The Big Green Book 📗

Note: Work in progress ...

A digitized version of the 1991 Toyota MR2 repair manuals.

Completion checklist:

Volume 1
- Contents
- Introduction
- Maintenance
  - Maintenance schedule
  - Maintenance operations
  - General maintenance
- Engine Mechanical
  - Description (3S-GTE)
  - Description (5S-FE)
  - Troubleshooting
  - Engine tune-up
  - Toyota-variable induction system
  - Idle and/or 2,500 RPM HC/CO checking
  - Compression check
  - Timing belt (3S-GTE)
  - Timing belt (5S-FE)
  - Cylinder head (3S-GTE)
  - Cylinder head (5S-FE)
  - Cylinder block (3S-GTE)
  - Cylinder block (5S-FE)
- Exhaust System
  - Exhaust pipes and heat insulators
- Turbocharger System
  - Description
  - Precautions
  - Troubleshooting
  - Turbocharger
  - Intercooler
- Emission Control Systems
  - 3S-GTE
    - System purpose
    - Component layout and schematic drawing
    - Positive crankcase ventilation system
    - Fuel evaporative emission control system
    - Exhaust gas recirculation system
    - Three-way catalyst system
  - 5S-FE
    - System purpose
    - Component layout and schematic drawing
    - Positive crankcase ventilation system
    - Fuel evaporative emission control system
    - Exhaust gas recirculation system
    - Three-way catalyst system
- EFI System
  - Description
  - Precautions
  - Inspection precautions
  - Troubleshooting
  - Diagnosis system
  - Troubleshooting with volt/ohmmeter
  - Fuel System
    - Fuel pump
    - Cold start injector (3S-GTE)
    - Cold start injector (5S-FE)
    - Fuel pressure regulator (3S-GTE)
    - Fuel pressure regulator (5S-FE)
    - Injectors (3S-GTE)
    - Injectors (5S-FE)
    - Fuel tank and lines
  - Air Induction System
    - Air flow meter (3S-GTE)
    - Throttle body (3S-GTE)
    - Throttle body (5S-FE)
    - Idle speed control valve (3S-GTE)
    - Idle speed control valve (5S-FE)
  - Electronic Control System
    - Location of electronic control parts
    - EFI main relay
    - Circuit opening relay
    - Cold start injector time switch
    - Solenoid resistor (3S-GTE)
    - Fuel pump relay and resistor (3S-GTE)
    - Fuel pressure VSV (5S-FE)
    - T-VIS VSV (3S-GTE)
    - Turbocharging pressure VSV (3S-GTE)
    - EGR VSV
    - Water temperature sensor
    - Intake air temperature sensor (5S-FE)
    - Vacuum sensor (5S-FE)
    - Turbocharging pressure sensor (3S-GTE)
    - EGR gas temperature sensor (3S-GTE & 5S-FE Calif. only)
    - Oxygen sensor (main)
    - Sub-oxygen sensor (5S-FE Calif. only)
    - Electronic controlled unit (ECU)
    - Fuel cut RPM
- Cooling System
  - Description
  - Troubleshooting
  - Engine coolant check
  - Replacement of engine coolant
  - Water pump
  - Thermostat
  - Radiator
  - Electric cooling fans
    - Radiator cooling fans (w/ A/C)
    - Radiator cooling fan (w/o A/C)
    - Engine compartment cooling fan (3S-GTE)
- Lubrication System
  - Description
  - Troubleshooting
  - Oil pressure check
  - Replacement of engine oil and oil filter
  - Oil pump
  - Oil cooler (3S-GTE)
  - Oil cooler (5S-FE)
  - Oil Nozzles (3S-GTE)
- Ignition System
  - Precautions
  - Troubleshooting
  - Ignition system circuit
  - On-vehicle inspection (3S-GTE)
  - On-vehicle inspection (5S-FE)
  - Distributor (3S-GTE)
  - Distributor (5S-FE)
- Starting System
  - Troubleshooting
  - Starter
  - Starter relay
  - Clutch start switch (M/T only)
- Charging System
  - Precautions
  - Troubleshooting
  - On-vehicle inspection
  - Alternator
  - Ignition main relay
- Service Specification
  - Maintenance
  - Engine Mechanical (3S-GTE)
  - Engine mechanical (5S-FE)
  - Exhaust system
  - Turbocharger system
  - EFI system (3S-GTE)
  - EFI system (5S-FE)
  - Cooling system
  - Lubrication system
  - Ignition system
  - Starting system
  - Charging system
  - Lubricant
- Standard Bolt Torque Specifications
  - Standard Bolt Torque Specifications
Volume 2
- Contents
- Clutch
  - Troubleshooting
  - Check and adjustment of clutch pedal
  - Bleeding of clutch system
  - Inspection of clutch start system
  - Clutch master cylinder
  - Clutch release cylinder
  - Clutch unit
- Manual Transaxle
  - Description
  - Precautions
  - Troubleshooting
  - Removal and installation of transaxle
  - S54 Transaxle / SW21 series
    - Removal of component parts
    - Component parts
      - Input shaft assembly
      - Output shaft assembly
      - Shift and select lever assembly
      - Differential
    - Installation of component parts
  - E153 Transaxle / SW20 series
    - Removal of component parts
    - Component parts
      - Input shaft assembly
      - Output shaft assembly
      - Oil pump
      - Shift and select lever shaft
      - Differential
    - Installation of component parts
  - Shift lever and control cable
- Automatic Transaxle (A241E)
  - Description
  - Operation
  - Troubleshooting
    - Basic Troubleshooting
    - Genaral troubleshooting
    - Preliminary check
    - Diagnosis system
    - Electronic control system
    - Mechanical system tests
    - Road test
    - Automatic shift schedule
  - On-vehicle repair
  - Removal and installation of transaxle
  - Torque converter
  - Removal of component parts
  - Component parts
    - General notes
    - Second coast brake
    - Oil pump
    - Direct clutch
    - Forward clutch
    - Front planetary gear
    - Second brake
    - Rear planetary gear
    - First and reverse brake
    - Intermediate shaft
    - Counter shaft
    - Underdrive clutch and one-way clutch no. 3
    - Underdrive brake and B4 accumulator piston
    - Valve body
    - Differential
  - Installation of component parts
  - Shift lock system
- Suspension and Axle
  - Troubleshooting
  - Wheel alignment
    - Front wheel alignment
    - Rear wheel alignment
  - Front axle hub
  - Front suspension
    - Front shock absorber
    - Ball joints, lower arm and stabilizer bar
  - Rear axle shaft and carrier
  - Rear drive shaft (5S-FE engine)
  - Rear drive shaft (3S-GTE engine)
  - Rear suspension
    - Rear shock absorber
    - Ball joint, lower arm and stabilizer bar
    - Engine lateral control rod
- Brake System
  - Precautions
  - Troubleshooting
  - Checks and adjustments
  - Master cylinder
  - Brake booster
  - Front brake
  - PE36T disc (for 3S-GTE)
  - PD51 disc (for 5S-FE)
  - Rear brake
  - Proportioning and by-pass valve
  - Anti-lock brake system
    - Description
    - Diagnosis system
    - Troubleshooting
    - Speed sensor diagnosis system
    - ABS actuator
    - Control relays
    - Front speed sensor
    - Rear speed sensor
    - Anti-lock brake system circuit
- Steering
  - Precautions
  - Troubleshooting
  - On-vehicle inspection
  - Steering column
  - Manual steering gear housing
  - Power steering
    - Description
    - On-vehicle inspection
    - Power steering pump
    - Gear housing
    - Electronic control system
    - Diagnosis system
    - Inspection of electronic control components
- SRS Airbag
  - General description
  - Description
  - Operation
  - Inspection items and replacement requirements
  - Removal and installation of component parts
    - Steering wheel pad and spiral cable
    - Front airbag Sensor
    - Center airbag sensor assembly
  - Replacement of repair wire for front airbag sensor
  - Troubleshooting
  - Disposal of steering wheel pad (with airbag)
  - Disposal of center airbag sensor assembly
- Body Electrical System
  - General information
  - Power source
  - Ignition switch
  - Lighting system
  - Wiper and washer system
  - Combination meter
  - Defogger system
  - Power window control system
  - Power door lock control system
  - Power mirror control system
  - Cruise control system
  - Theft deterrent system
  - Audio
  - Clock
- Body
  - General information
  - Hood
    - Front Hood
    - Engine Hood
  - Headlight
  - Front door
  - Luggage compartment door
  - Mouldings
    - Windshield moulding
    - Body outside moulding
    - Side protection moulding
    - Back window moulding
  - Windshield
  - Quarter window glass
  - Back window glass
  - T-bar roof
  - Moon roof
  - Instrument panel
  - Seat
  - Seat belts
  - Body dimensions
- Air Conditioning System
  - General information
  - Description
  - Preparation
  - Troubleshooting
  - Refrigeration system
  - Drive belt
  - Refrigeration lines
  - Compressor
  - Receiver
  - Condenser
  - Cooling unit
  - Evaporator
  - Expansion valve
  - Thermistor
  - A/C control assembly
  - Pressure switch
  - Water temperature sensor
  - Servomotors
  - Blower motor
  - Condenser fan motor
  - Heater main relay
  - Magnetic clutch relay
  - Fan main relays
  - Vacuum hose circuit
  - Vacuum switching valve
  - A/C amplifier
- Service Specifications
  - Clutch
  - Manual transaxle (S54)
  - Manual transaxle (E153)
  - Automatic transaxle (A241E)
  - Suspension and axle
  - Brake system
  - Steering
  - SRS Airbag
  - Body
  - Lubricant
- Standard Bolt Torque Specifications
  - Standard Bolt Torque Specifications
- Special Service Tools and Materials
  - Special service tools
  - Special service materials
- Electrical Wiring Diagrams
  - Abbreviations
  - How to read this section
  - System index
  - 1
  - 2
  - 3
  - 4
  - 5
  - 6
  - 7
  - 8
  - 9
  - 10
  - 11
  - 12
  - 13
  - 14
  - 15
  - 16
  - 17
  - 18
  - 19
  - 20
  - 21
  - 22
Fix "See page" references

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