Engine TOYOTA MR2 SPYDER 2002 W30 / 3.G Repair Manual

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SB41055
Discharged batteryBooster
battery
Positive terminal
(“+” mark)
Positive
terminal
(“+” mark)
Jumper
cable
4. Make the cable connections in the or-
der a, b, c, d.
a. Connect the clamp of the positive
(red) jumper cable to the positive (+)
terminal on the discharged battery.
b. Connect the clamp at the other end
of the positive (red) jumper cable to
the positive (+) terminal on the booster
battery.
SB41056
Jumper cable
Booster
battery Negative terminal
(“” mark)
Discharged
battery
c. Connect the clamp of the negative
(black) jumper cable to the negative ()
terminal on the booster battery.
d. Connect the clamp at the other end
of the negative (black) jumper cable to
a solid, stationary, unpainted, metallic
point of the vehicle with the discharged
battery.
The recommended connecting point is
shown in the following illustration:
SB41040
Connecting point
Do not connect the cable to or near
any part that moves when the engine
is cranked.
CAUTION
When making the connections, to
avoid serious injury, do not lean over
the battery or accidentally let the
jumper cables or clamps touch any-
thing except the correct battery termi-
nals or the ground.

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5.Sequential manual transmission: Turn
the ignition switch to “ON” position.
Hold down the brake pedal firmly, and
place the selector lever to “N” position.
Make sure that the “N” indicator in the
instrument cluster comes on. Then
start your engine in a normal way.
Manual transmission: Start your en-
gine in the normal way.
After starting, run it at about 2000 rpm
for several minutes with the accelerator
pedal lightly depressed.
6. Carefully disconnect the cables in the exact reverse order: the negative cable
and then the positive cable.
7. Carefully dispose of the battery cover cloths—they may now contain sulfuric
acid.
8. If removed, replace all the battery vent plugs.
If the cause of your battery discharging is
not apparent (for example, lights left on),
you should have it checked. If your engine stalls while driving...
1. Reduce your speed gradually, keeping a straight line. Move cautiously off the
road to a safe place.
2. Turn on your emergency flashers.
3. Sequential manual transmission: Turn
the ignition key to “ACC” or “LOCK”
position. Approximately 5 seconds after,
try starting the engine again.
Manual transmission: Turn the ignition
key to “ACC” or “LOCK”, and try start-
ing the engine again.
If the engine will not start, see “If your
vehicle will not start—” on page 146 in
this section.
CAUTION
If the engine is not running, the pow-
er assist for the brakes and steering
will not work so steering and braking
will be much harder than usual.
If the engine speed does not increase with
the accelerator pedal depressed down to
about the middle position, there may be
a problem somewhere in your electronic
throttle control system.
At this time, if you depress the accelera-
tor pedal more firmly and slowly, you can
drive you vehicle at low speeds. Have
your vehicle checked by your Toyota deal-
er as soon as possible.
Even if the abnormality of the electronic
throttle control system is corrected during
low speed driving, the system may not be
recovered until the engine is stopped and
the ignition key is turned to ”ACC” or
”LOCK” position.
CAUTION
Be especially careful to prevent erro-
neous pedal operation.
If your engine stalls while
driving If you cannot incr
ease the
engine speed

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If your vehicle overheats
If your engine coolant temperature
gauge indicates overheating, if you ex-
perience a loss of power, or if you hear
a loud knocking or pinging noise, the
engine has probably overheated. You
should follow this procedure...1. Pull safely off the road, stop the ve- hicle and turn on your emergency
flashers. Put the transmission in “N”
(sequential manual transmission) or in
neutral (manual transmission) and ap-
ply the parking brake. Turn off the air
conditioning if it is being used.
2. If coolant or steam is boiling out of the radiator or reservoir, stop the engine.
Wait until the steam subsides before
opening the hood. If there is no coolant
boiling over or steam, leave the engine
running and make sure the electric
cooling fan is operating. If it is not,
turn the ignition off.
CAUTION
To help avoid personal injury, keep
the hood closed until there is no
steam. Escaping steam or coolant is
a sign of very high pressure.
3. Look for obvious coolant leaks from theradiator, hoses, and under the vehicle.
However, note that water draining from
the air conditioning is normal if it has
been used.
CAUTION
When the engine is running, keep
hands and clothing away from the
moving fan and engine drive belts.
4. If the coolant is leaking, stop the en-gine immediately. Call a Toyota dealer
for assistance.
5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add
coolant to the reservoir while the en-
gine is running. Fill it about half full.
CAUTION
Do not attempt to remove the coolant
reservoir cap or air release valve
when the engine and radiator are hot.
Serious injury could result from
scalding hot fluid and steam blown
out under pressure.
6. After the engine coolant temperaturehas cooled to normal, again check the
coolant level in the reservoir. If neces-
sary, bring it up to half full again. Seri-
ous coolant loss indicates a leak in the
system. You s hould have it checked as
soon as possible at your Toyota dealer.

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If you have a flat tire—
1. Reduce your speed gradually, keepinga straight line. Move cautiously off the
road to a safe place well away from
the traffic. Avoid stopping on the center
divider of a highway. Park on a level
spot with firm ground.
2. Stop the engine and turn on your emergency flashers.
3. Firmly engage the parking brake and put the transmission lever in “R” (se-
quential manual transmission) or in re-
verse (manual transmission).
4. Have everyone get out of the vehicle on the side away from traffic.
5. Read the following instructions thor- oughly.CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transmission in “R”
(sequential manual transmission) or
in reverse (manual transmission).
Block the wheel diagonally opposite
to the one being changed if neces-
sary.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone.
Use the jack only for lifting your
vehicle during wheel changing.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
put an object on or under the jack.
Raise the vehicle only high enough
to remove and change the tire.

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NOTICE
Use only a cable or chain specifi-
cally intended for use in towing ve-
hicles. Securely fasten the cable or
chain to the towing eyelets pro-
vided.
 Do not use the left rear eyelet. It is
not designed for towing.
Before towing, release the parking brake
and put the transmission in “N” (sequential
manual transmission) or in neutral (manual
transmission).
Sequential manual transmission: The
key must be in “ACC”.
Manual transmission: The key must be
in “ACC” (engine off) or “ON” (engine run-
ning).
Sequential manual transmission only:
After shifting the selector lever to the “N”
position, always make sure that the gear
is actually disengaged and is in neutral by
pushing the vehicle by hand or other
means. In case the gear can not be put
in neutral, turn the ignition switch from the
“OFF” to “ON” position, and operate the
selector lever once from “N” to “S” or “R”,
then back to “N” again. Then turn the
ignition switch from the ”ON” to “OFF”
position. These procedures may help put
the gear in neutral. If the gear still can
not be put in neutral, you can not tow
with cables or chains.CAUTION
If the engine is not running, the
power assist for the brakes and
steering will not work so steering
and braking will be much harder
than usual.
Do not tow with a cable or chain
when the ignition switch is in the
“ON” position and/or when the
transmission is not in the neutral
gear position. Otherwise, you may
be involved in an unexpected acci-
dent.

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SD04002
In case the selector lever lock is not
released and the selector lever cannot
be moved even though the ignition
switch is turned to the ”ON” position,
follow the procedures below:1. Turn the ignition key to the ”LOCK” or “ACC” position. Make sure the
parking brake is applied.
2. Pry up the cover with a flatbladed screwdriver or equivalent.
SD04003
3. To push the link, insert a key orscrewdriver to the hole. The lever
can be operated while the link is
being pushed.
4. Shift into the ”N” position.
5. Reinsert the cover.
6. Start the engine while depressing the brake pedal.
Be sure to have the system checked by
your Toyota dealer as soon as possible.
If you lose your keys
You can purchase a new key at your
Toyota dealer if you can give them the
key number and master key.
Even if you lose only one key, contact
your Toyota dealer to make a new key. If
you lose all your master keys, you cannot
make new keys; the whole engine immobi-
liser system must be replaced.
See the suggestion given in “Keys” on
page 8 in Section 12.
If your keys are locked in the vehicle and
you cannot get a duplicate, many Toyota
dealers can still open the door for you,
using their special tools. If you must
break a window to get in, we suggest
breaking the side window because it is
the least expensive to replace. Be ex-
tremely cautious to avoid cuts from the
glass.
If you cannot shift the
sequential manual
transmission selector lever

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If you are a skilled doityourself
mechanic, the Toyota service manuals are
recommended. Please be aware that
doityourself maintenance can affect your
warranty coverage. See “Owner ’s Warranty
Information Booklet” or “Owner ’s Manual
Supplement” for the details.
General maintenance
Listed below are the general maintenance
items that should be performed as fre-
quently as specified. In addition to check-
ing the items listed, if you notice any
unusual noise, smell or vibration, you
should investigate the cause or take your
vehicle to your Toyota dealer or a quali-
fied service shop immediately. It is recom-
mended that any problem you notice be
brought to the attention of your dealer or
the qualified service shop for their advice.
CAUTION
Make these checks only where ade-
quate ventilation can be obtained if
you run the engine.
OUTSIDE THE VEHICLE
Items listed below should be performed
from time to time, unless otherwise
specified.
Tire pressure
Check the pressure with a gauge every
two weeks, or at least once a month. See
page 192 in Section 72 for additional
information.Tire surface and wheel nuts
Check the tires carefully for cuts, damage
or excessive wear. See page 193 in Sec-
tion 72 for additional information. When
checking the tires, make sure no nuts are
missing, and check the nuts for loose-
ness. Tighten them if necessary.
Fluid leaks
Check underneath for leaking fuel, oil, wa-
ter or other fluid after the vehicle has
been parked for a while. If you smell fuel
fumes or notice any leak, have the cause
found and corrected immediately.
Doors and trunk lid
Check that both the doors operate
smoothly and all latches lock securely.
Make sure the trunk lid secondary latch
secures the lid from opening when the
primary latch is released.

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INSIDE THE VEHICLE
Items listed below should be checked
regularly, e.g. while performing periodic
services, cleaning the vehicle, etc.
Lights
Make sure the headlights, stop lights, tail
lights, turn signal lights, and other lights
are all working. Check headlight aim.
Service reminder indicators and warning
buzzers
Check that all service reminder indicators
and warning buzzers function properly.
Steering wheel
Be alert for changes in steering condition,
such as hard steering or strange noise.
Seats
Check that all seat controls such as seat
adjusters, seatback recliner, etc. operate
smoothly and that all latches lock securely
in any position. Check that the latches
lock securely.
Seat belts
Check that the seat belt system such as
buckles and retractors operate properly
and smoothly. Make sure the belt webbing
is not cut, frayed, worn or damaged.Accelerator pedal
Check the pedal for smooth operation and
uneven pedal effort or catching.
Clutch pedal
Check the pedal for smooth operation.
Brake pedal
Check the pedal for smooth operation and
that the pedal has the proper clearance.
Check the brake booster function.
Brakes
At a safe place, check that the brakes do
not pull to one side when applied.
Parking brake
Check that the lever has the proper travel
and that, on a safe incline, your vehicle
is held securely with only the parking
brake applied.
IN THE ENGINE COMPARTMENT
Items listed below should be checked
from time to time, e.g. each time when
refueling.
Washer fluid
Make sure there is sufficient fluid in the
tank. See page 203 in Section 73 for
additional information.
Engine coolant level
Make sure the coolant level is between
the “FULL” and “LOW” lines on the see
through reservoir when the engine is cold.
See page 189 in Section 72 for addition-
al information.
Radiator, condenser and hoses
Check that the front of the radiator and
condenser are clean and not blocked with
leaves, dirt, or insects. See page 190 in
Section 72 for additional information.
Battery electrolyte level
Make sure the electrolyte level of all bat-
tery cells is between upper and lower lev-
el lines on the case. Add only distilled
water when replenishing. See pgae 200 in
Section 73 for additional information.
Brake fluid level
Make sure the brake fluid level is correct.
See page 191 in Section 72 for addition-
al information.

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Engine oil level
Check the level by the dipstick with the
engine turned off and the vehicle parked
on a level spot. See page 188 in Section
72 for additional information.
Power steering fluid level
Check the level through the reservoir. The
level should be in the “HOT” or “COLD”
range depending on the fluid temperature.
See page 191 in Section 72 for addition-
al information.
Exhaust system
If you notice any change in the sound of
the exhaust or smell exhaust fumes, have
the cause located and corrected immedi-
ately. (See “Engine exhaust cautions” on
page 127 in Section 2.)Be on the alert for changes in perfor-
mance, sounds, and visual tipoffs that
indicate service is needed. Some impor-
tant clues are as follows:
Engine missing, stumbling, or pinging
Appreciable loss of power
Strange engine noises
A leak under the vehicle (however, wa-
ter dripping from the air conditioning
after use is normal.)
Change in exhaust sound (This may
indicate a dangerous carbon monoxide
leak. Drive with the windows open and
have the exhaust system checked im-
mediately.)
Flatlooking tire; excessive tire squeal
when cornering; uneven tire wear
Vehicle pulls to one side when driving
straight on a level road
Strange noises related to suspension
movement
Loss of brake effectiveness; spongy
feeling brake or clutch pedal; pedal al-
most touches floor; vehicle pulls to one
side when braking
Engine coolant temperature continually
higher than normalIf 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.
Does your vehicle need
repairing?

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DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview180
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Trunk room overview 181
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Fuse locations 182
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Doityourself service precautions 183
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Parts and tools 184
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Positioning the jack 186
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SECTION 7 1