Block Components
Removal of Engine (4A-Ge)
Disconnect Control Cables
Remove Front Mounting Insulator
Remove Rear Mounting Insulator
Remove Engine with Transaxle
Remove Water Inlet with Housing
Disconnect Following Connectors
Remove Flywheel Housing under Cover
Removal of Engine (4A-Gze)
Disconnect Following Connectors and Wires
Remove A/C Drive Belt
Disconnect A/C Compressor
Preparation for Disassembly
Disassembly of Cylinder Block
Remove Rear Oil Seal Retainer
Measure Connecting Rod Thrust Clearance
Remove Rod Caps and Measure Oil Clearance
Remove Main Bearing Caps and Measure Oil Clearance
Remove Crankshaft
Inspection of Cylinder Block
Remove Gasket Material
Clean Cylinder Block
Inspect Top of Block
Disassembly of Piston and Connecting Rod Assemblies
Check Fit between Piston and Pin
Remove Piston Rings
Disconnect Connecting Rod from Piston
Inspection of Piston and Connecting Rod Assemblies
Clean Piston
Inspect Piston Diameter and Oil Clearance
Inspect Piston Ring Groove Clearance
Inspect Piston Ring End Gap
Inspect Piston Pin Fit
Inspect Connecting Rods
Inspect Connecting Rod Bolts
Inspect Piston Pin Oil Clearance
Boring of Cylinders
Calculate Amount to Bore Cylinder
Bore and Hone Cylinders to Calculated Dimensions
Inspection of Crankshaft
Measure Crankshaft for Runout
Inspect Main Journals and Crank Pins
Replacement of Rear Oil Seal
Replace Crankshaft Rear Oil Seal
Assembly of Piston and Connecting Rod
Install Piston Rings
Install Bearings
Assembly of Cylinder Block
Install Main Bearings
Install Upper Thrust Washers
Install Piston and Connecting Rod Assembles
Install Connecting Rod Caps
Post Assembly
Install Rear Oil Seal Retainer
Installation of Engine (4A-Ge)
Install Transaxle to Engine
Install Six Torque Converter Mounting Bolt
Install Flywheel Housing under Cover
Install Engine with Transaxle
Install Rear Mounting Insulator
Install Front Mounting Insulator
Install Clutch Release Cylinder and Control Bracket
Connect Control Cables
Connect A/C Compressor
Installation of Engine (4A-Gze)
Install Water Inlet with Housing
Supercharger System
Supercharger
On-Vehicle Inspection of Supercharger
Check Supercharger Oil Level
Inspect Magnet Clutch
Inspect Air By-Pass Valve (Abv)
Inspect Supercharger Pressure
Removal of Supercharger
Remove Intercooler
Remove Air Flow Meter with No.3 Air Cleaner Hose
Remove Drive Belt (for Supercharger)
Disassembly of Supercharger
Drain Supercharger Oil
Remove N0.2 Air Inlet Duct
Remove Clutch Hub
Remove Clutch Pulley
Remove Clutch Flange
Remove Front Cover
Remove Rear Cover
Remove Rear Plate
Inspection of Supercharger Components
Inspection of Air By-Pass Valve (Abv)/Air Control Valve (Acv) System
Installation of Supercharger
Install Elbows
Install Union
Install Rear Plate
Install Rear Cover
Install Housing Front Cover
Install Clutch Flange
Install Clutch Stator
Install Clutch Pulley
Install Clutch Hub
Inspect and Adjust Air Gap of Magnet Clutch
Install N0.2 Air Inlet Duct
Fill with Supercharger Oil
Install Air Inlet Duct Stay
Supercharger Relay
Inspection of Supercharger Relay
Inspect Relay Continuity
Inspect Relay Operation
Emission Control Systems
System Purpose
Component Layout and Schematic Drawing (4A-Ge
Component Layout and Schematic
Positive Crankcase Ventilation (Pcv) System
Inspection of Pcv Hoses and Connections
Fuel Evaporative Emission Control (Evap) System
Inspection of Charcoal Canister
Clean Filter in Canister
Check Bvsv by Blowing Air into Pipe
Dash Pot (Dp) System
Inspection of Dp System
Check Dp Setting Speed
Check Vtv Operation
Exhaust Gas Recirculation (Egr) System (4A-Ge
Inspection of Egr System
Check Seating of Egr Valve
Check Bvsv with Cold Engine
Inspection of Egr Valve
Inspection of Egr Vacuum Modulator
Check Egr Valve
Inspection of Bvsv
Inspection of Vsv
Inspection of Check Valve
Check for Open Circuit
Exhaust Gas Recirculation (Egr) System (4A-Gze
Three-Way Catalyst (Twc) System
EFI System
EFI System Description
Fuel System
Air Induction System
Electronic Control System
Maintenance Precautions
If Car Is Equipped with Mobile Radio System (Ham, Cb, Etc.}
Inspection Precautions
Troubleshooting Hints
Difficult to Start or no Start
Engine Often Stalls
Engine Sometimes Stalls
Rough Idling And/Or Missing
High Engine Idle Speed (no Drop)
Engine Backfires
Muffler Explosion (after Fire)
Engine Hesitates And/Or Poor Acceleration
Diagnosis System
"Check Engine" Warning Light Check
Output of Diagnostic Codes
Cancelling Diagnostic Code
Diagnostic Codes
Inspection of Diagnosis Circuit
Efi System Check Procedure
Connectors of ECU
Troubleshooting with Volt/ Ohmmeter (4A-Ge
Voltage at ECU Wiring Connectors
Troubleshooting with Volt/ Ohmmeter (4A-Gze
Location of Fuses and Fusible Links
Troubleshooting Efi Electronic Circuit with Volt/Ohmmeter (4A-Ge
Troubleshooting Efi Electronic Circuit with Volt/Ohmmeter (4A-Gze
Fuel Pump
Fuel System
Check Fuel Pump Operation
Check Fuel Pressure
Fuel Pump
Pressure Regulator (4A-GE
Pressure Regulator (4A-GZE
Removal of Fuel Pump
Installation of Fuel Pump
Remove Fuel Pump Filter from Fuel Pump
Install Fuel Pump to Fuel Pump Bracket
Install Fuel Tank
Cold Start Injector
Measure Resistance of Cold Start Injector
Removal of Cold Start Injector
Inspection of Cold Start Injector
Check Injection of Cold Start Injector
Installation of Cold Start Injector
Install Cold Start Injector
Install Cold Start Injector Pipe
Pressure Regulator (4A-GE)
Removal of Pressure Regulator
Installation of Pressure Regulator
Pressure Regulator (4A-GZE)
Injector
Check Injector Operation
Measure Resistance of Injector
Removal of Injector
Remove Fuel Inlet Pipe
Remove Delivery Pipe
Remove Injectors
Inspection of Injector
Test Injection of Injectors
Check Leakage
Installation of Injectors
Install Injectors into Delivery Pipe
Install Delivery Pipe with Injectors
Connect Injector Connectors
Connect Fuel Inlet Pipe
Fuel Tank and Line
Air Flow Meter
Measure Resistance of Air Flow Meter
Air Induction System
Removal of Air Flow Meter
Inspection of Air Flow Meter
Installation of Air Flow Meter
Throttle Body
Check Throttle Body
Check Throttle Position Sensor
Removal of Throttle Body
Disconnect Following Hoses
Inspection of Throttle Body
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TOYOTA
MR2
1988 Repair Manual
•Engine
·Chassis
·Body
• Electrical
·Specifications
FOR USA 8l CANADA
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting
26
Troubleshooting hints
205
Efi system check procedure
225
TROUBLESHOOTING WITH VOLT/ OHMMETER (4A-GZE
227
Location of fuses and fusible links
229
TROUBLESHOOTING EFI ELECTRONIC CIRCUIT WITH VOLT/OHMMETER (4A-GZE
244
Check of engine coolant
326
PRECAUTIONS
388
PRECAUTIONS
419
System description
520
General Troubleshooting
521
Troubleshooting of electronic control system
535
TROUBLESHOOTING
667
PRECAUTIONS
733
PRECAUTIONS
773
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