2002 Toyota MR2 Spyder Owners Manual

(cid:1) Vehicle pulls to one side when driving

straight on a level road

(cid:1) Strange noises related to suspension

movement

(cid:1) Loss of brake effectiveness; spongy feeling brake or clutch pedal; pedal al- most touches floor; vehicle pulls to one side when braking

(cid:1) Engine coolant temperature continually

higher than normal

If you notice any of these clues, take your vehicle to your Toyota dealer as soon as possible. It probably needs adjustment or repair.

CAUTION

Do not continue driving with the ve- hicle unchecked. It could result in se- rious vehicle damage and possibly personal injury.

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The malfunction indicator lamp will go off after taking several driving trips, but the error code in the OBD system will not be cleared unless about 40 trips or more are taken. If your vehicle does not pass the I/M test even the malfunction indicator lamp does not come on, contact your Toyota dealer to prepare the vehicle for re–testing.

and

indicator

the malfunction

Inspection

in- include OBD

Emissions Maintenance (I/M) programs Some states have vehicle emission spection programs which (On–Board Diagnostics) checks. The OBD system monitors the operation of the emission control system. When the OBD system determines that a problem exists somewhere in the emission control system, lamp comes on. In this case, your vehicle may the I/M test and need to be not pass repaired. Contact your Toyota dealer to service the vehicle. lamp Even does not come on, your vehicle may not pass readiness codes have not been set in the OBD system. Readiness codes are automatically set during ordinary driving. However, when the battery is disconnected or run down, the codes are erased. Also, depending on your driving habits, the codes may not be completely set. Also, if the malfunction indicator lamp had come on recently due to temporary mal- function such as a loose fuel tank cap, your vehicle may not pass the I/M test.

the malfunction

indicator

test as

I/M

the

if

180

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02 MY MR2 SMT(U) L/O 0108

SECTION 7– 1

DO–IT–YOURSELF MAINTENANCE Introduction Engine compartment overview Trunk room overview Fuse locations Do–it–yourself service precautions Parts and tools Positioning the jack

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182
183
184
185
186
188

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02 MY MR2 SMT(U) L/O 0108

1. Fuse block 2. Battery 3. Engine oil filler cap 4. Engine oil level dipstick 5. Engine coolant reservoir

Engine compartment overview

SC71012

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1. Brake fluid reservoir 2. Fuse block 3. Power steering fluid reservoir 4. Radiator 5. Condenser 6. Windshield washer fluid tank

Trunk room overview

SB71020

183

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Fuse locations

SB71010

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02 MY MR2 SMT(U) L/O 0108

SB71011

SB71013

SB71017

SB71019

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02 MY MR2 SMT(U) L/O 0108

Do–it–yourself service precautions If you perform maintenance by yourself, be sure to follow the correct procedure given in this section. You should be aware that improper or in- complete servicing may result in operating problems. Performing do–it–yourself maintenance during the warranty period may affect your warranty coverage. Read the separate Toyota Warranty statement for details and suggestions. This section gives for those items that are relatively easy for an owner to perform. As explained in Section 6, there are still a number of items that must be done by a qualified technician with special tools. For information on tools and parts for do– it–yourself maintenance, see “Parts and tools” on page 186. Utmost care should be taken when work- ing on your vehicle to prevent accidental injury. Here are a few precautions that you should be especially careful to ob- serve:

instructions only

CAUTION

(cid:1) When the engine is running, keep hands, clothing, and tools away from the moving fan and engine drive rings, watches, and ties is advisable.)

(Removing

belts.

(cid:1) Right after driving,

the engine compartment and trunk room—the engine, radiator, exhaust manifold, power steering fluid reservoir and spark plug boots, etc.—will be hot. So be careful not to touch them. Oil, fluids and spark plugs may also be hot.

(cid:1) If the engine is hot, do not remove the coolant reservoir cap or air re- lease valve or the drain plugs to prevent burning yourself.

loosen

(cid:1) Do not smoke, cause sparks or al- low open flames around fuel or the battery. Their fumes are flammable. (cid:1) Do not get under your vehicle with just the body jack supporting it. Al- ways use automotive jack stands or other solid supports.

(cid:1) Be sure that the ignition is off if you work near the electric cooling fans or radiator grille. With the ignition on, the electric cooling fans will automatically start to run if the engine coolant temperature is high and/or the air conditioning is on.

(cid:1) Use eye protection whenever you work on or under your vehicle where you may be exposed to flying or falling material, fluid spray, etc. (cid:1) Be extremely cautious when work- ing on the battery. It contains poi- sonous and corrosive sulfuric acid. terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause reproductive harm. Wash hands after handling

(cid:1) Warning: Battery posts,

cancer

and

(cid:1) Used engine oil contains potentially harmful contaminants which may cause skin disorders such as in- flammation or skin cancer, so care should be taken to avoid prolonged and repeated contact with it. To re- move used engine oil from your skin, wash thoroughly with soap and water.

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(cid:1) Do not

leave used oil within the

reach of children.

(cid:1) Dispose of used oil and filter only in a safe and acceptable manner. Do not dispose of used oil and fil- ter in household trash, in sewers or onto the ground. Call your dealer or a service station information concerning recycling or disposal.

for

fluid

(cid:1) Take care when filling the brake and clutch reservoirs because brake fluid can harm your eyes and damage painted surfaces. fluid gets in your eyes, flush your eyes with clean water.

If

(cid:1) When racing the engine, make sure that the gear position is in the “N” position. In case the accelerator is operated with the gear in any other positions, the vehicle may move, re- sulting in an unexpected accident.

NOTICE

(cid:2) Remember that battery and ignition cables carry high currents or volt- ages. Be careful of accidentally causing a short circuit.

186

(cid:2) Add only demineralized or distilled water to fill the radiator. And if you spill some of the coolant, be sure to wash it off with water to prevent it from damaging the parts or paint. (cid:2) Do not allow dirt or anything else to fall through the spark plug holes. (cid:2) Do not pry the outer electrode of a spark plug against the center elec- trode.

(cid:2) Use only spark plugs of the speci- fied type. Using other types will cause engine damage, loss of per- formance or radio noise.

(cid:2) Do not reuse iridium–tipped spark

plugs by cleaning or regapping.

(cid:2) Do not drive with the air cleaner filter removed, or excessive engine wear could result. Also backfiring could cause a fire in the engine compartment.

(cid:2) Be careful not to scratch the glass

surface with the wiper frame.

(cid:2) When closing the engine hood or trunk, check to see that you have not forgotten any tools, rags, etc.

Parts and tools Here is a list of parts and tools you will need on performing do–it–yourself mainte- nance. Remember all Toyota parts are de- signed in metric sizes, so your tools must be metric. CHECKING THE ENGINE OIL LEVEL Parts (if level is low): (cid:1) Engine

SJ API SL “Energy–Conserving”, “Energy–Conserving” ILSAC multigrade having viscosity proper for your climate

grade

oil

or

Tools: (cid:1) Rag or paper towel (cid:1) Funnel (only for adding oil) CHECKING THE ENGINE COOLANT LEVEL Parts (if level is low): (cid:1) “TOYOTA Long Life Coolant” or equiva-

lent See page 191 in Section 7–2 for de- tails about coolant type selection.

(cid:1) Demineralized or distilled water Tools: (cid:1) Funnel (only for adding coolant) CHECKING BRAKE FLUID Parts (if level is low):

01 06 12

(cid:1) SAE J1703 or FMVSS No.116 DOT 3

brake fluid

02 MY MR2 SMT(U) L/O 0108

Tools: (cid:1) Rag or paper towel (cid:1) Funnel (only for adding fluid) CHECKING POWER STEERING FLUID Parts (if level is low): (cid:1) Toyota P.S fluid EH or equivalent Tools: (cid:1) Rag or paper towel (cid:1) Funnel (only for adding fluid) CHECKING BATTERY CONDITION Tools: (cid:1) Warm water (cid:1) Baking soda (cid:1) Grease (cid:1) Conventional wrench

(for

terminal

clamp bolts)

CHECKING AND REPLACING FUSES Parts (if replacement is necessary): (cid:1) Genuine Toyota fuse or equivalent with

same amperage rating as original

ADDING WASHER FLUID Parts: (cid:1) Water (cid:1) Washer fluid containing antifreeze

(for winter use)

Tools: (cid:1) Funnel REPLACING LIGHT BULBS Parts: (cid:1) Bulb with same number and wattage rating as original in “Replacing light bulbs—” on page 206
in Section 7–3.)

charts

(See

Tools: (cid:1) Screwdriver

187

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Positioning the jack

SB71008

Front of vehicle

When jacking up your vehicle with the jack, position jack correctly as shown in the illustration. Jack position . . . . . . . . . . . . . . . . .

the

Front– Front crossmember Rear– Rear engine mounting bracket

Support position and Pantograph jack position . . . . .

188

CAUTION

When jacking, be sure to observe the following to reduce the possibility of personal injury: (cid:1) Follow jacking instructions. (cid:1) Do not put any part of your body under the vehicle supported by a jack. Personal injury may occur.

(cid:1) Do not start or run the engine while is supported by the

your vehicle jack.

(cid:1) Stop the vehicle on a

level firm ground, firmly set the parking brake and put the transmission in reverse. Block the wheel diagonally opposite to the one being changed if neces- sary.

(cid:1) Make sure to set the jack properly in the jack point. Raising the ve- hicle with improperly posi- tioned will damage the vehicle or may allow the vehicle to fall off the jack and cause personal injury.

jack

(cid:1) Never get under the vehicle when the vehicle is supported by the jack alone; use vehicle support stands.

(cid:1) Do not raise the vehicle with some-

one in the vehicle.

(cid:1) When raising the vehicle, do not put an object on or under the jack.

NOTICE

Make sure to place the jack correctly, or your vehicle may be damaged.

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02 MY MR2 SMT(U) L/O 0108

SECTION 7– 2

DO–IT–YOURSELF MAINTENANCE Engine and Chassis Checking the engine oil level Checking the engine coolant level Checking the radiator and condenser Checking brake fluid Checking power steering fluid Checking tire pressure Checking and replacing tires Rotating tires Installing snow tires and chains Replacing wheels Aluminum wheel precautions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190
191
192
193
193
194
195
196
197
198
199

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Checking the engine oil level

Low level

Full level

SB72010

Add oil

O.K.

Too full

With the engine at operating tempera- ture and turned off, check the oil level on the dipstick. 1. To get a

the vehicle should be on a level spot. After turning off the engine, wait a few minutes for the oil to drain back into the bottom of the engine.

reading,

true

2. Pull out the dipstick, and wipe it clean

with a rag.

3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be correct.

4. Pull the dipstick out and look at the oil

level on the end.

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02 MY MR2 SMT(U) L/O 0108

CAUTION

Be careful not to touch the hot ex- haust manifold.

If the oil level is below or only slightly above the low level, add engine oil of the same type as already in the engine. Remove the oil filler cap and add engine oil in small quantities at a time, checking the dipstick. The approximate quantity of oil needed to fill between the low level and the full level on the dipstick is indicated below for ref- erence. When the level reaches within the correct range, install the filler cap hand–tight. Oil quantity, L (qt., lmp. qt.):

1.3 (1.4, 1.1)

NOTICE

(cid:3) Avoid overfilling, or the engine

could be damaged.

(cid:3) Check the oil level on the dipstick

once again after adding the oil.

ENGINE OIL SELECTION Use API grade SJ “Energy–Conserving”, SL “Energy–Conserving” or ILSAC multi- grade engine oil. Recommended viscosity (SAE):

for good

SAE 5W–30 is the best choice for your vehicle, fuel economy, and good starting in cold weather. If you use SAE 10W–30 engine oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W–30 engine oil is recommended.

01 06 11

02 MY MR2 SMT(U) L/O 0108

Oil identification marks Either or both API registered marks are added to some oil containers to help you select the oil you should use. The API Service Symbol is located any- where on the outside of the container. The top portion of the label shows the oil quality by API (American Petroleum Institute) designations such as SL. The center portion of the label shows the SAE viscosity grade such as SAE 5W–30. “Energy–Conserving” shown in the lower portion, has fuel–saving capabilities. The ILSAC (International Lubricant Stan- dardization and Approval Committee) Certi- fication Mark is displayed on the front of the container.

indicates

that

the

oil

Checking the engine coolant level Look at the see–through coolant reser- voir when the engine is cold. The cool- ant level is satisfactory if it is between the “FULL” and “LOW” lines on the reservoir. If the level is low, add ethyl- ene–glycol type coolant for a proper corrosion protection of aluminum com- ponents. The coolant level in the reservoir will vary with engine temperature. However, if the level is on or below the “LOW” line, add coolant. Bring the level up to the “FULL” line. Always use ethylene–glycol type coolant for a proper corrosion protection of alumi- num components. See information in the next column. If the coolant level drops within a short time after replenishing, there may be a leak the radiator, hoses, drain cock and water pump. If you can find no leak, have your Toyota dealer test the cap pressure and check for leaks in the cooling system.

the system. Visually check

in

191

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SOIL13

API service symbol

ILSAC certification mark

CAUTION

To prevent burning yourself, do not remove the coolant reservoir cap or air release valve when the engine is hot.

Coolant type selection Use of improper coolants may damage your engine cooling system. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of your engine that contains aluminum compo- nents. Use “TOYOTA Long Life Coolant” or equivalent. In addition to preventing freezing and sub- sequent damage to the engine, this type of coolant will also prevent corrosion. Fur- ther supplemental inhibitors or additives are neither needed nor recommended. Read the coolant container for information on freeze protection. Follow the manufac- turer’s directions to mix with plain water (preferably demineralized water or distilled water). The total capacity of the cooling system is given on page 217 in Section 8.

for how much

192

02 MY MR2 SMT(U) L/O 0108

We recommend to use 50% solution for your Toyota, to provide protection down to about –35(cid:2)C (–31(cid:2)F). When it is extreme- ly cold, to about –50(cid:2)C (–58(cid:2)F), 60% solution is rec- ommended. Do not use more than 70% solution for better coolant performance.

to provide protection down

NOTICE

Do not use alcohol type antifreeze or plain water alone.

Checking the radiator and condenser If any of the above parts are extremely dirty or you are not sure of their condi- tion, take your vehicle to Toyota dealer.

CAUTION

To prevent yourself from burning, be careful not to touch the radiator or condenser when the engine is hot.

NOTICE

To prevent damage to the radiator and condenser, do not perform the work by yourself.

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02 MY MR2 SMT(U) L/O 0108

Checking brake fluid

SB72015

reservoir. The

To check the fluid level, simply look at the see–through level should be between the “MAX” and “MIN” lines on the reservoir. It is normal for the brake fluid level to go down slightly as the brake pads wear. So be sure to keep the reservoir filled. If the reservoir needs frequent refilling, it may indicate a serious mechanical prob- lem.

If the level is low, add SAE J1703 or FMVSS No.116 DOT 3 brake fluid to the brake reservoir. Remove and replace the reservoir cap by hand. Fill the brake fluid to the dotted line. This brings the fluid to the correct level when you put the cap back on. Use only newly opened brake fluid. Once opened, brake fluid absorbs moisture from the air, and excess moisture can cause a dangerous loss of braking.

CAUTION

Take care when filling the reservoir because brake fluid can harm your eyes and damage painted surfaces. If fluid gets in your eyes, flush your eyes with clean water immediately. If you still feel uncomfortable with your eyes, go to the doctor.

NOTICE

If you spill the fluid, be sure to wash it off with water to prevent it from damaging the parts or paint.

Checking power steering fluid

If cold O.K.

Close

Open

If hot O.K.

SB72002

If cold add

If hot add

inside

remove

the cover

Check the fluid level through the reser- voir. If necessary, add Toyota P.S fluid EH or equivalent. the power steering Before checking fluid, the trunk. (See “Replacing light bulbs” on page 206 in Section 7–3.) If the vehicle has been driven around 80
km/h (50 mph) for 20 minutes (a little more in frigid temperatures), the fluid is hot (60°C—80°C or 140°F—175°F). You may also check the level when the fluid is temperature, 10°C—30°C or 50°F—85°F) if the engine has not been run for about five hours.

(about

room

cold

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Checking tire pressure

SB72016

Keep your tire pressures at the proper level. The recommended cold tire pressures, tire size and the vehicle capacity weight are given on page 220 in Section 8. They are also on the tire pressure label as shown. You should check the tire pressures every two weeks, or at least once a month. And do not forget the spare!

Clean all dirt from outside of the reservoir tank and look at the fluid level. If the fluid is cold, the level should be in the “COLD” range. Similarly, if it is hot, the fluid level should be in the “HOT” range. If the level is at the low side of either range, add Toyota P.S fluid EH or equivalent to bring the level within the range. To remove the reservoir cap, turn it coun- terclockwise and it, turn it clockwise. After replacing the reser- voir cap, visually check the steering box case, vane pump and hose connections for leaks or damage.

lift up. To reinstall

CAUTION

The reservoir tank may be hot so be careful not to burn yourself.

NOTICE

Avoid overfilling, or the power steer- ing could be damaged.

194

the

results

tire pressure

tire pressure

is excessively

Incorrect tire pressure can reduce tire life and make your vehicle less safe to drive. Low in excessive wear, poor handling, reduced fuel econo- my, and the possibility of blowouts from overheated tires. Also, low tire pressure can cause poor sealing of the tire bead. If low, there is the possibility of wheel deforma- tion and/or tire separation. High tire pressure produces a harsh ride, handling problems, excessive wear at the center of the tire tread, and a greater possibility of tire damage from road haz- ards. If a tire frequently needs refilling, have it checked by your Toyota dealer. The following instructions for checking tire pressure should be observed: (cid:1) The pressure should be checked only when the tires are cold. If your ve- hicle has been parked for at least 3
hours and has not been driven for more than 1.5 km or 1 mile since, you will get an accurate cold tire pressure reading.

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02 MY MR2 SMT(U) L/O 0108

(cid:1) Always use a tire pressure gauge. The appearance of a tire can be mis- leading. Besides, that are even just a few pounds off can degrade ride and handling.

tire pressures

(cid:1) Take special care when adding air to the compact spare tire. The smaller tire size can gain pressure very quick- ly. Add compressed air in small quanti- ties and check the pressure often until it reaches the specified pressure.

(cid:1) Do not bleed or reduce tire pressure after driving. It is normal for the tire pressure to be higher after driving.

(cid:1) Never exceed

the vehicle capacity weight. The passenger and luggage weight should be located so that the vehicle is balanced.

(cid:1) Be sure to reinstall the tire inflation valve caps. Without the valve caps, dirt or moisture could get into the valve core and cause air leakage. If the caps have been lost, have new ones put on as soon as possible.

Checking and replacing tires

Tread wear indicator

SB72007

CHECKING YOUR TIRES Check the tire tread for the tread wear indicators. If the indicators show, re- place the tires. The tires on your Toyota have built–in tread wear indicators to help you know when the tires need replacement. When the tread depth wears to 1.6 mm (0.06
in.) or less, the indicators will appear. If you can see the indicators in two or more adjacent grooves, the tire should be re- placed. The lower the tread, the higher the risk of skidding. The effectiveness of snow tires is lost if the tread wears down below 4 mm (0.16 in.).

Check the tires regularly for damage such as cuts, splits and cracks. If any damage is found, consult with a techni- cian and have the tire repaired or re- placed. Even if the damage does not appear seri- ous, a qualified technician should examine the damage. Objects which have pene- trated the tire may have caused internal damage. Any tires which are over 6 years old must be checked by a qualified techni- cian even if damage is not obvious. Tires deteriorate with age even have never or seldom been used. This also applies to the spare tire and tires stored for future use. REPLACING YOUR TIRES When replacing a tire, use only the same size and construction as original- ly installed and with the same or great- er load capacity. Using any other size or type of tire may seriously affect handling, ride, speedome- ter/odometer calibration, ground clearance, and clearance between the body and tires or snow chains.

they

if

195

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02 MY MR2 SMT(U) L/O 0108

Rotating tires

CAUTION

(cid:1) Do not mix radial, bias belted, or bias–ply tires on your vehicle. It can cause dangerous handling char- acteristics, resulting in loss of con- trol.

SB72017

Turning direction

SB72019

(cid:1) Do not use tires or wheels other recom-

the manufacturer’s

than mended size.

tire

Toyota recommends all four tires, or at least both front or rear tires be re- placed as a set. See “If you have a flat tire—” on page 153 in Section 4 for tire change proce- dure. When a is replaced, should always be balanced. An unbalanced wheel may affect vehicle handling and tire life. Wheels can get out of balance with regular use and should therefore be balanced occasionally. When replacing a tubeless tire, the air valve should also be replaced with a new one.

the wheel

Turning direction indicators (type A)

SB72018

Turning direction

Turning direction indicators (type B)

196

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Do not rotate the tires as the tire sizes are different such as with front to rear, left to right or using the compact spare tire. Performing such tire rotation may result in the tires interfering with the body or in uneven wear of the tires, so that steerability of the vehicle is im- paired. Tires with turning direction indicator— The tire is a uni–directional type and can- not be used for tire rotation. Using the tire on the opposite side to the designated side will impair the tire performance. The compact spare tire— The temporary use tire is designed for only and cannot be used for tire rotation.

02 MY MR2 SMT(U) L/O 0108

tires, select

Installing snow tires and chains WHEN TO USE SNOW TIRES OR CHAINS Snow tires or chains are recommended when driving on snow or ice. On wet or dry roads, conventional tires provide better traction than snow tires. SNOW TIRE SELECTION If you need snow the 185/55R15 snow tires for front and the 205/50R15 snow tires for rear, construc- tion and load capacity as the original tires on your Toyota. Do not use tires other than those men- tioned above. Do not install studded tires without first checking local regulations for possible restrictions. SNOW TIRE INSTALLATION Snow tires should be installed on all wheels. Installing snow tires on the rear wheels only can lead to an excessive difference in road grip capability between the front and rear tires which could cause loss of vehicle control. When storing removed tires, you should store them in a cool dry place.

Mark the direction of rotation and be sure to install them in the same direction when replacing.

CAUTION

(cid:1) Do not drive with the snow tires

incorrectly inflated.

(cid:1) Never drive over 120 km/h (75 mph)

with any type of snow tires.

TIRE CHAIN SELECTION Use the tire chains which are the cor- rect size for your rear tires. For 205/50R15 tires, use genuine Toyota tire chains or equivalent for use on the MR2. Regulations regarding the use of tire chains vary according to location or type of road, so always check them before installing chains.

NOTICE

If the wrong combination of tire and chain is used, the chains could dam- age the vehicle body.

(cid:1) MR2 genuine tire chains

(Part No.08325–11010)

197

01 06 11

the

CHAIN INSTALLATION Install the chains on the rear tires as tightly as possible. Do not use tire tires. Retighten chains on chains after km (1/4—1/2 mile). When installing chains on your tires, care- fully follow the instructions of the chain manufacturer.

front driving

0.5—1.0

CAUTION

(cid:1) Do not exceed 50 km/h (30 mph) or recom- is

the chain manufacturer’s mended speed lower.

limit, whichever

(cid:1) Drive carefully avoiding bumps, holes, and sharp turns, which may cause the vehicle to bounce.

(cid:1) Avoid sharp turns or locked–wheel braking, as use of chains may ad- versely affect vehicle handling.

(cid:1) When driving with chains installed, be sure to drive carefully. Slow down before entering the curves to avoid losing control of the vehicle. Otherwise an accident may occur.

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02 MY MR2 SMT(U) L/O 0108

NOTICE

Do not attempt to use a tire chain on the compact spare tire, as it may re- sult in damage to the vehicle as well as the tire.

Replacing wheels WHEN TO REPLACE YOUR WHEELS If you have wheel damage such as bending, cracks or heavy corrosion, the wheel should be replaced. If you fail to replace damaged wheels, the tire may slip off the wheel or cause loss of handling control. WHEEL SELECTION When replacing wheels, care should be taken to ensure that the wheels are re- placed by ones with the same load ca- pacity, diameter, rim width, and offset. This must be observed on compact spare tires, too. Correct replacement wheels are available at your Toyota dealer. A wheel of a different size or type may adversely affect handling, wheel and bear- ing life, brake cooling, speedometer/odom- eter calibration, stopping ability, headlight aim, bumper height, vehicle ground clear- ance, and tire or snow chain clearance to the body and chassis.

01 06 11

Replacement with used wheels is not rec- ommended as they may have been sub- jected to rough treatment or high mileage and could fail without warning. Also, bent wheels which have been straightened may have structural damage and therefore should not be used. Never use an inner tube in a leaking wheel which is designed for a tubeless tire.

02 MY MR2 SMT(U) L/O 0108

Aluminum wheel precautions (cid:1) When check after driving your vehicle 1600km (1000 miles).

the wheel nuts are the

aluminum wheels, tight first

installing that

(cid:1) If you have repaired or changed your tires, check that the wheel nuts are still tight after driving 1600 km (1000
miles).

(cid:1) When using tire chains, be careful not

to damage the aluminum wheels.

(cid:1) Use only the Toyota wheel nuts and for your aluminum

wrench designed wheels.

(cid:1) When balancing your wheels, use only Toyota balance weights or equivalent and a plastic or rubber hammer.

(cid:1) As with any wheel, periodically check your aluminum wheels for damage. If damaged, replace immediately.

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SECTION 7– 3

DO–IT–YOURSELF MAINTENANCE Electrical components Checking battery condition Battery recharging precautions Checking and replacing fuses Adding washer fluid Replacing light bulbs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

202
203
204
205
206

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Checking battery condition— —Precautions

CAUTION

BATTERY PRECAUTIONS The battery produces flammable and explosive hydrogen gas. (cid:1) Do not cause a spark from the bat-

tery with tools.

(cid:1) Do not smoke or light a match near

the battery.

The electrolyte contains poisonous and corrosive sulfuric acid. (cid:1) Avoid contact with eyes, skin or

clothes.

(cid:1) Never ingest electrolyte. (cid:1) Wear protective safety glasses when

working near the battery.

(cid:1) Keep children away from the bat-

tery.

EMERGENCY MEASURES (cid:1) If electrolyte gets

in your eyes, flush your eyes with clean water immediately immediate medical attention. If possible, con- tinue to apply water with a sponge or cloth while en route to the medi- cal office.

and get

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02 MY MR2 SMT(U) L/O 0108

(cid:1) If electrolyte gets on your skin, thoroughly wash the contact area. If you feel pain or burning, get medi- cal attention immediately.

(cid:1) If electrolyte gets on your clothes, there is a possibility of its soaking through to your skin, so immediate- ly take off the exposed clothing and follow the procedure above, if nec- essary.

(cid:1) If you accidentally swallow electro- lyte, drink a large quantity of water or milk. Follow with milk of magne- sia, beaten raw egg or vegetable oil. Then go immediately for emer- gency help.

Warning: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause can- cer and reproductive harm. Wash hands after handling.

—Checking battery exterior

Hold–down clamp

SB73076

Ground cable

Terminals

Check the battery for corroded or loose terminal connections, cracks, or loose hold–down clamp. a. If the battery is corroded, wash it off with a solution of warm water and bak- ing soda. Coat the outside of the termi- nals with grease to prevent further cor- rosion.

b. If the terminal connections are loose, their clamp nuts—but do not

tighten overtighten.

c. Tighten

the hold–down clamp only enough to keep the battery firmly in place. Overtightening may damage the battery case.

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02 MY MR2 SMT(U) L/O 0108

NOTICE

Type A

—Checking battery condition

(cid:2) Be sure the engine and all accesso- ries are off before performing main- tenance.

(cid:2) When checking the battery, remove the ground cable from the negative terminal (“–” mark) first and rein- stall it last.

(cid:2) Be careful not to cause a short cir-

cuit with tools.

(cid:2) Take care no solution gets into the

battery when washing it.

Green

Dark

Clear or light yellow

Z73001

Type B

Blue

White

Red

CHECKING BY INDICATOR Check the battery condition by the indi- cator color.

Indicator color

Type A

Green

Type B

Blue

Dark

White

Clear or

light yellow

Red

Condition Condition

Good

Charging necessary. Have battery checked by your Toyota dealer. Have battery checked by your Toyota dealer.

Battery recharging precautions During recharging, the battery is pro- ducing hydrogen gas. Therefore, before recharging: 1. If recharging with the battery installed on the vehicle, be sure to disconnect the ground cable.

2. Be sure the power switch on the re- charger the charger cables to the battery and when disconnecting them.

is off when connecting

CAUTION

(cid:1) Always charge the battery in an un- confined area. Do not charge the battery in a garage or closed room where there is not sufficient ventila- tion.

(cid:1) Only do a slow charge (5 A or less). Charging at a quicker rate is dangerous. The battery may explode causing personal injuries.

NOTICE

Never recharge the battery while the engine is running. Also, be sure all accessories are turned off.

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Checking and replacing fuses

SB73035

SB73037

SB73066

Good

Blown

Good

Blown

Type A

Type C

SB73036

Good

Blown

Type B

204

If the headlights or other electrical components do not work, check the fuses. If any of the fuses are blown, they must be replaced. See “Fuse locations” on page 184 in Sec- tion 7–1 for locations of the fuses. Turn the ignition switch and inoperative component off. Pull a suspected fuse straight out and check it. Determine which fuse may be causing the problem. The lid of the fuse box shows the name of the circuit for each fuse. See page 221 in Section 8 of this manual for the functions controlled by each circuit. Type A fuses can be pulled out by the pull–out tool. The location of the pull–out tool is shown in the illustration.

01 03 29

If you are not sure whether the fuse has blown, try replacing the suspected fuse with one that you know is good. If the fuse has blown, push a new fuse into the clip. Only install a fuse with the amperage rat- ing designated on the fuse box lid. If you do not have a spare fuse, in an emergency you can pull out the “D P/W”, “P P/W” or “CIG” fuse, which may be dispensable for normal driving, and use it if its amperage rating is the same. If you cannot use one of the same amper- age, use one that is lower, but as close as possible to the rating. If the amperage is fuse might blow out again but this does not indicate anything wrong. Be sure to get the correct fuse as soon as possible and return the substitute to its original clip. It is a good idea to purchase a set of spare fuses and keep them in your ve- hicle for emergencies. If fuse immediately blows out, there is a problem with the electrical sys- tem. Have your Toyota dealer correct it as soon as possible.

that specified,

the new

lower

than

the

02 MY MR2 SMT(U) L/O 0108

CAUTION

Never use a fuse with a higher am- perage rating, or any other object, in place of a fuse. This may cause ex- tensive damage and possibly a fire.

Adding washer fluid

SB73003

If any washer does not work, the wash- er tank may be empty. Check the wash- er fluid level on the level gauge. If the washer fluid level is below “LOW”, add washer fluid. You may use plain water as washer fluid. in cold areas where tempera- However, tures freezing point, use fluid containing antifreeze. This washer product is available at your Toyota dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water.

range below

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NOTICE

Do not use engine antifreeze or any other substitute because it may dam- age your vehicle’s paint.

02 MY MR2 SMT(U) L/O 0108

the

The inside of the lens of exterior lights such as headlights may temporarily fog up when the lens becomes wet in the rain or in a car wash. This is not a problem because the is caused by fogging temperature difference between the outside and inside of the lens, just like the wind- shield fogged up in the rain. However, if there is large drop of water on the inside of the lens, or if there is water pooled inside the light, contact your Toyota deal- er.

following

illustrations show how

Replacing light bulbs— The to gain access to the bulbs. When replacing a bulb, make sure the ignition switch and light switch are off. Use bulbs with the wattage ratings given in the table.

CAUTION

(cid:1) To prevent yourself from burning, do not replace the light bulbs while they are hot.

(cid:1) Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped. Hold a bulb only by its plastic or metal case. Do not touch the glass part of a bulb with bare hands.

NOTICE

Only use a bulb of the listed type.

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W Type

Bulb No. — 60/55
—

Light bulbs

Headlights

Parking lights

turn

signal

Front lights Front side marker lights Rear lights Stop/tail lights Stop lights

signal

turn

Back–up lights License plate lights — — Interior light

High mounted stop light

—

A: HB2 halogen bulbs B: Wedge base bulbs C: Single end bulbs D: Double end bulbs

— 21

— 3.8

— 21

— 21/5
— 21
— 21

02 MY MR2 SMT(U) L/O 0108

BEFORE REPLACING LIGHT BULBS Replacing headlights, parking lights and front turn signal lights.

SB73069

1. Remove the front box cover.

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—Headlights

SC73012

SC18005

SB73043

2. Remove the cover in the trunk. Remove and shown in the following illustrations.

install

the cover clips as

Removing clips

1. Unplug the connector. Remove the

rubber cover.

If the connector is tight, wiggle it.

SC18006

Installing clips

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—Parking lights

SB73044

SB73075

SB73046

2. Release the bulb retaining spring

and remove the bulb. Install a new bulb and the bulb retaining spring.

To install a bulb, align the tabs of the bulb with the mounting hole.

the cutouts of

3. Install the rubber cover as shown

and snuggle on the boss. Plug in the connector.

Make sure the rubber cover fits snugly on the connector and the headlight body. Aiming is not necessary after replacing the bulb. When aiming adjustment is nec- essary, contact your Toyota dealer.

SB73047

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—Front turn signal lights

—Front side marker lights

SB73048

SB73071

SB73072

Phillips–head screw: Use a phillips–head screwdriver.

SB73049

SB73073

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—Rear turn signal, stop/tail, stop and back–up lights

SB73074

SB73019

SB73065

a: Back–up light b: Rear turn signal light c: Stop/tail light d: Stop light

CAUTION

Be careful when you work in the area around the engine after driving in or- der to prevent burning yourself. The engine hood, the support rod, or sur- rounding area could be hot after driv- ing.

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—License plate lights

—High mounted stop light

SB73021

SB73023

SB73062

SB73022

SB73052

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SB73060

SB73058

CAUTION

Be careful when you work in the area around the engine after driving in or- der to prevent burning yourself. The engine hood, the support rod, or sur- rounding area could be hot after driv- ing.

SB73057

SB73059

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02 MY MR2 SMT(U) L/O 0108

SECTION 8

SPECIFICATIONS Dimensions and weight Engine Fuel Service specifications Tires Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

216
216
216
217
220
221

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Engine Model:

1ZZ–FE

Type:

4 cylinder in line, 4 cycle, gasoline

Bore and stroke, mm (in.):

79.0 (cid:1) 91.5 (3.11 (cid:1) 3.60)

Displacement, cm3 (cu. in.):

1794 (109.5)

Fuel Fuel type:

Unleaded gasoline, Octane Rating 87
(Research Octane Number 91) or higher

Fuel tank capacity, L (gal., Imp. gal.):

48 (12.7, 10.6)

Dimensions and weight Overall length mm (in.) Overall width mm (in.) Overall height mm (in.) mm (in.) Wheelbase mm (in.) Front tread Rear tread mm (in.) Vehicle capacity weight (occupants + luggage) kg (lb.)

* : Unladen vehicle

3885 (153.0) (66.7) 1695
(48.8)* 1240
(96.5) 2450
(58.1) 1475
1460
(57.5)

193

(425)

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02 MY MR2 SMT(U) L/O 0108

Service specifications ENGINE Valve clearance (engine cold), mm (in.):

Intake Exhaust

0.15—0.25 (0.006—0.010) 0.25—0.35 (0.010—0.014)

Spark plug type:

DENSO SK16R11
NGK IFR5A11

Spark plug gap, mm (in.):

1.1 (0.043)

ENGINE LUBRICATION Oil capacity (drain and refill), L (qt., Imp. qt.):

With filter Without filter

3.7 (3.9, 3.3) 3.5 (3.7, 3.1)

Oil grade:

API grade SJ “Energy–Conserving”, SL “Energy–Conserving” or ILSAC multi- grade engine oil is recommended.

Recommended oil viscosity (SAE):

COOLING SYSTEM Total capacity, L (qt., Imp. qt.):

10.4 (11.0, 9.2)

Coolant type:

“TOYOTA Long Life Coolant” or equiva- lent With ethylene–glycol type coolant for a proper corrosion protection of aluminum components Do not use alcohol type antifreeze or plain water alone.

BATTERY Open voltage* at 20°C (68°F):

12.6—12.8 V 12.2—12.4 V 11.8—12.0 V

Fully charged Half charged Discharged

* : Voltage that is checked 20 minutes af- ter the key is removed with all the lights turned off Charging rates:

5 A max.

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CLUTCH (manual transmission only) Pedal free play, mm (in.):

5—15 (0.2—0.6)

Fluid type:

SAE J1703 or FMVSS No.116 DOT 3

MANUAL TRANSAXLE Oil capacity, L (qt., Imp. qt.):

Vehicle with limited–slip differential

1.8 (1.9, 1.6)

Vehicle without limited–slip differential

1.9 (2.0, 1.7)

Oil type:

Gear oil API GL–4 or GL–5

Recommended oil viscosity:

SAE 75W–90

SEQUENTIAL MANUAL TRANSMISSION SYSTEM Fluid type:

Sequential M/T Fluid

NOTICE: Using Fluid other than Toyota Genuine Sequential M/T Fluid may cause deterioration in shift performance and durability, and ultimately damage the sequential manual transmission of your vehicle.

BRAKES Minimum pedal clearance when depressed with the force of 490 N (50 kgf, 110 lbf) with the engine running, mm (in.):

85 (3.4)

Pedal free play, mm (in.):

1—6 (0.04—0.24)

Pad wear limit, mm (in.):

1.0 (0.04)

Parking brake adjustment when pulled with the force of 196 N (20 kgf, 44 lbf):

5—8 clicks

Fluid type:

SAE J1703 or FMVSS No.116 DOT 3

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STEERING Wheel free play:

Less than 30 mm (1.2 in.)

Power steering fluid type:

Toyota P.S fluid EH or equivalent

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Tires Tire size and pressure: Except compact spare tire

Front

Rear

Compact spare tire

Tire size

T125/70D16

Tire size Tire size

185/55R15 81V

205/50R15 85V

Tire pressure ressure Tire

kPa (kgf/cm2 or bar, psi)

180 (1.8, 26)

220 (2.2, 32)

Tire pressure kPa (kgf/cm2 or bar, psi)

420 (4.2, 60)

Wheel nut torque, N·m (kgf·m, ft·Ibf):

103 (10.5, 76)

Wheel size Wheel size

15 (cid:1) 6JJ

15 (cid:1) 6 1/2JJ

Wheel size

16 (cid:1) 4T

NOTE: For a complete information on tires (e.g. replacing tires or replacing wheels), see “Checking tire pressure” through “Aluminum