1986 Toyota MR2 Haynes Manual

The 1986 Toyota MR2 Haynes Manual provides comprehensive service and repair information for the first-generation AW11 MR2 model. This manual covers the 1.6L 4A-GE engine, 5-speed manual transmission, front-engine/rear-wheel-drive layout, and all mechanical, electrical, and body systems. Below are key sections for maintenance, repair procedures, specifications, and troubleshooting.

1. Vehicle Specifications 2. Routine Maintenance 3. Engine Systems 4. Transmission & Drivetrain 5. Suspension & Steering 6. Brake Systems 7. Electrical Systems 8. Body & Interior 9. Troubleshooting Guide 10. Wiring Diagrams 11. Technical Data

Vehicle Specifications

Key specifications for the 1986 Toyota MR2 AW11 model with 4A-GE engine.

Specification	Details
Engine	1.6L 4A-GE DOHC 16-valve inline-4
Power Output	112 hp @ 6600 rpm
Torque	97 lb-ft @ 4800 rpm
Transmission	5-speed manual (C50)
Drivetrain	Mid-engine, rear-wheel drive
Weight	2350 lbs (1066 kg)
Fuel System	Electronic fuel injection (EFI)
Brakes	Front disc, rear drum
Suspension	MacPherson strut front, dual link rear
Fuel Capacity	13.2 gallons (50 liters)

Routine Maintenance

Scheduled maintenance intervals and procedures for optimal performance.

Oil Change: Every 3,000 miles or 3 months - Use 10W-30 motor oil
Spark Plugs: Replace every 30,000 miles - NGK BCPR5EY
Timing Belt: Replace every 60,000 miles
Coolant Flush: Every 30,000 miles or 2 years
Brake Fluid: Replace every 2 years - DOT 3

WARNING! Always disconnect battery before electrical work. Use jack stands when lifting vehicle.

Engine Systems

Detailed procedures for 4A-GE engine service and repair.

Valve Adjustment: Cold adjustment - Intake 0.008 in, Exhaust 0.012 in
Timing Belt Replacement: Align marks on cam gears and crank pulley
Fuel System: Fuel pressure should be 38-44 psi
Ignition System: Set base timing to 10° BTDC
Cooling System: Thermostat opens at 180-195°F

CAUTION! Engine must be cool before opening cooling system. Relieve fuel pressure before fuel line work.

Transmission & Drivetrain

Transmission Fluid: 75W-90 GL-4 gear oil, 2.1 quarts
Clutch Adjustment: Free play 0.4-0.8 inches at pedal
Shift Linkage: Inspect for wear in bushings and joints
Drive Axles: Check CV boots for cracks and grease leaks
Differential: Limited-slip requires special friction modifier

Suspension & Steering

Front MacPherson strut and rear dual-link suspension service procedures.

Front Suspension: Strut replacement, ball joint inspection, control arm bushings. Rear Suspension: Trailing arm bushings, toe adjustment, camber adjustment. Steering: Rack and pinion, tie rod ends, alignment specifications.

Alignment Specs: Front toe 0±0.08 in, camber -0°40'±45', caster 2°55'±45'

Brake Systems

Front disc and rear drum brake maintenance and repair.

Brake Pad Replacement: Minimum thickness 0.08 inches
Rotor Specifications: Minimum thickness 0.630 inches
Drum Brakes: Adjust automatically during reverse application
Bleeding Procedure: Right rear, left rear, right front, left front
Parking Brake: Adjust at equalizer under center console

Tip: Always replace brake fluid when servicing hydraulic system.

Electrical Systems

Complete electrical system diagnosis and repair procedures.

Battery: Group 26R, 450 CCA minimum
Alternator Output: 60 amps at 2000 rpm
Starter Draw: 130-160 amps typical
Fuse Box: Located in engine compartment and under dash
Lighting: Headlight adjustment screws behind bezel

WARNING! Disconnect battery before electrical repairs. Use circuit tester for diagnosis.

Body & Interior

Body panel removal, interior trim, and accessory installation.

Troubleshooting Guide

Common problems and solutions for the 1986 MR2.

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel pump relay, cold start valve	Check fuel pressure, test cold start system
Overheating	Thermostat, water pump, radiator	Pressure test system, check fan operation
Poor idle	ISC valve, vacuum leaks, TPS	Clean ISC valve, check for vacuum leaks
Transmission noise	Low fluid, worn bearings	Check fluid level, inspect for metal particles
Brake pull	Stuck caliper, contaminated pads	Clean and lubricate slides, replace pads

Wiring Diagrams

Complete electrical schematics for all systems.

Includes engine management, charging system, lighting, instruments, and accessory circuits with wire colors, connector locations, and ground points.

Technical Data

Torque Specifications: Cylinder head bolts 58 ft-lbs, main bearings 43 ft-lbs
Fluid Capacities: Engine oil 3.7 qt, coolant 6.3 qt, transmission 2.1 qt
Bulb Types: Headlight H4 60/55W, brake/tail 1157, turn signal 1156
Tire Pressure: Front 28 psi, rear 32 psi (cold)
Wheel Alignment: See suspension section for detailed specifications

Service: Refer to Toyota dealership for factory technical service bulletins