Toyota 2002 Camry Page 765 Service Manual Download

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42027–01

D26272

SST

CL0672

42–12

–

CLUTCH

CLUTCH RELEASE CYLINDER ASSY

2227

Author:

Date:

2002 CAMRY REPAIR MANUAL (RM881U)

CLUTCH RELEASE CYLINDER ASSY

OVERHAUL

DISCONNECT CLUTCH RELEASE CYLINDER TO
FLEXIBLE HOSE TUBE

(a)

Using SST, disconnect the flexible hose tube.
SST

09023–00100

HINT:
Use a container to catch the fluid.

REMOVE CLUTCH RELEASE CYLINDER ASSY

(a)

Remove the 2 bolts and clutch release cylinder assy.

REMOVE CLUTCH RELEASE CYLINDER KIT

(a)

Remove the boot from the cylinder body.

(b)

Remove the push rod from the cylinder body.

(c)

Remove the piston from the cylinder body.

NOTICE:
Be careful not to damage the inside of the cylinder body.
(d)

Remove the spring from the cylinder body.

(e)

Remove the bleeder plug cap from the bleeder plug.

REMOVE RELEASE CYLINDER BLEEDER PLUG

INSTALL RELEASE CYLINDER BLEEDER PLUG

Torque: 8.3 N

⋅

m (85 kgf

⋅

cm, 73 in.

⋅

lbf)

INSTALL CLUTCH RELEASE CYLINDER KIT

(a)

Install the bleeder plug cap to the bleeder plug.

(b)

Install a new spring to the cylinder body.

(c)

Coat piston with lithium soap base glycol grease, as
shown in the illustration.

(d)

Install the piston to the cylinder body.

NOTICE:
Be careful not to damage the inside of the cylinder body.
(e)

Install the push rod to the cylinder body.

(f)

Install the boot to the cylinder body.

Summary of Contents for 2002 Camry

Page 1: ...e 3rd process of Final Inspection is omitted d The following essential operations are not written in this manual However these operations must be done in the practical situation 1 Operation with a jack or lift 2 Cleaning of a removed part when necessary 3 Visual check 2 INDEX a An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be repaired 3 PREPARATI...

Page 2: ... a case where the illustrations of the similar models are used In that case the details may be different from the actual vehicle h The procedures are presented in a step by step format 1 The illustration shows what to do and where to do it 2 The task heading tells what to do 3 The detailed text tells how to perform the task and gives other information such as specifications and warnings Example HI...

Page 3: ...AMRY REPAIR MANUAL RM881U 7 SI UNIT a The UNITS given in this manual are primarily expressed according to the SI UNIT International Sys tem of Unit and alternately expressed in the metric system and in the English System Example Torque 30 N m 310 kgf cm 22 ft lbf ...

Page 4: ...dentification Number Plate B Certification Label 2 FACTORY OF PRODUCTION a World manufacture identifier is used to distinguish be tween TMC and TMMK made vehicles The first 3 digits and letters of the vehicle identification number shows the world manufacturer identifier WMI TMC made JTD TMMK made 4T1 World Manufacturer Identifier 3 ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER a The engine seri...

Page 5: ... gauge Before starting operation prepare a tool stand SST gauge oil shop rag and parts for replacement 5 Removal and installation disassembly and assem bly operations Diagnose with a thorough understanding of the trouble phenomenon and perform effective operations Before removing the parts check the assembly for general condition deformation and damage When the structure is complicated take a note...

Page 6: ... adhesive 3 When reusing precoated parts clean off the old adhesive and dry the part with compressed air Then apply the specified seal lock adhesive to the bolt nut or threads NOTICE Perform the torque checking with the lower limit value of the torque tolerance 4 Depending on the seal lock agent to apply there may be a case where it is necessary to leave it for a specified time until it hardens d ...

Page 7: ... Clip Protective Tape INTRODUCTION REPAIR INSTRUCTION 01 7 7 Author Date 2002 CAMRY REPAIR MANUAL RM881U g CLIPS 1 The removal and installation methods of typical clips used in body parts are shown in the table below HINT If the clip is damaged during the operation always replace it with a new clip ...

Page 8: ...hoses pull them by holding the end not the middle of the hose 2 When disconnecting vacuum hoses use tags to identify where they should be reconnected 3 After completing the job make a double check whether the vacuum hoses are properly connected A label under the hood shows the proper layout 4 When using a vacuum gauge never force the hose onto a connector that is too large Use a step down adapter ...

Page 9: ...tallation of parts inspection or replacement be sure to read the following items carefully Then follow the correct procedure described in this manual a GENERAL NOTICE 1 Malfunction symptoms of the supplemental restraint system are difficult to confirm so the diag nostic trouble codes become the most important source of information when troubleshooting When troubleshooting the supplemental restrain...

Page 10: ...uit 10 Information labels are attached to the SRS components Follow the instructions on the notices 11 After work on the supplemental restraint system is completed check the SRS warning light See page 05 690 b SPIRAL CABLE in Combination Switch 1 The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position otherwise cable disconnection and other ...

Page 11: ...n facing downward could cause a serious accident if the airbag inflates 2 Never measure the resistance of the airbag squib This may cause the airbag to inflate which is very dangerous 3 Grease should not be applied to the instrument panel passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind 4 Store the airbag assembly where the ambient temperature remains...

Page 12: ...ib This may cause the airbag to inflate which is very dangerous 3 Grease should not be applied to the front seat airbag assembly and the airbag door should not be cleaned with detergents of any kind 4 Store the airbag assembly where the ambient temperature remains below 93 C 200 F without high humidity and away from electrical noise 5 When using electric welding first disconnect the airbag connect...

Page 13: ... the airbag to inflate which is very dangerous 3 Grease should not be attached to the curtain shield airbag assembly and the surface should not be cleared with detergents of any kind 4 Store the airbag assembly where the ambient temperature remains below 93 C 200 F with out high humidity and away from electrical noise 5 When using electric welding first disconnect the airbag connector 2 yellow 2 p...

Page 14: ... to cool down the seat belt pretensioner 8 Oil or water should not be put on the front seat outer belt and the front seat outer belt should not be cleaned with detergents of any kind h AIRBAG SENSOR ASSEMBLY 1 Never reuse the airbag sensor assembly involved in a collision where the SRS has deployed 2 The connectors to the airbag sensor assembly should be connected or disconnected with the sensor m...

Page 15: ...he cover or case of the ECU unless absolutely necessary If the IC terminals are touched the IC may be destroyed by static electric ity 2 To disconnect electronic connectors pull the con nector itself not the wires 3 Be careful not to drop electronic components such as sensors or relays If they are dropped on a hard floor they should be replaced and not be reused 4 When cleaning the engine with ste...

Page 16: ...lean shop rag or gummed tape c When installing the inlet system parts check that there is no mixing of a metal tip 6 HANDLING OF HOSE CLAMPS a Before removing the hose check the clamp position to re store it securely b Change a deformed or dented clamp into a new one c In case of reusing the hose install the clamp on the hose where it has a clamp track d For a spring type clamp make adjustment by ...

Page 17: ...sten the vehicle with lock chains b NOTICES OF RELATED OPERATIONS TO VSC 1 Do not carry out unnecessary installation and re moval because it might disorder the adjustment of related parts to VSC 2 Be sure to carry out the preparation for operation and the confirmation of operation completion in ac cordance with the instruction of the text when the related operations to VSC are performed 10 FOR VEH...

Page 18: ...s with a free wheel beam c Using a wheel stopper fix the vehicle 3 NOTICE FOR USING JACK AND SAFETY STAND a Work in the flat place using a wheel stopper at all times b Use a safety stand with a rubber attachment as shown in the illustration c Support the specified location with the jack and safety stand accurately d When jacking up the front wheels release the parking brake and place wheel stopper...

Page 19: ...by adjusting the height of the cradle and match the groove of the cradle and the safety stand support location accurately e Be sure to lock the swing arm during the operation f Lift the vehicle up until the tires float and shake the vehicle to make sure that the vehicle is stable 5 NOTICE FOR USING PLATE TYPE LIFT a Follow the instruction manual of the lift for a safe operation b Use a plate lift ...

Page 20: ...S with EBD BA TRAC VSC System 05 448 6 Electronic Controlled Automatic Transmission ECT 05 548 7 Air Conditioning System 05 616 8 Supplemental Restraint System 05 687 9 Lighting System 05 896 10 Audio System 05 928 11 Navigation System 05 991 12 Combination Meter 05 1070 13 Power Door Lock Control System 05 1132 14 Wireless Door Lock Control System 05 1148 15 Engine Immobiliser System 05 1165 16 T...

Page 21: ...itive voltage Voltage 10 14 V Engine stopped b Visually check the wire harness connectors and fuses for open and short etc c Warm up the engine to the normal operating temperature d Confirm the problem symptoms and conditions and check the DTCs according to the applicable chart OK Go to step 5 NG 4 DTC chart a Check the results obtained in step 3 then confirm the inspection procedure for the syste...

Page 22: ... 2002 CAMRY REPAIR MANUAL RM881U 8 Confirmation test a After completing repairs confirm that the problem has been solved If the problem dose not reoccur perform a confirmation test under the same conditions and in the same environment as when it occurred for the first time END ...

Page 23: ...eration INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 01 23 23 Author Date 2002 CAMRY REPAIR MANUAL RM881U CUSTOMER PROBLEM ANALYSIS HINT In troubleshooting the problem symptoms must be confirmed accurately and all preconceptions must be cleared in order to give an accurate judgment To ascertain what the problem symptoms are it is extremely important to ask the customer about the problem...

Page 24: ...System Body Multiplex Communication System Cruise Control System In the DTC check it is very important to determine whether the problem indicated by the DTC is still occurring or has occurred in the past but returned to normal at present In addition it must be checked in the problem symptom check whether the malfunction indicated by the DTC is directly related to the problem symptom or not For thi...

Page 25: ...ion No problem symptoms exist Problem symptoms exist If a DTC is displayed in the initial DTC check it indicates that a trouble may have occurred in a wire harness or connector in that circuit in the past therefore check the wire harness and connectors See page 01 31 a System normal b Troubleshooting of each problem symptom The problem is still occurring in a place other than the diagnostic circui...

Page 26: ...tant points in the symptom simulation test In the symptom simulation test the problem symptoms should be confirmed and the problem area or parts must also be found out To do so narrow down the possible problem circuits according to the symptoms before starting this test and have a hand held tester connected beforehand After that carry out the symp tom simulation test judging whether the circuit be...

Page 27: ...compartment but indirectly change the temperature and humidity by applying water spray onto the radia tor front surface Never apply water directly onto the electronic compo nents HINT If a vehicle is subject to water leakage the leaked water may contaminate the ECU When testing a vehicle with a water leak age problem special caution must be taken 4 OTHERS When the malfunction seems to occur when e...

Page 28: ...Wire harness B0106 54 Open in P squib circuit Airbag sensor assembly Wire harness Short in P squib circuit to Ground ON ON B0100 13 05 119 Short in P squib circuit Front passenger airbag assembly squib Airbag sensor assembly Wire harness Front passenger airbag assembly squib Front passenger airbag assembly squib Page or Instructions Indicates the page where the inspection proce dure for each circu...

Page 29: ...he SRS warning light sometimes lights up after approx 6 seconds have elapsed 2 SRS warning light is always lit up even when ignition switch is in the LOCK position 1 With the ignition switch in the ACC or ON position the SRS warning light does not light up PROBLEM SYMPTOMS TABLE 1 DTC is not displayed 05 187 05 183 Problem Symptom Page Indicates the page where the flow chart for each circuit is lo...

Page 30: ... Y Yellow SB Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal and if it is abnormal use it to determine whether the problem is located in the sensors actuators wire harness or ECU Indicates the condition of the connector of ECU during t...

Page 31: ...r 3 Before connecting the connector check that there are no deformation damage and missing of the ter minals 4 Connection of the connector with a lock should be securely done until it makes a click sound 5 In case of checking the connector with a Toyota electrical tester perform it at the back side harness side of the connector using a mini test lead NOTICE As a water proof connector cannot be che...

Page 32: ... terminal At this time if a male terminal is gold plated gold color use gold plated female terminals and if it is silver plated silver color use silver plated female terminals e HANDLING OF WIRE HARNESS 1 In case of removing the wire harness check the wir ing and clamping condition before the work so as to is restore it correctly 2 Never twist pull or slack off the wire harness more than necessary...

Page 33: ...nce between the connectors In the case of Fig 3 Between terminal 1 of connector A and terminal 1 of connector B1 Continuity Between terminal 1 of connector B2 and terminal 1 of connector C No continuity open Therefore it is found out that there is an open circuit between terminal 1 of connector B2 and terminal 1 of connector C c Check the voltage 1 In a circuit in which voltage is applied to the E...

Page 34: ...e the resistance while lightly shaking the wire harness vertically and horizontally In the case of Fig 6 Between terminal 1 of connector A and body ground Continuity short Between terminal 2 of connector A and body ground No continuity Therefore it is found out that there is a short circuit between terminal 1 of connector A and terminal 1 of connector C 2 Disconnect connector B and measure the res...

Page 35: ... When no measuring condition is specified perform the inspection with the engine stopped and also the ignition switched ON a First check the ECU ground circuit If it is faulty repair it If it is normal the ECU could be faulty So replace the ECU with a normal functioning one and check if the symp toms appear 1 Measure the resistance between the ECU ground terminal and body ground Resistance 1 Ω or ...

Page 36: ... ATM Automatic Transmission Transaxle ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension B Battery Voltage BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B L Bi Level B S Bore Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif California CB Circuit Breaker CCo Cata...

Page 37: ...l Unit ED Electro Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E G Engine EGR Exhaust Gas Recirculation EGR VM EGR Vacuum Modulator ELR Emergency Locking Retractor EMPS Electric Motor Power Steering ENG Engine ESA Electronic Spark Advance ETCS i Electronic Throttle Control System intelligent EVAP Evaporative Emission Control EVP...

Page 38: ...or KD Kick Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand LHD Left Hand Drive L H W Length Height Width LLC Long Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAP Manifold Absolute Pressure MAX M...

Page 39: ...ating Ball Type Steering R F Reinforcement RFS Rigid Front Suspension RH Right Hand RHD Right Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear Engine Rear Wheel Drive RRS Rigid Rear Suspension RWD Rear Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Rest...

Page 40: ...ee Way Catalyst U D Underdrive U S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve VVT i Variable Valve Timing intelligent W With WGN Wagon W H Wire Harness W O Without WU TWC Warm Up Three way Catalytic Converter WU OC Warm Up Oxidation Catalytic ...

Page 41: ... Data Link Connector 2 Data Link Connector 3 1 Check Connector 2 Total Diagnosis Communication Link TDCL 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Trouble Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU Electronic Control Unit ECT Engine Coolant Temperature Coolant Temperature Water Temperature THW EEPROM Electrically Erasable ...

Page 42: ...ess Memory O2S Oxygen Sensor Oxygen Sensor O2 Sensor O2S OBD On Board Diagnostic On Board Diagnostic System OBD OC Oxidation Catalytic Converter Oxidation Catalyst Convert OC CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction AS PCM Powertrain Control Module PNP Park Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer ...

Page 43: ... Thermostatic Vacuum Switching Valve TVSV TWC Three Way Catalytic Converter Three Way Catalytic TWC Manifold Converter CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU OC Warm Up Oxidation Catalytic Converter WU TWC Warm Up Three...

Page 44: ...ols 09082 00040 TOYOTA Electrical Tester ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE ECT SUPPLEMENTAL RESTRAINT SYSTEM LIGHTING SYSTEM SFI SYSTEM 1MZ FE SFI SYSTEM 2AZ FE 09083 00150 Test Lead Set AIR CONDITIONING SYSTEM ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE ECT SUPPLEMENTAL RESTRAINT SYSTEM LIGHTING SYSTEM AUDIO SYSTEM ABS WITH EBD BA TRAC VSC SYSTEM NAVIGATION SYSTEM POWER DOOR LOCK CONTROL SY...

Page 45: ...C TRANSAXLE ECT SUPPLEMENTAL RESTRAINT SYSTEM LIGHTING SYSTEM AUDIO SYSTEM ABS WITH EBD BA TRAC VSC SYSTEM NAVIGATION SYSTEM POWER DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM ENGINE IMMOBILISER SYSTEM BODY MULTIPLEX COMMUNICATION SYSTEM CRUISE CONTROL SYSTEM COMBINATION METER ABS WITH EBD SYSTEM DENSO MADE SFI SYSTEM 1MZ FE SFI SYSTEM 2AZ FE ...

Page 46: ...020TK 01 PREPARATION ENGINE CONTROL SYSTEM 02 3 46 Author Date 2002 CAMRY REPAIR MANUAL RM881U ENGINE CONTROL SYSTEM PREPARATION Equipment Radiator cap tester Torque wrench Ohmmeter ...

Page 47: ...e FUEL SYSTEM 1MZ FE FUEL SYSTEM 2AZ FE 09842 30070 Wire F EFI Inspection FUEL SYSTEM 1MZ FE 95333 06030 Hose FUEL SYSTEM 1MZ FE FUEL SYSTEM 2AZ FE 09842 30080 Wire H EFI Inspection FUEL SYSTEM 2AZ FE 95333 06030 Hose FUEL SYSTEM 1MZ FE FUEL SYSTEM 2AZ FE 90467 13001 Clip FUEL SYSTEM 1MZ FE FUEL SYSTEM 2AZ FE Recomended Tools 09040 00011 Hexagon Wrench Set FUEL INJECTOR ASSY 1MZ FE 09043 20050 Soc...

Page 48: ...082 00040 TOYOTA Electrical Tester FUEL SYSTEM 1MZ FE 09083 00150 Test Lead Set FUEL SYSTEM 1MZ FE FUEL SYSTEM 2AZ FE Equipment Service Wire Harness Stopwatch Measuring Flask Ohmmeter Radiator cap tester Torque wrench SSM 08850 00065 Butyl Tape Set FUEL PUMP ASSY 1MZ FE FUEL TANK ASSY 1MZ FE FUEL PUMP ASSY 2AZ FE FUEL TANK ASSY 2AZ FE ...

Page 49: ...e 2002 CAMRY REPAIR MANUAL RM881U EMISSION CONTROL PREPARATION SST 09992 00242 Turbocharger Pressure Gauge EMISSION CONTROL SYSTEM 1MZ FE EMISSION CONTROL SYSTEM 2AZ FE Equipment Service Wire Harness Ohmmeter Torque wrench Vacuum gauge Hand held vacuum pump ...

Page 50: ...ecomended Tools 09082 00040 TOYOTA Electrical Tester INTAKE AIR CONTROL SYSTEM 1MZ FE 09083 00150 Test Lead Set INTAKE AIR CONTROL SYSTEM 1MZ FE Equipment Service Wire Harness Torque wrench Hand held vacuum pump SSM 08826 00080 Seal Packing Black or equivalent FIPG INTAKE AIR CONTROL VALVE ASSY 1MZ FE ...

Page 51: ...er 5 CYLINDER HEAD ASSY 2AZ FE 09201 41020 Valve Stem Oil Seal Replacer CYLINDER HEAD ASSY 1MZ FE CYLINDER HEAD ASSY 2AZ FE 09202 70020 Valve Spring Compressor CYLINDER HEAD ASSY 1MZ FE CYLINDER HEAD ASSY 2AZ FE 09202 00010 Attachment CYLINDER HEAD ASSY 1MZ FE CYLINDER HEAD ASSY 2AZ FE 09213 54015 Crankshaft Pulley Holding Tool PARTIAL ENGINE ASSY 1MZ FE CAMSHAFT RH BANK 1MZ FE OIL PUMP SEAL 1MZ F...

Page 52: ...L 1MZ FE 09223 15030 Oil Seal Bearing Replacer PARTIAL ENGINE ASSY 1MZ FE ENGINE REAR OIL SEAL 1MZ FE PARTIAL ENGINE ASSY 2AZ FE ENGINE REAR OIL SEAL 2AZ FE 09223 22010 Crankshaft Front Oil Seal Replacer PARTIAL ENGINE ASSY 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE 09228 06501 Oil Filter Wrench PARTIAL ENGINE ASSY 2AZ FE 09228 07501 Oil Filter Wrench PARTIAL ENGINE ASSY 1MZ FE 0...

Page 53: ...KET 1MZ FE CYLINDER HEAD GASKET NO 2 1MZ FE TIMING BELT 1MZ FE CAMSHAFT LH BANK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE ENGINE REAR OIL SEAL 2AZ FE CYLINDER HEAD GASKET 2AZ FE 09520 01010 Drive Shaft Remover Attachment PARTIAL ENGINE ASSY 1MZ FE CYLINDER HEAD GASKET 2AZ FE 09520 24010 Differential Side Gear Shaft Puller PARTIAL ENGINE AS...

Page 54: ...HAIN CASE OIL SEAL 2AZ FE 09952 04010 Slide Arm PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE 09953 04030 Center Bolt 200 PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE 09954 04010 Arm 25 PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE 09955 04041 Claw No 4 P...

Page 55: ...CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE CYLINDER HEAD GASKET 2AZ FE 09953 05010 Center Bolt 100 PARTIAL ENGINE ASSY 1MZ FE CAMSHAFT RH BANK 1MZ FE OIL PUMP SEAL 1MZ FE CYLINDER HEAD GASKET 1MZ FE CYLINDER HEAD GASKET NO 2 1MZ FE TIMING BELT 1MZ FE CAMSHAFT LH BANK 1MZ FE 09953 05020 Center Bolt 150 PARTIAL ENGINE ASSY 1MZ FE OIL PUMP SEAL 1MZ FE PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEA...

Page 56: ...FE CYLINDER BLOCK 2AZ FE ENGINE REAR OIL SEAL 2AZ FE 09960 10010 Variable Pin Wrench Set PARTIAL ENGINE ASSY 1MZ FE CAMSHAFT RH BANK 1MZ FE OIL PUMP SEAL 1MZ FE CYLINDER HEAD GASKET 1MZ FE CYLINDER HEAD GASKET NO 2 1MZ FE TIMING BELT 1MZ FE CAMSHAFT LH BANK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL 2AZ FE ENGINE REAR OIL SEAL 2AZ FE 09962 01000 V...

Page 57: ...ARTIAL ENGINE ASSY 1MZ FE PARTIAL ENGINE ASSY 2AZ FE 09031 00040 Pin Punch CYLINDER HEAD ASSY 2AZ FE 09040 00011 Hexagon Wrench Set PARTIAL ENGINE ASSY 1MZ FE CYLINDER HEAD ASSY 1MZ FE CYLINDER BLOCK 1MZ FE CAMSHAFT RH BANK 1MZ FE CYLINDER HEAD GASKET 1MZ FE CYLINDER HEAD GASKET NO 2 1MZ FE VALVE CLEARANCE 1MZ FE CAMSHAFT LH BANK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE 09043 20050 Socket Hexagon Wrench ...

Page 58: ...E CYLINDER HEAD GASKET NO 2 1MZ FE VALVE CLEARANCE 1MZ FE 09043 20100 Socket Hexagon Wrench 10 PARTIAL ENGINE ASSY 1MZ FE CYLINDER BLOCK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE 09043 20120 Socket Hexagon Wrench 12 PARTIAL ENGINE ASSY 1MZ FE PARTIAL ENGINE ASSY 2AZ FE 09043 30140 Straight Hexagon Wrench 14 CYLINDER HEAD ASSY 1MZ FE 09043 50100 Bi hexagon Wrench 10 mm PARTIAL ENGINE ASSY 2AZ FE CYLINDER H...

Page 59: ...ket Wrench for 12 Pointed Head Reamer V block Piston ring compressor Piston ring expander Valve seat cutter CO HC meter Compression gauge Connecting rod aligner Cylinder gauge Feeler gauge Micrometer Precision straight edge Radiator cap tester Steel square Tachometer Torque wrench Hexagon Wrench Set Vernier calipers Dial indicator with magneticbase Tire pressure gauge Alignment tester Toe in gauge...

Page 60: ...HAFT LH BANK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE CHAIN 2AZ FE CAMSHAFT 2AZ FE CYLINDER HEAD GASKET 2AZ FE VALVE CLEARANCE 2AZ FE 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG PARTIAL ENGINE ASSY 1MZ FE CYLINDER BLOCK 1MZ FE PARTIAL ENGINE ASSY 2AZ FE 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent PARTIAL ENGINE ASSY 1MZ FE CYLINDER HEAD ASSY 1MZ FE CYLINDER BLOCK 1MZ FE...

Page 61: ...020TO 01 02 18 PREPARATION EXHAUST 61 Author Date 2002 CAMRY REPAIR MANUAL RM881U EXHAUST PREPARATION Equipment Torque wrench ...

Page 62: ...021 Companion Flange Holding Tool WATER PUMP ASSY 1MZ FE 09950 50013 Puller C Set WATER PUMP ASSY 1MZ FE 09951 05010 Hanger 150 WATER PUMP ASSY 1MZ FE 09952 05010 Slide Arm WATER PUMP ASSY 1MZ FE 09953 05010 Center Bolt 100 WATER PUMP ASSY 1MZ FE 09954 05030 Claw No 3 WATER PUMP ASSY 1MZ FE 09960 10010 Variable Pin Wrench Set WATER PUMP ASSY 1MZ FE WATER PUMP ASSY 2AZ FE 09962 01000 Variable Pin W...

Page 63: ... Assy WATER PUMP ASSY 1MZ FE WATER PUMP ASSY 2AZ FE 09963 01000 Pin 10 WATER PUMP ASSY 1MZ FE Recomended Tools 09216 00021 Belt Tension Gauge WATER PUMP ASSY 1MZ FE Equipment Ohmmeter Radiator cap tester Thermomete Torque wrench Vernier calipers Heater SSM 08826 00080 Seal Packing Black or equivalent FIPG WATER PUMP ASSY 1MZ FE WATER PUMP ASSY 2AZ FE ...

Page 64: ...AZ FE 09223 00010 Cover Seal Replacer OIL PUMP ASSY 1MZ FE 09228 06501 Oil Filter Wrench OIL FILTER SUB ASSY 2AZ FE 09228 07501 Oil Filter Wrench OIL FILTER SUB ASSY 1MZ FE 09249 63010 Torque Wrench Adaptor OIL PUMP ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 09309 37010 Transmission Bearing Replacer OIL PUMP ASSY 2AZ FE 09330 00021 Companion Flange Holding Tool OIL PUMP ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 0995...

Page 65: ... ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 09951 05010 Hanger 150 OIL PUMP ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 09952 05010 Slide Arm OIL PUMP ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 09953 05010 Center Bolt 100 OIL PUMP ASSY 1MZ FE 09953 05020 Center Bolt 150 OIL PUMP ASSY 1MZ FE OIL PUMP ASSY 2AZ FE 09954 05010 Claw No 1 OIL PUMP ASSY 1MZ FE 09954 05021 Claw No 2 OIL PUMP ASSY 2AZ FE 09954 05030 Claw No 3 OIL PUMP A...

Page 66: ...Z FE Recomended Tools 09040 00011 Hexagon Wrench Set OIL PUMP ASSY 1MZ FE 09043 20100 Socket Hexagon Wrench 10 OIL PUMP ASSY 1MZ FE 09043 20100 Socket Hexagon Wrench 10 OIL PUMP ASSY 1MZ FE 09216 00021 Belt Tension Gauge OIL PUMP ASSY 1MZ FE Equipment Feeler gauge Precision straight edge Radiator cap tester Torque wrench SSM 08826 00080 Seal Packing Black or equivalent FIPG OIL PUMP ASSY 1MZ FE OI...

Page 67: ...MRY REPAIR MANUAL RM881U IGNITION PREPARATION Recomended Tools 09200 00010 Engine Adjust Kit IGNITION SYSTEM 1MZ FE IGNITION SYSTEM 2AZ FE 09857 00031 Spark Plug Gap Gauge IGNITION SYSTEM 1MZ FE IGNITION SYSTEM 2AZ FE Equipment Spark plug cleaner Torque wrench ...

Page 68: ...Z FE GENERATOR ASSY 2AZ FE 09820 06020 Alternator Pulley Set Nut 22 mm Wrench GENERATOR ASSY 1MZ FE GENERATOR ASSY 2AZ FE Recomended Tools 09083 00150 Test Lead Set STARTING SYSTEM 1MZ FE GENERATOR ASSY 1MZ FE STARTER ASSY 1MZ FE GENERATOR ASSY 2AZ FE STARTER ASSY 2AZ FE STARTING SYSTEM 2AZ FE 09216 00021 Belt Tension Gauge GENERATOR ASSY 1MZ FE 09904 00010 Expander Set STARTER ASSY 1MZ FE STARTER...

Page 69: ... SPRING 09930 00010 Drive Shaft Nut Chisel LOWER BALL JOINT ASSY FRONT LH Recomended Tools 09011 12301 Socket Wrench 30 mm LOWER BALL JOINT ASSY FRONT LH 09040 00011 Hexagon Wrench Set FRONT SHOCK ABSORBER WITH COIL SPRING STABILIZER BAR FRONT 09043 20060 Socket Hexagon Wrench 6 FRONT SHOCK ABSORBER WITH COIL SPRING STABILIZER BAR FRONT Equipment Torque wrench Dial indicator with magnetic base Tir...

Page 70: ...nch Set SHOCK ABSORBER ASSY REAR LH REAR SUSPENSION ARM ASSY NO 1 LH REAR SUSPENSION ARM ASSY NO 2 LH STABILIZER BAR REAR 09043 20050 Socket Hexagon Wrench 5 SHOCK ABSORBER ASSY REAR LH REAR SUSPENSION ARM ASSY NO 1 LH REAR SUSPENSION ARM ASSY NO 2 LH STABILIZER BAR REAR 09043 20060 Socket Hexagon Wrench 6 SHOCK ABSORBER ASSY REAR LH Equipment Torque wrench Dial indicator with magnetic base Wheel ...

Page 71: ...020T4 01 02 28 PREPARATION TIRE WHEEL 71 Author Date 2002 CAMRY REPAIR MANUAL RM881U TIRE WHEEL PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer ...

Page 72: ... Axle Shaft Puller FRONT AXLE HUB SUB ASSY LH 09520 01010 Drive Shaft Remover Attachment FRONT DRIVE SHAFT 09520 24010 Differential Side Gear Shaft Puller FRONT DRIVE SHAFT 09520 32040 Shocker Set FRONT DRIVE SHAFT 09521 24010 Rear Axle Shaft Puller FRONT DRIVE SHAFT 09527 10011 Rear Axle Shaft Bearing Remover FRONT DRIVE SHAFT 09527 17011 Rear Axle Shaft Bearing Remover FRONT AXLE HUB SUB ASSY LH...

Page 73: ...Joint Puller FRONT AXLE HUB SUB ASSY LH FRONT DRIVE SHAFT 09726 40010 Lower Control Shaft Bearing Replacer FRONT DRIVE SHAFT 09930 00010 Drive Shaft Nut Chisel FRONT AXLE HUB SUB ASSY LH FRONT DRIVE SHAFT 09950 00020 Bearing Remover FRONT AXLE HUB SUB ASSY LH FRONT DRIVE SHAFT 09950 60010 Replacer Set FRONT AXLE HUB SUB ASSY LH 09951 00410 Replacer 41 FRONT AXLE HUB SUB ASSY LH 09951 00600 Replace...

Page 74: ...1 Hexagon Wrench Set FRONT DRIVE SHAFT 09043 20060 Socket Hexagon Wrench 6 FRONT DRIVE SHAFT 09905 00012 Snap Ring No 1 Expander FRONT DRIVE SHAFT 09905 00013 Snap Ring Pliers FRONT AXLE HUB SUB ASSY LH Equipment Torque wrench Dial indicator with magnetic base Alingment tester Toe in gauge Angle gauge Lubricant Item Capacity Front drive shaft 1MZ FE 2AZ FE MT Outboard joint grease 2AZ FE AT Outboa...

Page 75: ...040 Shocker SKID CONTROL SENSOR 09521 00020 Drive Shaft Boot Clamping Tool SKID CONTROL SENSOR 09703 30010 Brake Shoe Return Spring Tool REAR DRUM BRAKE 09718 00010 Shoe Hold Down Spring Driver REAR DRUM BRAKE 09737 00011 Brake Booster Push Rod Gauge BRAKE BOOSTER ASSY BRAKE MASTER CYLINDER SUB ASSY 09737 00020 Brake Booster Push Rod Wrench BRAKE BOOSTER ASSY BRAKE MASTER CYLINDER SUB ASSY 09751 3...

Page 76: ...BRAKE PEDAL SUPPORT ASSY 09954 05021 Claw No 2 STEERING SENSOR BRAKE PEDAL SUPPORT ASSY 09950 60010 Replacer Set SKID CONTROL SENSOR 09951 00650 Replacer 65 SKID CONTROL SENSOR 09950 70010 Handle Set SKID CONTROL SENSOR 09951 07100 Handle 100 SKID CONTROL SENSOR 09992 00242 Turbocharger Pressure Gauge BRAKE FLUID 09992 00350 Brake Reservoir Pressure Adapter BRAKE FLUID Recomended Tools 09042 00010...

Page 77: ...2 CAMRY REPAIR MANUAL RM881U 09905 00013 Snap Ring Pliers BRAKE MASTER CYLINDER SUB ASSY Equipment Vernier calipers Dial indicator Torque wrench Brake drum gauge Lubricant Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT3 ...

Page 78: ...AKE 02 35 78 Author Date 2002 CAMRY REPAIR MANUAL RM881U PARKING BRAKE PREPARATION Recomended Tools 09070 20010 Moulding Remover PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CABLE ASSY NO 1 Equipment Brake drum gauge Torque wrench ...

Page 79: ...DIFFERENTIAL OIL SEAL U140E FRONT DIFFERENTIAL OIL SEAL U241E 09350 32014 TOYOTA Automatic Transmission Tool Set TORQUE CONVERTER CLUTCH AND DRIVE PLATE AUTOMATIC TRANSAXLE ASSY 1MZ FE AUTOMATIC TRANSAXLE ASSY 2AZ FE 09351 32010 One way Clutch Test Tool TORQUE CONVERTER CLUTCH AND DRIVE PLATE AUTOMATIC TRANSAXLE ASSY 1MZ FE AUTOMATIC TRANSAXLE ASSY 2AZ FE 09649 17010 Steering Knuckle Tool FRONT DI...

Page 80: ...refill 8 60 liters 9 1 US qts 7 6 lmp qts 3 50 liters 3 7 US qts 3 1 lmp qts ATF Type T IV U241E Automatic transaxle fluid Dry fill Drain and refill 8 20 liters 8 7 US qts 7 2 lmp qts 3 90 liters 4 1 US qts 3 4 lmp qts ATF Type T IV SSM Special Service Materials 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent ...

Page 81: ...cer B OUTPUT SHAFT ASSY E351 09316 00041 Replacer C INPUT SHAFT ASSY E351 09319 60020 Output Shaft Needle Roller Bearing Remover MANUAL TRANSAXLE ASSY E351 SHIFT SELECT LEVER SHAFT ASSY E351 09387 00041 Bearing Puller Assembly MANUAL TRANSAXLE ASSY E351 09387 02010 Oil Seal Replacer MANUAL TRANSAXLE ASSY E351 09387 02020 One way Clutch Test Tool Set MANUAL TRANSAXLE ASSY E351 09506 30012 Different...

Page 82: ... FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY E351 09608 32010 Steering Knuckle Oil Seal Replacer FRONT DIFFERENTIAL OIL SEAL MANUAL TRANSAXLE ASSY E351 09930 00010 Drive Shaft Nut Chisel MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY E351 DIFFERENTIAL CASE ASSY E351 09950 00020 Bearing Remover MANUAL TRANSAXLE ASSY E351 INPUT SHAFT ASSY E351 OUTPUT SHAFT ASSY E351 09950 00030 Bearing Remover At...

Page 83: ... TRANSAXLE ASSY E351 09950 50013 Puller C Set MANUAL TRANSAXLE ASSY E351 09957 04010 Attachment MANUAL TRANSAXLE ASSY E351 09950 60010 Replacer Set MANUAL TRANSAXLE ASSY E351 OUTPUT SHAFT ASSY E351 SHIFT SELECT LEVER SHAFT ASSY E351 09951 00180 Replacer 18 MANUAL TRANSAXLE ASSY E351 09951 00210 Replacer 21 SHIFT SELECT LEVER SHAFT ASSY E351 09951 00280 Replacer 28 MANUAL TRANSAXLE ASSY E351 SHIFT ...

Page 84: ...ANSAXLE ASSY E351 09951 00600 Replacer 60 MANUAL TRANSAXLE ASSY E351 09951 00680 Replacer 68 MANUAL TRANSAXLE ASSY E351 09955 03011 Claw No 1 MANUAL TRANSAXLE ASSY E351 09950 60020 Replacer Set No 2 MANUAL TRANSAXLE ASSY E351 09951 00680 Replacer 68 MANUAL TRANSAXLE ASSY E351 09951 00730 Replacer 73 MANUAL TRANSAXLE ASSY E351 09951 00790 Replacer 79 MANUAL TRANSAXLE ASSY E351 09951 00890 Replacer ...

Page 85: ...h 30 mm MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY E351 09031 00040 Pin Punch MANUAL TRANSAXLE ASSY E351 SHIFT SELECT LEVER SHAFT ASSY E351 DIFFERENTIAL CASE ASSY E351 09043 20060 Socket Hexagon Wrench 6 MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY E351 09040 00011 Hexagon Wrench Set MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY E351 09043 20060 Socket Hexagon Wrench 6 MANUAL TRANSAXLE ASSY MANUAL T...

Page 86: ...quipment Dial indicator with magnetic base Torque wrench Slide calipers V block Micrometer Dial indicator Cylinder gauge Feeler gauge Precision straight edge Lubricant Item Capacity Classification Manual transaxle oil w Differential oil 2 5 liters 2 6 US qts 2 2 lmp qts API GL 4 or GL 5 SAE 75W 90 ...

Page 87: ...int Bearing Remover Replacer CLUTCH UNIT Recomended Tools 09031 00030 Pin Punch CLUTCH MASTER CYLINDER ASSY 09040 00011 Hexagon Wrench Set CLUTCH MASTER CYLINDER ASSY CLUTCH PEDAL SUB ASSY 09082 00040 TOYOTA Electrical Tester CLUTCH START SWITCH ASSY 09905 00013 Snap Ring Pliers CLUTCH MASTER CYLINDER ASSY Equipment Vernier calipers Dial indicator with magnetic base Torque wrench Lubricant Item Ca...

Page 88: ... COLUMN ASSY TMC MADE STEERING COLUMN ASSY TMMK MADE 09952 05010 Slide Arm STEERING COLUMN ASSY TMC MADE STEERING COLUMN ASSY TMMK MADE 09953 05020 Center Bolt 150 STEERING COLUMN ASSY TMC MADE STEERING COLUMN ASSY TMMK MADE 09954 05021 Claw No 2 STEERING COLUMN ASSY TMC MADE STEERING COLUMN ASSY TMMK MADE Recomended Tools 09904 00010 Expander Set STEERING COLUMN ASSY TMC MADE 09904 00050 No 4 Cla...

Page 89: ... Puller RACK PINION POWER STEERING GEAR ASSY 09527 21011 Rear Axle Shaft Bearing Remover RACK PINION POWER STEERING GEAR ASSY 09612 00012 Rack Pinion Steering Rack Housing Stand RACK PINION POWER STEERING GEAR ASSY 09612 22011 Tilt Handle Bearing Replacer RACK PINION POWER STEERING GEAR ASSY 09612 24014 Steering Gear Housing Overhaul Tool Set RACK PINION POWER STEERING GEAR ASSY 09613 22011 Steeri...

Page 90: ...FE 09631 12071 Steering Rack Oil Seal Test Tool RACK PINION POWER STEERING GEAR ASSY 09633 00010 Packing RACK PINION POWER STEERING GEAR ASSY 09631 20081 Seal Ring Tool RACK PINION POWER STEERING GEAR ASSY 09631 33010 Steering Rack Cover I RACK PINION POWER STEERING GEAR ASSY 09640 10010 Power Steering Pressure Gauge Set POWER STEERING SYSTEM 09641 01010 Gauge Assy POWER STEERING SYSTEM 09641 0102...

Page 91: ...No 2 RACK PINION POWER STEERING GEAR ASSY 09950 60010 Replacer Set RACK PINION POWER STEERING GEAR ASSY VANE PUMP ASSY 1MZ FE VANE PUMP ASSY 2AZ FE 09951 00180 Replacer 18 RACK PINION POWER STEERING GEAR ASSY 09951 00250 Replacer 25 RACK PINION POWER STEERING GEAR ASSY 09951 00280 Replacer 28 VANE PUMP ASSY 2AZ FE 09951 00290 Replacer 29 RACK PINION POWER STEERING GEAR ASSY 09951 00320 Replacer 32...

Page 92: ...ACK PINION POWER STEERING GEAR ASSY VANE PUMP ASSY 1MZ FE VANE PUMP ASSY 2AZ FE 09951 07150 Handle 150 RACK PINION POWER STEERING GEAR ASSY 09951 07360 Handle 360 RACK PINION POWER STEERING GEAR ASSY 09960 10010 Variable Pin Wrench Set VANE PUMP ASSY 1MZ FE 09962 01000 Variable Pin Wrench Arm Assy VANE PUMP ASSY 1MZ FE 09963 01000 Pin 10 VANE PUMP ASSY 1MZ FE Recomended Tools 09025 00010 Torque Wr...

Page 93: ...tension gauge Vane pump assy Vernier calipers Vane pump assy Dial indicator Steering gear assy Feeler gauge Vane pump assy Micrometer Vane pump assy Torque wrench Lubricant Item Capacity Classification Power steering fluid Total 2AZ FE 1MZ FE 1 0 liters 1 1 US qts 0 9 lmp qts ATF DEXRON II or III SSM 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent RACK PINION POWER STEERING GEA...

Page 94: ...OMPRESSOR ASSY 2AZ FE 07117 58070 T Joint REFRIGERANT AIR CONDITIONING RADIATOR ASSY COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY 1MZ FE COOLER COMPRESSOR ASSY 2AZ FE 07117 58080 Quick Disconnect Adapter REFRIGERANT AIR CONDITIONING RADIATOR ASSY COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY 1MZ FE COOLER COMPRESSOR ASSY 2AZ FE 07117 58090 Quick Disconnect Adapter REFRIGERANT AIR CONDITIONING RADIA...

Page 95: ...ERANT AIR CONDITIONING RADIATOR ASSY COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY 1MZ FE COOLER COMPRESSOR ASSY 2AZ FE 09249 63010 Torque Wrench Adaptor COOLER COMPRESSOR ASSY 2AZ FE 09870 00015 A C Quick Joint Puller No 1 AIR CONDITIONING RADIATOR ASSY 09870 00025 A C Quick Joint Puller No 2 AIR CONDITIONING RADIATOR ASSY 09950 50013 Puller C Set AIR CONDITIONING RADIATOR ASSY BLOWER ASSY 09951 0...

Page 96: ... 00010 Expander Set COOLER COMPRESSOR ASSY 1MZ FE COOLER COMPRESSOR ASSY 2AZ FE 09904 00050 No 4 Claw COOLER COMPRESSOR ASSY 1MZ FE COOLER COMPRESSOR ASSY 2AZ FE 09082 00040 TOYOTA Electrical Tester Equipment Voltmeter Anmeter Ohmmeter Vinyl tape Hexagon wrench 10 mm Hexagon wrench 4 mm Torque socket wrench E 8 Vise pliers Gas leak detector Belt tension gauge Dial indicator Torque wrench Lubricant...

Page 97: ...oyment Wire Sub Harness No 8 HORN BUTTON ASSY INSTR PNL PASS L DOOR AIR BAG ASSY CURTAIN SHIELD AIR BAG ASSY LH 09082 10801 Wire A HORN BUTTON ASSY INSTR PNL PASS L DOOR AIR BAG ASSY CURTAIN SHIELD AIR BAG ASSY LH 09082 20801 Wire B CURTAIN SHIELD AIR BAG ASSY LH 09082 30801 Wire C HORN BUTTON ASSY INSTR PNL PASS L DOOR AIR BAG ASSY 09950 50013 Puller C Set SPIRAL CABLE SUB ASSY 09951 05010 Hanger...

Page 98: ... ASSY SPIRAL CABLE SUB ASSY INSTR PNL PASS L DOOR AIR BAG ASSY Equipment Torque wrench Bolt Length 35 0 mm 1 387 in Pitch 1 0 mm 0 039 in Diam 6 0 mm 0 236 in Airbag disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Vinyl bag Airbag disposal ...

Page 99: ...SEAT BELT 99 Author Date 2002 CAMRY REPAIR MANUAL RM881U SEAT BELT PREPARATION SST 09082 00700 SRS Airbag Deployment Tool FRONT SEAT BELT 09082 00770 Airbag Deployment Wire Sub harness No 5 FRONT SEAT BELT Equipment Torque wrench ...

Page 100: ...HTING 02 57 100 Author Date 2002 CAMRY REPAIR MANUAL RM881U LIGHTING PREPARATION Recomended Tools 09082 00040 TOYOTA Electrical Tester LIGHTING SYSTEM 09083 00150 Test Lead Set LIGHTING SYSTEM Equipment Torque wrench Voltmeter ...

Page 101: ...ate 2002 CAMRY REPAIR MANUAL RM881U WIPER WASHER PREPARATION SST 09843 18040 Diagnosis Check Wire No 2 WIPER AND WASHER SYSTEM Recomended Tools 09082 00040 TOYOTA Electrical Tester WIPER AND WASHER SYSTEM 09083 00150 Test Lead Set WIPER AND WASHER SYSTEM ...

Page 102: ...2 CAMRY REPAIR MANUAL RM881U AUDIO VISUAL SYSTEM PREPARATION Recomended Tools 09070 20010 Moulding Remover REAR SPEAKER ASSY ANTENNA CORD SUB ASSY NAVIGATION ANTENNA ASSY POWER POINT SOCKET ASSY POWER POINT SOCKET ASSY RR CIGARETTE LIGHTER ASSY Equipment Torque wrench ...

Page 103: ...020UC 01 02 60 PREPARATION COMMUNICATION SYSTEM 103 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMMUNICATION SYSTEM PREPARATION Recomended Tools 09082 00040 TOYOTA Electrical Tester HORN SYSTEM ...

Page 104: ...R WINDOW CONTROL SYSTEM WINDOW DEFOGGER SYSTEM POWER MIRROR CONTROL SYSTEM 09070 20010 Moulding Remover OUTER REAR VIEW MIRROR SUB ASSY LH Equipment Adhesive Hand riveter Torque wrench Knife Sealer gun Tape To avoid surface damage Piano wire Windshield Plastic sheet To avoid surface damage Wooden block or similar object For tying both piano wire ends SSM 08833 00030 Three cement black or equivalen...

Page 105: ... SAFETY PAD SUB ASSY 09952 05010 Slide Arm INSTRUMENT PANEL SAFETY PAD SUB ASSY 09953 05020 Center Bolt 150 INSTRUMENT PANEL SAFETY PAD SUB ASSY 09954 05021 Claw No 2 INSTRUMENT PANEL SAFETY PAD SUB ASSY Recomended Tools 09041 00030 Torx Driver T30 INSTRUMENT PANEL SAFETY PAD SUB ASSY 09042 00010 Torx Socket T30 INSTRUMENT PANEL SAFETY PAD SUB ASSY 09070 20010 Moulding Remover INSTRUMENT PANEL SAF...

Page 106: ...020V8 01 PREPARATION SEAT 02 63 106 Author Date 2002 CAMRY REPAIR MANUAL RM881U SEAT PREPARATION Equipment Hog ring pliers Hog ring Torque wrench Tape To avoid surface damage Ohmmeter ...

Page 107: ...E 107 Author Date 2002 CAMRY REPAIR MANUAL RM881U SLIDING ROOF CONVERTIBLE PREPARATION Recomended Tools 09041 00020 Torx Driver T25 SLIDING ROOF TMMK Made SLIDING ROOF TMC Made 09070 20010 Moulding Remover SLIDING ROOF TMC Made Equipment Torque wrench ...

Page 108: ...9812 00010 Door Hinge Set Bolt Wrench FRONT DOOR REAR DOOR Recomended Tools 09041 00020 Torx Driver T25 FRONT DOOR REAR DOOR 09042 00010 Torx Socket T30 FRONT DOOR REAR DOOR 09042 00020 Torx Socket T40 REAR DOOR 09070 20010 Moulding Remover FRONT DOOR REAR DOOR Equipment Clip remover Tape To avoid surface damage Torque wrench ...

Page 109: ...10 Moulding Remover FRONT DOOR BELT MOULDING ASSY LH REAR DOOR BELT MOULDING ASSY LH ROOF HEADLINING ASSY ROOF DRIP SIDE FINISH MOULDING CENTER LH Equipment Adhesive tape To avoid surface damage Torque wrench Clip remover Cleaner Heat light Moulding Piano wire Moulding Tape To avoid surface damage Wooden block or similar object For tying both piano wire ends ...

Page 110: ...2 67 110 Author Date 2002 CAMRY REPAIR MANUAL RM881U VEHICLE CONTROL SYSTEM PREPARATION Recomended Tools 09082 00040 TOYOTA Electrical Tester IGNITION OR STARTER SWITCH ASSY 09082 00050 TOYOTA Electrical Tester Set IGNITION OR STARTER SWITCH ASSY ...

Page 111: ...nger 150 CRUISE CONTROL MAIN SWITCH ASSY 09952 05010 Slide Arm CRUISE CONTROL MAIN SWITCH ASSY 09953 05020 Center Bolt 150 CRUISE CONTROL MAIN SWITCH ASSY 09954 05021 Claw No 2 CRUISE CONTROL MAIN SWITCH ASSY Recomended Tools 09041 00030 Torx Driver T30 INSTRUMENT PANEL SAFETY PAD SUB ASSY 09042 00010 Torx Socket T30 INSTRUMENT PANEL SAFETY PAD SUB ASSY Equipment Torque wrench Adhesive Tape ...

Page 112: ...Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class 4T 5T 6T 7T 8T 9T 10T 11T No Mark w Washer No Mark No Mark w Washer SERVICE SPECIFICATIONS STANDARD BOLT 03 1 112 Author Date 2002 CAMRY REPAIR MANUAL RM881U STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH ...

Page 113: ... 100 75 175 360 670 1 050 65 in lbf 13 26 48 76 6T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 8 19 39 71 110 170 80 195 400 730 1 100 1 750 69 in lbf 14 29 53 80 127 9 21 44 80 125 90 210 440 810 1 250 78 in lbf 15 32 59 90 7T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 10 5 25 52 95 145 230 110 260 530 970 1 500 2 300 8 19 38 70 108 166 12 28 58 105 165 120 290 590 1 050 1 700 9 21 43 76 123 8T 8 10 1...

Page 114: ...rk w Washer No Mark No Mark Nut with 1 or more marks on one side surface of the nut SERVICE SPECIFICATIONS STANDARD BOLT 03 3 114 Author Date 2002 CAMRY REPAIR MANUAL RM881U HOW TO DETERMINE NUT STRENGTH HINT Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas sification number when tightening parts with a bolt and nut Example Bolt 4T Nut ...

Page 115: ...ss 5 0 kΩ or less 2 25 4 75 kΩ 2 25 4 75 kΩ Throttle body assy 3 VC 6 GND 2 M 1 M 1 2 3 2 kΩ at 20 C 68 F 0 3 100 kΩ at 20 C 68 F E F I Engine coolant temperature sensor Resistance Approx 20 C 68 F Approx 80 C 176 F 2 29 2 6 kΩ 0 300 0 327 kΩ E F I Circuit opening relay assy Specified condition 1 2 3 5 Continuity No continuity 1MZ FE Throttle body Standard throttle valve opening percentage 60 or m...

Page 116: ...MRY REPAIR MANUAL RM881U TORQUE SPECIFICATION 2AZ FE Part Tightened N m kgf cm ft lbf Throttle body assy x Intake manifold 30 305 22 1MZ FE Part Tightened N m kgf cm ft lbf Throttle position sensor x Throttle body 2 0 20 17 in lbf Throttle body assy x Intake air surge tank 20 199 14 ...

Page 117: ...akage 13 4 14 2Ω 68 82 cm2 4 1 4 9 cu in per 15 seconds 14 cm3 0 9 cu in or less 1 drop or less per 12 minutes Fuel pump Resistance at 20 C 68 F 0 2 3 0 Ω 1MZ FE Fuel pressure 304 343 kPa 3 1 3 5 kgf cm2 44 50 psi Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more Fuel injector Resistance at 20 C 68 F Injection volume Difference between each cylinder Fuel leakage 13 4 14 2Ω 60 73 cm2 3 7 4 5 cu in p...

Page 118: ... 5 4 55 48 in lbf Parking brake cable assy No 2 x Body 5 4 55 48 in lbf 1MZ FE Part Tightened N m kgf cm ft lbf Delivery pipe x Cylinder head 10 102 7 Pulsation damper x Delivery pipe 33 336 24 Fuel pipe x Delivery pipe 33 336 24 Fuel pipe x Intake manifold 20 204 15 Front suspension brace sub assy upper center x Body 80 816 59 Fuel tank vent tube set plate x Fuel tank 3 5 36 31 in lbf Fuel main t...

Page 119: ...t 500 C 932 F No continuity 1MZ FE VSV for pressure switching valve Resistance at 20 C 68 F at 120 C 248 F 37 44 Ω 51 62 Ω VSV for EVAP Resistance at 20 C 68 F 27 33 Ω VSV for canister closed valve Resistance at 20 C 68 F 25 30 Ω Oxygen sensor Resistance at 20 C 68 F 11 16 Ω A F sensor Resistance at 20 C 68 F at 800 C 1 472 F 0 8 1 4 Ω 1 8 3 2 Ω EGR valve position sensor Resisrance VC E2 Power sou...

Page 120: ...or Date 2002 CAMRY REPAIR MANUAL RM881U TORQUE SPECIFICATION 1MZ FE Part Tightened N m kgf cm ft lbf EGR gas temperature sensor x EGR valve 20 200 14 EGR valve x Intake air surge tank 12 120 9 EGR pipe No 2 x EGR valve 12 120 9 EGR pipe No 2 x EGR cooler 12 120 9 ...

Page 121: ...PECIFICATIONS INTAKE 121 Author Date 2002 CAMRY REPAIR MANUAL RM881U INTAKE SERVICE DATA 1MZ FE Intake air control valve No 3 VSV Resistance at 20 C 68 F 37 44 Ω Vacuum switching valve assy No 1 Resistance at 20 C 68 F 33 39 Ω ...

Page 122: ... SERVICE SPECIFICATIONS INTAKE 03 11 122 Author Date 2002 CAMRY REPAIR MANUAL RM881U TORQUE SPECIFICATION 1MZ FE Part Tightened N m kgf cm ft lbf Intake air control valve assy x Intake air surge tank 15 153 11 ...

Page 123: ...rk 2 Mark 3 0 050 0 090 mm 0 0020 0 0035 in 0 090 mm 0 0035 in 0 004 0 031 mm 0 0002 0 0012 in 0 031 mm 0 0012 in 26 000 26 006 mm 1 0236 1 0239 in 26 007 26 012 mm 1 0239 1 0241 in 26 013 26 018 mm 1 0241 1 0243 in 22 985 23 000 mm 0 9049 0 9055 in 1 486 1 489 mm 0 0585 0 0586 in 1 489 1 492 mm 0 0586 0 0587 in 1 492 1 495 mm 0 0587 0 0589 in Oil pump drive gear Gear diameter w chain Minimum 48 2...

Page 124: ... 0 0039 in Valve clearance Intake cold Exhaust 0 19 0 29 mm 0 0075 0 0114 in 0 30 0 40 mm 0 0118 0 0157 in Cylinder head Warpage Maximum Cylinder block side Intake manifold side Exhaust manifold side 0 05 mm 0 0020 in 0 08 mm 0 0031 in 0 08 mm 0 0031 in Inner compression spring Free length Deviation Maximum Angle reference Maximum 45 7 mm 1 799 in 1 6 mm 0 063 in 2 Intake valve Overall length Stan...

Page 125: ...3 4822 in 0 051 0 074 mm 0 0020 0 0029 in 0 1 mm 0 0039 in Piston ring Ring groove clearance End gap Standard No 1 No 2 Oil side rail Maximum No 1 No 2 Oil side rail 0 030 0 070 mm 0 0012 0 0028 in 0 22 0 32 mm 0 0087 0 0126 in 0 50 0 60 mm 0 0197 0 0236 in 0 10 0 35 mm 0 0039 0 0138 in 0 89 mm 0 0350 in 1 35 mm 0 0531 in 0 73 mm 0 0287 in Piston pin Bushing inside diameter Piston pin diameter Oil...

Page 126: ...ight Standard Intake Exhaust Minimum Intake Exhaust Camshaft Journal diameter 0 06 mm 0 0024 in 42 11 42 21 mm 1 6579 1 6618 in 41 96 42 06 mm 1 6520 1 6559 in 41 96 mm 1 6520 in 41 81 mm 1 6461 in 26 959 26 975 mm 1 0614 1 0620 in 12 pointed head cylinder head set bolt diameter at tension portion Standard Minimum 8 95 9 05 mm 0 3524 0 3563 in 8 75 mm 0 3775 in Valve clearance at cold Intake Exhau...

Page 127: ...ing rod thrust clearance Standard Maximum Connecting rod oil clearance Standard Maximum 0 15 0 30 mm 0 0059 0 0118 in 0 35 mm 0 0138 in 0 038 0 066 mm 0 0015 0 0026 in 0 08 mm 0 0031 in Crankshaft thrust clearance Standard Maximum 0 04 0 24 mm 0 0016 0 0094 in 0 30 mm 0 0118 in Cylinder block warpage Maximum 0 05 mm 0 0020 in Cylinder bore diameter Standard Maximum 87 500 87 512 mm 3 4449 3 4453 i...

Page 128: ... diameter Crank pin taper and out of round Maximum 0 06 mm 0 0024 in 60 988 61 000 mm 2 4011 2 4016 in 0 02 mm 0 0008 in 52 992 53 000 mm 2 0863 2 0866 in 0 02 mm 0 0008 in Crankshaft oil clearance Standard No 1 and No 4 journals No 2 and No 3 journals Maximum No 1 and No 4 journals No 2 and No 3 journals 0 014 0 034 mm 0 0006 0 0013 in 0 026 0 046 mm 0 0010 0 0018 in 0 05 mm 0 0020 in 0 06 mm 0 0...

Page 129: ...ifold converter insulator No 1 x Exhaust manifold converter 12 122 9 Oil level gauge guide x Water by pass pipe No 1 9 0 92 80 in lbf Intake manifold x Cylinder head 30 306 22 Drive plate ring gear Automatic transaxle x Crankshaft 98 1 000 72 Flywheel sub assy Manual transaxle x Crankshaft 130 1 330 96 Starter assy x Automatic transaxle assy 39 398 29 Starter assy x Manual transaxle assy 39 398 29...

Page 130: ...bearing cap No 1 9 0 92 80 in lbf Timing chain cover See page14 41 Bolt A Bolt B Bolt C Nut 9 0 21 43 9 0 92 214 438 92 80 in lbf 15 32 80 in lbf Oil pan x Stiffening crankcase assy 9 0 92 80 in lbf Oil pan drain plug x Oil pan 25 250 18 Water pump assy x Cylinder block 9 0 92 80 in lbf Water pump pulley x Water pump assy 26 265 19 Crank position sensor x Timing chain cover 9 0 92 80 in lbf Cranks...

Page 131: ...ont frame assy See page 14 155 Bolt C 85 867 63 See age 14 155 Bolt C Bolt D Nut 85 32 32 867 326 326 63 24 24 Compressor and magnetic clutch x Compressor mounting bracket No 1 See page 14 155 Bolt 25 250 18 See page 14 155 Bolt Nut 25 26 250 260 18 19 Generator belt adjusting bar x Cylinder block See page 14 155 Nut A Bolt B Bolt C 43 18 8 0 438 184 82 32 13 71 in lbf Generator bracket No 2 x Tra...

Page 132: ... 2 cover x Timing belt No 3 cover 8 5 87 76 in lbf Timing belt No 1 cover x OIl pump assy 8 5 87 76 in lbf Crankshaft pulley x Crankshaft 215 2 192 159 Camshaft position sensor x Cylinder head 8 0 82 71 in lbf Cylinder head cover x Cylinder head 8 0 82 71 in lbf Spark plug x Cylinder head 18 184 13 W head straight screw plug No 1 x Cylinder head 44 449 32 W head straight screw plug No 2 x Cylinder...

Page 133: ...CATIONS ENGINE MECHANICAL 133 Author Date 2002 CAMRY REPAIR MANUAL RM881U Part Tightened ft lbf kgf cm N m EGR pipe No 1 x Exhaust manifold LH 12 120 9 Exhaust pipe support bracket No 1 x Automatic transaxle assy 21 214 15 ...

Page 134: ... support bracket x Exhaust pipe assy front 33 337 24 Exhaust pipe No 1 support bracket x Exhaust pipe assy front 33 337 24 Oxygen sensor x Exhaust pipe assy front 44 450 33 1MZ FE Part Tightened N m kgf cm ft lbf Exhaust pipe assy center x Tail pipe assy 56 571 41 Exhaust pipe assy front x Exhaust manifold RH 62 633 47 Exhaust pipe assy front x Exhaust manifold converter No 2 62 633 47 Exhaust pip...

Page 135: ...5 kgf cm2 13 4 17 6 psi 78 kPa 0 8 kgf cm2 11 2 psi Cooling fan Standard amperage at 20 C 68 F 4 9 8 5 A Coolant Capacity 6 2 liters 6 6 US qts 5 4 lmp qts 1MZ FE Thermostat Valve opening temperature Valve lift at 95 C 203 F 80 84 C 176 183 F 10 mm 0 394 in or more Radiator cap sub assy Standard opening pressure Minimum opening pressure 83 4 112 8 kPa 0 85 1 15 kgf cm2 12 1 16 4 psi 69 kPa 0 7 kgf...

Page 136: ... assy 5 0 51 44 in lbf Radiator support upper x body 14 142 10 1MZ FE Part Tightened N m kgf cm ft lbf Water pump assy x Cylinder block 8 82 71 in lbf Idler sub assy No 2 x Cylinder block 43 438 32 Transverse engine engine mounting bracket x Cylinder block 28 286 21 Generator bracket No 2 x Cylinder block 28 286 21 Front wheel 103 1051 76 Water inlet x Cylinder block 8 82 71 in lbf Water inlet pip...

Page 137: ... w oil filter change Drain and refill w o oil filter change Dry fill 3 8 liters 4 0 US qts 3 3 lmp qts 3 6 liters 3 8 US qts 3 2 lmp qts 4 5 liters 4 8 US qts 4 0 lmp qts 1MZ FE Oil pressure at idle speed at 3 000 rpm 29 kPa 0 3 kgf cm2 4 3 psi or more 294 539 kPa 3 0 5 5 kgf cm2 43 78 psi Oil pump Side clearance Standard Maximum Tip clearance Standard Maximum Body clearance Standard Maximum 0 03 ...

Page 138: ...Cylinder block 10 mm head See page 17 10 12 mm head 8 20 82 199 71 in lbf 14 Oil strainer x Main bearing cap 8 82 71 in lbf Oil pan sub assembly No 2 x Oil pan sub assembly No 1 8 82 71 in lbf Transverse engine engine mounting bracket x Cylinder block Bolt A See page 17 10 Nut B 54 54 550 550 40 40 Transverse engine engine mounting bracket x PS pump bracket 43 439 32 Engine mounting insulator RH x...

Page 139: ...1 3 mm 0 051 in Camshaft position sensor Resistance at cold at hot 835 1 400Ω 1 060 1 645Ω Crank position sensor Resistance at cold at hot 985 1 600Ω 1 265 1 890Ω 1MZ FE Spark plug Recommended spark plug DENSO NGK Electrode gap Standard Maximum SK20R11 IFR6A11 1 0 1 1mm 0 039 0 043 in 1 2mm 0 047 in Camshaft position sensor Resistance at cold at hot 835 1400Ω 1060 1645Ω Crank position sensor Resis...

Page 140: ...U TORQUE SPECIFICATION 2AZ FE Part Tightened N m kgf cm ft lbf Spark plug x Cylinder head cover 19 194 14 Ignition coil x Cylinder head cover 9 0 92 80 in lbf 1MZ FE Part Tightened N m kgf cm ft lbf Spark plug x Cylinder head cover 18 184 13 Ignition coil x Cylinder head cover 8 0 82 71 in lbf ...

Page 141: ... Slip ring diameter Standard Minimum Brush exposed length Standard Minimum 2 7 3 1 Ω 14 2 14 4 mm 0 559 0 567 in 12 8 mm 0 504 in 9 5 11 5 mm 0 374 0 453 in 1 5 mm 0 059 in 1MZ FE Starter assy Specified current Circle runout Standard Maximum Commutator length Standard Maximum Brush holder length Standard Maximum Snap ring length 90 A or less at 11 5 V 0 02 mm 0 0008 in 0 05 mm 0 0020 in 3 3 mm 0 1...

Page 142: ...erator pulley x Rotor 4 5 5 4 2 9 2 0 2 0 4 4 3 9 4 1 111 46 55 30 20 20 45 39 42 1 125 39 in lbf 47 in lbf 26 in lbf 18 in lbf 18 in lbf 39 in lbf 35 in lbf 36 in lbf 81 1MZ FE Part Tightened N m kgf cm ft lbf Lead wire of field frame x Magnetic switch 5 9 60 52 in lbf Starter x Engine Bolt Nut 42 9 8 429 100 31 7 Starter Assy Commutator end frame assy x Motor terminal starter kit Repair service ...

Page 143: ...wheel align ment Wheel angle 15 inch USA Canada Inside wheel Outside wheel Reference 15 inch Mexico Inside wheel Outside wheel Reference 16 inch USA Canada Inside wheel Outside wheel Reference 16 inch Mexico Inside wheel Outside wheel Reference 39 04 2 39 07 2 33 44 33 73 39 30 2 39 50 2 34 02 34 03 36 39 2 36 65 2 32 11 32 18 37 00 2 37 00 2 32 28 32 47 Camber USA Canada Mexico Right left error 0...

Page 144: ...pport x Piston rod 49 500 36 Speed sensor wire harness bracket set bolt w ABS 18 8 192 14 Flexible hose x Shock absorber w o ABS 18 8 192 14 Lower suspension arm set bolt Front side Rear side 200 206 2 039 2 101 148 152 Transverse engine engine mounting insulator set nut 87 887 64 Transverse engine engine mounting insulator x Bracket MT 64 653 47 Stabilizer bar bracket x Suspension member 19 194 1...

Page 145: ...al 0 22 11 0 3 0 2 4 2 mm 0 16 0 08 in Rear wheel align No 2 lower suspension arm length difference 1 0 mm 0 039 in or less Rear wheel align ment Camber USA Canada Mexico Right left error 1 16 45 1 27 0 75 1 09 45 1 15 0 75 45 0 75 or less Rear suspension Stabilizer bar link ball joint turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 in lbf ...

Page 146: ...iston rod set nut 49 500 36 Shock absorber x Stabilizer bar link 39 400 29 Rear suspension member x Rear suspensio arm assy No 1 LH 100 1 020 74 Rear suspension member x Body A B C 55 38 561 387 41 28 Rear suspension arm assy No 1 x Rear axle carrier 100 1 020 74 Rear suspension arm assy No 2 x Rear axle carrier 100 1 020 74 Stabilizer bar bracket 19 195 14 Stabilizer bar x Stabilizer bar link 39 ...

Page 147: ...0E6 01 03 36 SERVICE SPECIFICATIONS TIRE WHEEL 147 Author Date 2002 CAMRY REPAIR MANUAL RM881U TIRE WHEEL SERVICE DATA Tire runout 1 0 mm 0 039 in or less Imbalance after adjustment 8 0 g 0 018 lb or less ...

Page 148: ... REPAIR MANUAL RM881U DRIVE SHAFT PROPELLER SHAFT AXLE SERVICE DATA Front axle hub bearing Backlash Maximum 0 05 mm 0 0020 in Front axle hub bearing Deviation Maximum 0 05 mm 0 0020 in Rear axle hub bearing Backlash Maximum 0 05 mm 0 0020 in Rear axle hub bearing Deviation Maximum 0 07 mm 0 0027 in ...

Page 149: ...98 217 Front drive shaft center bearing set bolt 32 4 330 24 Front speed sensor set bolt w ABS 8 0 82 71 Front flexible hose and speed sensor wire harness x Shock absorber w ABS 18 8 192 14 Front flexible hose x Shock absorber w o ABS 18 8 192 14 Rear wheel set nut 103 1 050 76 Rear flexible hose x Shock absorber 18 8 192 14 Shock absorber x Rear axle carrier 255 2 600 188 Rear axle hub set bolt 8...

Page 150: ...ness Minimum thickness 12 0 mm 0 472 in 1 0 mm 0 039 in Front brake disc thickness Standard thickness Minimum thickness 28 0 mm 0 433 in 26 0 mm 0 039 in Front brake disc runout Maximum disc runout 0 05 mm 0 0020 in Rear brake pad thickness Standard thickness Minimum thickness 10 0 mm 0 472 in 1 0 mm 0 039 in Rear disc brake thickness Standard thickness Minimum thickness 12 0 mm 0 472 in 10 5 mm 0...

Page 151: ... 350 25 Front brake cylinder x Flexible hose 29 4 300 22 Rear disc brake cylinder mounting set bolt TMC made TMMK made 61 8 47 630 475 46 34 Rear disc brake cylinder slide pin x Rear disc brake cylinder mounting TMC made Upper side TMC made Lower side TMMK made 34 3 39 2 43 350 400 440 25 29 32 Rear disc brake cylinder x Flexible hose 29 4 300 22 Rear drum brake wheel cylinder x Backing plate 10 1...

Page 152: ...bf 3 6 clicks Parking brake lever travel at 200 N 20 kgf 44 1 lbf 6 9 clicks Rear brake disc inside diameter Standard inside diameter Maximum inside diameter 170 mm 6 69 in 171 mm 6 73 in Parking brake shoe lining thickness Standard thickness Minimum thickness 2 0 mm 0 079 in 1 0 mm 0 039 in Parking brake shoe clearance between rear shoe and lever Less than 0 35 mm 0 0138 in ...

Page 153: ...ng pedal type Parking lever type 5 4 5 0 55 51 48 in lbf 44 in lbf Parking brake lever set bolt 12 5 128 9 Parking brake control pedal set bolt 39 398 29 Console box mounting set bolt 12 5 128 9 Parking brake cable No 1 x Turn buckle 5 4 55 48 in lbf Parking brake cable No 3 x Backing plate 7 8 80 69 in lbf Parking brake cable heart insulator set nut 5 4 55 48 in lbf Parking brake cable No 4 x Bod...

Page 154: ...on Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 3 2 2 1 57 66 km h 35 41 mph 107 117 km h 66 73 mph 171 188 km h 106 117 mph 163 180 km h 101 112 mph 98 108 km h 61 67 mph 47 55 km h 29 34 mph 40 47 km h 25 29 mph 18 24 km h 11 15 mph 57 66 km h 35 41 mph 107 117 km h 66 73 mph 47 55 km h 29 34 mph 107 117 km h 66 73 mph 53 60 km h 33 37 mph Lock up point Throttle...

Page 155: ...ly opened 1 2 3 2 2 1 L position Throttle valve fully opened 3 2 2 1 57 66 km h 35 41 mph 108 118 km h 67 73 mph 165 181 km h 103 112 mph 154 171 km h 96 106 mph 101 110km h 63 68 mph 43 50 km h 27 31 mph 38 45 km h 24 28 mph 18 24 km h 11 15 mph 57 66 km h 35 41 mph 111 121 km h 69 75 mph 43 50 km h 27 31 mph 111 121 km h 69 75 mph 50 58 km h 31 36 mph Lock up point Throttle valve opening 5 O D g...

Page 156: ... tube x Transaxle 5 5 56 49 in lbf Control cable bracket x Transaxle 11 8 122 9 Oil cooler tube clamp x Control cable bracket 5 4 55 48 in lbf Oil cooler inlet tube x Transaxle 34 3 350 25 Oil cooler outlet tube x Transaxle 34 3 350 25 Starter x Transaxle 37 377 27 Wire harness x Transaxle 25 5 260 19 Control cable clamp x Transaxle 11 8 122 9 Wire harness clamp x Transaxle 8 4 86 74 in lbf Speed ...

Page 157: ...7 mm 1 3772 1 3778 in 34 997 mm 1 3778 in Control shaft cover bimetal formed bush clearance 0 081 0 149 mm 0 0032 0 0059 in Front transaxle case cover oil seal driven in depth 0 0 5 mm 0 0 020 in Transmission case oil seal driven in depth 3 5 0 5 mm 0 138 0 020 in Output shaft rear bearing clearance 3 8 4 4 mm 0 150 0 173 in Output shaft bearing preload New bearing Used bearing 0 8 1 6 N m 8 16 16...

Page 158: ... in 5th gear thrust clearance Standard clearance 0 10 0 65 mm 0 0039 0 0260 in Input shaft assy 4th gear thrust clearance Standard clearance 0 10 0 57 mm 0 0039 0 0224 in 3rd gear thrust clearance Standard clearance 0 10 0 35 mm 0 0039 0 0138 in 4th gear radial clearance KOYO made NSK made 0 009 0 053 mm 0 0004 0 0021 in 0 009 0 051 mm 0 0004 0 0020 in 3rd gear radial clearance KOYO made NSK made ...

Page 159: ...51 mm 0 0004 0 0020 in 2nd gear radial clearance KOYO made NSK made 0 009 0 053 mm 0 0004 0 0021 in 0 009 0 051 mm 0 0004 0 0020 in Output shaft run out Maximum run out 0 03 mm 0 0012 in Output shaft standard outer diameter A B 37 610 37 626 mm 1 4807 1 4813 in 34 802 34 512 mm 1 3702 1 3587 in Output shaft minimum outer diameter A B 37 610 mm 1 4807 in 34 802 mm 1 3702 in 2nd gear inside diameter...

Page 160: ...3 4 1 00 mm 0 0394 in 1 10 mm 0 0433 in 1 20 mm 0 0472 in 1 30 mm 0 0512 in Shift select lever shaft assy Control shaft cover bimetal formed bush drive in depth 0 0 25 mm 0 0 010 in Control shaft cover oil seal drive in depth 28 5 0 50 mm 1 122 0 020 in Shift lever slotted pin clearance to the shift lever inner assy 0 5 0 5 mm 0 0197 0 0197 in Shift lever slotted pin clearance to the shift lever i...

Page 161: ...4 32 Transverse engine engine mounting insulator x Manual transaxle 64 653 47 Exhaust pipe support bracket No 1 x Manual transaxle 8 0 82 71 in lbf Manual transmission case protector x Manual transaxle 18 184 13 Transverse engine engine mounting bracket x Manual transaxle 64 653 47 Starter assy x Manual transaxle 37 377 27 Wire harness clamp x Manual transaxle 8 0 82 71 in lbf Engine wire No 3 x M...

Page 162: ...cover x Transmission case 20 204 15 Control shift lever x Shift select lever assy 6 4 65 57 in lbf Selecting bell crank assy x Transmission case 20 204 15 Selecting bellcrank support x Selecting bellcrank No 2 plate washer 12 122 9 Release fork support x Manual transaxle case 47 1 480 35 Front differential ring gear x Front differential case 106 1 081 78 ...

Page 163: ... at pedal top 1 0 5 0 mm 0 039 0 197 in Slotted spring pin protrusion Maximum 1 5 3 5 mm 0 059 0 138 in Disc rivet head depth Maximum 0 3 mm 0 012 in Disc runout Minimum 0 8 mm 0 031 in Diaphragm spring finger wear Maximum depth Maximum width 0 5 mm 0 020 in 6 0 mm 0 236 in Flywheel runout Maximum 0 1 mm 0 004 in Diaphragm spring finger wear Maximum depth 0 5 mm 0 020 in Clutch release point from ...

Page 164: ... 25 5 260 19 Clutch master cylinder assy x Clutch pedal support 11 8 120 9 Clutch master cylinder assy x Flexible hose tube 15 2 155 11 Master cylinder bleeder plug 8 3 85 73 in lbf Release cylinder bleeder plug 8 3 85 73 in lbf Clutch release cylinder assy x Transaxle housing 11 8 120 9 Clutch release cylinder assy x flexible hose tube 15 2 155 11 Clutch cover assy x Flywheel 19 1 195 14 Release ...

Page 165: ... SPECIFICATIONS STEERING COLUMN 165 Author Date 2002 CAMRY REPAIR MANUAL RM881U STEERING COLUMN SERVICE DATA Steering wheel freeplay Maximum 30 mm 1 18 in Steering main shaft length Standard length 474 5 1 mm 18 681 0 039 in ...

Page 166: ...f Tie rod end lock nut 74 750 54 Universal joint assy x Main shaft assy 35 3 360 26 Steering column assembly set bolt and nut 20 6 210 15 Intermediate shaft sub assy x Universal joint assembly 35 3 360 26 Intermediate shaft sub assy x Control valve shaft 35 3 360 26 Steering wheel set nut 50 510 37 Steering wheel pad set screw Torx screw 8 8 90 78 in lbf ...

Page 167: ...plate length Minimum 11 993 mm 0 47216 in Vane plate and vane rotor groove clearance Maximum 0 03 mm 0 0012 in Spring free length Minimum 35 8 mm 1 409 in POWER STEERING VANE PUMP 1MZ FE Vane pump rotating torque 0 27 N m 2 8 kgf cm 2 4 in lbf or less Vane pump shaft and vane pump housing oil clearance STD Maximum 0 027 0 054 mm 0 00106 0 00213 in 0 07 mm 0 0028 in Vane plate height Minimum 8 7 mm...

Page 168: ...2 Vane pump pulley set nut TYPE A VANE PUMP 44 449 32 Vane pump assy set bolt 43 438 32 Pressure feed tube assy x Vane pump assy 51 5 525 38 Power steering oil pressure switch 21 214 15 POWER STEERING GEAR Control valve housing set bolt 21 214 15 Control valve shaft lock nut 24 5 250 18 Rack housing cap 58 5 597 43 Rack guide spring cap nut 48 68 5 489 699 35 51 Power steering rack x Steering rack...

Page 169: ...ATER AIR CONDITIONER SERVICE DATA Refrigerant charge volume Standard 550 50 g 19 37 1 76 oz V cooler compressor to crankshaft pulley belt No 1 tension New belt Used belt 165 27 lbf 88 22 lbf Magnetic clutch clearance 1MZ FE 0 35 0 60 mm 0 014 0 024 in Magnetic clutch clearance 2AZ FE 0 35 0 60 mm 0 014 0 024 in ...

Page 170: ...lutch hub x Cooler compressor assy 18 184 13 Compressor and magnet clutch x Engine Bolt A B C F Nut D 25 250 18 Compressor and magnet clutch x Engine Bolt E 18 184 13 Cooler refrigerant suction hose No 1 x Compressor and magnet clutch 9 8 100 87 in lbf Cooler refrigerant discharge hose No 1 x Compressor and magnet clutch 9 8 100 87 in lbf COOLER COMPRESSOR ASSY 2AZ FE Magnet clutch hub x Cooler co...

Page 171: ... Steering wheel assy x Steering column assy 50 510 37 Instr pnl pass l door airbag assy x Instrument panel reinforcement 20 200 14 Curtain shield airbag assy x Body 9 8 100 87 in lbf Airbag sensor assy center x Body 17 5 178 13 Airbag front sensor set bolt 17 5 178 13 Side airbag sensor assy LH x Body 20 200 14 Airbag sensor rear LH x Body Property class 8T Property class 6T 20 17 5 200 178 14 13 ...

Page 172: ... CAMRY REPAIR MANUAL RM881U WIPER WASHER TORQUE SPECIFICATION Part Tightened N m kgf cm ft lbf Wind shield wiper motor assy Wiper link assy 5 4 55 48 in lbf Wiper link assy Body 7 0 71 62 in lbf FR Wiper arm RH Wiper link 20 1 205 15 FR Wiper arm LH Wiper link 20 1 205 15 ...

Page 173: ...UMENT PANEL METER 173 Author Date 2002 CAMRY REPAIR MANUAL RM881U INSTRUMENT PANEL METER TORQUE SPECIFICATION Part Tightened N m kgf cm ft lbf Instrument panel reinforce Body Bolt E 20 200 14 Front pillar garnish Body 7 5 20 76 204 66 117 in lbf ...

Page 174: ...HOOD DOOR TORQUE SPECIFICATION Part Tightened N m kgf cm ft lbf HOOD Hood x Hood hinge 26 265 19 FRONT DOOR Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 Door lock striker x Body 23 235 17 REAR DOOR Door hinge x Body 26 265 19 Door hinge x Door panel 26 265 19 Door lock striker x Body 23 235 17 ...

Page 175: ...hat the throttle valve opening percentage THROTTLE POS of the CURRENT DATA shown the standard value Standard throttle valve opening percentage 60 or more 2 INSPECT ACCELERATOR PEDAL POSITION SENSOR a When turning ignition switch ON check that the voltage of the throttle position sensor of the CURRENT DATA shown the standard value Standard voltage 0 6 1 0 V 3 INSPECT CAMSHAFT TIMING OIL CONTROL VAL...

Page 176: ...F meter and check that the volt age fluctuates b Resistance inspection 1 Using an ohmmeter measure the resistance be tween terminals 4 THA and 5 E2 Resistance 20 C 4 F 13 6 18 4 kΩ 20 C 68 F 2 21 2 69 kΩ 60 C 140 F 0 493 0 667 kΩ 2 CAMSHAFT TIMING OIL CONTROL VALVE ASSY a Resistance inspection 1 Using an ohmmeter measure the resistance be tween the terminals Resistance 6 9 7 9 Ω at 20 C 68 F b Mov...

Page 177: ... or less 5 VPA1 1 EP2 5 0 kΩ or less 6 VCP1 3 EP1 2 25 4 75 kΩ 4 VCP2 1 EP2 2 25 4 75 kΩ 4 THROTTLE BODY ASSY a Using an ohmmeter measure the resistance between the terminals Resistance Terminal No Resistance 3 VC 6 GND 1 2 3 2 kΩ 20 C 2 M 1 M 0 3 100 kΩ 20 C 5 E F I ENGINE COOLANT TEMPERATURE SENSOR a Resistance inspection 1 Using an ohmmeter measure the resistance be tween terminal 1 and 2 Resis...

Page 178: ...between the terminal and body 7 E F I CIRCUIT OPENING RELAY ASSY E F I ECU RELAY a Continuity inspection 1 Using an ohmmeter check that continuity exists be tween each terminal Specified condition Between terminal 1 and 2 Continuity Between terminal 3 and 5 No continuity 2 Using an ohmmeter check that continuity exists be tween terminals 3 and 5 when the battery voltage is applied across terminals...

Page 179: ...rottle Body Gasket Water By pass Hose No 2 Throttle Body Assy Fuel Pipe Support Air Cleaner Cap Sub Assy Water By pass Hose 30 305 22 ENGINE CONTROL SYSTEM THROTTLE BODY ASSY 2AZ FE 10 5 1435 Author Date 2002 CAMRY REPAIR MANUAL RM881U THROTTLE BODY ASSY 2AZ FE COMPONENTS ...

Page 180: ... the throttle body c Disconnect 2 water by pass hoses d Remove 4 bolts and throttle body assy from intake man ifold e Remove the throttle body gasket 4 INSTALL THROTTLE BODY ASSY a Install a new gasket on the intake manifold as shown in the illustration b install the throttle body assy with 4 bolts Torque 30 N m 305 kgf cm 22 ft lbf c Connect 2 water by pass hoses to the throttle body assy d Conne...

Page 181: ...no friction sound b Inspect the throttle position sensor 1 Connect the hand held tester or OBD II scan tool to the DLC3 2 Turn the ignition switch ON 3 Check that the check engine warning light does not light up 4 Check that the throttle valve opening percentage THROTTLE POS of the CURRENT DATA shown the standard value Standard throttle valve opening percentage 60 or more 2 INSPECT ACCELERATOR PED...

Page 182: ...2 Using a voltmeter connect the positive tester probe to terminal VG and negative tester probe to terminal E2G 3 Blow air into the MAF meter and check that the volt age fluctuates b Resistance inspection 1 Using an ohmmeter measure the resistance be tween terminals 4 THA and 5 E2 Resistance 20 C 4 F 13 6 18 4 kΩ 20 C 68 F 2 21 2 69 kΩ 60 C 140 F 0 493 0 667 kΩ 2 ACCELERATOR PEDAL ASSY a Resistance...

Page 183: ...SENSOR a Resistance inspection 1 Using an ohmmeter measure the resistance be tween terminals 1 VC and 4 E2 Resistance 1 2 3 2 kΩ 5 E F I ENGINE COOLANT TEMPERATURE SENSOR a Resistance inspection 1 Using an ohmmeter measure the resistance be tween each terminal Resistance Approx 20 C 68 F 2 32 2 59 kΩ Approx 80 C 176 F 0 310 0 326 kΩ NOTICE In case of checking the water temperature sensor in the wa...

Page 184: ... FUEL RATIO SENSOR HEATER RELAY a Continuity inspection 1 Using an ohmmeter check that continuity exists be tween each terminal Specified condition Between terminal 1and 2 Continuity Between terminal 3and 5 No continuity 2 Using an ohmmeter check that continuity exists be tween terminals 3 and 5 when the battery voltage is applied across terminals 1 and 2 ...

Page 185: ...w Air Cleaner Hose Non reusable part N m kgf cm ft lbf Specified torque Throttle Body Gasket 2 0 20 18 in lbf 20 199 14 in lbf 20 199 14 in lbf ENGINE CONTROL SYSTEM THROTTLE BODY ASSY 1MZ FE 10 11 1441 Author Date 2002 CAMRY REPAIR MANUAL RM881U THROTTLE BODY ASSY 1MZ FE COMPONENTS ...

Page 186: ...oses and the ventilation hose d Remove the air cleaner cap with the hose 3 REMOVE FRONT SUSPENSION UPPER BRACE CENTER W FRONT SUSPENSION BRACE UPPER CENTER 4 REMOVE THROTTLE BODY ASSY a Disconnect the throttle position sensor connector b Disconnect the throttle control motor connector c Disconnect the 2 water bypass hoses d Remove the 2 bolts 2 nuts throttle body and gasket 5 REMOVE E F I THROTTLE...

Page 187: ... sensor at the center value of the standard value and then tighten the screws Standard throttle valve opening percentage 16 8 18 4 Torque 2 0 N m 20 kgf cm 18 in lbf NOTICE After turning the ignition switch ON do not depress the ac celerator pedal h Recheck throttle valve opening percentage If the throttle valve opening percentage is not as specified re peat step g i Perform fully closed throttle ...

Page 188: ...2 CAMRY REPAIR MANUAL RM881U 8 INSTALL FRONT SUSPENSION UPPER BRACE CENTER W FRONT SUSPENSION BRACE UPPER CENTER Torque 80 N m 816 kgf cm 59 ft lbf 9 ADD COOLANT See page 16 20 10 CHECK ENGINE COOLANT LEAK See page16 20 11 INSPECT FUNCTION OF THROTTLE BODY ASSY See page 10 7 ...

Page 189: ...e vehicle compart ment by covering them with a shop rag a Remove the circuit opening relay in the engine room relay block b Start the engine After the engine has stopped on its own turn the ignition switch OFF HINT There is a case that DTC P0171 system to lean is output c Check that the engine does not start d Remove the fuel tank cap and let the air out of the fuel tank e Disconnect negative term...

Page 190: ...ing a new O ring on the injector take care not to damage it in any way 3 Coat a new O ring with spindle oil or gasoline be fore installing Never use engine gear or brake oil c Install the injector to the delivery pipe and cylinder head as shown in the illustration Before installing the injector be sure to apply spindle oil or gasoline on the place where the delivery pipe touches O ring of the inje...

Page 191: ...r towards the fuel tube assembly e Observe these following precautions when disconnecting the fuel tube connector quick type 1 Remove the fuel pipe clamp No 1 2 Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away 3 Disconnect the connector from the hose while pinching part A with fingers as shown in the illustra tion 4 When the...

Page 192: ... CAMRY REPAIR MANUAL RM881U 6 Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag 4 CHECK FUEL LEAK a Check that there are no fuel leaks after doing maintenance anywhere on the fuel system See page 11 5 ...

Page 193: ... pipe HINT Part No 23901 28130 b Work for prevent gasoline from spilling out See page 11 1 c Remove the fuel pipe clamp No 1 from the fuel tube con nector d Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra tion CAUTION Perform disconnecting operations of the fuel tube connector quick type after observing the precau tions As there is ...

Page 194: ... engine l Measure the fuel pressure at idle Fuel pressure 304 343 kPa 3 1 3 5 kgf cm2 44 50 psi m Stop the engine n Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more If pressure is not as specified check the fuel pump pressure regulator and or injectors o After checking fuel pressure disconnect the negative...

Page 195: ...ing relay 2 Using a service wire connect terminals FP and B of the relay block NOTICE Pay due attention to the terminal connecting position to avoid a malfunction 3 Turn the ignition switch ON and check that the fuel pump operates NOTICE Do not start the engine c Check that there are no fuel leaks after doing mainte nance anywhere on the fuel system ...

Page 196: ...ks during the test 1 Purchase the new fuel tube and take out the fuel tube connector from its pipe HINT Part No 23901 28130 2 Connect SST and fuel tube connector to the fuel pipe SST 09268 41047 90467 13001 95336 08070 CAUTION Perform connecting operations of the fuel tube connector quick type after observing the precautions 3 Install the O ring to the injector 4 Connect SST union and hose to the ...

Page 197: ...ide If the injection volume is not as specified replace the injector c Inspect leakage 1 In the condition above disconnect the test probes of SST wire from the battery and check the fuel leakage from the injector Fuel drop 1 drop or less per 12 minutes 2 FUEL PUMP a Insect fuel pump resistance 1 Using an ohmmeter measure the resistance be tween terminals Resistance 0 2 3 0 Ω at 20 C 68 F b Inspect...

Page 198: ... Cap w Air Cleaner Hose Fuel Delivery Pipe O ring Insulator Fuel Injector Assy 20 204 15 20 204 15 Engine Wire Engine Cover Sub assy No 1 Ventilation Hose No 2 11 10 FUEL FUEL INJECTOR ASSY 2AZ FE 1454 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL INJECTOR ASSY 2AZ FE COMPONENTS ...

Page 199: ...e harness from the delivery pipe d Remove 2 bolts and delivery pipe together with 4 injector e Remove 2 spacers from the cylinder head 6 REMOVE FUEL INJECTOR ASSY a Pull out 4 injector from the delivery pipe 7 INSTALL FUEL INJECTOR ASSY a Install the new insulator to each injector b Apply a light coat of spindle oil or gasoline to new O ring and install them to each injector c Apply a light coat o...

Page 200: ...ectors in position on the cylinder head c Temporarily install 2 bolts holding the delivery pipe to the cylinder d Check that the injectors rotate smoothly HINT If injectors do not rotate smoothly the probable cause is incor rect installation of O ring Replace the O ring e Position the injector connector outward f Tighten 2 bolts holding the delivery pipe to the cylinder head Torque 20 N m 204 kgf ...

Page 201: ...ube Set Plate Fuel Suction Tube Assy w Pump Gage Fuel Pump Tube Sub assy Non reusable part N m kgf cm ft lbf Specified torque Fuel Suction Tube Set Gasket 3 5 36 31 in lbf FUEL FUEL PUMP ASSY 2AZ FE 11 13 1457 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL PUMP ASSY 2AZ FE COMPONENTS ...

Page 202: ...ender Gage Assy Fuel Suction Plate Sub assy Fuel Pump Fuel Filter Assy Fuel Pump Filter Fuel Suction Support No 2 Fuel Pressure Regulator Assy O ring Cushion Rubber Clip 11 14 FUEL FUEL PUMP ASSY 2AZ FE 1458 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 203: ...ctor before this work and clean dirt away b Remove the joint clip and pull out the fuel pump tube NOTICE Be careful of dirt like mud because the quick connec tor has an O ring to seal the pipe and the connector Do not use any tool in this work Do not bend or twist the nylon tube by force Keep off plug from foreign subjects To protect the fuel tube cover it with a vinyl bag after checking 5 REMOVE ...

Page 204: ...he claw holes and remove the fuel suction plate 13 REMOVE FUEL SENDER GAGE ASSY a Unlock the sender gage and move it downward to remove 14 REMOVE FUEL PUMP HARNESS a Disconnect the connector and remove the fuel pump harness 15 INSTALL FUEL SENDER GAGE ASSY a Lock the sender gage by pushing it upward NOTICE By pushing the sender gage downward confirm that it is certainly locked 16 INSTALL FUEL PUMP...

Page 205: ... scratch or foreign objects on the connecting part Check that the connector is inserted fully and secure ly Check that the clip of the tube joint is on the coller of the connector After installing the clip of the tube joint check that the connector is not pulled off 21 INSTALL REAR FLOOR SERVICE HOLE COVER a Using a new butyl tape set and install the rear floor service hole cover 22 INSPECT FUEL L...

Page 206: ...ube Set Plate Fuel Suction Tube Assy w Pump Gage Fuel Pump Tube Sub assy Non reusable part N m kgf cm ft lbf Specified torque Fuel Suction Tube Set Gasket 3 5 36 31 in lbf 11 18 FUEL FUEL TANK ASSY 2AZ FE 1462 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL TANK ASSY 2AZ FE COMPONENTS ...

Page 207: ...ce Rear Exhaust Pipe Gasket Fuel Tank Band Sub assy No 1 LH Parking Brake Cable Assy No 3 Non reusable part N m kgf cm ft lbf Specified torque Exhaust Pipe Gasket 39 400 29 5 4 55 48 in lbf 39 400 29 56 571 41 5 4 55 48 in lbf 56 571 41 19 5 199 14 5 4 55 48 in lbf FUEL FUEL TANK ASSY 2AZ FE 11 19 1463 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 208: ...w Tube Fuel Tank Over Fill Check Valve Assy Location of Fuel Tank Cushion Fuel Tank Inlet Pipe Sub assy Fuel Pump Tube Sub assy Fuel Main Tube Support Check Valve Gasket Fuel Tank Breather Tube Gasket Fuel Tank Protector Sub assy No 1 5 4 55 48 in lbf 11 20 FUEL FUEL TANK ASSY 2AZ FE 1464 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 209: ...UEL PUMP TUBE SUB ASSY See page 11 15 5 REMOVE FUEL TANK VENT TUBE SET PLATE 6 REMOVE FUEL SUCTION TUBE ASSY W PUMP GAGE 7 DRAIN FUEL 8 REMOVE FLOOR PANEL BRACE REAR See page 15 2 9 REMOVE EXHAUST PIPE ASSY CENTER 10 DISCONNECT PARKING BRAKE CABLE ASSY NO 2 a Remove the bolt and nut and disconnect the parking brake cable 11 DISCONNECT PARKING BRAKE CABLE ASSY NO 3 a Remove the bolt and nut and dis...

Page 210: ...d the pipe are stuck pinch the tube between fingers and turn it carefully to free and then disconnect the tube 14 DISCONNECT FUEL TANK TO FILLER PIPE HOSE a Disconnect the fuel tank to filler pipe hose from the fuel tank 15 DISCONNECT FUEL TANK BREATHER HOSE a Disconnect the fuel tank breather hose from the fuel tank 16 REMOVE FUEL TANK ASSY a Set the mission jack to the fuel tank b Remove the fue...

Page 211: ...heck valve and the gasket remove the valve by gradually pushing it upward NOTICE Work accurately to maintain the sealing performance of the check valve since it is made from resin It is easy to damage by removing and installing forcibly Be sure to install new check valve and gasket 18 REMOVE FUEL TANK PROTECTOR NO 3 a Remove the fuel tank protector No 3 by sliding as shown in the illustration 19 R...

Page 212: ...oving and installing forcibly Be sure to install new cut off valve and gasket 21 REMOVE FUEL MAIN TUBE SUPPORT 22 REMOVE FUEL TANK CUSHION NO 1 23 REMOVE FUEL TANK CUSHION NO 2 24 INSTALL FUEL TANK CUSHION NO 1 a Install new fuel tank cushions as shown in the illustration 25 INSTALL FUEL TANK CUSHION NO 2 a Install new fuel tank cushion as shown in the illustration 26 INSTALL FUEL MAIN TUBE SUPPOR...

Page 213: ...pipe until con nector makes a click sound NOTICE Check if there is any damage or foreign objects on the connected part of the pipe After connecting check if the pipe and the connector are securely connected by pulling them 31 INSTALL FUEL TANK PROTECTOR LOWER CENTER a Install the protector with the 4 bolts Torque 5 4 N m 55 kgf cm 48 in lbf 32 INSTALL PARKING BRAKE CABLE ASSY NO 3 Torque 5 4 N m 5...

Page 214: ...he vehicle compart ment by covering them with a shop rag a Remove the circuit opening relay in the engine room relay block b Start the engine After the engine has stopped on its own turn the ignition switch OFF HINT There is a case that DTC P0171 system to lean is output c Check that the engine does not start d Remove the fuel tank cap and let the air out of the fuel tank e Disconnect negative ter...

Page 215: ...ngs with spindle oil or gasoline be fore installing Never use engine gear or brake oil c Install the injector to the delivery pipe and intake manifold as shown in the illustration Before installing the injector be sure to apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O ring of the injector d Observe these precautions when disconnecting the fuel t...

Page 216: ...free to disconnect and pull it out Do not use any tool at this time 5 Inspect if there is any dirt or the likes on the seal sur face of the disconnected pipe and clean it away 6 Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag 4 CHECK FUEL LEAK a Check that there are no fuel leaks after doing maintenance anywhere on the fuel sys...

Page 217: ...its pipe HINT Part No 23801 20140 b Work for prevent gasoline from spilling out See page 11 26 c Remove the fuel pipe clamp No 1 from the fuel tube con nector d Disconnect the fuel tube connector from the fuel pipe while pinching part A with fingers as shown in the illustra tion CAUTION Perform disconnecting operations of the fuel tube connector quick type after observing the precau tions As there...

Page 218: ...t idle Fuel pressure 304 343 kPa 3 1 3 5 kgf cm2 44 50 psi m Stop the engine n Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more If pressure is not as specified check the fuel pump pressure regulator and or injectors o After checking fuel pressure disconnect the negative terminal cable from the battery and ...

Page 219: ...ing relay 2 Using a service wire connect terminals FP and B of the relay block NOTICE Pay due attention to the terminal connecting position to avoid a malfunction 3 Turn the ignition switch ON and check that the fuel pump operates NOTICE Do not start the engine c Check that there are no fuel leaks after doing mainte nance anywhere on the fuel system ...

Page 220: ...parks during the test 1 Purchase the new No 1 fuel pipe and take out the fuel tube connector from its pipe HINT Part No 23801 20140 2 Connect SST and fuel tube connector to the fuel pipe SST 09268 41047 95336 08070 CAUTION Perform connecting operations of the fuel tube connector quick type after observing the precautions 3 Install the grommet and O ring to the injector 4 Connect SST union and hose...

Page 221: ...ction volume is not as specified replace the injector c Inspect leakage 1 In the condition above disconnect the test probes of SST wire from the battery and check the fuel leakage from the injector Fuel drop 1 drop or less per 12 minutes 2 FUEL PUMP a Inspect fuel pump resistance 1 Using an ohmmeter measure the resistance be tween terminals Resistance 0 2 3 0 Ω at 20 C 68 F b Inspect fuel pump ope...

Page 222: ... O Ring Grommet Fuel Injector Assy Injector Vibration Insulator Fuel Pressure Pulsation Damper Assy Union Bolt Non reusable part N m kgf cm ft lbf Specified torque Gasket Gasket Gasket 39 398 29 43 438 32 43 438 32 43 438 32 20 199 14 12 120 9 20 199 14 33 336 24 33 336 24 10 102 7 11 34 FUEL FUEL INJECTOR ASSY 1MZ FE 1478 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL INJECTOR ASSY 1MZ FE COMPO...

Page 223: ...ake manifold 9 REMOVE FUEL INJECTOR ASSY a Disconnect the injector connectors b Remove the 2 bolts and fuel delivery pipe while pulling out both ends of the fuel delivery pipe equally c While turning the injector clockwise and counterclockwise pull out the injector from the delivery pipe 10 INSTALL FUEL INJECTOR ASSY a Apply a light coat of gasoline to a new O ring and install them to each injecto...

Page 224: ... and a bolt to the fuel pipe No 1 Torque 33 N m 336 kgf cm 24 ft lbf c Install the fuel pipe No 1 to the intake manifold with a bolt Torque 20 N m 199 kgf cm 14 ft lbf 12 INSTALL INTAKE AIR SURGE TANK See page 14 142 13 INSTALL FRONT SUSPENSION UPPER BRACE CENTER W FRONT SUSPENSION BRACE UPPER CENTER Torque 80 N m 816 kgf cm 59 ft lbf 14 INSTALL AIR CLEANER ASSEMBLY WITH HOSE See page 10 12 15 INS...

Page 225: ...ube Set Plate Fuel Suction Tube Assy W Pump Gage Fuel Pump Tube Sub assy Non reusable part N m kgf cm ft lbf Specified torque Fuel Suction Tube Set Gasket 3 5 36 31 in lbf FUEL FUEL PUMP ASSY 1MZ FE 11 37 1481 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL PUMP ASSY 1MZ FE COMPONENTS ...

Page 226: ...ender Gage Assy Fuel Suction Plate Sub assy Fuel Pump Fuel Filter Assy Fuel Pump Filter Fuel Suction Support No 2 Fuel Pressure Regulator Assy O ring Cushion Rubber Clip 11 38 FUEL FUEL PUMP ASSY 1MZ FE 1482 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 227: ...ut the fuel pump tube NOTICE Be careful of dirt like mud because the quick connec tor has an O ring to seal the pipe and the connector Do not use any tool in this work Do not bend or twist the nylon tube by force Keep off plug from foreign objects To protect the fuel tube cover it with a vinyl bag after checking 5 REMOVE FUEL TANK VENT TUBE SET PLATE a Remove the 8 bolts and fuel tank vent tube se...

Page 228: ...SSY a Unlock the sender gage and move it downward to remove 14 REMOVE FUEL PUMP HARNESS a Disconnect the connector and remove the fuel pump harness 15 INSTALL FUEL SENDER GAGE ASSY a Lock the sender gage by pushing it upward NOTICE By pushing the sender gage downward confirm that it is certainly locked 16 INSTALL FUEL PUMP FILTER a Install the fuel pump filter with a new fuel pump filter clip 17 I...

Page 229: ... scratch or foreign objects on the connecting part Check that the connector is inserted fully and secure ly Check that the clip of the tube joint is on the collar of the connector After installing the clip of the tube joint check that the connector is not pulled off 21 INSTALL REAR FLOOR SERVICE HOLE COVER a Using a new butyl tape set and install the rear floor service hole cover 22 INSPECT FUEL L...

Page 230: ...ube Set Plate Fuel Suction Tube Assy W Pump Gage Fuel Pump Tube Sub assy Non reusable part N m kgf cm ft lbf Specified torque Fuel Suction Tube Set Gasket 3 5 36 31 in lbf 11 42 FUEL FUEL TANK ASSY 1MZ FE 1486 Author Date 2002 CAMRY REPAIR MANUAL RM881U FUEL TANK ASSY 1MZ FE COMPONENTS ...

Page 231: ...ace Rear Exhaust Pipe Gasket Fuel Tank Band Sub assy No 1 LH Parking Brake Cable Assy No 3 Non reusable part N m kgf cm ft lbf Specified torque Exhaust Pipe Gasket 39 400 29 39 400 29 5 4 55 48 in lbf 5 4 55 48 in lbf 56 571 41 20 199 14 56 571 41 5 4 55 48 in lbf FUEL FUEL TANK ASSY 1MZ FE 11 43 1487 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 232: ...w Tube Fuel Tank Over Fill Check Valve Assy Location of Fuel Tank Cushion Fuel Tank Inlet Pipe Sub assy Fuel Pump Tube Sub assy Fuel Main Tube Support Check Valve Gasket Fuel Tank Breather Tube Gasket Fuel Tank Protector Sub assy No 1 5 4 55 48 in lbf 11 44 FUEL FUEL TANK ASSY 1MZ FE 1488 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 233: ...B ASSY See page 11 39 5 REMOVE FUEL TANK VENT TUBE SET PLATE See page 11 39 6 REMOVE FUEL SUCTION TUBE ASSY W PUMP GAGE See page 11 39 7 DRAIN FUEL 8 REMOVE FLOOR PANEL BRACE REAR See page 15 5 9 REMOVE EXHAUST PIPE ASSY CENTER 10 DISCONNECT PARKING BRAKE CABLE ASSY NO 2 a Remove the bolt and nut and disconnect the parking brake cable 11 DISCONNECT PARKING BRAKE CABLE ASSY NO 3 a Remove the bolt a...

Page 234: ...d the pipe are stuck pinch the tube between fingers and turn it carefully to free and then disconnect the tube 14 DISCONNECT FUEL TANK TO FILLER PIPE HOSE a Disconnect the fuel tack to filler pipe hose from the fuel tank 15 DISCONNECT FUEL TANK BREATHER HOSE a Disconnect the fuel tank breather hose from the fuel tank 16 REMOVE FUEL TANK ASSY a Set the mission jack to the fuel tank b Remove the fue...

Page 235: ...alve and the gasket remove the valve by gradually pushing it upward NOTICE Work accurately to maintain the sealing performance of the check valve since it is made from resin It is easy to damage by removing and installing forcibly Be sure to install new check valve and gasket 18 REMOVE FUEL TANK PROTECTOR NO 3 a Remove the fuel tank protector No 3 by sliding as shown in the illustration 19 REMOVE ...

Page 236: ...oving and installing forcibly Be sure to install new cut off valve and gasket 21 REMOVE FUEL MAIN TUBE SUPPORT 22 REMOVE FUEL TANK CUSHION NO 1 23 REMOVE FUEL TANK CUSHION NO 2 24 INSTALL FUEL TANK CUSHION NO 1 a Install new fuel tank cushions as shown in the illustration 25 INSTALL FUEL TANK CUSHION NO 2 a Install new fuel tank cushions as shown in the illustration 26 INSTALL FUEL MAIN TUBE SUPPO...

Page 237: ...pipe until con nector makes a click sound NOTICE Check if there is any damage or foreign objects on the connected part of the pipe After connecting check if the pipe and the connector are securely connected by pulling them 31 INSTALL FUEL TANK PROTECTOR LOWER CENTER a Install the protector with the 4 bolts Torque 5 4 N m 55 kgf cm 48 in lbf 32 INSTALL PARKING BRAKE CABLE ASSY NO 3 Torque 5 4 N m 5...

Page 238: ...rm up the A F sensor with the engine speed at 2 500 r p m for approx 2 minutes e Keep the engine speed at 2 500 r p m and confirm that the displays of A FS B1 S1 and A FS B2 S1 are as shown in the illustration CAUTION The illustration differs from the real display Only hand held tester displays the waveform of A F sensor f Confirm that the display of O2S B1 S2 changes between 0V to 1V with the eng...

Page 239: ...VSV for the EVAP 1 Connect a hand held tester to the DLC3 2 Start the engine 3 Push the hand held tester main switch ON 4 Use the ACTIVE TEST mode on the hand held tes ter to operate the VSV for the EVAP d If you have no Hand Held Tester Forced driving of the VSV for the EVAP 1 Disconnect the VSV connector for the EVAP 2 Connect the positive and negative leads from the battery to the VSV terminals...

Page 240: ...ine j Check the pressure 1 Close off the air drain hose at the marked position of the canister with a hose clipper or similar instru ment 2 Add the pressure 13 5 15 5 in Aq from the EVAP service port Pressure 2 minutes after the pressure is added the gauge should be over 7 7 8 8 in Aq HINT If you can not add pressure you can conclude that the hose connecting the VSV canister fuel tank has slipped ...

Page 241: ...VAP line hose to the charcoal canister 6 INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE a Disconnect the purge line hose and EVAP line hose from the charcoal canister b Plug the cap to the air drain hose c Pressurize 4 kPa 41 gf cm2 0 58 psi to the purge port and check that there is ventilation through the EVAP line hose HINT In the condition that the fuel is full as the float value of the fill c...

Page 242: ...B11449 EMISSION CONTROL EMISSION CONTROL SYSTEM 2AZ FE 12 5 1498 Author Date 2002 CAMRY REPAIR MANUAL RM881U 8 VISUALLY INSPECT HOSES CONNECTIONS AND GASKETS a Check for cracks leaks or damage ...

Page 243: ...he charcoal canister operation 1 Plug the vent port with the cap 2 While holding the purge port closed blow air 1 76 kPa 18 gf cm2 0 26 psi into the EVAP port and check that air flows from the air drain port 3 While holding the purge port and the air drain port closed blow air 1 76 kPa 18 gf cm2 0 26 psi into the EVAP port and check that air does not flow from the air inlet port 4 Apply vaccum 3 4...

Page 244: ...ion is not as spacified replace the charcoal canister 6 Remove the hose and cap from vent port c Inspect VSV for Pressure Swiching Valve 1 Using an ohmmeter check that there is continuity between the terminals Resistance 30 36 Ω at 20 C 68 F If there is no continuity replace the VSV 2 Using an ohmmeter check that there is no continu ity between each terminal and the body If there is continuity rep...

Page 245: ...alve air harmful 2 Blow air into the intake manifold side and check that air passes through with difficulty If operation is not as specified replace the PCV valve c Remove clean hose from the PCV valve 3 FUEL TANK CAP ASSY a Visually check if cap and or gasket are deformed or dam aged If necessary repair or replace the cap 4 VACUUM SWITCHING VALVE ASSY NO 1 a Inspect VSV for open circuit 1 Using a...

Page 246: ...attery voltage across the terminals 3 Check that air flows from port E to port F If operation is not as specified replace the VSV 5 AIR CLEANER CAP SUB ASSY a Inspect VSV for Canister Closed valve CCV 1 Using an ohmmeter check that there is continuity between the terminals Resistance 24 30 Ω at 20 C 68 F If there is no continuity replace the VSV 2 Using an ohmmeter check that there is no continu i...

Page 247: ...ecified replace the VSV 6 OXYGEN SENSOR a Using an ohmmeter measure the resistance between the terminals Resistance Terminal No Resistance 1 HT 2 B 11 16 Ω at 20 C 68 F 1 HT 4 E1 No Continuity If the resistance is not as specified replace the sensor 7 AIR FUEL RATIO SENSOR a Using an ohmmeter measure the resistance between the terminals Resistance Terminal No Resistance 1 HT 2 B 1 8 3 4 Ω at 20 C ...

Page 248: ...to display the monitor d Warm up the A F sensor with the engine speed at 2 500 r p m for approx 2 minutes e Keep the engine speed at 2 500 r p m and confirm that the displays of A FS B1 S1 and A FS B2 S1 are as shown in the illustration CAUTION The illustration differs from the real display Only hand held tester displays the waveform of A F sensor f Confirm that the display of O2S B1 S2 changes be...

Page 249: ...ng of the VSV for the EVAP 1 Connect a hand held tester to the DLC3 2 Start the engine 3 Push the hand held tester main switch ON 4 Use the ACTIVE TEST mode on the hand held tes ter to operate the VSV for the EVAP d If you have no Hand Held Tester Forced driving of the VSV for the EVAP 1 Disconnect the VSV connector for the EVAP 2 Connect the positive and negative leads from the battery to the VSV...

Page 250: ... purge line j Check the pressure 1 Close off the air drain hose at the marked position of the canister with a hose clipper or similar instru ment 2 Add the pressure 13 5 15 5 in Aq from the EVAP service port Pressure 2 minutes after the pressure is added the gauge should be over 7 7 8 8 in Aq HINT If you can not add pressure you can conclude that the hose connecting the VSV canister fuel tank has ...

Page 251: ...VAP line hose to the charcoal canister 6 INSPECT FUEL CUT OFF VALVE AND FILL CHECK VALVE a Disconnect the purge line hose and EVAP line hose from the charcoal canister b Plug the cap to the air drain hose c Pressurize 4 kPa 41 gf cm2 0 58 psi to the purge port and check that there is ventilation through the EVAP line hose HINT In the condition that the fuel is full as the float value of the fill c...

Page 252: ...P12931 EMISSION CONTROL EMISSION CONTROL SYSTEM 1MZ FE 12 15 1508 Author Date 2002 CAMRY REPAIR MANUAL RM881U 8 VISUALLY INSPECT HOSES CONNECTIONS AND GASKETS a Check for cracks leaks or damage ...

Page 253: ...the charcoal canister operation 1 Plug the vent port with the cap 2 While holding the purge port closed blow air 1 76 kPa 18 gf cm2 0 26 psi into the EVAP port and check that air flows from the air drain port 3 While holding the purge port and the air drain port closed blow air 1 76 kPa 18 gf cm2 0 26 psi into the EVAP port and check that air does not flow from the air inlet port 4 Apply vacuum 3 ...

Page 254: ...ecified replace the charcoal canister 6 Remove the hose and cap from vent port c Inspect VSV for pressure switching valve 1 Using an ohmmeter check that there is continuity between the terminals Resistance 37 44 Ω at 20 C 68 F 51 62 Ω at 120 C 248 F If there is no continuity replace the VSV 2 Using an ohmmeter check that there is no continu ity between each terminal and the body If there is contin...

Page 255: ...stances inside the valve air harmful 2 Blow air into the intake manifold side and check that air passes through with difficulty If operation is not as specified replace the PCV valve c Remove clean hose from the PCV valve 3 FUEL TANK CAP ASSY a Visually check if cap and or gasket are deformed or dam aged If necessary repair or replace the cap 4 EMISSION CONTROL VALVE SET a Inspect VSV for EVAP 1 U...

Page 256: ...the terminals 5 Check that air flows from ports E to F If operation is not as specified replace the VSV set 5 AIR CLEANER CAP SUB ASSY a Inspect VSV for Canister Closed valve CCV 1 Using an ohmmeter check that there is continuity between the terminals Resistance 25 30 Ω at 20 C 68 F If there is no continuity replace the VSV 2 Using an ohmmeter check that there is no continu ity between each termin...

Page 257: ...replace the VSV 6 OXYGEN SENSOR OXYGEN NO 2 SENSOR a Using an ohmmeter measure the resistance between the terminals Resistance Terminal No Resistance 1 HT 2 B 11 16 Ω at 20 C 68 F 1 HT 4 E1 No Continuity If the resistance is not as specified replace the sensor 7 AIR FUEL RATIO SENSOR a Using an ohmmeter measure the resistance between the terminals Resistance Terminal No Resistance 1 HT 2 B 1 8 3 4...

Page 258: ...n sensor 3 Reconnect the EGR valve position sensor connec tor b Inspect the power output voltage of the EGR valve posi tion sensor 1 Disconnect the vacuum hose from the EGR valve 2 Turn the ignition switch ON 3 Connect a voltmeter to terminals VC and E2 of the ECM and measure the power source voltage Voltage 4 5 5 5V 4 Connect a voltmeter to terminals EGLS and E2 of the ECM and measure the power o...

Page 259: ...Vacuum Pump to port S of the VCV b Plug port Z completely with fingers c Perform pumping 3 times and apply vacuum as shown in the illustration d Stop the performing pumping and check the indicated val ue of the MITYVAC after about 10 seconds Standard value 15 24 kPa 112 180 mmHg 4 4 7 1 in Hg If the indicated value is not as specified replace the VCV 3 E G R GAS TEMPERATURE SENSOR a Resistance ins...

Page 260: ...is continuity between the terminals Resistance 27 33 Ω at 20 C 68 F If there is no continuity replace the VSV b Inspect VSV for ground 1 Using an ohmmeter check that there is no continu ity between each terminal and the body If there is continuity replace the VSV c Inspect VSV operation 1 Check that air flows from port E to port G 2 Apply battery positive voltage across the terminals 3 Check that ...

Page 261: ...ct the vacuum hose from the EGR valve d Disconnect the EGR valve position sensor connector e Remove the 3 nuts EGR valve and gasket 3 REMOVE E G R GAS TEMPERATURE SENSOR 4 REPLACE EGR VALVE ASSY 5 INSTALL E G R GAS TEMPERATURE SENSOR Torque 20 N m 200 kgf cm 14 ft lbf 6 INSTALL EGR VALVE ASSY a Install a new gasket and the EGR valve with the 3 nuts Torque 12 N m 120 kgf cm 9 ft lbf b Connect the E...

Page 262: ...SION CONTROL EGR VALVE ASSY 1MZ FE 12 25 1518 Author Date 2002 CAMRY REPAIR MANUAL RM881U 7 INSTALL EGR PIPE SUB ASSY NO 2 a Install 2 new gaskets and the EGR pipe with the 4 nuts Torque 12 N m 120 kgf cm 9 ft lbf ...

Page 263: ...ct vacuum gauge to the actuator hose b Connect the hand held tester to the DLC 3 c Start the engine d Select the active test mode according to the message on the hand held tester Vacuum VSV ON Approx 27 kPa 200 mm Hg 7 9 in Hg VSV OFF 0 kPa 0 mm Hg 0 in Hg e Shift transmission into P range and control the accelera tor pedal f Check the data monitor operation according to the il lustration HINT The...

Page 264: ... to the actuator check that the actuator rod moves 2 One minute after applying the vacuum check that the actuator rod does not return 3 If the operation is not as specified replace the in take air control valve No 3 b Inspect VSV operation 1 Using an ohmmeter check that there is continuity between each terminals Resistance 37 44 Ω at 20 C 68 F 2 Check that air flows form port E to the filter 3 App...

Page 265: ...IR MANUAL RM881U 4 VACUUM SWITCHING VALVE ASSY NO 1 a Using an ohmmeter check that there is continuity be tween each terminals Resistance 33 39 Ω at 20 C 68 F b Check that air flows form port B to the filter c Apply battery voltage across the terminals d Check that air flows from port B to port A ...

Page 266: ...the vacuum hose b Remove the 4 nuts and the intake air control valve assem bly by prying a screwdriver between intake air control valve and intake air surge tank 2 INSTALL INTAKE AIR CONTROL VALVE ASSY a Apply seal packing to the intake air control valve assem bly as shown in the illustration Seal packing Part No 08226 00080 or equivalent b Install a new gasket and intake air control valve assembl...

Page 267: ...for fur ther details c When not using hand held tester 1 Using SST connect terminals 13 TC and 4 CG of DLC3 SST 09843 18040 NOTICE Be sure not to connect incorrectly It causes breakage of the engine Turn OFF all electrical systems Operate the inspection when the cooling fan motor is turned OFF 2 Remove the cylinder head cover No 2 3 Pull out the wire harness as shown in the illustration Connect th...

Page 268: ...dle speed A T 610 710 r min M T 650 750 r min NOTICE Check idle speed with cooling fan OFF Switch off all accessories and air conditioning HINT Please refer to the hand held tester operator s manual for fur ther details c When not using hand held tester 1 Using SST connect tachometer test prove to termi nal 9 TAC of DLC3 SST 09843 18040 2 Check the idle speed Idle speed A T 610 710 r min M T 650 7...

Page 269: ...increases the compression it is likely that the piston rings and or cylinder bore are worn or damaged If pressure stays low a valve may be sticking or seating improperly or there may be leakage past the gasket 10 INSPECT CO HC a Start the engine b Race engine at 2 500 r min for approx 180 seconds c Insert CO HC meter testing probe at least 40 cm 1 3 ft into tailpipe during idling d Immediately che...

Page 270: ...ntake and exhaust valves 4 Leaky cylinders Low High Rough idle Fluctuating HC reading 1 Vacuum leaks PCV hoses Intake manifold Throttle body ISC valve Brake booster line 2 Lean mixture causing misfire High High Rough idle Black smoke from exhaust 1 Restricted air filter 2 Plugged PCV valve 3 Faulty EFI systems Faulty pressure regulator Defective water temperature sensor DEFECTIVE Air flow meter Fa...

Page 271: ...e the 3 bolts and engine mounting control rod w bracket 5 REMOVE ENGINE MOUNTING STAY NO 2 RH 6 REMOVE ENGINE MOUNTING BRACKET NO 2 RH 7 REMOVE FAN AND GENERATOR V BELT a Slowly turn the drive belt tensioner clockwise in more than 3 seconds and remove the drive bolt by using SST SST 09249 63010 8 INSTALL FAN AND GENERATOR V BELT a Slowly turn the drive belt tensioner clockwise in more than 3 secon...

Page 272: ...NUAL RM881U 10 INSTALL ENGINE MOUNTING STAY NO 2 RH Torque 64 N m 653 kgf cm 47 ft lbf 11 INSTALL ENGINE MOVING CONTROL ROD W BRACKET a Install the engine mounting control rod with the 3 bolts w bracket Torque 64 N m 653 kgf cm 47 ft lbf 12 INSTALL FRONT WHEEL RH Torque 103 N m 1 050 kgf cm 76 ft lbf ...

Page 273: ...6 DISCONNECT VENTILATION HOSE NO 2 7 DISCONNECT ENGINE WIRE 8 REMOVE CYLINDER HEAD COVER SUB ASSY a Remove the bolt and disconnect the engine wire harness clamp b Remove the 8 bolts 2 nuts cylinder head cover and gas ket 9 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with the timing mark 0 of the timing chain cover b Check that the timing marks of the cams...

Page 274: ...urn the crankshaft clockwise 1 revolution 360 and set No 4 cylinder to TDC compression c Check only the valve indicated 1 Using a feeler gauge measure the clearance be tween the valve lifter and camshaft 2 Record the out of specification valve clearance measurements They will be used later to determine the required replacement adjusting shim Valve clearance Cold Intake 0 19 0 29 mm 0 0075 0 0114 i...

Page 275: ... bolt g Remove the timing chain sprocket from the camshaft with timing chain h Remove the timing chain sprocket from the timing chain i Loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustration in several passes and remove the caps j Remove the intake camshaft k Tie the timing chain with a string NOTICE Be careful not to drop anything inside the timing chain cov e...

Page 276: ...e 0 44 mm 0 0173 in 0 44 mm 0 0173 in 0 24 mm 0 0094 in 0 20 mm 0 0079 in Measured Specification Excess clearance Used shim measurement 5 30 mm 0 2087 in 0 20 mm 0 0079 in 5 30 mm 0 2087 in 5 50 mm 0 2165 in Excess clearance Used shim Ideal new shim Closest new shim 5 50 mm 0 2165 in Shim No 50 1 Select a new lifter with a thickness as close as pos sible to the calculated values HINT Lifters are a...

Page 277: ...008 5 120 0 2016 5 140 0 2024 5 160 0 2031 5 180 0 2039 5 200 0 2047 5 220 0 2055 5 240 0 2063 5 260 0 2071 5 280 0 2079 Valve Lifter Selection Chart Intake Intake valve clearance Cold 0 19 to 0 29 mm 0 008 to 0 011 in EXAMPLE The 5 250 mm 0 2067 in lifter is installed and the measured clearance is 0 400 mm 0 0157 in Replace the 5 250 mm 0 2067 in lifter with a new No 42 lifter New Lifte 1533 Auth...

Page 278: ... 203 5 200 0 204 5 220 0 205 5 240 0 206 5 260 0 207 5 280 0 207 Valve Lifter Selection Chart Exhaust Exhaust valve clearance Cold 0 30 to 0 40 mm 0 012 to 0 016 in EXAMPLE The 5 340 mm 0 2102 in lifter is installed and the measured clearance is 0 440 mm 0 0173 in Replace the 5 340 mm 0 2102 in lifter with a new No 44 lifter 1534 Author Date ...

Page 279: ...ine the front marks and numbers and tighten the bolts in the order shown in the illustration Torque Bearing cap No 1 30 N m 301 kgf cm 22 ft lbf Bearing cap No 3 9 0 N m 92 kgf cm 80 in lbf q Put the camshaft No 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets r Raising the camshaft tighten the set bolt temporarily s Examine the f...

Page 280: ...ful not to damage the valve lifter u As shown in the illustration check the matchmarks on the timing chain and camshaft timing sprockets and the align ment of the pulley groove with timing mark of the chain cover v Install chain tensioner 1 Release the ratchet pawl fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out 2 Install a new gasket and chain tension...

Page 281: ...SSY a Remove any old packing FIPG material b Apply seal packing to 2 locations as shown in the illustra tion Seal packing Part No 08826 00080 or equivalent NOTICE Remove any oil the contact surface Install the cylinder head cover within 5 minutes after applying seal packing Do not put into engine oil 2 hours after installing c Install the cylinder head cover with the 8 bolts and 2 nuts Torque 11 N...

Page 282: ... Assy Compressor and Magnetic Clutch Air Cleaner Inlet Assy Engine Under Cover RH Engine Under Cover LH Specified torque N m kgf cm ft lbf 64 653 47 64 653 47 52 531 38 21 214 15 25 250 18 52 531 38 Radiator Hose Inlet Radiator Hose Outlet Heater Inlet Water Hose Heater Outlet Water Hose ABS R B 14 14 ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 1538 Author Date 2002 CAMRY REPAIR MANUAL RM881U PAR...

Page 283: ...xhaust Pipe Gasket Exhaust Pipe No 1 Support Bracket Specified torque N m kgf cm ft lbf 15 150 11 127 1 295 94 294 3 000 217 8 82 71 in lbf 49 500 36 56 571 41 33 337 24 62 633 46 35 357 26 Non reusable part Exhaust Pipe No 1 Support Bracket Oil Cooler Hose Oil Reservoir Hose Return Tube Floor Shift Cable Transmission Control Shift M T Clutch Release Cylinder 33 337 24 ENGINE MECHANICAL PARTIAL EN...

Page 284: ...sion Member Brace Rear RH Front Frame Assy Transverse Engine Engine Mounting Bracket Vane Pump Assy Frame Side Rail Plate Sub Assy LH 95 969 70 87 888 64 95 969 70 54 551 40 43 439 31 32 326 24 32 326 24 85 867 63 85 867 63 A T 14 16 ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 1540 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 285: ...rame Assy Vane Pump Assy Engine Mounting Bracket Rear No 2 Transverse Engine Engine Mounting Bracket Frame Suspension Member Brace Rear LH 143 1 459 106 87 888 64 95 969 70 54 551 40 43 439 31 89 910 66 64 653 47 32 326 24 32 326 24 85 867 63 85 867 63 M T ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 14 17 1541 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 286: ...Automatic Transaxle Assy Front Drive Shaft Assy LH Starter Assy Specified torque N m kgf cm ft lbf Drive Shaft Bearing Bracket 64 653 47 98 1 000 72 41 418 30 46 470 34 64 650 47 44 450 32 39 398 29 Flywheel Housing Under Cover A T 14 18 ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 1542 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 287: ... cm ft lbf Engine Mounting Bracket Rear Flywheel Sub Assy Clutch Disc Assy Clutch Cover Assy Manual Transaxle Assy 64 653 47 M T 44 450 32 13 1 330 96 19 195 14 64 560 47 46 470 34 64 650 47 46 470 34 39 398 29 ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 14 19 1543 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 288: ...verter Sub assy Manifold Stay No 2 Manifold Stay 44 449 32 Manifold Converter Insulator No 1 Ventilation Hose Intake Manifold To Head Gasket Specified torque N m kgf cm ft lbf Non reusable part 30 306 12 12 122 9 37 378 27 30 306 12 9 92 80 in lbf 44 449 32 59 5 607 44 12 122 9 14 20 ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 1544 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 289: ...o 1 Knock Control Sensor Thermostat Water Inlet Oil Level Gage Guide O ring Oil Level Gage 39 398 29 15 153 11 20 208 15 9 92 80 in lbf 9 92 80 in lbf Oil Level Gage Guide 9 92 80 in lbf 9 92 80 in lbf 9 92 80 in lbf Oil Level Gage Oil Level Gage Guide Oil Level Gage Guide O ring TMMK Made Gasket Gasket ENGINE MECHANICAL PARTIAL ENGINE ASSY 2AZ FE 14 21 1545 Author Date 2002 CAMRY REPAIR MANUAL RM...

Page 290: ...raining engine oil Torque 25 N m 255 kgf cm 18 ft lbf 7 REMOVE EXHAUST PIPE ASSY FRONT 8 REMOVE ENGINE MOVING CONTROL ROD W BRACKET a Remove the 3 bolts and engine moving control rod w bracket 9 REMOVE ENGINE MOUNTING STAY NO 2 RH 10 REMOVE ENGINE MOUNTING BRACKET NO 2 RH 11 REMOVE FAN AND GENERATOR V BELT See page 14 5 12 REMOVE ENGINE COVER SUB ASSY NO 1 13 DISCONNECT ENGINE WIRE 14 REMOVE GENER...

Page 291: ... 8 bolts and 2 nuts and disconnect the cylin der head cover 20 SET NO 1 CYLINDER TO TDC COMPRESSION See page 14 7 21 REMOVE CRANKSHAFT PULLEY a Remove the crankshaft pulley TMC made 1 Using SST loosen the pulley bolt SST 09213 54015 91651 60855 09330 00021 2 Using SST remove the crankshaft pulley SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 b Remove the crankshaft pulley TMMK ma...

Page 292: ...1014 22 REMOVE CRANK POSITION SENSOR 23 REMOVE OIL PAN SUB ASSY a Remove the 12 bolts and 2 nuts b Insert the blade of SST between the crank case and oil pan cut off applied sealer and remove the oil pan SST 09032 00100 NOTICE Be careful not to damage the contact surface of the cylin der block and oil pan 24 REMOVE CHAIN TENSIONER ASSY NO 1 a Remove the 2 nuts timing chain tensioner and gasket NOT...

Page 293: ...the illustration Torque 38 N m 387 kgf cm 30 ft lbf Parts No Engine hanger No 1 12281 28010 Engine hanger No 2 12282 28010 Bolt 91512 61020 27 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR a Attach the engine chain hoist to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part b Remove the bolt and disconnect the engine mounting in sulator c Remov...

Page 294: ...ounting bracket RH 29 REMOVE TIMING CHAIN OR BELT COVER SUB ASSY a Remove the stud bolt for drive belt tensioner from the cyl inder block b Remove the 14 bolts and 2 nuts c Remove the timing chain cover with a screwdriver NOTICE Be careful not to damage the contact surfaces of timing chain cover cylinder block and cylinder head 30 REMOVE CRANKSHAFT POSITION SENSOR PLATE NO 1 31 REMOVE CHAIN TENSIO...

Page 295: ...of the oil pump drive shaft gear with the groove of the oil pump b Put a bar φ4mm in the adjusting hole of the oil pump drive shaft gear to lock in position and remove a nut c Remove the bolt chain tensioner plate and spring d Remove the chain tensioner oil pump drive shaft gear and No 2 chain 36 INSTALL NO 2 CHAIN SUB ASSY a Set the crankshaft key into the left horizontal position b Turn the cuto...

Page 296: ...and oil pump shaft e Temporarily tighten the oil pump drive shaft gear by a nut f Inset the damper spring into the adjusting hole and install the chain tensioner plate by a nut Torque 12 N m 122 kgf cm 9 ft lbf g Align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump h Put a bar φ4mm in the adjusting hole of the oil pump drive shaft gear to lock in position and as...

Page 297: ...m 92 kgf cm 80 in lbf 38 INSTALL CHAIN SUB ASSY a Set No 1 cylinder to TDC compression 1 Align the timing marks of the camshaft timing sprockets with No 1 bearing caps 2 Using the crankshaft pulley bolt turn the crankshaft and set the set key on the crankshaft upward b Align the mark link gold or orange colored link with the timing mark of the crankshaft timing gear c Using a SST install the sproc...

Page 298: ...ATE NO 1 a Install the crankshaft position sensor plate the F mark facing forward 41 INSTALL TIMING CHAIN OR BELT COVER SUB ASSY NOTICE Remove any oil from the contact surface Install the chain cover within 3 minutes after applying seal packing Do not start the engine 2 hours after installing a Remove any old packing FIPG material and be careful not to drop any oil on the contact surfaces of the t...

Page 299: ...ain cover with the 14 bolts and 2 nuts Torque Bolt A 9 0 N m 92 kgf cm 80 in lbf Bolt B 21 N m 214 kgf cm 15 ft lbf Bolt C 43 N m 438 kgf cm 32 ft lbf Nut 9 0 N m 92 kgf cm 80 in lbf e Install the stud bolt to the drive belt tensioner Torque 10 N m 102 kgf cm 7 ft lbf 42 INSTALL V RIBBED BELT TENSIONER ASSY a Install the drive belt tensioner with the bolt and nut Torque 59 5 N m 607 kgf cm 44 ft l...

Page 300: ...RH b Install the engine mounting insulator RH with the 4 nuts Torque Bolt A 95 N m 969 kgf cm 70 ft lbf Bolt B 87 N m 888 kgf cm 64 ft lbf c Install the bolt and disconnect the steering gear return hose cramp from the frame Torque 8 0 N m 80 kgf cm 69 in lbf d Install the engine mounting insulator FR with the bolt Torque 87 N m 888 kgf cm 64 in lbf e Install the engine lateral control rod with the...

Page 301: ...4 mm 0 157 in as shown in the illustration and install the oil pan Seal packing Part No 08826 00080 or equivalent c Install the oil pan with the 12 bolts and 2 nuts Torque 9 0 N m 92 kgf cm 80 in lbf 46 INSTALL CHAIN TENSIONER ASSY NO 1 See page 14 88 47 INSTALL CRANK POSITION SENSOR a Install the bolt and crankshaft position sensor Torque 9 0 N m 92 kgf cm 80 in lbf b Confirm the wire harness of ...

Page 302: ...Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook d Turn the crankshaft clockwise and check that the slipper is pushed by the plunger 49 INSTALL CYLINDER HEAD COVER SUB ASSY See page 14 88 50 INSTALL IGNITION COIL ASSY Torque 9 0 N m 92 kgf cm 80 in lbf 51 INSTALL VANE PUMP ASSY See page 51 8 52 INSTALL GENERATOR ASSY See page 19 13 53 INSTALL ENGINE WIRE 54 I...

Page 303: ...L ROD W BRACKET a Install the engine mounting control rod w bracket with 3 bolts Torque 64 N m 653 kgf cm 47 ft lbf 58 INSTALL EXHAUST PIPE ASSY FRONT See page 15 2 59 INSTALL FRONT WHEEL RH Torque 103 N m 1 050 kgf cm 76 ft lbf 60 INSTALL HOOD SUB ASSY Torque 13 N m 133 kgf cm 10 ft lbf 61 ADD ENGINE OIL 62 INSPECT OIL LEAK ...

Page 304: ...E 6 DISCONNECT VENTILATION HOSE NO 2 7 DISCONNECT ENGINE WIRE 8 REMOVE CYLINDER HEAD COVER SUB ASSY a Remove the bolt and disconnect the engine wire harness clamp b Remove the bolts 2 nuts cylinder head cover and gas ket 9 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with the timing mark 0 of the timing chain cover b Check that the timing marks of the cams...

Page 305: ... on then loosen the camshaft timing gear set blot NOTICE Be careful not to damage the valve lifter b Loosen the camshaft bearing cap bolts on No 2 camshaft in the sequence shown in the illustration in several passes and remove the caps c Raising the camshaft remove the set bolt d Remove the camshaft timing gear from the camshaft with timing chain e Remove the camshaft timing gear from the timing c...

Page 306: ...ath with 150 kpa 1 5 kgf cm2 21 psi and turn the camshaft timing gear assembly to the advance direction counterclockwise by force CAUTION Cover the paths with shop rag to avoid oil splashing HINT Depending on the air pressure the VVT timing sprocket will turn to the advance angle side without applying force by hand Also under the condition that the pressure can be hardly applied be cause of the ai...

Page 307: ...the right direction c Check that there is no clearance between the gear s fringe and the camshaft d Tighten the fringe bolt with the camshaft timing gear fixed Torque 54 N m 551 kgf cm 40 ft lbf e Check that the camshaft timing gear assembly can move to the retard angle side to the right direction and is locked at the most retarded position 15 INSTALL CAMSHAFT a Install the timing chain on the cam...

Page 308: ...numbers and tighten the bolts in the sequence shown in the illustration Torque Bearing cap No 2 30 N m 301 kgf cm 22 ft lbf Bearing cap No 3 9 0 N m 92 kgf cm 80 in lbf d Fix the camshaft with a spanner and so on then tighten the camshaft timing gear set bolt Torque 54 N m 551 kgf cm 40 ft lbf NOTICE Be careful not to damage the valve lifter e As shown in the illustration check the match marks on ...

Page 309: ...awl fully push in the plunger and ap ply the hook to the pin so that the plunger cannot spring out b Install a new gasket and chain tensioner with the 2 nuts Torque 9 0 N m 92 kgf cm 80 in lbf NOTICE When installing the tensioner set the hook again if the hook releases the plunger c Turn the crankshaft counterclockwise and disconnect the plunger knock pin from the hook d Turn the crankshaft clockw...

Page 310: ...cking Part No 08826 00080 or equivalent NOTICE Remove any oil the contact surface Install the cylinder head cover within 5 minutes after applying seal packing Do not put into engine oil 2 hours after installing c Install the cylinder head cover with the 8 bolts and 2 nuts Torque 11 N m 110 kgf cm 8 ft lbf 19 CONNECT ENGINE WIRE 20 INSTALL IGNITION COIL ASSY Torque 9 0 N m 92 kgf cm 80 in lbf 21 IN...

Page 311: ... DRAIN COOLANT See page 16 6 5 DISCONNECT RADIATOR HOSE OUTLET 6 DISCONNECT UNION TO CONNECTOR TUBE HOSE 7 DISCONNECT HEATER INLET WATER HOSE 8 DISCONNECT FUEL TUBE SUB ASSY See page 11 1 9 REMOVE INTAKE MANIFOLD a Disconnect the 2 water by pass hoses of the throttle body b Remove the 5 bolts 2 nuts intake manifold and gasket 10 DISCONNECT ENGINE WIRE 11 REMOVE INTAKE MANIFOLD INSULATOR NO 1 12 RE...

Page 312: ... manifold and gasket 14 REMOVE NO 2 CAMSHAFT a Remove the No 2 and No 3 camshaft bearing cap in the sequence shown in the illustration b Remove the No 2 camshaft 15 REMOVE CAMSHAFT a Remove the No 1 and No 3 camshaft bearing cap in the sequence shown in the illustration b Remove the No 1 camshaft 16 REMOVE CAMSHAFT BEARING NO 2 17 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY ...

Page 313: ...rs measure the length of head bolts from the seat to the end Standard bolt length 161 3 162 3 mm 6 350 6 390 in Maximum bolt length 164 2 mm 6 465 in If the length is greater than maximum replace the bolt 21 INSTALL CYLINDER HEAD GASKET a Place a new cylinder head gasket on the cylinder block surface with the Lot No stamp upward NOTICE Remove any oil from contact surface Be careful of the installa...

Page 314: ... sequence shown Torque 79 N m 806 kgf cm 58 ft lbf d Mark the front side of the cylinder head bolt with paint e Retighten the cylinder head bolts by 90 in the sequence shown f Check that the paint mark is now at a 90 angle to the front 23 INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque 9 0 N m 92 kgf cm 80 in lbf 24 INSTALL CAMSHAFT BEARING NO 2 25 INSTALL CAMSHAFT a Tighten the camshaft bea...

Page 315: ...80 in lbf 27 INSTALL EXHAUST MANIFOLD CONVERTER SUB ASSY a Install a new gasket and the exhaust manifold with the 5 nuts Torque 37 N m 378 kgf cm 27 ft lbf b Install the No 1 and No 2 exhaust manifold stay with the 3 bolts and 2 nuts Torque 44 N m 449 kgf cm 32 ft lbf 28 INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO 1 Torque 12 N m 122 kgf cm 9 ft lbf 29 INSTALL INTAKE MANIFOLD a Install a new gasket...

Page 316: ... 2002 CAMRY REPAIR MANUAL RM881U 32 ADD ENGINE OIL 33 ADD COOLANT See page 16 6 34 INSPECT OIL LEAK 35 CHECK ENGINE COOLANT LEAK See page 16 1 36 INSPECT FUEL LEAK See page 11 5 37 INSPECT CHECK IDLE SPEED AND IGNITION TIMING See page 14 1 38 INSPECT CO HC See page 14 1 ...

Page 317: ...VER SUB ASSY NO 1 4 REMOVE ENGINE MOVING CONTROL ROD W BRACKET a Remove the 3 bolts and engine moving control rod w bracket 5 REMOVE ENGINE MOUNTING STAY NO 2 RH 6 REMOVE ENGINE MOUNTING BRACKET NO 2 RH 7 REMOVE FAN AND GENERATOR V BELT See page14 5 SST 09249 63010 8 REMOVE CRANKSHAFT PULLEY a Remove the crankshaft pulley TMC made 1 Using SST loosen the pulley bolt SST 09213 54015 91651 60855 0933...

Page 318: ...4010 09955 04041 09957 04010 91111 51014 9 REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL a Using a knife cut off the oil seal lip b Using a screwdriver with taping tip pry out the oil seal HINT After the removal check if the crankshaft is not damaged If there is mend it with a sandpaper 400 10 INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL a Apply MP grease to a new oil seal lip NO...

Page 319: ...y TMMK made 1 Align the pulley set key with the key groove of the pulley 2 Using SST install the pulley bolt SST 09960 10010 09962 01000 09963 01000 Torque 170 N m 1 733 kgf cm 125 ft lbf 12 INSTALL FAN AND GENERATOR V BELT See page 14 5 SST 09249 63010 13 INSTALL ENGINE MOUNTING BRACKET NO 2 RH Torque 52 N m 531 kgf cm 38 ft lbf 14 INSTALL ENGINE MOUNTING STAY NO 2 RH Torque 64 N m 653 kgf cm 47 ...

Page 320: ...stall the transaxle assembly after removing the engine assy w transaxle 3 REMOVE DRIVE PLATE RING GEAR SUB ASSY A T TRANSAXLE a Fix the crankshaft with SST TMC made SST 09213 54015 91651 60855 09330 00021 b Fix the crankshaft with SST TMMK made SST 09960 10010 09962 01000 09963 01000 c Remove the 8 bolts rear spacer drive plate and front spacer 4 REMOVE CLUTCH COVER ASSY M T TRANSAXLE See page 42 ...

Page 321: ...he lip off foreign materials b Using SST and a hammer tap in the oil seal until its sur face is flush with the rear oil seal retainer edge SST 09223 15030 09950 70010 09951 07100 NOTICE Wipe off extra grease on the crankshaft 9 INSTALL DRIVE PLATE RING GEAR SUB ASSY A T TRANSAXLE a Fix the crankshaft with SST TMC made SST 09213 54015 91651 60855 09330 00021 b Fix the crankshaft with SST TMMK made ...

Page 322: ...olt hole c Apply Adhesive to 2 or 3 threads of the bolt end Adhesive Part No 08833 00070 THREE BOND or equivalent d Install and uniformly tighten the 8 bolts in several passes in the sequence shown Torque 130 N m 1 330 kgf cm 96 ft lbf 11 INSTALL CLUTCH DISC ASSY M T TRANSAXLE See page 42 14 12 INSTALL CLUTCH COVER ASSY M T TRANSAXLE See page 42 14 13 INSTALL AUTOMATIC TRANSAXLE ASSY A T TRANSAXLE...

Page 323: ...valve spring retainer locks SST 09202 70020 09202 00010 b Remove the parts below from the cylinder head 1 Retainer 2 Valve spring 3 Intake valve HINT Arrange the removed parts in the correct order 3 REMOVE EXHAUST VALVE a Using SST and wooden blocks compress and remove the 8 valve spring retainer locks SST 09202 70020 09202 00010 b Remove the parts below from the cylinder head 1 Retainer 2 Valve s...

Page 324: ...t manifold side 0 08 mm 0 0031 in 8 INSPECT CYLINDER HEAD FOR CRACKS a Using a dye penetrate check the intake ports exhaust ports and cylinder surface for cracks 9 INSPECT VALVE SEATS a Apply a light coat of prussian blue or white lead to the valve face b Lightly press the valve against the seat c Check the valve face and seat according to the following procedure 1 If blue appears 360 around the f...

Page 325: ...k the valve seating position 11 INSPECT CAMSHAFT THRUST CLEARANCE a Install the camshafts b Using a dial indicator measure the thrust clearance while moving the camshaft back and forth Standard thrust clearance Intake 0 040 0 095 mm 0 0016 0 0037 in Exhaust 0 080 0 135 mm 0 0032 0 0053 in Maximum thrust clearance Intake 0 11 mm 0 0043 in Exhaust 0 15 mm 0 0059 in c If the thrust clearance is great...

Page 326: ...n Exhaust No 1 journal 0 040 0 079 mm 0 00157 0 00311 in Other journals 0 025 0 062 mm 0 00098 0 00244 in Maximum oil clearance Intake No 1 journal 0 07 mm 0 0028 in Other journals 0 10 mm 0 0039 in NOTICE Completely remove the plastigage after the inspection f If the oil clearance is greater than maximum replace the camshaft If necessary replace the cylinder head g If the oil clearance on No 1 jo...

Page 327: ...aximum deviation 1 6 mm 0 063 in Maximum angle reference 2 14 INSPECT INTAKE VALVE a Check the valve overall length 1 Using vernier calipers measure the valve overall length Standard overall length 101 71 mm 4 0043in Minimum overall length 101 21 mm 3 9846in b Check the diameter of the valve stem 1 Using a micrometer measure the diameter of the valve stem Valve stem diameter 5 470 5 485 mm 0 2154 ...

Page 328: ...r of the valve stem Valve stem diameter 5 465 5 480 mm 0 2152 0 2157 in c Check the valve head margin thickness 1 Using vernier calipers measure the valve head margin thickness Standard margin thickness 1 2 1 6 mm 0 047 0 063 in Minimum margin thickness 0 5 mm 0 020 in 16 INSPECT INTAKE VALVE GUIDE BUSH a Using a caliper gauge measure the inside diameter of the guide bushing Bushing inside diamete...

Page 329: ... 030 0 065 mm 0 0012 0 0026 in Maximum oil clearance 0 10 mm 0 0039 in 18 REMOVE INTAKE VALVE GUIDE BUSH a Using SST and a hammer tap out the guide bushing SST 09201 10000 09201 01050 09950 70010 09951 07100 19 REMOVE EXHAUST VALVE GUIDE BUSH a Using SST and a hammer tap out the guide bushing SST 09201 10000 09201 01050 09950 70010 09951 07100 20 INSTALL INTAKE VALVE GUIDE BUSH a Using a caliper g...

Page 330: ...d diameter HINT STD 10 333 10 344 mm 0 4068 0 4072 in c Using SST and a hammer tap in a new guide bushing to the specified protrusion height Protrusion height 9 6 10 0 mm 0 3779 0 3937 in d Using a sharp 5 5 mm reamer ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem SST 09201 10000 09201 01050 09950 70010 09951 07100 23801 Standard oil clea...

Page 331: ...E MECHANICAL CYLINDER HEAD ASSY 2AZ FE 14 115 1639 Author Date 2002 CAMRY REPAIR MANUAL RM881U 23 INSTALL RING W HEAD PIN a Using a plastic faced hammer tap in a new ring pin to the specified protrusion height Protrusion height 3 mm 0 12 in ...

Page 332: ... A52448 14 116 ENGINE MECHANICAL CYLINDER HEAD ASSY 2AZ FE 1640 Author Date 2002 CAMRY REPAIR MANUAL RM881U 24 INSTALL STUD BOLT Torque Bolt A 5 N m 51 kgf cm 44 in lbf Bolt B 5 N m 51 kgf cm 44 in lbf Bolt C 10 N m 97 kgf cm 84 in lbf Bolt D 10 N m 97 kgf cm 84 in lbf 25 INSTALL VALVE SPRING SEAT ...

Page 333: ... Assembling the wrong one may cause a failure HINT The intake valve oil seal is gray and the exhaust valve oil seal is black b Using SST push in a the oil seal SST 09201 41020 27 INSTALL INTAKE VALVE a Install the parts below to the cylinder head 1 Intake valve 2 Spring 3 Retainer b Using SST and wooden blocks compress and install 2 valve spring retainer locks SST 09202 70020 09202 00010 c Using a...

Page 334: ...ng SST and wooden blocks compress and install 2 valve spring retainer locks SST 09202 70020 09202 00010 c Using a plastic faced hammer and the valve stem not in use tip wound with vinyl tape lightly tap the valve stem tip to ensure a proper fit NOTICE Be careful not to damage the valve stem tip 29 INSTALL VALVE LIFTER a Assemble the valve lifter and the tip of the valve stem with a light coat of e...

Page 335: ...NCE HINT The connecting rod cap bolts are tightened in 2 progressive steps a Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly HINT The matchmarks on the connecting rods and caps are for en suring correct reassembly b Using a 12 mm socket wrench remove the 2 connecting rod cap bolts c Clean the crank pin and bearing d Check the crank pin and bearing for pi...

Page 336: ...TICE Completely remove the plastigage m If replacing a bearing replace it with one having the same number as marked on the connecting rod There are 3 sizes of standard bearings marked 1 2 and 3 ac cordingly HINT Standard bearing center wall thickness Mark 1 1 485 1 488 mm 0 0585 0 0586 in Mark 2 1 488 1 491 mm 0 0586 0 0587 in Mark 3 1 491 1 494 mm 0 0587 0 0588 in 3 REMOVE PISTON SUB ASSY W CONNE...

Page 337: ...sing a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod HINT The piston and pin are a matched set Arrange the pistons pins rings connecting rods and bearings in the correct order 8 INSPECT CRANKSHAFT THRUST CLEARANCE a Using a dial indicator measure the thrust clearance while prying the crankshaft back and forth with a screwdriver Standard thrust clea...

Page 338: ...ing cap and crankshaft 10 REMOVE CRANKSHAFT THRUST WASHER UPPER 11 REMOVE CRANKSHAFT BEARING NOTICE Arrange the bearings in the correct order 12 REMOVE CRANKSHAFT BEARING NO 2 NOTICE Arrange the main bearings and thrust washers in the correct order 13 REMOVE STUD BOLT 14 INSPECT CYLINDER BLOCK FOR FLATNESS a Using a precision straight edge and feeler gauge mea sure the surface contacting the cylin...

Page 339: ...on diameter at right angles to the piston pin center line 30 3 mm 1 193 in from the piston head Piston diameter 88 439 88 449 mm 3 4818 3 4822 in 17 INSPECT PISTON CLEARANCE a Subtract the piston diameter measurement from the cylinder bore diameter measurement Standard oil clearance 0 051 0 074 mm 0 0020 0 0029 in Maximum oil clearance 0 1 mm 0 0039 in b If the clearance is greater than maximum re...

Page 340: ...0039 0 0138 in Maximum end gap No 1 0 89 mm 0 0350 in No 2 1 35 mm 0 0531 in Oil side rail 0 73 mm 0 0287 in 20 INSPECT PISTON PIN OIL CLEARANCE a Using a caliper gauge measure the inside diameter of the piston bushing Bushing inside diameter 22 001 22 010 mm 0 8662 0 8665 in HINT Bushing inside diameter Mark mm in A 22 001 22 004 0 8662 0 8663 B 22 114 22 007 0 8663 0 8664 C 22 007 22 010 0 8664 ...

Page 341: ...1 0 007 mm 0 00004 0 00028 in Maximum oil clearance 0 010 mm 0 0020 in e If the oil clearance is greater than maximum replace the connecting rod If necessary replace the piston and pis ton pin as a set f Subtract the piston pin diameter measurement form the bushing inside diameter measurement Standard oil clearance 0 005 0 011 mm 0 0002 0 0004 in Maximum oil clearance 0 010 mm 0 0020 in g If the o...

Page 342: ... 276 in b If the diameter is less than minimum replace the bolt 23 INSPECT CRANKSHAFT a Using a dial indicator and V blocks measure the circle runout as shown in the illustration Maximum circle runout 0 03 mm 0 0012 in b Using a micrometer measure the diameter of each main journal Diameter 54 988 55 000 2 1648 2 06535 in c Check each main journal for taper and out of round as shown Maximum taper a...

Page 343: ... e Check each crank pin for taper and out of round as shown Maximum taper and out of round 0 003 mm 0 0001 in 24 INSPECT CRANKSHAFT BEARING CAP SET BOLT a Using vernier calipers measure the tension portion diam eter of the bolt Standard diameter 7 5 7 6 mm 0 295 0 299 in Minimum diameter 7 2 mm 0 283 in If the diameter is less than minimum replace the bolt 25 INSTALL RING PIN a Using a plastic fac...

Page 344: ...e upper bearing with an oil groove on cylinder block c Install the lower bearing on the bearing cap sub assem bly d Place the crankshaft on the cylinder block e Lay a strip of plastigage across each journal f Examine the front marks and install the bearing caps on the cylinder block g Apply a light coat of engine oil on the threads and under the bearing cap bolts h Tighten the bolts in several pas...

Page 345: ...ge at its widest point Standard oil clearance 0 017 0 040 mm 0 0007 0 0016 in Maximum oil clearance 0 07 mm 0 0028 in NOTICE Completely remove the plastigage o If using a standard bearing replace it with one having the same number If the number of the bearing cannot be de termined select the correct bearing by adding together the numbers imprinted on the cylinder block and crank shaft then selecti...

Page 346: ...5 000 1 94528 2 16535 54 996 54 998 1 94521 2 16527 54 994 54 996 1 94514 2 16519 54 992 54 994 1 94507 2 16511 54 990 54 992 1 94500 2 16504 54 988 54 990 1 94493 2 16496 Standard bearing center wall thickness 1 2 3 4 1 993 1 996 0 07846 0 07858 1 996 1 999 0 07858 0 07870 1 999 2 002 0 07870 0 07882 2 002 2 005 0 07882 0 07894 27 INSTALL TIGHT PLUG a Apply adhesive around tight plugs Adhesive Pa...

Page 347: ...2AZ FE 14 131 1655 Author Date 2002 CAMRY REPAIR MANUAL RM881U 28 INSTALL STUD BOLT a Install the stud bolts as shown in the illustration Torque Stud bolt A 5 0 N m 51 kgf cm 44 in lbf Stud bolt B 10N m 97 kgf cm 84 in lbf Stud bolt C 5 0N m 51 kgf cm 44 in lbf 29 INSTALL STRAIGHT PIN a Using a plastic faced hammer tap into the straight pin Standard protrusion Pin A 7 5 mm 0 295 in Pin B 12 mm 0 4...

Page 348: ...n hole b Gradually hat the piston to 80 90 C 176 194 F c Align the front marks on the piston with connecting rod and push in the piston with your thumb d Using a small screwdriver install a new snap ring on the other end of the piston pin hole 31 INSTALL PISTON RING SET a Install the oil ring expander and 2 side rails by hand b Using a piston ring expander install the 2 compression rings with the ...

Page 349: ...g on bearing cap NOTICE Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats 34 INSTALL CRANKSHAFT THRUST WASHER UPPER a Install the 2 thrust washers under the No 3 journal posi tion of the cylinder block with the oil grooves facing out ward 35 INSTALL CRANKSHAFT a Apply engine oil to upper bearing and install the crank shaft on the cyli...

Page 350: ...w at a 90 angle to the front j Check the crankshaft turns smoothly 36 INSTALL CONNECTING ROD BEARING a Align the bearing claw with the groove of the connecting rod or connecting cap NOTICE Clean the back side of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats 37 INSTALL PISTON NOTICE The connecting rod cap bolts are tightened in 2 progres sive steps a App...

Page 351: ...g in the correct direction e Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts f Using a 12 mm socket wrench tighten the bolts in several passes by the specified torque Torque 25 N m 250 kgf cm 18 ft lbf g Mark the front of the connecting cap blots with paint h Retighten the cap bolts by 90 as shown in the illustration i Check that the crankshaft t...

Page 352: ...ket Floor Panel Brace Rear Exhaust Pipe Assy Center Exhaust Pipe Damper Tail Pipe Assy 56 571 41 56 571 41 19 194 14 33 337 24 62 633 46 44 450 33 A T Exhaust Pipe Gasket Exhaust Pipe Gasket 19 5 199 14 33 337 24 Exhaust Pipe No 1 Support Bracket EXHAUST EXHAUST PIPE 2AZ FE 15 1 1814 Author Date 2002 CAMRY REPAIR MANUAL RM881U EXHAUST PIPE 2AZ FE COMPONENTS ...

Page 353: ...ar 6 REMOVE EXHAUST PIPE ASSY CENTER 7 REMOVE EXHAUST PIPE DAMPER A T TRANSAXLE 8 REMOVE TAIL PIPE ASSY 9 INSTALL TAIL PIPE ASSY 10 INSTALL EXHAUST PIPE DAMPER A T TRANSAXLE a Install the exhaust pipe damper with the 2 bolts Torque 19 N m 194 kgf cm 14 ft lbf HINT Be careful not to install the damper in the wrong direction 11 INSTALL EXHAUST PIPE ASSY CENTER a Install a new gasket and the center p...

Page 354: ...O 1 SUPPORT BRACKET a Install the exhaust pipe No 1 support bracket with the 2 bolts Torque 33 N m 337 kgf cm 24 ft lbf HINT Be careful not to install the damper in the wrong direction 15 INSTALL EXHAUST PIPE NO 1 SUPPORT BRACKET Torque 33 N m 337 kgf cm 24 ft lbf 16 INSTALL OXYGEN SENSOR Torque 44 N m 450 kgf cm 33 ft lbf 17 CHECK EXHAUST GAS LEAK ...

Page 355: ...e part N m kgf cm ft lbf Specified torque Exhaust Pipe Assy Front Exhaust Pipe No 1 Support Bracket Oxygen Sensor Exhaust Pipe Gasket 56 571 41 20 199 14 44 449 32 62 633 46 44 449 32 62 633 46 56 571 41 33 337 24 Exhaust Pipe No 1 Support Bracket 33 337 24 15 4 EXHAUST EXHAUST PIPE 1MZ FE 1817 Author Date 2002 CAMRY REPAIR MANUAL RM881U EXHAUST PIPE 1MZ FE COMPONENTS ...

Page 356: ...nector b Remove the oxygen sensor 3 REMOVE EXHAUST PIPE NO 1 SUPPORT BRACKET a Remove the 2 nuts and remove the support bracket 4 REMOVE FLOOR PANEL BRACE REAR a Remove the 2 bolts and remove the floor panel brace rear 5 REMOVE EXHAUST PIPE NO 1 SUPPORT BRACKET 6 REMOVE EXHAUST PIPE ASSY FRONT 7 REMOVE EXHAUST PIPE ASSY CENTER 8 REMOVE TAIL PIPE ASSY 9 INSTALL TAIL PIPE ASSY 10 INSTALL EXHAUST PIP...

Page 357: ...m 46 ft lbf c Install a new gasket and the front pipe to the center pipe Torque 56 N m 571 kgf cm 41 ft lbf 12 INSTALL EXHAUST PIPE NO 1 SUPPORT BRACKET Torque 33 N m 337 kgf cm 24 ft lbf HINT Be careful not to install the bracket in the wrong direction 13 INSTALL FLOOR PANEL BRACE REAR Torque 20 N m 199 kgf cm 14 ft lbf 14 INSTALL EXHAUST PIPE NO 1 SUPPORT BRACKET Torque 33 N m 337 kgf cm 24 ft l...

Page 358: ...r water pump for leaks If no external leaks are found check the heater core cylinder block and head 2 CHECK ENGINE COOLANT LEVEL AT RESERVOIR a The engine coolant level should be between the LOW and FULL lines when the engine is cold If low check for leaks and add Toyota Long Life Coolant or equivalent up to the FULL line 3 CHECK ENGINE COOLANT QUALITY a Remove the radiator cap CAUTION To avoid th...

Page 359: ...183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 10 mm 0 394 in or more at 95 C 203 F If the valve lift is not as specified replace the thermostat d Check that the valve is fully closed when the thermostat is at low temperatures below 77 C 171 F If not closed replace the thermostat 2 RADIATOR CAP SUB ASSY NOTICE If the reservoir ca...

Page 360: ...ming from the vacuum valve replace the reservoir cap b Pump the tester and measure the relief valve opening pressure Pump speed 1 push within 1 second NOTICE This pump speed is for the first pump only in order to close the vacuum valve After this the pump speed can be re duced Standard opening pressure 93 122 kPa 0 95 1 25 kgf cm2 13 4 17 6 psi Minimum opening pressure 78 kPa 0 8 kgf cm2 11 2 psi ...

Page 361: ... water temperature sensor connector d Check that the cooling fan rotates If not check the fuses cooling fan relay engine ECU and cooling fan and check for a short circuit between the cooling fan relay and water temperature sensor e Reconnect the water temperature sensor connector 2 CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE Above 98 C 208 F a Start the engine and raise coolant temperature t...

Page 362: ... ohmmeter check that there is continuity between terminals 3 and 5 If there is no continuity replace the relay 2 COOLING FAN RELAY NO 2 a Inspect the cooling fan relay continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Using an ohmmeter check that there is continuity between terminals 3 and 4 If there is no continui...

Page 363: ...s 5 4 lmp qts HINT Press the radiator inlet and outlet hose several times with hard If the coolant level gets lower pour coolant Use of improper coolants may damage engine cooling system Use Toyota Long Life Coolant or equivalent and mix it with plain water according to the manufactur er s directions Using of coolant with includes more than 50 freezing protection down to 35 C 31 F or 60 freezing p...

Page 364: ... cap i Warm up the engine until the thermostat valve begins to open HINT Press the radiator inlet and outlet hose several times with hand during the warming up j Stop the engine and wait until the coolant temp gets cold Pour the coolant if the coolant level is lower k Install the radiator cap and check the radiator reservoir tank coolant level 3 INSPECT CHECK ENGINE COOLANT LEAK a Fill the radiato...

Page 365: ...olts and pump pulley SST 09960 10010 09962 01000 09963 00700 b Disconnect the crankshaft position sensor wire harness clamp 5 REMOVE WATER PUMP ASSY a Remove 4 bolts 2 nuts bracket and water pump 6 INSTALL WATER PUMP ASSY a Remove any old packing FIPG material from the contact surface b Apply seal packing to the water pump as shown in the il lustration Seal packing Part No 08826 00080 or equivalen...

Page 366: ...f d Connect the crankshaft position sensor wire harness clamp 7 INSTALL WATER PUMP PULLEY a Using SST install the pump pulley with 4 bolts SST 09960 10010 09962 01000 09963 00700 Torque 26 N m 265 kgf cm 19 ft lbf 8 INSTALL GENERATOR ASSY See page 19 13 9 INSTALL FAN AND GENERATOR V BELT See page 14 5 SST 09249 63010 10 ADD COOLANT See page 16 6 11 INSPECT CHECK ENGINE COOLANT LEAK See page 16 1 ...

Page 367: ...R PUMP ASSY 2AZ FE 1829 Author Date 2002 CAMRY REPAIR MANUAL RM881U INSPECTION 1 INSPECT WATER PUMP ASSY a Visually check the drain hole coolant leakage b Turn the pulley and check that the water pump bearing moves smoothly and quietly ...

Page 368: ...water inlet from the cylinder block 3 REMOVE THERMOSTAT 4 INSTALL THERMOSTAT a Install a new gasket to the thermostat b Install the thermostat with the jiggle valve upward HINT The jiggle valve may be set within 10 on either side of the pre scribed position 5 INSTALL WATER INLET a Install the water inlet with 2 nuts Torque 9 N m 92 kgf cm 80 in lbf 6 ADD COOLANT See page 16 6 7 INSPECT CHECK ENGIN...

Page 369: ...RADIATOR HOSE INLET 3 DISCONNECT RADIATOR HOSE OUTLET 4 DISCONNECT OIL COOLER INLET HOSE A T TRANSAXLE 5 DISCONNECT OIL COOLER OUTLET HOSE A T TRANSAXLE 6 REMOVE AIR CLEANER INLET ASSY a Remove the 2 bolts and the air cleaner inlet 7 REMOVE RADIATOR SUPPORT UPPER a Disconnect the 2 horn connector b Remove the hood lock release lever cover c Remove the bolt shown in the illustration d Remove the 4 ...

Page 370: ...ION 10 REMOVE RADIATOR SUPPORT LOWER 11 REMOVE FAN ASSY W MOTOR 12 INSTALL FAN ASSY W MOTOR a Install the fan assy w motor to the radiator Torque 5 0N m 51 kgf cm 44 in lbf 13 INSTALL RADIATOR SUPPORT UPPER a Install the radiator support upper with the 4 bolts Torque 14 N m 142 kgf cm 10 ft lbf 14 ADJUST HOOD SUB ASSY See page 16 6 15 ADD COOLANT See page 16 6 16 CHECK ENGINE COOLANT LEAK See page...

Page 371: ...or water pump for leaks If no external leaks are found check the heater core cylinder block and head 2 CHECK ENGINE COOLANT LEVEL AT RESERVOIR a The engine coolant level should be between the LOW and FULL lines when the engine is cold If low check for leaks and add Toyota Long Life Coolant or equivalent up to the FULL line 3 CHECK ENGINE COOLANT QUALITY a Remove the radiator cap CAUTION To avoid t...

Page 372: ...specified replace the thermostat c Check the valve lift Valve lift 10 mm 0 394 in or more at 95 C 203 F If the valve lift is not as specified replace the thermostat d Check that the valve is fully closed when the thermostat is at low temperatures below 77 C 171 F If not closed replace the thermostat 2 WATER OUTLET CAP SUB ASSY NOTICE If the reservoir cap has contaminations always rinse it with wat...

Page 373: ...ing from the vacuum valve replace the reservoir cap b Pump the tester and measure the relief valve opening pressure Pump speed 1 push within 1 second NOTICE This pump speed is for the first pump only in order to close the vacuum valve After this the pump speed can be re duced Standard opening pressure 83 4 112 8 kPa 0 85 1 15 kgf cm2 12 1 16 4 psi Minimum opening pressure 69 kPa 0 7 kgf cm2 10 0 p...

Page 374: ... on the water temperature switch No 1 connector e Check that the No 1 cooling fan rotates at high speed If not check the No 1 cooling fan relay and No 1 cooling fan f Reconnect the water temperature switch No 1 connector g Disconnect the water temperature switch No 2 connector h Ground terminal on the water temperature switch No 2 wire harness side connector i Check that the No 1 and No 2 cooling ...

Page 375: ... continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Using an ohmmeter check that there is continuity between terminals 3 and 4 If there is no continuity replace the relay 3 Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay 4 Apply battery voltage across terminals 1 ...

Page 376: ...TCH NO 2 a Using an ohmmeter check that there is continuity be tween the terminals when the coolant temperature is above 93 C 199 F If there is no continuity replace the switch b Check that there is no continuity between terminals when the coolant temperature is below 83 C 181 F If there is continuity replace the switch ...

Page 377: ...em with coolant HINT Use of improper coolants may damage engine cooling system Use Toyota Long Life Coolant or equivalent and mix it with plain water according to the manufactur er s directions Using of coolant with includes more than 50 freezing protection down to 35 C 31 F or 60 freezing protection down to 50 C 58 F of ethylene glycol is recommended but not more than 70 NOTICE Do not use an alco...

Page 378: ... RH See page 14 155 8 REMOVE GENERATOR BRACKET NO 2 9 REMOVE CRANKSHAFT PULLEY See page 14 206 SST 09213 54015 91651 60855 09330 00021 09950 50013 09951 05010 09952 05010 09953 05010 09954 05030 10 REMOVE TIMING BELT NO 1 COVER 11 REMOVE TIMING BELT NO 2 COVER See page 14 206 12 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET 13 REMOVE TIMING BELT GUIDE NO 2 14 REMOVE TIMING BELT See page 14 243 ...

Page 379: ...2 ft lbf 23 INSPECT TIMING BELT See page 14 206 24 INSTALL TIMING BELT See page 14 243 SST 09960 10010 09962 01000 09963 01000 25 INSTALL CHAIN TENSIONER ASSY NO 1 See page 14 206 26 INSTALL TIMING BELT GUIDE NO 2 See page 14 206 27 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Torque 28 N m 286 kgf cm 21 ft lbf 28 INSTALL TIMING BELT NO 2 COVER See page 14 206 29 INSTALL TIMING BELT NO 1 COVE...

Page 380: ...U 35 INSTALL V COOLER COMPRESSOR TO CRANKSHAFT PULLEY BELT NO 1 See page 14 140 36 INSPECT DRIVE BELT DEFLECTION AND TENSION REFERENCE See page 14 136 37 ADD COOLANT See page 16 20 38 CHECK ENGINE COOLANT LEAK See page 16 20 39 INSTALL FRONT WHEEL RH Torque 103 N m 1051 kgf cm 76 ft lbf ...

Page 381: ...PUMP ASSY 1MZ FE 1843 Author Date 2002 CAMRY REPAIR MANUAL RM881U INSPECTION 1 INSPECT WATER PUMP ASSY a Visually check the drain hole for coolant leakage b Turn the pulley and check that the water pump bearing moves smoothly and quietly ...

Page 382: ...ALL THERMOSTAT a Install a new gasket to the thermostat b Align the thermostat jiggle valve with the upper stud bolt and insert the thermostat in the water inlet housing HINT The jiggle valve may be set within 15 of either side of the pre scribed position 12 INSTALL WATER INLET Torque 8 N m 82 kgf cm 71 in lbf 13 INSTALL WATER INLET PIPE a Install a new O ring to the water inlet pipe b Apply soapy...

Page 383: ...CT RADIATOR HOSE INLET 3 DISCONNECT RADIATOR HOSE OUTLET 4 DISCONNECT OIL COOLER INLET HOSE 5 DISCONNECT OIL COOLER OUTLET HOSE 6 REMOVE AIR CLEANER INLET ASSY a Remove the 3 bolts the air cleaner inlet and air cleaner inlet No 1 7 REMOVE RADIATOR SUPPORT UPPER a Disconnect the 2 horn connector b Remove the hood lock release lever cover c Remove the bolt shown in the illustration d Remove the 4 bo...

Page 384: ...N 10 REMOVE RADIATOR SUPPORT LOWER 11 REMOVE FAN ASSY W MOTOR 12 INSTALL FAN ASSY W MOTOR a Install the fan assy w motor to the radiator Torque 5 0 N m 51 kgf cm 44 in lbf 13 INSTALL RADIATOR SUPPORT UPPER a Install the radiator support upper with the 4 bolts Torque 14 N m 142 kgf cm 10 ft lbf 14 ADJUST HOOD SUB ASSY See page 75 1 15 ADD COOLANT See page 16 20 16 CHECK ENGINE COOLANT LEAK See page...

Page 385: ... and full level marks of the dipstick If low check for leakage and add oil up to the full level mark NOTICE Do not fill with engine oil above the full level mark 2 CHECK ENGINE OIL QUALITY a Check the oil for deterioration entry of water discoloring or thinning If the quality is visibly poor replace the oil Oil grade API grade SJ or SL Energy Conserving or ILSAC multigrade engine oil is recommende...

Page 386: ...0 rpm 245 539 kPa 2 5 5 5 kgf cm2 36 78 psi or more 7 INSTALL OIL PRESSURE SWITCH a Remove the oil pressure gauge b Apply adhesive to 2 or 3 threads of the oil pressure switch Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Install the oil pressure switch Torque 15 N m 152 kgf cm 11 ft lbf d Connect the oil pressure switch connector 8 START ENGINE AND CHECK FOR LEAKS ...

Page 387: ...NUAL RM881U OIL PUMP ASSY 2AZ FE REPLACEMENT 1 REMOVE CHAIN SUB ASSY See page 14 74 2 REMOVE OIL PUMP ASSY a Remove 3 bolts and oil pump assembly 3 INSTALL OIL PUMP ASSY a Place a new gasket on the cylinder block b Install the oil pump assembly with 3 bolts Torque 19 N m 194 kgf cm 14 ft lbf ...

Page 388: ...e 2 nuts and oil pump strainer b Remove oil pump relief valve 1 Using a socket wrench 27mm remove the relief valve plug 2 Remove the oil pump relief valve spring and oil pump relief valve c Inspect oil pump relief valve 1 Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight d Remove the oil pump cover 1 Remove 5 bolts and oil pump body cover ...

Page 389: ...a feeler gauge measure the clearance be tween the drive and driven rotor tips Standard tip clearance 0 080 0 160 mm 0 0031 0 0063 in Maximum tip clearance 0 35 mm 0 0138 in g Inspect rotor body clearance 1 Using a feeler gauge measure the clearance be tween the driven rotor and body Standard body clearance 0 100 0 170 mm 0 00394 0 00669 in Maximum body clearance 0 325 mm 0 01280 in h Remove the oi...

Page 390: ...orque 8 8 N m 90 kgf cm 78 in lbf k Install oil pump relief valve 1 Coat the oil pump relief valve with engine oil 2 Insert the relief valve and spring into the pump body hole 3 Using a socket wrench 27mm install the relief valve plug l Install oil pump strainer 1 Place a new gasket on the oil pump 2 Install the oil pump strainer with 2 nuts Torque 8 8 N m 90 kgf cm 78 in lbf ...

Page 391: ... oil and used oil filter must be disposed of only at designated disposal sites 1 DRAIN ENGINE OIL a Remove the oil filler cap b Remove the oil drain plug and drain the oil into a container 2 REMOVE OIL FILTER SUB ASSY a Using SST remove the oil filter SST 09228 06501 3 INSTALL OIL FILTER SUB ASSY a Check and clean the oil filter installation surface b Apply clean engine oil to the gasket of a new ...

Page 392: ... and full level marks of the dipstick If low check for leakage and add oil up to the full level mark NOTICE Do not fill with engine oil above the full level mark 2 CHECK ENGINE OIL QUALITY a Check the oil for deterioration entry of water discoloring or thinning If the quality is visibly poor replace the oil Oil grade API grade SJ or SL Energy Conserving or ILSAC multigrade engine oil is recommende...

Page 393: ...3 000 rpm 294 539 kPa 3 0 5 5 kgf cm2 43 78 psi 7 INSTALL OIL PRESSURE SWITCH a Remove the oil pressure gauge b Apply adhesive to 2 or 3 threads of the oil pressure switch Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Install the oil pressure switch Torque 15 N m 152 kgf cm 11 ft lbf d Connect the oil pressure switch connector 8 START ENGINE AND CHECK FOR LEAKS ...

Page 394: ... See page 14 140 7 REMOVE VANE PUMP V BELT See page 14 140 8 REMOVE ENGINE MOVING CONTROL ROD See page 14 155 9 REMOVE ENGINE MOUNTING STAY NO 2 RH See page 14 155 10 REMOVE GENERATOR BRACKET NO 2 11 REMOVE CRANKSHAFT PULLEY See page 14 206 SST 09213 54015 91651 60855 09330 00021 09950 50013 09951 05010 09952 05010 09953 05010 09954 05030 12 REMOVE TIMING BELT NO 1 COVER 13 REMOVE TIMING BELT NO 2...

Page 395: ...e harness cramp d Remove the 3 bolts the compressor and magnetic clutch HINT Hung up the hoses instead of detaching 21 REMOVE TIMING BELT IDLER SUB ASSY NO 2 See page 16 21 22 REMOVE CAMSHAFT TIMING PULLEY See page 14 212 SST 09960 10010 09962 01000 09963 01000 09249 63010 23 REMOVE TIMING BELT IDLER SUB ASSY NO 1 a Using a 10mm socket hexagon wrench remove the timing belt idler sub assembly No 1 ...

Page 396: ...GINE ENGINE MOUNTING INSULATOR a Remove the 3 nuts and a bolt and separate the engine mounting insulator front 29 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR a Remove the bolt and disconnect the power steering re turn hose cramp from the frame b Remove the 4 nuts c Place a wooden block between the jack and engine and set the jack then remove the engine mounting insulator d Handle a jack up ...

Page 397: ...RACKET a Remove the 4 bolts nut and bracket 31 REMOVE OIL PAN SUB ASSY NO 2 a Remove the 10 bolts and 2 nuts b Using SST remove the oil pan No 2 SST 09032 00100 NOTICE Be careful not to damage the oil pan No 2 flange 32 REMOVE OIL STRAINER SUB ASSY a Remove the bolt 2 nuts and oil strainer sub assembly 33 REMOVE OIL PAN SUB ASSY a Remove the 17 bolts and 2 nuts ...

Page 398: ...ION SENSOR a Disconnect the crank position sensor connector b Remove the bolt and crank position sensor 35 REMOVE OIL PUMP ASSY a Remove the 9 bolts O ring and oil pump 36 INSTALL OIL PUMP ASSY a Using SST and a hammer tap in a new oil seal until its sur face is flush with the oil pump body edge SST 09223 00010 NOTICE Be careful not to tap the oil seal slantingly b Apply a small amount of MP greas...

Page 399: ...minutes after applying seal packing Do not put into engine oil within 2 hours after instal ling f Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft and slide the oil pump on the crankshaft g Install the oil pump with the 9 bolts Uniformly tighten the bolts in several passes Torque 10 mm head 8 N m 82 kgf cm 71 in lbf 12 mm head 20 N m 199 kgf cm 14 ft lbf 14...

Page 400: ...n within 3 minutes after applying seal packing Do not put into engine oil within 2 hours after instal ling b Install the oil pan with the 17 bolts and 2 nuts Torque 10 mm head 8 N m 82 kgf cm 71 in lbf 12 mm head 20 N m 199 kgf cm 14 ft lbf 39 INSTALL OIL STRAINER SUB ASSY a Install a new gasket and the oil strainer with the bolt and 2 nuts Torque 8 N m 82 kgf cm 71 in lbf 40 INSTALL OIL PAN SUB A...

Page 401: ...INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque Nut A 95 N m 969 kgf cm 70 ft lbf Nut B 87 N m 887 kgf cm 64 ft lbf 43 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR Torque Bolt A 87 N m 887 kgf cm 64 ft lbf Nut B 52 N m 531 kgf cm 38 ft lbf 44 INSTALL OIL LEVEL GAGE GUIDE a Install a new O ring bolt and oil level gage guide Torque 8 N m 82 kgf cm 71 in lbf 45 INSTALL COMPRESSOR MO...

Page 402: ...UPPORT BRACKET See page 15 5 54 INSPECT TIMING BELT See page 14 206 55 INSTALL TIMING BELT See page 14 243 SST 09960 10010 09962 01000 09963 01000 56 INSTALL CHAIN TENSIONER ASSY NO 1 See page 14 206 57 INSTALL TIMING BELT GUIDE NO 2 58 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET 59 INSTALL TIMING BELT NO 2 COVER See page 14 206 60 INSTALL TIMING BELT NO 1 COVER 61 INSTALL CRANKSHAFT PULLEY ...

Page 403: ... REPAIR MANUAL RM881U 68 INSTALL FRONT SUSPENSION UPPER BRACE CENTER W FRONT SUSPENSION BRACE UPPER CENTER Torque 80 N m 816 kgf cm 59 ft lbf 69 ADD ENGINE OIL 70 INSPECT OIL LEAK 71 INSTALL FRONT WHEEL RH Torque 103 N m 1 051 kgf cm 76 ft lbf 72 CHECK EXHAUST GAS LEAK ...

Page 404: ...t NOTICE Do not change the combination and install direction of the two rotors c Inspect oil pump rotor set 1 Apply a light coat of engine oil to the oil pump rotor set and place them into the oil pump body Check that the rotors revolve smoothly d Inspect rotor tip clearance 1 Using a feeler gauge measure the clearance be tween the drive and driven rotor tips Standard tip clearance 0 11 0 24 mm 0 ...

Page 405: ...ide clearance 0 15 mm 0 0059 in g Install oil pump rotor set 1 Apply a light coat of engine oil to the oil pump gear set and place it into pump body with the marks fac ing the pump body cover side h Install oil pump cover 1 Install the 10 screws and oil pump cover Torque 10 N m 105 kgf cm 8 ft lbf 4 INSTALL OIL PUMP RELIEF VALVE a Apply a light coat of engine oil to the relief valve and insert the...

Page 406: ... the oil filter installation surface b Apply clean engine oil to the gasket of a new oil filter c Lightly screw the oil filter into place and tighten it until the gasket contacts the seat d Using SST tighten it an additional 3 4 turn SST 09228 07501 4 ADD ENGINE OIL a Add new oil Oil capacity Drain and refill w oil filter change 4 7 liters 5 0 US qts 4 1 lmp qts Drain and refill w o oil filter cha...

Page 407: ...ove the cylinder head cover No 2 2 Remove the ignition coils with igniter 3 Using a 16 mm 0 63 in plug wrench remove the all spark plugs 4 Install the spark plugs to each ignition coils with igniter and connect the ignition coil connectors 5 Disconnect the all injector connectors 6 Ground the spark plugs 7 Check if spark occurs while engine is being cranked NOTICE Be sure to ground the spark plug ...

Page 408: ... NOTICE This engine is fitted with irridium tipped spark plugs Never attempt to adjust the electrode gap Do not scratch the irridium and platinum tip between electrode gap 2 CAMSHAFT POSITION SENSOR a Using an ohmmeter measure the resistance between terminals RESISTANCE at cold 835 1 400 Ω at hot 1 060 1 645 Ω NOTICE Cold and Hot on the table express the temperature of the coils themselves Cold is...

Page 409: ...s 1 Remove the intake air surge tank See page 14 142 2 Remove the ignition coils 3 Using a 16 mm 0 63 in plug wrench remove the all spark plugs 4 Install the spark plugs to each ignition coils and connect the ignition coil connectors 5 Disconnect the all injector connectors 6 Ground the spark plugs 7 Check if spark occurs while engine is being cranked NOTICE Be sure to ground the spark plug when c...

Page 410: ...NOTICE This engine is fitted with irridium tipped spark plugs Never attempt to adjust the electrode gap Do not scratch the irridium and platinum tip between electrode gap 2 CAMSHAFT POSITION SENSOR a Using an ohmmeter measure the resistance between terminals RESISTANCE at cold 835 1 400 Ω at hot 1 060 1 645 Ω NOTICE Cold and Hot on the table express the temperature of the coils themselves Cold is ...

Page 411: ... the coil a Disconnect the field coil lead wire from terminal C b Connect the battery to the magnetic switch as shown Check that the clutch pinion gear moves outward c With battery connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Check that the pinion gear remains out d Disconnect the negative lead from the switch body Check that the clutch pinion gea...

Page 412: ...nt Specified current 90 A or less at 11 5 V 2 STARTER RELAY ASSY a Inspect the relay continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay b Inspect the relay operation 1 Apply battery positive voltage across terminals ...

Page 413: ...IR CLEANER BRACKET 4 REMOVE AIR CLEANER INLET ASSY 5 REMOVE STARTER ASSY a Disconnect the starter connector b Remove the nut and disconnect the terminal 30 c Remove 2 bolts and starter 6 INSTALL STARTER ASSY Torque Bolt 39 N m 398 kgf cm 29 ft lbf Terminal 30 13 N m 130 kgf cm 9 ft lbf 7 INSTALL AIR CLEANER INLET ASSY 8 INSTALL AIR CLEANER BRACKET 9 INSTALL AIR CLEANER ASSY 10 INSTALL BATTERY ...

Page 414: ...arter Yoke Assy Starter Armature Assy Repair Servise Starter Kit N m kgf cm ft lbf Specified torque 6 0 61 53 in lbf 6 5 66 58 in lbf 7 5 77 66 in lbf 19 4 STARTING CHARGING STARTER ASSY 2AZ FE 1876 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 415: ...er kit b Remove the 2 screws holding the repair service starter kit to the starter housing c Remove the repair service starter kit d Remove the return spring and plunger 2 REMOVE STARTER COMMUTATOR END FRAME ASSY a Using a screwdriver remove the starter commutator end frame cover b Using snap ring pliers remove the snap ring and plate washer c Remove the 2 through bolts and pull out the starter yo...

Page 416: ... ohmmeter check that there is no continu ity between the commutator and armature coil core If there is continuity replace the armature c Check the commutator for dirty and burn on surface If the surface is dirty or burnt correct it with sandpaper No 400 or a lathe d Check for the commutator circuit runout 1 Place the commutator on V blocks 2 Using a dial indicator measure the circle runout Standar...

Page 417: ... continu ity between the positive and negative brush holders If the there is continuity repair or replace the starter commutator end frame assy 6 INSPECT REPAIR SERVICE STARTER KIT a Check the plunger 1 Push in the plunger and check that it returns quickly to its original position If necessary replace the repair service starter kit b Check the pull in coil for open circuit 1 Using an ohmmeter chec...

Page 418: ...late washer and new snap ring d Using vernier calipers mesure the snap ring Maximum length 5 0 mm 0 197 in If the length is greater than maximum replace the new snap ring 8 INSTALL STARTER COMMUTATOR END FRAME ASSY a Align the starter commutator rubber end frame with the cutout of starter yoke b Install starter yoke assy to starter commutator end frame c Align the starer yoke assy with the cutout ...

Page 419: ...ER KIT a Apply grease to the plunger and hook b Hang the plunger hook of the repair service starter kit to the drive lever c Install the plunger and return spring d Install the repair service starter kit with the 2 screws Torque 7 5 N m 77 kgf cm 66 in lbf e Apply grease to the nut of the lead wire f Connect the lead wire to the terminal with the nut Torque 6 5 N m 66 kgf cm 58 in lbf ...

Page 420: ... terminals b Disconnect the battery cables when the battery is given a quick charge c Do not perform tests with a high voltage insulation resistance tester d Never disconnect the battery while the engine is running e Check that the charging cable is tightened on terminal B of the alternator and the fuse box f Do not check whether the alternator generators or not with connecting terminal F to the o...

Page 421: ... the electrical sys tems c Measure the battery voltage between the negative and positive terminals of the battery Standard voltage 12 5 12 9 V at 20 C 68 F If the voltage is less than specification charge the battery d Check the indicator as shown in the illustration HINT Blue OK White Charging Necessary Red Insufficient Water 3 CHECK BATTERY TERMINALS FUSIBLE LINK AND FUSES a Check that the batte...

Page 422: ...battery alternator tester is available connect the tester to the charging circuit as per manufacturer s instructions a If a tester is not available connect a voltmeter to the charging circuit as follows 1 Disconnect the wire from terminal B of the alterna tor and connect it to the negative tester probe of the ammeter 2 Connect the positive tester probe of the amme ter to terminal B of the alternat...

Page 423: ...lustration b Remove 2 bolts and alternator assembly 3 INSTALL GENERATOR ASSY a Confirm the wire harness of the crank position sensor is placed as shown in the illustration b Install the alternator assembly Torque M8 21 N m 214 kgf cm 15 ft lbf M10 52 N m 530 kgf cm 38 ft lbf Wiring harness clamp 8 4 N m 85 kgf cm 74 in lbf Alternator wire 9 8 N m 100 kgf cm 7 ft lbf NOTICE Be careful not to put th...

Page 424: ...sher Rectifier End Frame Voltage Regulator Brush Holder Cover Brush Holder Rear End Cover N m kgf cm ft lbf Specified torque 111 1 125 81 Rectifier Holder 19 14 STARTING CHARGING GENERATOR ASSY 2AZ FE 1886 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 425: ...SST 1 B clockwise to the specified torque Torque 39 N m 400 kgf cm 29 ft lbf NOTICE Check that SST is secured to the rotor shaft b Mount SST 2 in a vise c Insert SST 1 A B into SST 2 and attach the pulley nut to SST 2 d To loosen the pulley nut turn SST 1 A in the direction shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a tu...

Page 426: ...rews and rectifier holder 5 REMOVE ALTERNATOR RECTIFIRE END FRAME a Remove the rubber insulator b Remove the seal plate c Remove the 4 nuts d Using bearing puller set remove the rectifier end frame 6 REMOVE GENERATOR ROTOR ASSY a Remove the alternator washer from the rotor b Remove the rotor from drive end frame NOTICE Do not drop the rotor 7 INSPECT GENERATOR REGULATOR ASSY a Using an ohmmeter ch...

Page 427: ...ontinuity between the slip rings Standard resistance 2 7 3 1 Ω at 20 C 68 F If there is no continuity replace the rotor b Inspect rotor for ground 1 Using an ohmmeter check that there is no continu ity between the slip ring and rotor If there is continuity replace the rotor c Inspect slip rings 1 Using vernier calipers measure the slip ring diame ter Standard diameter 14 2 14 4 mm 0 559 0 567 in M...

Page 428: ...RATOR ROTOR ASSY a Install the generator rotor b Install the alternator washer to the rotor 12 INSTALL ALTERNATOR RECTIFIRE END FRAME a Using a 17 mm socket wrench and press slowly press in the rectifier end frame b Install the cord clip and 4 nuts Torque Nut A 4 5 N m 46 kgf cm 39 in lbf Nut B 5 4 N m 55 kgf cm 47 in lbf c Install the seal plate on the rectifier end frame d Install the 4 rubber i...

Page 429: ...all the brush cover c Install the end cover and plate terminal with the bolt and 3 nuts Torque Nut 4 4 N m 45 kgf cm 39 in lbf Bolt 3 9 N m 39 kgf cm 35 in lbf d Install the terminal insulator with the nut Torque 4 1 N m 42 kgf cm 36 in lbf 16 INSTALL GENERATOR PULLEY SST 09820 63010 09820 06010 09820 06020 HINT SST1 A B 09820 06010 SST2 09820 06020 a Install the pulley to the rotor shaft by tight...

Page 430: ...t SST 2 in a vise d Insert SST 1 A B into SST 2 and attach the pulley nut to SST 2 e Tighten the pulley nut turn SST 1 A in the direction shown in the illustration Torque 111 N m 1 125 kgf cm 81 ft lbf f Remove the alternator form SST 2 g Turn SST 1 B and remove SST 1 A B h Turn the pulley and check that the pulley moves smooth ly ...

Page 431: ... the coil a Disconnect the field coil lead wire from terminal C b Connect the battery to the magnetic switch as shown Check that the clutch pinion gear moves outward c With battery connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Check that the pinion gear remains out d Disconnect the negative lead from the switch body Check that the clutch pinion gea...

Page 432: ...nt Specified current 90 A or less at 11 5 V 2 STARTER RELAY ASSY a Inspect the relay continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay b Inspect the relay operation 1 Apply battery positive voltage across terminals ...

Page 433: ... 3 REMOVE AIR CLEANER ASSEMBLY WITH HOSE 4 REMOVE AIR CLEANER BRACKET 5 REMOVE AIR CLEANER INLET NO 1 6 REMOVE STARTER ASSY a Disconnect the starter connector b Remove the nut and disconnect the lead wire from termi nal 30 c Remove the 2 bolts and starter 7 INSTALL STARTER ASSY Torque Bolt 42 N m 429 kgf cm 31 ft lbf Nut 9 8 N m 100 kgf cm 7 ft lbf 8 INSTALL AIR CLEANER ASSEMBLY WITH HOSE ...

Page 434: ...arter Yoke Assy Starter Armature Assy Repair Servise Starter Kit N m kgf cm ft lbf Specified torque 6 0 61 53 in lbf 6 5 66 58 in lbf 7 5 77 66 in lbf 19 24 STARTING CHARGING STARTER ASSY 1MZ FE 1896 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 435: ...ter kit b Remove the 2 screws holding the repair service starter kit to the starter housing c Remove the repair service starter kit d Remove the return spring and plunger 2 REMOVE STARTER COMMUTATOR END FRAME ASSY a Using a screwdriver remove the starter commutator end frame cover b Using snap ring pliers remove the snap ring and plate washer c Remove the 2 through bolts and pull out the starter y...

Page 436: ...n ohmmeter check that there is no continu ity between the commutator and armature coil core If there is continuity replace the armature c Check the commutator for dirty and burn on surface If the surface is dirty or burnt correct it with sandpaper No 400 or a lathe d Check for the commutator circuit runout 1 Place the commutator on V blocks 2 Using a dial indicator measure the circle runout Standa...

Page 437: ...o continu ity between the positive and negative brush holders If the there is continuity repair or replace the starter commutator end frame assy 6 INSPECT REPAIR SERVICE STARTER KIT a Check the plunger 1 Push in the plunger and check that it returns quickly to its original position If necessary replace the repair service starter kit b Check the pull in coil for open circuit 1 Using an ohmmeter che...

Page 438: ... ring d Using vernier calipers mesure the snap ring Maximum length 5 0 mm 0 197 in If the length is greater than maximum replace the new snap ring 8 INSTALL STARTER COMMUTATOR END FRAME ASSY a Align the starter commutator rubber end frame with the cutout of starter yoke b Install starter yoke assy to starter commutator end frame c Align the starer yoke assy with the cutout of motor termi nal start...

Page 439: ... the plunger and hook b Hang the plunger hook of the repair service starter kit to the drive lever c Install the plunger and return spring d Install the repair service starter kit with the 2 screws Torque 7 5 N m 77 kgf cm 66 in lbf e Apply grease to the nut of the lead wire f Connect the lead wire to the terminal with the nut Torque 6 5 N m 66 kgf cm 58 in lbf ...

Page 440: ...t terminals b Disconnect the battery cables when the battery is given a quick charge c Do not perform tests with a high voltage insulation resistance tester d Never disconnect the battery while the engine is running e Check that the charging cable is tightened on terminal B of the alternator and the fuse box f Do not check whether the alternator generates or not with conncting terminal F to the ot...

Page 441: ... the ignition switch OFF and turn off the electrical sys tems c Measure the battery voltage between the negative and positive terminals of the battery Standard voltage 12 5 12 9 V at 20 C 68 F If the voltage is less than specification charge the battery d Check the indicator as shown in the illustration HINT Blue OK White Charging Necessary Red Insufficient Water 3 CHECK BATTERY TERMINALS FUSIBLE ...

Page 442: ...battery alternator tester is available connect the tester to the charging circuit as per manufacturer s instructions a If a tester is not available connect a voltmeter to the charging circuit as follows 1 Disconnect the wire from terminal B of the alterna tor and connect it to the negative tester probe of the ammeter 2 Connect the positive tester probe of the amme ter to terminal B of the alternat...

Page 443: ...B d Loosen the bolt C to lessen the tension of the drive belt e Remove the bolt A B and the generator 2 INSTALL GENERATOR ASSY a Temporarily install the bolt A and B b Adjust the V ribbed belt tension by tightening the adjusting bolt C See page 14 136 c Tighten the bolt A and B Torque Bolt A 58 N m 592 kgf cm 43 ft lbf Bolt B 18 N m 184 kgf cm 13 ft lbf d Install the lead wire from terminal B Torq...

Page 444: ...rame Voltage Regulator Brush Holder Cover Rear End Cover Brush Holder Rectifier Holder Rectifier End Frame N m kgf cm ft lbf Specified torque 111 1 125 81 19 34 STARTING CHARGING GENERATOR ASSY 1MZ FE 1906 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 445: ...SST 1 B clockwise to the specified torque Torque 39 N m 400 kgf cm 29 ft lbf NOTICE Check that SST is secured to the rotor shaft b Mount SST 2 in a vise c Insert SST 1 A B into SST 2 and attach the pulley nut to SST 2 d To loosen the pulley nut turn SST 1 A in the direction shown in the illustration NOTICE To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a tu...

Page 446: ...rews and rectifier holder 5 REMOVE ALTERNATOR RECTIFIRE END FRAME a Remove the rubber insulator b Remove the seal plate c Remove the 4 nuts d Using bearing puller set remove the rectifier end frame 6 REMOVE GENERATOR ROTOR ASSY a Remove the alternator washer from the rotor b Remove the rotor from drive end frame NOTICE Do not drop the rotor 7 INSPECT GENERATOR REGULATOR ASSY a Using an ohmmeter ch...

Page 447: ...ontinuity between the slip rings Standard resistance 2 7 3 1 Ω at 20 C 68 F If there is no continuity replace the rotor b Inspect rotor for ground 1 Using an ohmmeter check that there is no continu ity between the slip ring and rotor If there is continuity replace the rotor c Inspect slip rings 1 Using vernier calipers measure the slip ring diame ter Standard diameter 14 2 14 4 mm 0 559 0 567 in M...

Page 448: ... 12 INSTALL ALTERNATOR RECTIFIRE END FRAME a Using a 17 mm socket wrench and press slowly press in the rectifier end frame b Install the cord clip and the 4 nuts Torque 4 5 N m 46 kgf cm 39 in lbf for without cord clip Torque 5 4 N m 55 kgf cm 47 in lbf for with cord clip c Install the seal plate on the rectifier end frame d Install the 4 rubber insulators on the lead wires NOTICE Be careful of th...

Page 449: ...4 4 N m 45 kgf cm 39 in lbf Bolt 3 9 N m 39 kgf cm 35 in lbf d Install the terminal insulator with the nut Torque 4 1 N m 42 kgf cm 36 in lbf 16 INSTALL GENERATOR PULLEY SST 09820 63010 09820 06010 09820 06020 HINT SST1 A B 09820 06010 SST2 09820 06020 a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST 1 A with a torque wrench and tighten SST 1 B clockwise to t...

Page 450: ...te 2002 CAMRY REPAIR MANUAL RM881U e Tighten the pulley nut turn SST 1 A in the direction shown in the illustration Torque 111 N m 1 125 kgf cm 81 ft lbf f Remove the alternator form SST 2 g Turn SST 1 B and remove SST 1 A B h Turn the pulley and check that the pulley moves smooth ly ...

Page 451: ...ttoming 1 Vehicle Overloaded 2 Spring Weak 3 Shock absorber Worn 26 9 26 9 Sways pitches 1 Tire Worn or improperly inflated 2 Stabilizer bar Bent or broken 3 Shock absorber Worn 28 1 26 9 26 9 Front wheel shimmy 1 Tire Worn or improperly inflated 2 Wheel Out of balance 3 Shock absorber Worn 4 Wheel alignment Incorrect 5 Ball joint Worn 6 Hub bearing Worn 7 Steering linkage Loose or worn 28 1 28 1 ...

Page 452: ... Adjust front tie rods NO YES Is the lead pull stronger than before YES NOTICE Do not exceed 1 of cross camber Do not exceed adjustment range Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 35mph Please confirm safety and set the steering wheel to its straight position Drive the vehicle in a straight line for 100 meters at a constant spee...

Page 453: ... Spring LH Front Spring Bumper LH Front Coil Spring Insulator Lower LH Shock Absorber Assy Front LH Front Stabilizer Link Assy LH w ABS Front Flexible Hose No 1 74 755 55 Speed Sensor Front LH Front Axle Assy LH 80 816 59 49 500 36 18 8 192 14 SPORT Front Suspension Upper Brace Center 210 2 141 155 Washer FRONT SUSPENSION FRONT SUSPENSION 26 3 1915 Author Date 2002 CAMRY REPAIR MANUAL RM881U FRONT...

Page 454: ...y Front LH Front Suspension Arm Sub assy Lower No 1 LH Front Brake Caliper Assy Front Axle Assy LH Cotter Pin 19 194 14 Transverse Engine Engine Mounting Insulator Cotter Pin N m kgf cm ft lbf Specified torque Non reusable part Front Disc 74 755 55 143 1 458 105 74 755 55 206 2 101 152 294 2 998 217 49 500 36 87 887 64 123 1 254 91 200 2 039 148 200 2 039 148 127 1 295 94 70 714 52 70 714 52 8 0 8...

Page 455: ...77 in 33 mm 1 30 in 2AZ FE PREMIUM Front A B 120 mm 4 72 in Rear D C 45 mm 1 77 in 2AZ FE SPORT Front A B 120 mm 4 72 in Rear D C 48 mm 1 89 in Measuring points A Ground clearance of front wheel center B Ground clearance of lower suspension arm No 2 set bolt center C Ground clearance of strut rod set bolt center D Ground clearance of rear wheel center NOTICE Before inspecting the wheel alignment a...

Page 456: ...le Wheel turning angle 15 inch USA Canada Mexico Inside wheel 39 04 2 39 07 2 39 30 2 39 50 2 Outside wheel Reference 33 44 33 73 34 02 34 03 16 inch USA Canada Mexico Inside wheel 36 39 2 36 65 2 37 00 2 37 00 2 Outside wheel Reference 32 11 32 18 32 28 32 47 If the right and left inside wheel angles differ from the specified value check the right and left rack end lengths 6 INSPECT CAMBER CASTER...

Page 457: ... Right left error 2 39 45 2 65 0 75 45 0 75 or less 2 36 45 2 60 0 75 45 0 75 or less If the caster and steering axis inclination are not within the spe cified values after the camber has been correctly adjusted re check the suspension parts for damaged and or worn out parts 7 ADJUST CAMBER NOTICE After the camber has been adjusted inspect the toe in a Remove the front wheel b Remove the 2 nuts on...

Page 458: ...bf NOTICE When installing nut stop the bolt from rotating and torque the nut g Install the front wheel Torque 103 N m 1 050 kgf cm 76 ft lbf h Check the camber HINT Try to adjust the camber to the center of the specified val ue Adjusting value for the set bolts is 6 30 0 1 0 5 If the camber is not within the specified value using the follow ing table estimate how much additional camber adjustment ...

Page 459: ...all joint turns together with the nut use a hexagon 6 mm wrench to hold the stud 3 REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING a Loosen the lock nut NOTICE Do not loosen except for the case with disassembling the shock absorber assy front LH with coil spring Do not remove the lock nut b w ABS Remove the bolt disconnect the front flexible hose No 1 and speed sensor front LH c w o ABS Remove the bo...

Page 460: ...0021 NOTICE Do not use an impact wrench It will damage the SST HINT Use 2 of the same type of SST b Remove the front suspension support sub assy LH front suspension support bearing LH front coil spring seat upper LH front coil spring insulator upper LH front coil spring LH front spring bumper LH and front coil spring insulator upper LH 6 INSPECT SHOCK ABSORBER ASSY FRONT LH a Compress and extend t...

Page 461: ...will damage the SST HINT Use 2 of the same type of SST d Install the front coil spring LH to the shock absorber assy front LH HINT Fit the lower end of the front coil spring LH into the gap of the spring lower seat e Install the front coil spring insulator upper LH as shown in the illustration f Install the front coil spring seat upper LH to the shock ab sorber assy front LH with the mark facing t...

Page 462: ...of front shock absorber with coil spring Torque 80 N m 816 kgf cm 59 ft lbf NOTICE Be careful not to drop the 2 washers in the case that there is front suspension upper brace center c Install the 2 bolts and 2 nuts to the lower side of front shock absorber with coil spring Torque 210 N m 2 141 kgf cm 155 ft lbf NOTICE When installing bolt stop the bolt from rotating and torque the nut d Fully tigh...

Page 463: ...NT STABILIZER LINK ASSY LH a Install the front stabilizer link assy LH with the nut Torque 74 N m 755 kgf cm 55 ft lbf HINT If the ball joint turns together with the nut use a hexagon 6 mm wrench to hold the stud 10 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 11 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page 26 5 ...

Page 464: ... Dispose the RH side by the same procedures with the LH side 1 DISPOSE SHOCK ABSORBER ASSY FRONT LH a Fully extend the shock absorber rod b Using a drill make a hole in the cylinder as shown in the illustration to discharge the gas inside CAUTION When drilling chips may fly out work carefully The gas is colorless odorless and non poisonous ...

Page 465: ...emove the 3 nuts and transverse engine engine mount ing insulator 4 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR M T TRANSAXLE a Remove the 3 nuts and transverse engine engine mounting insulator b Remove the 4 bolts and bracket from the manual transmission 5 REMOVE FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 LH a Remove the 2 bolts on the front side of the front suspen sion arm sub assy lower N...

Page 466: ...th the bolt and nut to the rear side Torque 206 N m 2 101 kgf cm 152 ft lbf 7 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR A T TRANSAXLE a Install the transverse engine engine mounting insulator with the 3 nuts Torque 87 N m 887 kgf cm 64 ft lbf 8 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR M T TRANSAXLE a Install the bracket with the 4 bolts to the manual transmission Torque 64 N m...

Page 467: ...VE LOWER BALL JOINT ASSY FRONT LH See page 30 21 SST 09628 62011 10 INSPECT LOWER BALL JOINT ASSY FRONT LH a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 3 5 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 98 3 43 N m 10 35 kgf cm 8 7 30 in lbf 11...

Page 468: ... CAMRY REPAIR MANUAL RM881U 19 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 20 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page 26 5 21 CHECK ABS SPEED SENSOR SIGNAL W ABS w VSC See page 05 452 w o VSC BOSCH MADE See page 05 363 w o VSC DENSO MADE See page 05 404 ...

Page 469: ...mm wrench to hold the stud 3 REMOVE FRONT STABILIZER LINK ASSY RH HINT Remove the RH side by the same procedures with the LH side 4 REMOVE FRONT SUSPENSION MEMBER DYNAMIC DAMPER EXCEPT 1MZ FE ENGINE TYPE a Remove the 2 bolts and front suspension member dynamic damper from the front frame assy 5 REMOVE FRONT STABILIZER BRACKET NO 1 LH a Remove the 2 bolts and 2 front stabilizer brackets No 1 LH 6 R...

Page 470: ...R BAR FRONT 14 REMOVE FRONT STABILIZER BAR BUSH NO 1 15 INSPECT FRONT STABILIZER LINK ASSY LH a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 05 1 96 N m 0 5 20 kgf cm 0 4 17 4 in lbf 16 INSTALL F...

Page 471: ... with the LH side 26 INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER EXCEPT 1MZ FE ENGINE TYPE a Install the front suspension member dynamic damper with 2 bolts to the front frame assy Torque 29 N m 296 kgf cm 21 ft lbf 27 INSTALL FRONT STABILIZER LINK ASSY LH a Install the front stabilizer link assy LH with the 2 nuts Torque 74 N m 755 kgf cm 55 ft lbf HINT If the ball joint turns together with th...

Page 472: ...om Suspect Area See page Bottoming 1 Vehicle Overloaded 2 Spring Weak 3 Shock absorber Worn 27 4 27 4 Sways pitches 1 Tire Worn or improperly inflated 2 Stabilizer bar Bent or broken 3 Shock absorber Worn 28 1 27 17 27 4 Rear wheel shimmy 1 Tire Worn or improperly inflated 2 Wheel Out of balance 3 Shock absorber Worn 4 Wheel alignment Incorrect 5 Hub bearing Worn 28 1 28 1 27 4 26 5 27 3 30 2 Abno...

Page 473: ...Bushing Shock Absorber Assy Rear LH Rear Stabilizer Link Assy LH Stabilizer Bar Rear Parking Brake Cable N m kgf cm ft lbf Specified torque 49 500 36 39 400 29 100 1 020 74 55 561 41 38 387 28 100 1 020 74 100 1 020 74 100 1 020 74 113 1 150 83 39 400 29 19 195 14 5 4 55 48 in lbf 255 2 600 188 113 1 150 83 19 195 14 Non reusable part 27 2 REAR SUSPENSION REAR SUSPENSION 1935 Author Date 2002 CAMR...

Page 474: ...nsion arms No 2 lower suspension arm length difference 1 0 mm 0 039 in or less If the left right difference is larger than 1 0 mm 0 039 in ad just it by following the procedures below b Loosen the lock nuts c Turn the right and left adjusting tube by an equal amount to adjust toe in HINT Try to adjust the toe in to the center value One turn of the each adjusting tube will adjust the toe in by appr...

Page 475: ...y the same procedures with the RH side 5 REMOVE ROOF SIDE GARNISH INNER RH See page 76 20 6 REMOVE ROOF SIDE GARNISH INNER LH HINT Remove the LH side by the same procedures with the RH side 7 REMOVE CENTER STOP LAMP ASSY See page 65 16 8 REMOVE PACKAGE TRAY TRIM PANEL ASSY a TMC made See page 61 14 b TMMK made See page 61 17 9 REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER a TMC made See page 61 14...

Page 476: ...rrier with a jack d Remove the rear suspension support No 1 cover LH e Loosen the suspension support center nut NOTICE Do not remove the nut HINT If not disassembling the rear shock absorber it is not necessary to loosen the nut f Remove the 3 nuts of the suspension support g Lower the rear axle carrier and remove the 2 nuts and bolts on the lower side of the shock absorber h Remove the shock abso...

Page 477: ...o abnormal resistance or unusual operation sound If there is any abnormality replace the shock absorber with a new one NOTICE When disposing the shock absorber see DISPOSAL on page 27 9 15 INSTALL SHOCK ABSORBER ASSY REAR LH a Install the spring bumper b Install the lower insulator as shown in the illustration c Using SST compress the coil spring SST 09727 30021 NOTICE Do not use an impact wrench ...

Page 478: ... Temporarily install a new nut h Remove the SST SST 09727 30021 HINT After removing SST recheck the direction of the suspension support 16 INSTALL REAR SHOCK ABSORBER WITH COIL SPRING a Install the shock absorber with the coil spring and 3 nuts Torque 39 N m 400 kgf cm 29 ft lbf b Install the shock absorber with the coil spring 2 bolts and nuts Torque 255 N m 2 600 kgf cm 188 ft lbf HINT Keep the ...

Page 479: ...the stabilizer bar link to the shock absorber with the nut Torque 39 N m 400 kgf cm 29 ft lbf HINT If the ball joint turns together with the nut use a hexagon 5 mm wrench to hold the stud 18 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER a TMC made See page 61 14 b TMMK made See page 61 17 19 INSTALL REAR SIDE SEAT BACK ASSY RH a TMC made See page 72 34 b TMMK made See page 72 38 20 INSTALL REAR S...

Page 480: ...MANUAL RM881U DISPOSAL 1 DISPOSE SHOCK ABSORBER ASSY REAR LH a Fully extend the shock absorber rod b Using a drill make a hole in the cylinder as shown in the illustration to discharge the gas inside CAUTION When drilling chips may fly out work carefully The gas is colorless odorless and non poisonous ...

Page 481: ...e 27 19 5 SEPARATE REAR SUSPENSION ARM ASSY NO 2 LH a Remove the bolt nut and rear suspension arm No 2 out er side from the rear carrier HINT Keep the nut fixed while loosening and removing the bolt 6 SEPARATE REAR SUSPENSION ARM ASSY NO 2 RH HINT Separate the RH side by the procedures with the LH side 7 SEPARATE REAR SUSPENSION ARM ASSY NO 1 LH a Remove the bolt nut and rear suspension arm No 1 o...

Page 482: ... member 10 REMOVE REAR SUSPENSION ARM ASSY NO 1 LH a Lower the rear suspension member b Remove the bolt and lower suspension arm No 1 11 INSTALL REAR SUSPENSION ARM ASSY NO 1 LH a Install the lower suspension No 1 with the bolt nut and temporary tighten the bolt b Set suspension arm in the position shown in the illustra tion and fully tighten the bolt Torque 100 N m 1 020 kgf cm 74 ft lbf HINT Ins...

Page 483: ... and nut and temporarily tighten the bolt and nut HINT Insert the bolt from the front side of the vehicle and temporarily install the bolt 14 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 RH HINT Temporarily tighten the RH side by the procedures with the LH side 15 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 LH a Connect the rear suspension arm No 2 outer side to the rear axle carrier with t...

Page 484: ...ile tightening the bolt 20 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 RH HINT Fully tighten the RH side by the procedures with the LH side 21 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 LH a Fully tighten the bolt Torque 100 N m 1 020 kgf cm 74 ft lbf HINT Keep the nut fixed while tightening the bolt 22 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 RH HINT Fully tighten the RH side by the procedure...

Page 485: ...TE REAR SUSPENSION ARM ASSY NO 1 RH HINT Separate the RH side by the procedures with the LH side 6 SEPARATE REAR SUSPENSION ARM ASSY NO 2 LH See page 27 14 7 SEPARATE REAR SUSPENSION ARM ASSY NO 2 RH HINT Separate the RH side by the procedures with the LH side 8 SEPARATE STRUT ROD ASSY REAR See page 27 19 9 REMOVE REAR SUSPENSION MEMBER SUB ASSY See page 27 10 10 REMOVE REAR SUSPENSION ARM ASSY NO...

Page 486: ...age 27 10 14 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 RH HINT Temporarily tighten the RH side by the procedures with the LH side 15 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 LH See page 27 14 16 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 RH HINT Temporarily tighten the RH side by the procedures with the LH side 17 TEMPORARY TIGHTEN STRUT ROD ASSY REAR See page 27 19 18 INSTALL ST...

Page 487: ... ARM ASSY NO 2 RH HINT Fully tighten the RH side by the procedures with the LH side 24 FULLY TIGHTEN STRUT ROD ASSY REAR See page 27 19 25 INSTALL EXHAUST PIPE ASSY CENTER a 1MZ FE engine See page 15 5 b 2AZ FE engine See page 15 2 26 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 27 INSPECT REAR WHEEL ALIGNMENT See page 27 3 ...

Page 488: ... wrench 5 mm to hold the stud 3 REMOVE REAR STABILIZER LINK ASSY RH HINT Remove the RH side by the same procedures with the LH side 4 INSPECT REAR STABILIZER LINK ASSY LH a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th...

Page 489: ...the correct bolts are installed Install the bushing to the inner side of the bushing stopper on the stabilizer bar 7 INSTALL REAR STABILIZER LINK ASSY LH a Remove the 2 nuts and stabilizer bar link Torque 39 N m 400 kgf cm 29 ft lbf HINT If the ball joint turns together with the nut use a hexagon 5 mm wrench to hold the stud 8 INSTALL REAR STABILIZER LINK ASSY RH HINT Install the RH side by the sa...

Page 490: ...le b Remove the bolt nut and disconnect the strut rod front side HINT Keep the nut fixed while loosening and removing the bolt c Remove the bolt nut and strut rod from rear axle carrier HINT Keep the nut fixed while loosening and removing the bolt 3 TEMPORARY TIGHTEN STRUT ROD ASSY REAR a Install the strut rod rear side bolt nut and temporarily tighten the bolt HINT Insert the bolt from the inner ...

Page 491: ... block be tween them Apply load to the suspension so that the installed bolt of the suspension arm assy No 1 vehicle side is horizontally aligned with the center of the rear axle hub 5 FULLY TIGHTEN STRUT ROD ASSY REAR a Fully tighten the bolt Torque 113 N m 1 152 kgf cm 83 ft lbf HINT Keep the nut fixed while tightening the bolt b Install the parking brake cable with the bolt and nut Torque 5 4 N...

Page 492: ...00 2 0 29 b Using a dial indicator check the tire runout Tire runout 1 0 mm 0 039 in or less 2 ROTATE TIRE HINT Rotate tires as shown in the illustration Rotate as shown in B if the spare tire is included in the rotation 3 INSPECT WHEEL BALANCE a Check and adjust the Off the car balance b If necessary check and adjust the On the car balance Imbalance after adjustment 8 0 g 0 018 lb or less 4 INSPE...

Page 493: ... numbers indicate the priority of the likely cause of the problem Check each part in order If necessary replace these parts Symptom Suspect Area See page Wander 5 Wheel alignment 6 Steering linkage Loosen or worn 7 Hub bearing Worn 8 Stabilizer bar 26 5 27 3 30 2 26 19 27 17 Front wheel shimmy 1 Wheel balance 2 Shock absorber 3 Ball joint Worn 4 Hub bearing Worn 28 1 26 9 27 4 26 17 30 2 Noise 1 I...

Page 494: ...ck the deviation at the surface of the axle hub outside the hub bolt Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the axle hub 6 INSTALL FRONT DISC 7 INSTALL FRONT DISC BRAKE CALIPER ASSY LH See page 30 21 8 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 9 REMOVE REAR WHEEL 10 DISCONNECT REAR DISC BRAKE CALIPER ASSY LH DISC REAR BRAKE TYPE See page 30 28 11 REMO...

Page 495: ... deviation at the surface of the axle hub outside the hub bolt Maximum 0 07 mm 0 0027 in If the backlash exceeds the maximum replace the axle hub as sembly 15 INSTALL REAR DISC DISC REAR BRAKE TYPE 16 INSTALL REAR DISC BRAKE CALIPER ASSY LH DISC REAR BRAKE TYPE See page 30 28 17 INSTALL REAR BRAKE DRUM SUB ASSY DRUM REAR BRAKE TYPE 18 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf ...

Page 496: ...ilizer Link Assy LH w ABS Speed Sensor Front LH Cotter Pin Front Drive Shaft Assy RH N m kgf cm ft lbf Specified torque Non reusable part 32 4 330 24 8 0 82 71 in lbf 294 2 998 217 49 500 36 127 1 295 94 74 755 55 Front Flexible Hose No 1 18 8 192 14 30 4 DRIVE SHAFT PROPELLER SHAFT DRIVE SHAFT PROPELLER SHAFT AXLE 1958 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 497: ...Dust Cover RH Front Drive Shaft Dust Cover Front Drive Shaft Hole Snap Ring RH Front Drive Inboard Joint Assy RH Front Drive Inner Shaft Inner RH Shaft Snap Ring LH Front Drive Shaft Bearing Front Axle Inboard Joint Boot Front Axle Inboard Joint Boot RH No 2 Clamp Front Drive Shaft Dust Cover LH Front Drive Inboard Joint Assy LH Front Drive Shaft LH Hole Snap Ring Front Wheel Bearing Dust Deflecto...

Page 498: ... Joint Assy LH Front Axle Assy LH Front Drive Shaft Assy LH 210 2 141 155 8 0 82 71 in lbf Front Disc 106 9 1 090 79 127 1 295 94 49 500 36 294 2 998 217 Front Axle Hub LH Hole Snap Ring Cotter Pin Front Axle Hub LH Bearing 123 1 254 91 Disc Brake Dust Cover Front LH Front Axle Hub Sub assy LH 8 3 85 73 in lbf 8 3 85 73 in lbf 30 6 DRIVE SHAFT PROPELLER SHAFT DRIVE SHAFT PROPELLER SHAFT AXLE 1960 ...

Page 499: ... Assy Rear 100 1 020 74 61 8 630 46 61 8 630 46 100 1 020 74 113 1 152 83 113 1 152 83 18 8 192 14 5 4 55 48 in lbf 5 4 55 48 in lbf Rear Axle LH Hub Bolt 80 816 59 X5 255 2 600 188 Rear Suspension Arm Assy No 1 LH 80 816 59 REAR DRUM BRAKE REAR DRUM BRAKE Parking Brake Assy Rear Brake Drum Sub assy DRIVE SHAFT PROPELLER SHAFT DRIVE SHAFT PROPELLER SHAFT AXLE 30 7 1961 Author Date 2002 CAMRY REPAI...

Page 500: ...unstake the staked part of the front axle hub LH nut SST 09930 00010 NOTICE Loosen the staked part of the lock nut completely other wise the screw of the drive shaft may be damaged b While applying the brakes remove the front axle hub LH nut 5 DISCONNECT FRONT STABILIZER LINK ASSY LH a Remove the nut disconnect the front stabilizer link assy LH from the shock absorber assy front LH HINT If the bal...

Page 501: ...28 62011 8 DISCONNECT FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 LH a Remove the bolt and 2 nuts and disconnect the front sus pension arm sub assy lower No 1 LH from the lower ball joint assy front LH 9 DISCONNECT FRONT AXLE ASSY LH a Using a plastic hammer disconnect the front drive shaft assy LH from the front axle hub sub assy LH NOTICE w ABS Be careful not to damage the boot and speed sensor rot...

Page 502: ...ace the vehicle weight on the hub bearing first support it with SST SST 09608 16042 09608 02021 09608 02041 13 INSPECT FRONT DRIVE SHAFT ASSY LH a Check to see that there is no remarkable play in the out board joint b Check to see that the inboard joint slides smoothly in the thrust direction c Check to see that there is no remarkable play in the radial direction of the inboard joint d Check the b...

Page 503: ...DRIVE SHAFT DAMPER LH M T TRANSAXLE a Using a side cutter cut the front drive shaft damper LH clamp and remove it b Remove the front drive shaft damper LH 18 REMOVE FRONT DRIVE SHAFT DAMPER RH EXCEPT 1MZ FE ENGINE TYPE a Using a side cutter cut the front drive shaft damper RH clamp and remove it b Remove the front drive shaft damper RH 19 REMOVE FRONT AXLE OUTBOARD JOINT BOOT CLAMP a Using a side ...

Page 504: ...p ring 23 REMOVE FRONT DRIVE SHAFT DUST COVER LH a Using SST and a press remove the front drive shaft dust cover LH SST 09950 00020 24 REMOVE FRONT DRIVE SHAFT DUST COVER RH a Using a press remove the front drive shaft dust cover RH 25 REMOVE FRONT DRIVE SHAFT DUST COVER a Using SST and a press remove the front drive shaft dust cover SST 09950 00020 26 REMOVE FRONT DRIVE SHAFT BEARING a Using a sn...

Page 505: ...t hole snap ring RH 28 INSTALL FRONT DRIVE SHAFT DUST COVER a Using SST an extension bar and a press install a new front drive shaft dust cover SST 09726 40010 HINT The clearance between the front drive shaft dust cover and the front drive shaft bearing should be kept in the range shown in the illustration 29 INSTALL FRONT DRIVE SHAFT DUST COVER RH a Using SST and a press install a new front drive...

Page 506: ...earing dust deflector LH No 2 reaches the specification as shown in the illustration SST 09387 00020 Distance 13 5 13 8 mm 0 531 0 543 in 33 INSTALL OUTBOARD JOINT BOOT HINT Before installing the boots wrap the spline of the drive shaft with vinyl tape to prevent the boots from being damaged a Temporarily install a new outboard joint boot with 2 clamps to the drive shaft b Pack the inboard joint s...

Page 507: ... Set the distance as described below Distance 207 2 0 mm 8 15 0 079 in b Make sure that the front drive shaft damper LH is on the shaft groove c Place SST onto the front drive shaft damper LH clamp SST 09521 24010 d Tighten the SST so that the front drive shaft damper LH clamp is pinched NOTICE Do not overtighten the SST e Using SST adjust the clearance of the front drive shaft damper LH clamp SST...

Page 508: ...rd the front drive outboard joint shaft assy LH b Align the matchmarks placed before removal c Using a brass bar and hammer tap in the tripod to the front drive outboard joint shaft assy LH NOTICE Do not tap the roller d Using a snap ring expander install a new front drive inner shaft inner RH shaft snap ring e Pack the front drive outboard joint shaft assy LH and front axle inboard joint boot wit...

Page 509: ... 40 INSPECT FRONT DRIVE SHAFT a Check to see that there is no remarkable play in the out board joint b Check to see that the inboard joint slides smoothly in the thrust direction c Check to see that there is no remarkable play in the radial direction of the inboard joint d Check the boots for damage NOTICE Move the drive shaft assy keeping it level e Make sure that the 2 boots are on the shaft gro...

Page 510: ...ving it 42 INSTALL FRONT DRIVE SHAFT ASSY RH a Using a screwdriver install the drive shaft bearing bracket hole snap ring b Install the bolt Torque 32 4 N m 330 kgf cm 24 ft lbf NOTICE Do not damage the oil seal 43 INSTALL FRONT AXLE ASSY LH a Install the front drive shaft assy LH to the front axle assy LH NOTICE Be careful not to damage the outboard joint boot w ABS Be careful not to damage the s...

Page 511: ...e careful not to damage the speed sensor Prevent foreign matter from being attached Do not twist the sensor wire when installing the sen sor 47 INSTALL FRONT STABILIZER LINK ASSY LH a Install the front stabilizer link assy LH with the nut Torque 74 N m 755 kgf cm 55 ft lbf HINT If the ball joint turns together with the nut use a hexagon 6 mm wrench to hold the stud 48 INSTALL FRONT AXLE HUB LH NUT...

Page 512: ...E SHAFT 1974 Author Date 2002 CAMRY REPAIR MANUAL RM881U 54 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page 26 5 55 CHECK ABS SPEED SENSOR SIGNAL W ABS w VSC See page 05 452 w o VSC BOSCH MADE See page 05 363 w o VSC DENSO MADE See page 05 404 ...

Page 513: ... CALIPER ASSY LH a Remove the 2 bolts disconnect the front disc brake cali per assy LH from the steering knuckle LH 5 REMOVE FRONT DISC 6 DISCONNECT TIE ROD ASSY LH See page 30 8 SST 09628 62011 7 DISCONNECT FRONT SUSPENSION ARM SUB ASSY LOWER NO 1 LH See page 30 8 8 REMOVE FRONT AXLE ASSY LH a Using a plastic hammer separate the front drive shaft assy LH from the front axle hub sub assy LH NOTICE...

Page 514: ...NAP RING a Using a snap ring plier remove the front axle hub LH hole snap ring 11 REMOVE FRONT AXLE HUB SUB ASSY LH a Using SST remove the front axle hub sub assy LH SST 09520 00031 b Using SST and a press remove the inner race outside from the front axle hub sub assy LH SST 09950 00020 09950 60010 09951 00410 09950 70010 09951 07100 12 REMOVE DISC BRAKE DUST COVER FRONT LH a Using a torx wrench T...

Page 515: ... V block as shown in the illustration NOTICE Be sure the steering knuckle is horizontally positioned d Using SST and a press remove the front axle hub LH bearing SST 09950 60010 09951 00600 09950 70010 09951 07100 14 INSTALL FRONT AXLE HUB LH BEARING a Using SST and a press install a new front axle hub LH bearing to the steering knuckle LH SST 09950 60020 09951 00790 09950 70010 09951 07100 15 INS...

Page 516: ...ASSY LH a Install the 2 bolts nuts and front axle assy LH to the shock absorber assy front LH Torque 210 N m 2 141 kgf cm 155 ft lbf HINT Insert the bolt from the rear side of the vehicle and tighten the nut b Push the front axle assy LH toward the outside of the ve hicle fit the splined part of the front drive shaft assy LH to that of the front axle assy LH and insert the front drive shaft assy L...

Page 517: ...25 DISCONNECT FRONT DISC BRAKE CALIPER ASSY LH a Remove the 2 bolts disconnect the front disc brake cali per assy LH from the steering knuckle LH 26 REMOVE FRONT DISC 27 INSPECT BEARING BACKLASH a Using a dial indicator check the backlash near the center of the axle hub Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the bearing 28 INSPECT AXLE HUB DEVIATION a Using a dial in...

Page 518: ... brake caliper assy LH with the 2 bolts to the steering knuckle LH Torque 106 9 N m 1 090 kgf cm 79 ft lbf 31 INSTALL SPEED SENSOR FRONT LH W ABS See page 30 8 32 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 33 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT See page 26 5 34 CHECK ABS SPEED SENSOR SIGNAL W ABS w VSC See page 05 452 w o VSC BOSCH MADE See page 05 363 w o VSC DENSO MADE See pa...

Page 519: ... ASSY LH See page 30 21 3 REMOVE FRONT DISC 4 REMOVE FRONT AXLE LH HUB BOLT a Using SST and a screwdriver or an equivalent to hold re move the front axle LH hub bolt SST 09628 10011 5 INSTALL FRONT AXLE LH HUB BOLT a Install a washer and nut to a new front axle LH hub bolt as shown in the illustration b Using a screwdriver to hold install the hub bolt by torqu ing the nut 6 INSTALL FRONT DISC 7 IN...

Page 520: ... REMOVE REAR WHEEL 2 DISCONNECT REAR DISC BRAKE CALIPER ASSY LH DISC REAR BRAKE TYPE a Remove the bolt and disconnect the rear flexible hose b Remove the 2 bolts and rear disc brake caliper assy LH c Support the brake caliper assy LH securely 3 REMOVE REAR DISC DISC REAR BRAKE TYPE 4 REMOVE REAR BRAKE DRUM SUB ASSY DRUM REAR BRAKE TYPE 5 DISCONNECT SKID CONTROL SENSOR WIRE W ABS 6 REMOVE REAR AXLE...

Page 521: ...816 kgf cm 59 ft lbf 10 INSTALL SKID CONTROL SENSOR WIRE W ABS 11 INSPECT BEARING BACKLASH a Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the axle hub as sembly 12 INSPECT AXLE HUB DEVIATION a Using a dial indicator check the deviation at the surface of the axle hub o...

Page 522: ...th the 2 bolts Torque 61 8 N m 630 kgf cm 46 ft lbf b Install the rear flexible hose with the bolt Torque 18 8 N m 192 kgf cm 14 ft lbf 15 INSTALL REAR BRAKE DRUM SUB ASSY DRUM REAR BRAKE TYPE 16 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 17 INSPECT AND ADJUST REAR WHEEL ALIGNMENT See page 27 3 18 CHECK ABS SPEED SENSOR SIGNAL W ABS w VSC See page 05 452 w o VSC BOSCH MADE See page 0...

Page 523: ... DRUM REAR BRAKE TYPE 6 DISCONNECT SKID CONTROL SENSOR WIRE W ABS 7 DISCONNECT REAR BRAKE TUBE NO 4 DRUM REAR BRAKE TYPE a Using SST disconnect the rear brake tube No 4 from the LH front or upper rear wheel brake cylinder assy SST 09023 00100 8 REMOVE REAR AXLE HUB BEARING ASSY LH See page 30 28 9 DISCONNECT REAR SUSPENSION ARM ASSY NO 2 LH a Remove the bolt nut and rear suspension arm assy No 2 L...

Page 524: ...t from rotating and torque the nut HINT Insert the bolt from the rear side of the vehicle and install the nut 13 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 LH a Install the rear suspension arm No 1 to the rear axle carri er sub assy LH with the bolt and nut temporarily tighten the bolt HINT Insert the bolt from the front side of the vehicle and while fixing the nut turn and install the bolt 1...

Page 525: ... ASSY REAR See page 27 19 22 STABILIZE SUSPENSION See page 27 19 23 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO 1 LH See page 27 10 24 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO 2 LH See page 27 14 25 FULLY TIGHTEN STRUT ROD ASSY REAR See page 27 19 26 FILL RESERVOIR WITH BRAKE FLUID DRUM REAR BRAKE TYPE 27 BLEED MASTER CYLINDER DRUM REAR BRAKE TYPE See page 32 4 SST 09023 00100 28 BLEED BRAKE LINE D...

Page 526: ...KE DRUM SUB ASSY DRUM REAR BRAKE TYPE 5 REMOVE REAR AXLE LH HUB BOLT a Using SST and a screwdriver or an equivalent to hold re move the rear axle LH hub bolt SST 09628 10011 6 INSTALL REAR AXLE LH HUB BOLT a Install a washer and nut to a new rear axle LH hub bolt as shown in the illustration b Using a screwdriver to hold install the rear axle LH hub bolt by torquing the nut 7 INSTALL REAR DISC DIS...

Page 527: ...as it could affect the performance of the brake system and result in a driving hazard Replace the parts with parts having the same part number or equivalent It is very important to keep parts and the area clean when repairing the brake system If the vehicle is equipped with a mobile communication system refer to the precaution in the INTRODUCTION section ...

Page 528: ...t of adjustment 32 4 32 25 32 33 32 39 32 12 32 12 Brake drag 1 Brake pedal freeplay Minimal 2 Parking brake pedal travel Out of adjustment 3 Parking brake wire Sticking 4 Rear brake shoe clearance Out of adjustment 5 Parking brake shoe clearance Out of adjustment 6 Pad or lining Cracked or distorted 7 Piston Stuck 8 Piston Frozen 9 Anchor tension or return spring Faulty 10 Booster push rod Out ad...

Page 529: ...Out of adjustment 32 4 32 25 32 33 32 39 32 25 32 33 32 39 32 39 32 25 32 33 32 39 32 25 32 33 32 39 32 25 32 33 32 12 Noise from brakes 1 Pad on lining Cracked or distorted 2 Installation bolt Loose 3 Disc Scored 4 Pad support plate Loose 5 Sliding pin Worn 6 Pad or lining dirty 7 Pad or lining Glanzed 8 Anchor tension or return spring Faulty 9 Anti squeal shim Damaged 10 Shoe hold down spring Da...

Page 530: ...s empty bleed the air from the master cylinder a Remove the air cleaner assembly with hose b Disconnect the brake lines from the master cylinder SST 09023 00100 c Slowly depress the brake pedal and hold it d Block off the outer holes with your fingers and release the brake pedal e Repeat c and d 3 or 4 times f Install the air cleaner assembly with hose 3 BLEED BRAKE LINE a Connect the vinyl tube t...

Page 531: ...eservoir SST 09992 00242 09992 00350 c Connect the vinyl tube to the bleeder plug of the ABS TRACTION actuator d Using SST apply the pressure described below to the res ervoir Pressure 98 1 kPa 1 0 kgf cm2 14 2 psi e Loosen the bleeder plug f Bleed the air out of the ABS TRACTION actuator tight en the bleeder plug Torque 8 3 N m 85 kgf cm 74 in lbf 5 CHECK FLUID LEVEL IN RESERVOIR a Check the flui...

Page 532: ...the connector from the stop lamp switch assy 3 Loosen the stop lamp switch lock nut and remove the stop lamp switch assy 4 Loosen the clevis lock nut 5 Adjust the pedal height by turning the pedal push rod 6 Tighten the push rod lock nut Torque 26 N m 265 kgf cm 19 ft lbf 7 Install the stop lamp switch assy 8 Connect the connector to the stop lamp switch assy 9 Push the brake pedal in 5 10 mm 0 20...

Page 533: ...ginning of the resistance is felt Measure the distance as shown Pedal freeplay 1 6 mm 0 04 0 24 in If incorrect check the stop lamp switch assy clearance If the clearance is OK then troubleshoot the brake system Stop lamp switch clearance 0 5 2 5 mm 0 020 0 098 in 3 CHECK PEDAL RESERVE DISTANCE a Release the parking brake pedal With engine running depress the pedal and measure the pedal reserve di...

Page 534: ... Pedal Brake Master Cylinder Push Rod Pin Brake Pedal Return Spring Clip Brake Pedal Pad Non reusable part N m kgf cm ft lbf Specified torque Lithium soap base glycol grease 26 265 19 37 375 27 13 130 9 20 204 15 13 130 9 M T models Brake Pedal Pad 32 8 BRAKE BRAKE PEDAL SUPPORT ASSY 1996 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 535: ...ke Master Cylinder Push Rod Pin Brake Pedal Support Sub Assy Stop Lamp Switch Cushion Stop Lamp Switch Assy 20 204 15 13 130 9 Clip Brake Pedal Pad 26 265 19 Lock Nut Brake Pedal Return Spring M T models BRAKE BRAKE PEDAL SUPPORT ASSY 32 9 1997 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 536: ...E BRAKE PEDAL PAD 8 REMOVE BRAKE PEDAL BUSH NORMAL TYPE BRAKE PEDAL a Remove the 2 brake pedal bushes from brake pedal 9 REMOVE STOP LAMP SWITCH CUSHION 10 INSTALL STOP LAMP SWITCH CUSHION 11 INSTALL BRAKE PEDAL BUSH NORMAL TYPE BRAKE PEDAL a Install the new 2 brake pedal bushes to brake pedal HINT Apply the lithium soap base glycol grease to the parts indicates by arrows See page 32 8 12 INSTALL ...

Page 537: ...in and clip HINT Apply the lithium soap base glycol grease to the parts indicates by arrows See page 32 8 17 INSTALL BRAKE PEDAL RETURN SPRING 18 INSTALL INSTRUMENT PANEL REINFORCEMENT See page 71 12 19 CHECK AND ADJUST BRAKE PEDAL HEIGHT See page 32 6 20 CHECK PEDAL FREE PLAY See page 32 6 21 CHECK PEDAL RESERVE DISTANCE See page 32 6 ...

Page 538: ...e tubes from the brake master cylinder SST 09023 00100 c w ABS Using SST disconnect the 6 brake tubes from the brake master cylinder SST 09023 00100 d w o ABS Remove the 2 nuts pull out the 3 way and brake master cylinder sub assy e w ABS Remove the 2 nuts pull out the 2 way and brake master cylinder sub assy 4 REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY a Pull out the master cylinder r...

Page 539: ...out not at an angle NOTICE If pulled out at an angle there is a possibility that the cylin der bore could be damaged f Place a waste cloth and 2 wooden blocks on the work table and lightly edges until the No 2 piston sub assy drops out of the cylinder HINT Make sure the distance A from the rag the top of the blocks is at least 100 mm 3 94 in NOTICE If pulled out at an angle there is a possibility ...

Page 540: ...LL BRAKE MASTER CYLINDER KIT W O VSC a Place master cylinder in vise b Apply the lithium soap base grycol grease on new No 1 and No 2 piston sub assy c Install the No 2 and No 1 piston sub assy NOTICE If the piston is inserted at an angle there is a possibil ity that the cylinder bore could be damaged Be careful not to damage the rubber lips on the pis tons d Push in the piston and install a new g...

Page 541: ... e Push in the piston and install the snap ring with snap ring pliers f Apply the lithium soap base glycol grease on a new O ring and install the O ring to the master cylinder 13 INSTALL MASTER CYLINDER RESERVOIR GROMMET a Apply the lithium soap base glycol grease on the 2 master cylinder reservoir grommets b Install the 2 master cylinder reservoir grommets to the master cylinder reservoir sub ass...

Page 542: ...mm 0 in HINT If there is a clearance between the SST main body and the booster shell It means that the specified value and no chalk attachment on the booster push rod means that it is more than the specified value Brake booster push rod clearance before shipment is ad justed to be 0 105 mm 0 004 in e Using SST adjust the booster push rod length until the push rod lightly touches the pin head SST 0...

Page 543: ...gf cm 11 ft lbf SST 09023 00100 d w ABS Using SST and connect the 6 brake tubes to the master cylinder sub assy Torque 15 N m 155 kgf cm 11 ft lbf SST 09023 00100 e Connect the level warning switch connector 19 FILL RESERVOIR WITH BRAKE FLUID 20 BLEED MASTER CYLINDER See page 32 4 SST 09023 00100 21 BLEED BRAKE LINE See page 32 4 22 INSTALL AIR CLEANER ASSY 23 CHECK FLUID LEVEL IN RESERVOIR 24 CHE...

Page 544: ... and stop the engine with the pedal depressed HINT If there is no change in the pedal reserve distance after holding the pedal for 30 seconds the booster is air tight b Operating check 1 Depress the brake pedal several times with the igni tion switch OFF and check that there is no change in the pedal reserve distance 2 Depress the brake pedal and start the engine HINT If the pedal goes down slight...

Page 545: ...ied torque 43 440 32 15 155 11 13 130 9 5 4 55 48 in lbf 13 130 9 15 155 11 15 155 11 13 130 9 w o ABS Front Brake Tube No 1 Vacuum Hose Bracket Front Brake Tube No 5 w ABS Front Brake Tube No 2 43 440 32 Front Brake Tube No 3 Front Brake Tube No 5 15 155 11 15 155 11 15 155 11 13 130 9 15 155 11 3 way 2 way 1MZ FE Engine Type BRAKE BRAKE BOOSTER ASSY 32 19 2007 Author Date 2002 CAMRY REPAIR MANUA...

Page 546: ...emove the 2 bolts and separate the charcoal canister from the body 5 DISCONNECT VACUUM HOSE ASSY a Remove the bolt and separate the vacuum hose from the vacuum hose bracket b Slide the clip and disconnect the vacuum hose from the brake booster 6 REMOVE FRONT DOOR SCUFF PLATE LH See page 71 12 7 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 8 REMOVE INSTRUMENT PANEL SUB ASSY UPPER See page 71 12...

Page 547: ...SSY a Remove the 4 nuts and clevis b Pull out the brake booster assy 14 REMOVE BRAKE BOOSTER GASKET 15 INSTALL BRAKE BOOSTER GASKET a Install a new brake booster gasket to the brake booster 16 INSTALL BRAKE BOOSTER ASSY a Install the brake booster with the 4 nuts Torque 13 N m 130 kgf cm 9 ft lbf 17 INSTALL FRONT BRAKE TUBE NO 5 a Using SST and install the front brake tube No 5 Torque 15 N m 155 k...

Page 548: ...E TRIM SUB ASSY LH See page 71 12 23 INSTALL FRONT DOOR SCUFF PLATE LH See page 71 12 24 INSTALL VACUUM HOSE ASSY a Install the vacuum hose and vacuum hose bracket to the body with a bolt Torque 5 4 N m 55 kgf cm 48 in lbf b Connect the vacuum hose to the brake booster with the clip 25 CONNECT CHARCOAL CANISTER ASSY 1MZ FE ENGINE TYPE a Install the charcoal canister with the 2 bolts Torque 43 N m ...

Page 549: ... BRAKE BRAKE BOOSTER ASSY 32 23 2011 Author Date 2002 CAMRY REPAIR MANUAL RM881U 32 CHECK BRAKE FLUID LEAKAGE 33 CHECK AND ADJUST BRAKE PEDAL HEIGHT See page 32 6 ...

Page 550: ...Cylinder Slide Bush Front Disc Brake Bush Dust Boot Front Disc Brake Bush Dust Boot Front Disc Brake Cylinder Slide Pin Front Disc Brake Cylinder Mounting LH Front Disc Brake Pad Support Plate Disc brake grease Lithium soap base glycol grease Non reusable part N m kgf cm ft lbf Specified torque Anti Squeal Shim No 2 Anti Squeal Shim No 1 Front Disc Brake Pad Pad Wear Indicator Plate Anti Squeal Sh...

Page 551: ...inder then disconnect the flexible hose from the disc brake cylinder 4 REMOVE DISC BRAKE CYLINDER ASSY FR LH a Remove the 2 bolts and disc brake cylinder 5 REMOVE DISC BRAKE PAD KIT FRONT PAD ONLY a Remove the 2 brake pads with anti squeal shim 6 REMOVE ANTI SQUEAL SHIM KIT FRONT a Remove the 2 anti squeal shims from each of 2 brake pads b Using a screwdriver remove the wear indicator from each of...

Page 552: ...ing 10 REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH a Remove the cylinder slide bush from the cylinder slide pin 11 REMOVE FRONT DISC BRAKE BUSH DUST BOOT a Remove the 2 bush dust boots from the disc brake cylinder mounting 12 REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH a Remove the 2 bolts and disc brake cylinder mounting LH 13 REMOVE CYLINDER BOOT a Using a screwdriver remove the set ring and cy...

Page 553: ...damage the inner cylinder and the cylinder groove 16 REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP 17 REMOVE FRONT DISC BRAKE BLEEDER PLUG 18 INSPECT BRAKE CYLINDER AND PISTON a Check the cylinder bore and piston for rust or scoring 19 INSPECT PAD LINING THICKNESS a Using a ruler measure the pad lining thickness Standard thickness 12 0 mm 0 472 in Minimum thickness 1 0 mm 0 039 in 20 INSPECT FRONT DISC...

Page 554: ...en the disc with hub nuts Torque 103 N m 1 050 kgf cm 76 ft lbf b Using a dial indicator measure the disc runout 10 mm 0 39 in away from the outer edge of the disc Maximum disc runout 0 05 mm 0 0020 in c If the disc s runout is maximum value or greater check the bearing play in the axial direction and check the axle hub runout See page 30 2 If the bearing play and axle hub runout are not abnormal ...

Page 555: ... Torque 107 N m 1 090 kgf cm 79 ft lbf 32 INSTALL FRONT DISC BRAKE BUSH DUST BOOT a Apply the lithium soap base glycol grease to seal surface of 2 new bush dust boots b Install the 2 bush dust boots to the disc brake cylinder mounting 33 INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH a Apply the lithium soap base glycol grease to a new cylinder slide bush b Install the cylinder slide bush to the cyl...

Page 556: ...NLY a Install the 2 pads with the pad wear indicator plate facing upward NOTICE There should be no oil or grease adhering to the friction surfaces of the pads and the disc 39 INSTALL DISC BRAKE CYLINDER ASSY FR LH a Install the disc brake cylinder with the 2 bolts Torque 34 N m 350 kgf cm 25 ft lbf 40 CONNECT FRONT FLEXIBLE HOSE a Install a new gasket and flexible hose with the union bolt Torque 2...

Page 557: ...isc Brake Piston Cylinder Boot Set Ring Rear Disc Brake Bush Dust Boot Rear Disc Brake Cylinder Slide Pin 39 2 400 29 Rear Disc Brake Pad Support Plate No 1 Rear Disc Brake Cylinder Mounting LH Anti Squeal Shim No 1 Rear Disc Brake Pad Rear Disc Brake Pad 61 8 630 46 61 8 630 46 Parking Brake Shoe Adjusting Hole Plug Rear Disc Anti Squeal Shim No 2 Pad Wear Indicator Plate TMC made Pad Wear Indica...

Page 558: ...Piston Cylinder Boot Set Ring Anti Squeal Shim No 4 Anti Squeal Shim No 3 Pad Wear Indicator Plate Rear Disc Brake Cylinder Mounting LH Anti Squeal Shim No 1 Anti Squeal Shim No 2 Rear Disc Brake Pad Support Plate No 2 Rear Disc Brake Pad Support Plate No 1 Rear Disc Brake Pad Rear Disc Brake Pad Rear Disc Brake Bush Dust Boot 8 3 85 74 in lbf Disc brake grease Lithium soap base glycol grease Non ...

Page 559: ...er slide pin and cylinder slide bush 5 REMOVE DISC BRAKE CYLINDER ASSY RR LH a TMC made Lift up the disc brake cylinder and remove the disc brake cylinder b TMMK made Remove the cylinder slide pin and disc brake cylinder 6 REMOVE DISC BRAKE PAD KIT REAR PAD ONLY a Remove the 2 brake pads with the anti squeal shim 7 REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM KIT a Remove the 2 anti squeal shims and pa...

Page 560: ...atter the brake fluid 14 REMOVE PISTON SEAL a Using a screwdriver remove the piston seal from the brake cylinder NOTICE Do not damage the inner cylinder and the cylinder groove 15 REMOVE REAR DISC BRAKE BLEEDER PLUG CAP 16 REMOVE REAR DISC BRAKE BLEEDER PLUG 17 INSPECT BRAKE CYLINDER AND PISTON a Check the cylinder bore and piston for rust or scoring 18 INSPECT PAD LINING THICKNESS a Using a ruler...

Page 561: ... lbf b Using dial indicator measure the disc runout 10 mm 0 39 in away from the outer edge of the disc Maximum disc runout 0 15 mm 0 0059 in c If the disc s runout is maximum value or greater check the bearing play in the axial direction and check the axle hub runout See page 30 2 If the bearing play and axle hub runout are not abnormal adjust the disc runout or grind it on a On car brake lathe 27...

Page 562: ...475 kgf cm 34 ft lbf 34 INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN a TMC made Using a hexagon wrench 8 mm install the cylinder slide pin Torque 39 2 N m 400 kgf cm 29 ft lbf b TMMK made Install the cylinder slide pin with the cylinder slide bush Torque 43 N m 440 kgf cm 32 ft lbf 35 INSTALL REAR DISC BRAKE CYLINDER SLIDE BUSH TMC MADE a Apply the lithium soap base glycol grease on a new cylin der ...

Page 563: ...AD KIT REAR PAD ONLY a Install the 2 brake pads with the anti squeal shim NOTICE There should be no oil or grease on to the friction surface of the pads and the disc 41 INSTALL DISC BRAKE CYLINDER ASSY RR LH TMC MADE a Apply the lithium soap base glycol grease to the cylinder slide pin b Install the disc brake cylinder assembly rear LH to the cylinder slide pin 42 INSTALL REAR DISC BRAKE CYLINDER ...

Page 564: ...matic Adjusting Lever LH E ring Adjusting Lever Spring Rear Disc Brake Bleeder Plug High temperature grease Lithium soap base glycol grease Non reusable part N m kgf cm ft lbf Specified torque 8 3 85 74 in lbf 10 100 7 Parking Brake Shoe Strut Set LH Rear Brake Shoe 15 2 155 11 Rear Brake Drum Sub assy Rear Disc Brake Bleeder Plug Cap 32 38 BRAKE REAR DRUM BRAKE 2026 Author Date 2002 CAMRY REPAIR ...

Page 565: ...in the brake drum and hold the automatic adjusting lever away from the adjuster b Using a screwdriver reduce the brake shoe adjustment by turning the adjuster c Remove the rear brake drum sub assy 4 INSPECT BRAKE DRUM INSIDE DIAMETER a Using a brake drum gauge or equivalent measure the in side diameter of the drum Standard inside diameter 228 0 mm 8 976 in Maximum inside diameter 230 6 mm 9 079 in...

Page 566: ...2 cups shoe hold down spring and pin SST 09718 00010 b Using a screwdriver disconnect the parking brake cable from the anchor plate c Using needle nose pliers disconnect the parking brake cable from the lever and remove the rear shoe NOTICE Do not allow oil or grease on the rubbing face 10 REMOVE REAR BRAKE AUTOMATIC ADJUST LEVER LH a Remove the adjusting lever spring b Remove the E ring c Remove ...

Page 567: ... grind drum the brake shoe lining to fit If the contact between the drum and the shoe lining is improper repair it using a brake shoe grinder or replace the brake shoe assembly 14 REMOVE LH FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSY a Using SST disconnect the brake tube use a container to catch brake fluid SST 09751 36011 b Remove the 2 bolts and wheel cylinder 15 REMOVE REAR WHEEL CYLINDER CUP...

Page 568: ...cylinder 22 INSTALL LH FRONT OR UPPER REAR WHEEL BRAKE CYLINDER ASSY a Install the wheel cylinder with the 2 bolts Torque 10 N m 100 N m 7 ft lbf b Using SST connect the brake tube SST 09751 36011 Torque 15 N m 155 N m 11 ft lbf 23 APPLICATION HIGH TEMPERATURE GREASE a Apply the high temperature grease to the parts indicates by arrows See page 32 38 24 INSTALL PARKING BRAKE SHOE LEVER LH a Install...

Page 569: ... spring and 2 cups SST 09718 00010 27 INSTALL PARKING BRAKE SHOE STRUT SET LH a Apply the high temperature grease to the part indicated by arrow See page 32 38 b Install the parking brake shoe strut set LH as shown in the installation c Connect the shoe return spring to the rear shoe 28 INSTALL FRONT BRAKE SHOE a Using SST install the front brake shoe pin shoe hold down spring and cup SST 09718 00...

Page 570: ... REAR BRAKE DRUM SUB ASSY 33 ADJUST REAR DRUM BRAKE SHOE CLEARANCE HINT If the brake drum cannot be removed easily do the following steps a Insert a bent wire or equivalent through the hole in the brake drum and hold the automatic adjusting lever away from the adjuster b Using a screwdriver reduce the brake shoe adjustment by turning the adjuster 34 FILL RESERVOIR WITH BRAKE FLUID 35 BLEED MASTER ...

Page 571: ...ue 103 N m 1 050 kgf cm 76 ft lbf 40 CHECK PARKING BRAKE LEVER TRAVEL LEVER TYPE PARKING BRAKE See page 33 2 41 CHECK PARKING BRAKE PEDAL TRAVEL PEDAL TYPE PARKING BRAKE See page 33 2 42 ADJUST PARKING BRAKE LEVER TRAVEL LEVER TYPE PARKING BRAKE See page 33 2 43 ADJUST PARKING BRAKE PEDAL TRAVEL PEDAL TYPE PARKING BRAKE See page 33 2 ...

Page 572: ...an 20 seconds e Turn the motor relay OFF and release the brake pedal 3 INSPECT RIGHT FRONT WHEEL OPERATION NOTICE Never turn ON the solenoid which is not described below a With the brake pedal depressed perform the following operations b Turn the SFRH and SFRR solenoid ON simultaneously and check that the pedal cannot be depressed NOTICE Do not keep solenoid ON for more than 10 seconds continuousl...

Page 573: ...Y 32 47 2035 Author Date 2002 CAMRY REPAIR MANUAL RM881U REPLACEMENT 1 DRAIN BRAKE FLUID NOTICE Wash off the brake fluied immediately if it comes into contact with a painted surface 2 REMOVE BRAKE ACTUATOR WITH BRACKET a Using SST disconnect the 6 brake lines from the actuator ...

Page 574: ...ake a memo to identify the place to recon nect c Disconnect the brake actuator connector d Remove the 3 nuts and brake actuator with bracket 3 REMOVE BRAKE ACTUATOR ASSY a Remove the 2 nuts and brake actuator from the bracket b Remove the 2 holders and 3 cushions from the brake actuator 4 INSTALL BRAKE ACTUATOR ASSY a Install the 3 cushions and 2 holders to the brake actuator b Install the brake a...

Page 575: ...To RR W C BRAKE BRAKE ACTUATOR ASSY 32 49 2037 Author Date 2002 CAMRY REPAIR MANUAL RM881U 5 INSTALL BRAKE ACTUATOR WITH BRACKET a Install the brake actuator with the 3 nuts Torque 19 N m 194 kgf cm 14 ft lbf b Connect the brake actuator connector c Using SST connect the each brake line to the correct position of brake actuator as shown in the illustration SST 09023 00100 Torque 15 N m 155 kgf cm ...

Page 576: ...RY REPAIR MANUAL RM881U 6 FILL RESERVOIR WITH BRAKE FLUID 7 BLEED MASTER CYLINDER See page 32 4 SST 09023 00100 8 BLEED BRAKE LINE See page 32 4 9 CHECK FLUID LEVEL IN RESERVOIR 10 CHECK BRAKE FLUID LEAKAGE 11 CHECK OPERATION OF BRAKE ACTUATOR See page 32 46 ...

Page 577: ...al of more than 20 seconds e Turn the motor relay OFF and release the brake pedal 3 INSPECT RIGHT FRONT WHEEL OPERATION NOTICE Never turn ON the solenoid which is not described below a With the brake pedal depressed perform the following operations b Turn the SFRH and SFRR solenoid ON simultaneously and check that the pedal cannot be depressed NOTICE Do not keep solenoid ON for more than 10 second...

Page 578: ...ct the master cylinder pressure sensor connec tor and harness clamp c Using SST disconnect the 6 brake lines from the actuator SST 09023 00100 d Use tags or make a memo to identify the place to recon nect e Disconnect the actuator connector f Remove the 3 nuts and brake actuator with bracket 3 REMOVE ABS TRACTION ACTUATOR ASSY a Remove the 2 nuts and ABS TRACTION actuator from the bracket b Remove...

Page 579: ...Torque 19 N m 194 kgf cm 14 ft lbf b Connect the brake actuator connector c Using SST connect the each brake line to the correct position of brake actuator as shown in the illustration SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 6 FILL RESERVOIR WITH BRAKE FLUID 7 BLEED MASTER CYLINDER See page 32 4 SST 09023 00100 8 BLEED BRAKE LINE See page 32 4 9 CHECK FLUID LEVEL IN RESERVOIR 10 CHECK B...

Page 580: ...aster cylinder pressure Rear wheel cylinder pressure 2 452 kPa 25 kgf cm2 356 psi 2 452 kPa 25 kgf cm2 356 psi 4 413 kPa 45 kgf cm2 639 psi 3 177 kPa 32 kgf cm2 460 psi 7 845 kPa 80 kgf cm2 1 138 psi 4 413 kPa 45 kgf cm2 639 psi HINT When inspecting the fluid pressure inspect the left front and right rear together and the right front and left rear together If the rear wheel cylinder pressure is im...

Page 581: ... b Remove the bolt and proportioning valve assy from the body 2 INSTALL PROPORTIONING VALVE ASSY a Install the proportioning valve assy with the bolt Torque 5 4 N m 55 kgf cm 48 in lbf b Using SST connect the 5 brake tubes to the proportioning valve assy SST 09023 00100 Torque 15 2 N m 155 kgf cm 11 ft lbf 3 FILL RESERVOIR WITH BRAKE FLUID 4 BLEED MASTER CYLINDER See page 32 4 SST 09023 00100 5 BL...

Page 582: ... RH side by the same procedures with LH side 1 REMOVE FRONT WHEEL 2 REMOVE FRONT FENDER LINER LH 3 REMOVE SPEED SENSOR FRONT LH a Disconnect the speed sensor connector and clamp b Remove the 2 clamp bolts holding the sensor harness and clamp from the body and shock absorber c Remove the bolt and speed sensor FR LH NOTICE Do not stick and foreign matter on the sensor tip ...

Page 583: ... sure the sensor tip is clean b Install the sensor harness clamps with the 2 bolts A and B to the body and shock absorber Torque Bolt A 5 0 N m 51 kgf cm 44 in lbf Bolt B 18 8 N m 192 kgf cm 14 ft lbf c Connect the clamp to the knuckle d Connect the speed sensor connector and clamp 5 INSTALL FRONT FENDER LINER LH 6 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 7 CHECK ABS SPEED SENSOR ...

Page 584: ...INT Replace the RH side by the same procedure with LH side 1 REMOVE REAR WHEEL 2 DISCONNECT SKID CONTROL SENSOR WIRE a Disconnect the connector from the skid control sensor 3 REMOVE REAR DISC BRAKE CALIPER ASSY LH See page 32 33 4 REMOVE REAR DISC 5 REMOVE REAR AXLE HUB BEARING ASSY LH a Remove the 4 bolts and rear axle hub bearing assy ...

Page 585: ...0 00020 NOTICE If a damage is inflicted to the sensor rotor replace the axle hub assembly Do not scratch the contacting surface of axle hub and speed sensor 7 INSTALL SKID CONTROL SENSOR a Clean the contacting surface of the axle hub and a new skid control sensor NOTICE Make sure the sensor rotor is clean b Place the speed sensor on the axle hub so that the con nector is positioned as shown in the...

Page 586: ... DISC 10 INSTALL REAR DISC BRAKE CALIPER ASSY LH See page 32 33 11 CONNECT SKID CONTROL SENSOR WIRE 12 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 13 INSPECT TIRE See page 27 3 14 MEASURE VEHICLE HEIGHT See page 27 3 15 INSPECT SIDE SLIP See page 27 3 16 INSPECT CAMBER See page 27 3 17 INSPECT TOE IN See page 27 3 18 ADJUST CAMBER AND TOE IN See page 27 3 19 CHECK ABS SPEED SENSOR SIG...

Page 587: ...MOVE YAWRATE SENSOR a Disconnect the yawrate sensor connector b Remove the 2 bolts and yawrate sensor 4 INSTALL YAWRATE SENSOR a Install the yawrate sensor with the 2 bolts Torque 12 5 N m 127 kgf cm 9 ft lbf b Connect the yawrate sensor connector 5 INSTALL RR CONSOLE BOX See page 71 12 6 INSTALL CONSOLE PANEL UPPER REAR See page 71 12 7 PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION See page 05 45...

Page 588: ...10 09952 05010 09953 05020 09954 05021 9 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 60 25 10 REMOVE STEERING COLUMN COVER See page 60 25 11 REMOVE SPIRAL CABLE SUB ASSY See page 60 25 12 REMOVE STEERING SENSOR 13 INSTALL STEERING SENSOR 14 INSPECT SPIRAL CABLE SUB ASSY a If the following condition is identified replace the spiral cable sub assy with new one Condition Scratches or cracks on th...

Page 589: ... Disconnect the skid control ECU connectors and remove the skid control ECU assy 4 INSTALL SKID CONTROL ECU ASSY a Connect the skid control ECU connectors b Install the skid control ECU to the reinforcement with the 2 nuts Torque 5 5 N m 56 kgf cm 49 in lbf 5 INSTALL INSTRUMENT PANEL SUB ASSY LOWER See page 71 25 6 INSTALL INSTRUMENT PANEL UNDER COVER SUB ASSY NO 1 See page 71 25 7 PERFORM YAWRATE...

Page 590: ... indicate the priority of the likely cause of the problem Check each part in order If necessary replace these parts Symptom Suspect Area See page Brake drag 1 Parking brake pedal or lever travel Out of adjustment 2 Parking brake wire Sticking 3 Parking brake shoe clearance Out of adjustment 4 Parking brake shoe lining Cracked or distorted 5 Tension or return spring Damaged 33 2 33 12 33 16 33 19 3...

Page 591: ...L TRAVEL PEDAL TYPE PARKING BRAKE a Depress the parking brake pedal 3 notches to make a room for the procedure and loosen the lock nut b Return the parking brake pedal to the original position c Turn the adjusting nut until the parking brake pedal travel is correct d Depress the parking brake pedal 3 notches to make a room for the procedure and tighten the lock nut Torque 5 4 N m 55 kgf cm 48 in l...

Page 592: ...ub assy Adjusting Nut Parking Brake Switch Assy Parking Brake Cable Assy No 1 N m kgf cm ft lbf Specified torque 23 235 17 23 235 17 23 235 17 Parking Brake Lever Sub assy Air Duct Rear No 1 PARKING BRAKE PARKING BRAKE 33 3 2054 Author Date PARKING BRAKE COMPONENTS ...

Page 593: ...ock Nut Adjusting Nut Parking Brake Control Pedal Assy Parking Brake Switch Assy Tension Spring Parking Brake Cable Assy No 1 Clip 39 398 29 39 398 29 Parking Brake Control Pedal Assy Parking Pedal Pad Return Spring Damper 33 4 PARKING BRAKE PARKING BRAKE 2055 Author Date ...

Page 594: ...e Control Pedal Models 12 5 128 9 Parking Brake Equalizer Parking Brake Cable Assy No 3 5 4 55 48 in lbf 5 4 55 48 in lbf 7 8 80 69 in lbf Parking Brake Cable Assy No 4 Parking Brake Cable Heat Insulator Parking Brake Cable 5 4 55 48 in lbf 8 0 85 73 in lbf 8 0 85 73 in lbf PARKING BRAKE PARKING BRAKE 33 5 2056 Author Date ...

Page 595: ...king Brake Shoe Return Tension Spring Parking Brake Shoe Strut LH Parking Brake Shoe Strut Compression Spring Parking Brake Shoe Shoe Hold down Spring Cup Shoe Adjusting Screw Set Parking Brake Shoe Return Tension Spring Rear Disc Hole Plug Adjusting Bolt Shoe Hold down Spring C Washer Shim 47 480 35 Parking Brake Shoe Lever Adjusting Bolt 33 6 PARKING BRAKE PARKING BRAKE 2057 Author Date ...

Page 596: ...ing brake cable No 1 and remove the parking brake lever sub assy 4 REMOVE PARKING BRAKE SWITCH ASSY a Remove the screw and parking brake switch assy 5 INSTALL PARKING BRAKE SWITCH ASSY a Install the parking brake switch assy with the screw 6 INSTALL PARKING BRAKE LEVER SUB ASSY a Connect the parking brake cable to the lever and install the adjusting nut and lock nut b Install the paking brake leve...

Page 597: ...33 8 PARKING BRAKE PARKING BRAKE LEVER SUB ASSY 2059 Author Date 10 ADJUST PARKING BRAKE LEVER TRAVEL See page 33 2 ...

Page 598: ... See page 71 12 3 REMOVE FRONT DOOR SCUFF PLATE LH See page 71 12 4 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 5 REMOVE INSTRUMENT PANEL SUB ASSY UPPER See page 71 12 6 REMOVE INSTRUMENT PNL INSERT SUB ASSY LWR LH See page 71 12 7 REMOVE PARKING BRAKE CONTROL PEDAL ASSY a Disconnect the parking brake switch connector b Remove the 2 bolts nut and parking brake control pedal assy 8 REMOVE PARK...

Page 599: ...ALL PARKING PEDAL PAD 14 INSTALL RETURN SPRING DAMPER 15 INSTALL TENSION SPRING 16 INSTALL PARKING BRAKE SWITCH ASSY a Install the parking brake switch assy with the screw 17 INSTALL PARKING BRAKE CABLE ASSY NO 1 a Install the parking brake cable assy No 1 with the clip ad justing nut and lock nut 18 INSTALL PARKING BRAKE CONTROL PEDAL ASSY a Install the parking brake control pedal assy with the 2...

Page 600: ...LH See page 71 12 20 INSTALL INSTRUMENT PANEL SUB ASSY UPPER See page 71 12 21 INSTALL COWL SIDE TRIM SUB ASSY LH See page 71 12 22 INSTALL FRONT DOOR SCUFF PLATE LH See page 71 12 23 INSTALL COMBINATION METER ASSY See page 71 12 24 INSTALL INSTRUMENT CLUSTER FINISH PANEL See page 71 12 25 INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL See page 33 2 ...

Page 601: ...ER REAR See page 71 12 6 REMOVE CONSOLE BOX CARPET See page 71 12 7 REMOVE RR CONSOLE BOX See page 71 12 8 REMOVE INSTRUMENT PANEL ASH RECEPTACLE ASSY See page 71 12 9 REMOVE CONSOLE PANEL UPPER See page 71 12 10 REMOVE CONSOLE BOX FRONT See page 71 12 11 REMOVE AIR DUCT REAR NO 1 See page 71 12 12 REMOVE AIR DUCT REAR NO 2 See page 71 12 13 REMOVE CONSOLE BOX DUCT NO 1 See page 71 12 14 REMOVE SH...

Page 602: ...arking brake control pedal assy d Remove the 2 nuts 2 bolts clip and parking brake cable assy No 1 17 REMOVE PARKING BRAKE CABLE ASSY NO 1 LEVER TYPE PARKING BRAKE a Remove the lock nut and adjusting nut from the parking brake cable assy No 1 b Remove the 2 bolts and console box mounting bracket No 2 c Remove the 2 bolts and separate the parking brake cable No 1 from the parking brake equalizer ...

Page 603: ...ssy Torque 5 4 N m 55 kgf cm 48 in lbf c Install the console box mounting bracket No 2 with the 2 bolts Torque 12 5 N m 128 kgf cm 9 ft lbf d Tighten the turn buckle connect the parking brake cable assy No 1 to the parking brake cable assy No 4 Torque 5 4 N m 55 kgf cm 48 in lbf 19 INSTALL PARKING BRAKE CABLE ASSY NO 1 LEVER TYPE PARKING BRAKE a Install the parking brake cable assy No 1 with the 2...

Page 604: ...L INSTRUMENT PANEL ASH RECEPTACLE ASSY See page 71 12 28 INSTALL RR CONSOLE BOX See page 71 12 29 INSTALL CONSOLE BOX CARPET See page 71 12 30 INSTALL CONSOLE PANEL UPPER REAR See page 71 12 31 INSTALL INSTRUMENT PNL INSERT SUB ASSY LWR LH PEDAL TYPE PARKING BRAKE See page 71 12 32 INSTALL INSTRUMENT PANEL SUB ASSY UPPER PEDAL TYPE PARKING BRAKE See page 71 12 33 INSTALL COWL SIDE TRIM SUB ASSY LH...

Page 605: ...separate the rear disc brake caliper assy LH HINT Do not the flexible hose from the brake caliper assy LH 3 REMOVE REAR BRAKE DRUM SUB ASSY DRUM REAR BRAKE TYPE See page 32 39 4 REMOVE REAR DISC DISC REAR BRAKE TYPE See page 33 21 5 REMOVE PARKING BRAKE SHOE See page 33 21 6 REMOVE PARKING BRAKE CABLE HEAT INSULATOR a Remove the 3 nuts and parking brake heat insulator 7 REMOVE PARKING BRAKE CABLE ...

Page 606: ...e assy No 3 with the 2 nuts and bolt Torque 5 4 N m 55 kgf cm 48 in lbf c Install the parking brake cable assy No 3 with the 2 bolts to the backing plate Torque 7 8 N m 80 kgf cm 69 in lbf 9 INSTALL PARKING BRAKE CABLE HEAT INSULATOR a Install the parking brake heat insulator with the 3 nuts Torque 5 4 N m 55 kgf cm 48 in lbf 10 APPLICATION HIGH TEMPERATURE GREASE See page 33 21 11 INSTALL PARKING...

Page 607: ...ARANCE See page 33 21 16 INSTALL REAR DISC BRAKE CALIPER ASSY LH a Install the rear disc brake caliper with the 2 bolts Torque 47 N m 480 kgf cm 35 ft lbf 17 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 18 INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL PEDAL TYPE PARKING BRAKE See page 33 2 19 INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL LEVER TYPE PARKING BRAKE See page 33 2 ...

Page 608: ...Remove the 2 bolts and console box mounting bracket No 2 5 REMOVE YAWRATE SENSOR W VSC See page 32 61 6 REMOVE PARKING BRAKE CABLE ASSY NO 4 a Loosen the turn buckle disconnect the parking brake cable assy No 4 from the parking brake cable assy No 1 b Disconnect the parking brake cable assy No 4 from the parking brake equolizer c Remove the 2 bolts and parking brake cable assy No 4 7 INSTALL PARKI...

Page 609: ... INSTALL YAWRATE SENSOR W VSC See page 32 61 9 INSTALL CONSOLE BOX MOUNTING BRACKET NO 2 a Install the console box mounting bracket No 2 with the 2 bolts Torque 12 5 N m 128 kgf cm 9 ft lbf 10 INSTALL RR CONSOLE BOX See page 71 12 11 INSTALL CONSOLE BOX CARPET See page 71 12 12 INSTALL CONSOLE PANEL UPPER REAR See page 71 12 13 INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL See page 33 2 14 PERFORM...

Page 610: ...C a Release the parking brake and remove the rear disc HINT Put matchmarks on the disc and the axle hub If the disc cannot be removed easily turn the shoe adjust er until the wheel turns freely 4 INSPECT BRAKE DISC INSIDE DIAMERTER a Using a brake drum gauge or equivalent measure the in side diameter of the disc Standard inside diameter 170 mm 6 69 in Maximum inside diameter 171 mm 6 73 in 5 REMOV...

Page 611: ...e 9 INSPECT PARKING BRAKE SHOE LINING THICKNESS a Using a ruler measure the thickness of the shoe lining Standard thickness 2 0 mm 0 079 in Minimum thickness 1 0 mm 0 039 in If the lining thickness is at the minimum thickness or less or if there is severe uneven wear replace the brake shoe 10 INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT a Apply chalk to the inside surface of...

Page 612: ...size Shim Thickness Shim Thickness 0 3 mm 0 012 in 0 9 mm 0 035 in 0 6 mm 0 024 in c Apply the high temperature grease to the adjusting bolt d Install the shoe adjusting screw set and tension spring to the front and rear shoe e Install the 2 pins 4 cups and 2 shoe hold down springs f Connect the parking brake cable to the shoe lever g Install the front and rear parking brake shoe 13 INSTALL PARKIN...

Page 613: ...ub nuts b Remove the hole plug and turn the adjuster and expand the shoes until the disc locks c Contract the shoe adjuster until the disc can rotate smoothly Standard Return 8 notches d Check shoe is no brake drag e Install the hole plug 19 CONNECT REAR DISC BRAKE CALIPER ASSY LH a Install the rear disc brake caliper with the 2 bolts Torque 47 N m 480 kgf cm 35 ft lbf 20 INSTALL REAR WHEEL Torque...

Page 614: ...mperature Fluid temperature 70 80 C 158 176 F a Park the vehicle on a level surface and set the parking brake b With the engine idling and the brake pedal depressed shift the shift lever into all positions from P to L position and return to P position c Take out the dipstick and wipe it clean d Put it back fully into the pipe e Take it out and check that the fluid level is in the HOT posi tion If ...

Page 615: ...ot aim at yourself to prevent accidentally spraying ATF or kerosene on your face 5 The recommended automatic transaxle fluid or kerosene should be used for cleaning 6 After cleaning the parts should be arranged in the correct order for efficient inspection repairs and reassembly 7 When disassembling a valve body be sure to match each valve together with the correspond ing spring 8 New discs for th...

Page 616: ...EMOVE AIR CLEANER HOSE NO 1 5 REMOVE INTAKE AIR RESONATOR SUB ASSY 6 REMOVE ENGINE UNDER COVER LH 7 DISCONNECT TRANSMISSION CONTROL CABLE ASSY a Remove the nut from the control shaft lever b Disconnect the control cable from the control shaft lever c Remove the clip and disconnect the control cable from the control cable bracket 8 REMOVE PARK NEUTRAL POSITION SWITCH ASSY a Disconnect the park neut...

Page 617: ...s and pull out the park neutral position switch 9 INSTALL PARK NEUTRAL POSITION SWITCH ASSY a Install the park neutral position switch to the manual valve shaft b Temporarily install the 2 bolts c Place a new lock plate and tighten the nut Torque 6 9 N m 70 kgf cm 61 in lbf d Temporarily install the control shaft lever e Turn the lever counterclockwise until it stops then turn it clockwise 2 notch...

Page 618: ...position and tighten the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf i Using a screwdriver stake the nut with the lock plate j Install the control shaft lever washer and nut Torque 12 7 N m 130 kgf cm 9 ft lbf 10 INSTALL TRANSMISSION CONTROL CABLE ASSY a Temporarily install the control cable to the control shaft le ver with the nut b Install the control cable and a new clip to the bracket c Connect...

Page 619: ...IFT LEVER POSITION See page 40 47 12 INSPECT SHIFT LEVER POSITION See page 40 47 13 INSPECT PARK NEUTRAL POSITION SWITCH ASSY See page 40 7 14 INSTALL ENGINE UNDER COVER LH 15 INSTALL INTAKE AIR RESONATOR SUB ASSY 16 INSTALL AIR CLEANER HOSE NO 1 17 INSTALL AIR CLEANER ASSY 18 INSTALL ENGINE COVER SUB ASSY NO 1 19 INSTALL BATTERY ...

Page 620: ...r is set in N or P posi tion c Check that the back up light is lit and the reverse warning buzzer sounds only when the shift lever is set in R position If a failure is found check the park neutral position switch for continuity 2 ADJUST PARK NEUTRAL POSITION SWITCH ASSY a Loosen the 2 bolts of park neutral position switch and set the shift lever to the N position b Align the groove with neutral ba...

Page 621: ...OVE FRONT DRIVE SHAFT ASSY RH See page 30 8 3 REMOVE FRONT DRIVE SHAFT ASSY LH See page 30 8 4 REMOVE TRANSMISSION CONTROL CABLE BRACKET NO 2 a Remove the bolt and transmission control cable bracket No 2 5 REMOVE WIRE HARNESS CLAMP a Disconnect the wire harness from the clamps b Remove the 2 bolts and 2 clamps 6 DISCONNECT WIRE HARNESS a Remove the bolt and wire harness 7 REMOVE STARTER ASSY a Dis...

Page 622: ...bolts and transmission control cable brack et No 1 10 REMOVE TRANSMISSION OIL FILLER TUBE SUB ASSY a Remove the ATF level gauge b Disconnect the wire harness clamp from the oil filler tube and remove the bolt and oil filler tube c Remove the O ring from the oil filler tube 11 REMOVE OIL COOLER INLET TUBE NO 1 a Using SST and spanner disconnect the oil cooler inlet tube No 1 SST 09023 12700 12 REMO...

Page 623: ...remove the 6 bolts while holding the crankshaft pulley bolt with a wrench b Remove the 8 bolts c Separate and remove the automatic transaxle 16 REMOVE TORQUE CONVERTER CLUTCH ASSY 17 INSPECT TORQUE CONVERTER CLUTCH ASSY See page 40 20 SST 09350 32014 09351 32010 09351 32020 18 INSTALL TORQUE CONVERTER CLUTCH ASSY a Install the torque converter clutch to the automatic trans axle b Using vernier cal...

Page 624: ... Torque Bolt A 64 N m 650 kgf cm 47 ft lbf Bolt B 44 N m 449 kgf cm 32 ft lbf b Apply a few drops of adhesive to each 2 threads on the tip of the 6 torque converter clutch mounting bolts Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent c Install the 6 torque converter clutch mounting bolts Torque 41 N m 420 kgf cm 30 ft lbf HINT First install green colored bolt and then the 5 bolts 20 IN...

Page 625: ...RACKET NO 1 a Install the control cable bracket No 1 and 2 bolts Torque 11 8 N m 122 kgf cm 9 ft lbf 24 INSTALL OIL COOLER INLET TUBE NO 1 a Temporarily install the oil cooler outlet tube No 1 b Temporarily install the oil cooler inlet tube No 1 c Install the oil cooler tube clamp and bolt Torque 5 4 N m 55 kgf cm 48 in lbf HINT Install them so that the oil cooler tube cushion is positioned as bei...

Page 626: ... harness and bolt Torque 25 5 N m 260 kgf cm 19 ft lbf 28 INSTALL WIRE HARNESS CLAMP a Install the 2 clamps and 2 bolts Torque 8 4 N m 86 kgf cm 74 in lbf b Connect the wire harness to the clamps 29 INSTALL TRANSMISSION CONTROL CABLE BRACKET NO 2 a Install the transmission control cable bracket No 2 with the bolt Torque 11 8 N m 122 kgf cm 9 ft lbf 30 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 ...

Page 627: ...OVE FRONT DRIVE SHAFT ASSY RH See page 30 8 3 REMOVE FRONT DRIVE SHAFT ASSY LH See page 30 8 4 REMOVE TRANSMISSION CONTROL CABLE BRACKET NO 2 a Remove the bolt and transmission control cable bracket No 2 5 REMOVE WIRE HARNESS CLAMP a Disconnect the wire harness from the clamps b Remove the 2 bolts and 2 clamps 6 DISCONNECT WIRE HARNESS a Remove the bolt and wire harness 7 REMOVE STARTER ASSY a Dis...

Page 628: ...bolts and transmission control cable brack et No 1 10 REMOVE TRANSMISSION OIL FILLER TUBE SUB ASSY a Remove the ATF level gauge b Disconnect the wire harness clamp from the oil filler tube and remove the bolt and oil filler tube c Remove the O ring from the oil filler tube 11 REMOVE OIL COOLER INLET TUBE NO 1 a Using SST and spanner disconnect the oil cooler inlet tube No 1 SST 09023 12700 12 REMO...

Page 629: ...olding the crankshaft pulley bolt with a wrench b Remove the 9 bolts c Separate and remove the automatic transaxle 16 REMOVE TORQUE CONVERTER CLUTCH ASSY 17 INSPECT TORQUE CONVERTER CLUTCH ASSY See page 40 20 SST 09350 32014 09351 32010 09351 32020 18 INSTALL TORQUE CONVERTER CLUTCH ASSY a Install the torque converter clutch to the automatic trans axle b Using vernier calipers measure the dimensio...

Page 630: ...gine Torque Bolt A 64 N m 650 kgf cm 47 ft lbf Bolt B 46 N m 470 kgf cm 34 ft lbf Bolt C 44 N m 449 kgf cm 32 ft lbf b Apply a few drops of adhesive to each 2 threads on the tip of the 6 torque converter clutch mounting bolts Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent c Install the 6 torque converter clutch mounting bolts Torque 41 N m 420 kgf cm 30 ft lbf HINT First install green ...

Page 631: ...RACKET NO 1 a Install the control cable bracket No 1 and 2 bolts Torque 11 8 N m 122 kgf cm 9 ft lbf 24 INSTALL OIL COOLER INLET TUBE NO 1 a Temporarily install the oil cooler outlet tube No 1 b Temporarily install the oil cooler inlet tube No 1 c Install the oil cooler tube clamp and bolt Torque 5 4 N m 56 kgf cm 49 in lbf HINT Install them so that the oil cooler tube cushion is positioned as bei...

Page 632: ...ire harness and bolt Torque 25 5 N m 260 kgf cm 19 ft lbf 28 INSTALL WIRE HARNESS CLAMP a Install the 2 clamps and 2 bolts Torque 8 4 N m 86 kgf cm 74 in lbf b Connect the wire harness to the clamps 29 INSTALL TRANSMISSION CONTROL CABLE BRACKET NO 2 a Install the transmission control cable bracket No 2 and bolt Torque 11 8 N m 122 kgf cm 9 ft lbf 30 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 8 ...

Page 633: ...ssary clean the converter and retest the one way clutch Replace the converter if the one way clutch still fails the test b Determine the condition of the torque converter clutch assy 1 If the inspection result of the torque converter clutch assy meets the following item replace the torque converter clutch Malfunction item Any metallic sound is heard from the torque convert er clutch during stall t...

Page 634: ... and clean it again 2 If the ATF is cloudy inspect the oil cooler radiator e Prevent deformation of the torque converter clutch and damage to the oil pump gear 1 When any marks due to interference are found on the end of the bolt for the torque converter clutch and on the bottom of the bolt hole replace the bolt and the torque converter clutch 2 All of the bolts must be the same length 3 The bolts...

Page 635: ...NSOR a Disconnect the transmission revolution sensor connector b Remove the bolt and transmission revolution sensor 6 REMOVE TRANSMISSION REVOLUTION SENSOR NC SENSOR a Disconnect the transmission revolution sensor connector b Remove the bolt and transmission revolution sensor 7 INSTALL TRANSMISSION REVOLUTION SENSOR NC SENSOR a Coat an O ring with ATF b Install the transmission revolution sensor w...

Page 636: ...R NT SENSOR a Coat an O ring with ATF b Install the transmission revolution sensor with the bolt Torque 11 3 N m 115 kgf cm 8 ft lbf HINT Make sure of the manufacturer s name c Connect the transmission revolution sensor connector 9 INSTALL AIR CLEANER HOSE NO 1 10 INSTALL AIR CLEANER ASSY Torque 5 0 N m 51 kgf cm 44 in lbf 11 INSTALL ENGINE COVER SUB ASSY NO 1 ...

Page 637: ...CLEANER HOSE NO 1 5 REMOVE SPEED SENSOR NT SENSOR a Disconnect the speed sensor connector b Remove the bolt and speed sensor 6 REMOVE SPEED SENSOR NC SENSOR a Disconnect the speed sensor connector b Remove the bolt and speed sensor 7 INSTALL SPEED SENSOR NC SENSOR a Coat an O ring with ATF b Install the speed sensor with the bolt Torque 11 3 N m 115 kgf cm 8 ft lbf HINT Make sure of the manufactur...

Page 638: ...R NT SENSOR a Coat an O ring with ATF b Install the speed sensor with the bolt Torque 11 3 N m 115 kgf cm 8 ft lbf HINT Make sure of the manufacturer s name c Connect the speed sensor connector 9 INSTALL AIR CLEANER HOSE NO 1 10 INSTALL AIR CLEANER ASSY Torque 5 0 N m 51 kgf cm 44 in lbf 11 INSTALL ENGINE COVER SUB ASSY NO 1 ...

Page 639: ...the oil pan Remove all pan bolts and carefully remove the oil pan assembly b Remove the 2 magnets from the oil pan c Examine particles in pan 1 Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle Steel magnetic bearing gear and plate wear Brass non magnetic bear...

Page 640: ...ture sensor with ATF b Install the ATF temperature sensor with the lock plate and bolt Torque 6 6 N m 67 kgf cm 58 in lbf c Connect the 5 shift solenoid valve connectors 8 INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB ASSY a Install the 2 magnets in the oil pan b Apply seal packing or equivalent to 18 bolts Seal packing THREE BOND 2430 or equivalent c Install a new gasket oil pan and 18 bolts to the tra...

Page 641: ...TOMATIC TRANSMISSION TRANS TRANSMISSION WIRE 2103 Author Date 2002 CAMRY REPAIR MANUAL RM881U 9 ADD AUTOMATIC TRANSAXLE FLUID 10 INSPECT AUTOMATIC TRANSAXLE FLUID See page 40 1 11 INSTALL ENGINE UNDER COVER LH ...

Page 642: ...il pan Remove all pan bolts and carefully remove the oil pan assembly b Remove the 2 magnets from the oil pan c Examine particles in pan 1 Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle Steel magnetic bearing gear and plate wear Brass non magnetic bearing w...

Page 643: ...ve body assy and remove the 17 bolts and the valve body assy NOTICE Be careful not to drop the check valve body spring and ac cumulator piston b Remove the check ball body and spring c Remove the 5 bolts and 5 shift solenoid valves 7 INSTALL TRANSMISSION VALVE BODY ASSY a Install the 5 shift solenoid valves with the 5 bolts Torque Bolt A 6 6 N m 67 kgf cm 58 in lbf Bolt B 10 8 N m 110 kgf cm 8 ft ...

Page 644: ... N m 110 kgf cm 8 ft lbf NOTICE Push the valve body against the accumulator piston spring and the check ball body to install it Tighten those bolts marked by in the illustration first temporarily because they are positioning bolts Bolt length Bolt A 25 mm 0 984 in Bolt B 41 mm 1 614 in Bolt C 45 mm 1 771 in 8 INSTALL VALVE BODY OIL STRAINER ASSY a Coat a new O ring with ATF b Install the O ring to...

Page 645: ...olenoid valve connectors 10 INSTALL AUTOMATIC TRANSAXLE OIL PAN SUB ASSY a Install the 2 magnets in the oil pan b Apply seal packing or equivalent to 18 bolts Seal packing THREE BOND 2430 or equivalent c Install a new gasket oil pan and 18 bolts to the transaxle case Torque 7 8 N m 80 kgf cm 69 in lbf NOTICE Because the bolts should be seal bolts apply seal packing to bolts and tighten them within...

Page 646: ... ATF b Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 5 REMOVE FRONT DRIVE SHAFT ASSY RH See page 30 8 6 REMOVE FRONT DRIVE SHAFT ASSY LH See page 30 8 7 REMOVE TRANSAXLE HOUSING OIL SEAL a Using SST pull out the oil seal SST 09308 00010 8 REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL a Using SST pull out the oil seal SST 09308 00010 9 INSTALL TRANSAXLE HOUSING OIL SEA...

Page 647: ...50 Oil seal drive in depth 0 0 5 mm 0 0 020 in b Coat the lip of the oil seal with MP grease 11 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 8 12 INSTALL FRONT DRIVE SHAFT ASSY RH See page 30 8 13 INSTALL ENGINE UNDER COVER LH 14 INSTALL ENGINE UNDER COVER RH 15 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 16 ADD AUTOMATIC TRANSAXLE FLUID 17 INSPECT AUTOMATIC TRANSAXLE FLUID See page...

Page 648: ... ATF b Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 5 REMOVE FRONT DRIVE SHAFT ASSY RH See page 30 8 6 REMOVE FRONT DRIVE SHAFT ASSY LH See page 30 8 7 REMOVE TRANSAXLE HOUSING OIL SEAL a Using SST pull out the oil seal SST 09308 00010 8 REMOVE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL a Using SST pull out the oil seal SST 09308 00010 9 INSTALL TRANSAXLE HOUSING OIL SEA...

Page 649: ...50 Oil seal drive in depth 0 0 5 mm 0 0 020 in b Coat the lip of the oil seal with MP grease 11 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 8 12 INSTALL FRONT DRIVE SHAFT ASSY RH See page 30 8 13 INSTALL ENGINE UNDER COVER RH 14 INSTALL ENGINE UNDER COVER LH 15 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 16 ADD AUTOMATIC TRANSAXLE FLUID 17 INSPECT AUTOMATIC TRANSAXLE FLUID See page...

Page 650: ...ng the shift lever with the shift lock release button pressed and the ignition key in ACC or ON check that the lever can be shifted to any other position 3 CHECK KEY INTERLOCK OPERATION a Turn the ignition switch to ON b Depress the brake pedal and shift the shift lever to any other positions other than P c Check that the ignition key cannot be turned to LOCK d Shift the shift lever to P position ...

Page 651: ...ISSION TRANS SHIFT LOCK SYSTEM 2113 Author Date 2002 CAMRY REPAIR MANUAL RM881U b Using an ohmmeter measure the resistance at terminal E 1 and body ground Terminal Measuring Condition Specified Value 1 E Body ground Always Continuity ...

Page 652: ...EMOVE CONSOLE PANEL UPPER See page 71 12 7 REMOVE CONSOLE BOX FRONT See page 71 12 8 REMOVE AIR DUCT REAR NO 1 See page 71 12 9 REMOVE AIR DUCT REAR NO 2 See page 71 12 10 REMOVE CONSOLE BOX DUCT NO 1 See page 71 12 11 DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Disconnect the parking lock cable from the transmission floor shift assy 12 DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT ...

Page 653: ...ing a screwdriver release the stopper of the connector d Using a small screwdriver disengage the locking lug of the terminals 3 and 4 and pull the terminals out from the rear e Disconnect the wire harness from the clamps and re move the indicator lamp wire f Remove the indicator lamp cap and indicator lamp bulb from the indicator lamp wire sub assy 15 REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB ASSY a...

Page 654: ...OVE SHIFT LEVER KNOB BUTTON a Using a screwdriver release the claw and remove the shift lever knob button b Remove the compression spring 19 REMOVE SHIFT LOCK RELEASE BUTTON COVER a Using a screwdriver remove the shift lock release button cover 20 REMOVE POSITION INDICATOR HOUSING UPPER a Using a screwdriver release the 4 claws and remove the position indicator housing upper 21 REMOVE POSITION IND...

Page 655: ...rewdriver release the 4 claws and remove the position indicator housing lower 25 REMOVE SHIFT LOCK CONTROL UNIT ASSY a Remove the toggle lever support pin and shift lock control unit assy 26 REMOVE SHIFT LEVER INSERT NO 1 a Remove the 4 shift lever No 1 inserts from the shift lever control plate 27 INSTALL SHIFT LEVER INSERT NO 1 a Install the 4 shift lever No 1 inserts to the shift lever control ...

Page 656: ...elease spring and shift lock release button b Install the shift lock release button and shift lock release spring to the position indicator housing lower HINT Fit the claws securely 31 INSTALL POSITION INDICATOR SLIDE COVER 32 INSTALL POSITION INDICATOR HOUSING COVER 33 INSTALL POSITION INDICATOR HOUSING UPPER a Install the control position indicator housing upper HINT Fit the claws securely 34 IN...

Page 657: ...ll the position indicator slide cover to the shift lever 38 INSTALL FLOOR SHIFT SHIFT LEVER KNOB SUB ASSY a Install the wire harness of the transmission control switch b Install the shift lever knob to the shift lever with 2 screws c Install the position indicator slide cover to the shift lever knob 39 INSTALL INDICATOR LAMP WIRE SUB ASSY a Install the indicator lamp bulb and indicator lamp cap to...

Page 658: ...TRANSMISSION CONTROL SHIFT a Connect the floor shift cable to the floor shift assy HINT Install it with the uneven surface facing to up Fit the claws securely 42 CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Set the accessory tool 1 Shift the shift lever to P position and turn the ignition switch to LOCK TMC made 2 Shift the shift lever to N position and turn the ignition switch to ACC TMMK made 3...

Page 659: ...be set to ACC TMMK Made e Remove the accessory tool Accessory tool parts NO TMC Made 33693 33010 TMMK Made 33693 06010 43 CHECK KEY INTERLOCK OPERATION See page 40 37 44 CHECK SHIFT LOCK OPERATION See page 40 37 45 CHECK SHIFT LOCK RELEASE BUTTON OPERATION See page 40 37 46 INSTALL CONSOLE BOX DUCT NO 1 47 INSTALL AIR DUCT REAR NO 2 48 INSTALL AIR DUCT REAR NO 1 49 INSTALL CONSOLE BOX FRONT 50 INS...

Page 660: ...essing the shift lever knob button D 2 L N R P Positions which can be operated only while pressing the shift lever knob button ignition switch ON and brake pedal depressed P R b Start the engine and make sure that the vehicle moves forward when shifting the lever from N to D position and moves rearward when shifting to R position 2 ADJUST SHIFT LEVER POSITION a Loosen the nut on the control shaft ...

Page 661: ...e 50 9 or 50 22 SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 10 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 71 12 11 REMOVE STEERING COLUMN COVER See page 50 9 or 50 22 12 REMOVE FRONT DOOR SCUFF PLATE LH See page 71 12 13 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 14 REMOVE INSTRUMENT PANEL COIN BOX SUB ASSY See page 71 12 15 REMOVE INSTRUMENT PANEL SUB ASSY UPPER See...

Page 662: ...OVE CONSOLE BOX DUCT NO 1 See page 55 29 27 REMOVE FLOOR SHIFT PARKING LOCK CABLE ASSY a Disconnect the parking lock cable end from the lever pin of the floor shift assembly b Using a screwdriver disconnect the parking lock cable from the floor shift assembly and clamp c Disconnect the cable clamp d Turn the ignition switch to ACC or ON e Using a screwdriver remove the cable from the upper bracket...

Page 663: ...gnition switch to ACC or ON b Connect the cable to the upper bracket c Connect the cable clamp d Insert the slide cap into the through hole and install e Set the accessory tool 1 Shift the shift lever to P position and turn the ignition switch to LOCK TMC made 2 Shift the shift lever to N position and turn the ignition switch to ACC TMMK made 3 Set the accessory tool to the shift lock control unit...

Page 664: ...set to LOCK TMC Made At this time the shift lever should be in N position and the ignition key should be set to ACC TMMK Made i Remove the accessory tool Accessory tool parts No TMC Made 33693 33010 TMMK Made 33693 06010 29 CHECK KEY INTERLOCK OPERATION See page 40 37 30 INSTALL CONSOLE BOX DUCT NO 1 31 INSTALL AIR DUCT REAR NO 1 32 INSTALL AIR DUCT REAR NO 2 33 INSTALL CONSOLE BOX FRONT 34 INSTAL...

Page 665: ...STALL INSTRUMENT CLUSTER FINISH PANEL 47 INSTALL STEERING WHEEL ASSY See page 50 9 or 50 22 48 INSPECT STEERING WHEEL CENTER POINT 49 INSTALL HORN BUTTON ASSY See page 50 9 or 50 22 50 INSTALL STEERING WHEEL COVER LOWER NO 2 See page 50 6 51 INSTALL STEERING WHEEL COVER LOWER NO 3 W O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL See page 50 6 52 INSTALL CONNECTOR COVER W STEERING PAD SWITCH 4 SPOKE ...

Page 666: ...55 29 3 REMOVE AIR BAG SENSOR ASSY CENTER See page 60 56 4 REMOVE BATTERY 5 REMOVE AIR CLEANER ASSY 6 REMOVE AIR CLEANER HOSE NO 1 7 REMOVE INTAKE AIR RESONATOR SUB ASSY 8 DISCONNECT SHIFT CABLE GROMMET RETAINER NO 2 a Remove the 2 bolts and disconnect shift cable grommet retainer No 2 9 REMOVE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT a Remove the nut from the control shaft lever b Disconnect ...

Page 667: ...ll out the control cable from the body g Remove the shift cable grommet retainer No 2 10 INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT a Put in the control cable to the body b Install the shift cable grommet retainer No 2 to the floor shift cable c Install the floor shift cable as shown in the illustration HINT Install it with the uneven surface facing to up Fit the claws securely d Connect...

Page 668: ...T CABLE GROMMET RETAINER NO 2 a Install the shift cable grommet retainer No 2 with the 2 bolts Torque 4 9 N m 50 kgf cm 43 in lbf 12 INSTALL AIR BAG SENSOR ASSY CENTER See page 60 56 13 INSTALL AIR CONDITIONING RADIATOR ASSY 14 ADJUST SHIFT LEVER POSITION See page 40 47 15 INSPECT SHIFT LEVER POSITION See page 40 47 16 INSTALL INTAKE AIR RESONATOR SUB ASSY 17 INSTALL AIR CLEANER HOSE NO 1 18 INSTA...

Page 669: ...ecessary replace or exchange these parts Symptom Suspect Area See page Noise 1 Oil Level low 2 Oil Wrong 3 Gear Worn or damaged 4 Bearing Worn or damaged 41 2 41 2 41 15 41 15 Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn or damaged 4 O Ring Worn or damaged 41 2 41 15 41 15 41 15 Hard to shift or will not shift 1 Control cable Faulty 2 Synchronizer ring Worn or damaged 3 Shift ...

Page 670: ...e the transmission filler plug and gasket c Check that the oil surface is within 5 mm 0 20 in from the lowest position of the inner surface of the transmission fill er plug opening NOTICE Excessively large or small amount of oil may cause troubles After exchanging oil drive the vehicle and check the oil level d Check for oil leakage when the oil level is low e Install the transmission filler plug ...

Page 671: ...0 8 SST 09520 01010 09520 24010 09520 32040 4 REMOVE FRONT DRIVE SHAFT ASSY RH See page 30 8 5 REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL a Using SST remove the oil seal SST 09308 00010 6 REMOVE TRANSMISSION CASE OIL SEAL a Using SST remove the oil seal SST 09308 00010 7 INSTALL FRONT TRANSAXLE CASE COVER OIL SEAL a Coat a new oil seal lip with MP grease b Using SST and a hammer install the oil se...

Page 672: ...138 0 020 in NOTICE Be careful not to damage the oil seal lip 9 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 8 10 INSTALL FRONT DRIVE SHAFT ASSY RH See page 30 8 11 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 12 ADD MANUAL TRANSAXLE OIL Oil grade API GL 4 or GL 5 Viscosity SAE 75W 90 Capacity 2 5 liters 2 6 US qts 2 2 lmp qts Torque 49 N m 500 kgf cm 36 ft lbf 13 INSPECT AND ADJUST ...

Page 673: ... b Turn the lock and separate the shift cable from the shift lever retainer 8 REMOVE FLOOR SHIFT SHIFT LEVER ASSY a Remove the 4 bolts and shift lever assy 9 INSTALL FLOOR SHIFT SHIFT LEVER ASSY a Install the shift lever assy with 4 the bolts Torque 12 N m 122 kgf cm 9 ft lbf 10 CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT a Connect the shift cable to the shift lever retainer NOTICE The pr...

Page 674: ...nstall the clip NOTICE The serrate part of the select cable point should face upward when the select cable point is connected the clip should be inserted to the direction shown in the illustration 12 INSTALL AIR DUCT REAR NO 2 See page 55 29 13 INSTALL AIR DUCT REAR NO 1 See page 55 29 14 REMOVE CONSOLE BOX FRONT See page 71 12 15 REMOVE RR CONSOLE BOX 16 REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB AS...

Page 675: ...f the shift cable from the transaxle b Remove the clip and shift cable from the control cable bracket c Turn the lock and separate the shift cable from the shift lever retainer d Separate the top of the shift cable from the shift lever assy e Remove the 2 retainer set bolts from the floor f Separate the retainer from the grommet g Remove the select cable from the grommet h Remove the shift cable t...

Page 676: ...re that after installation the cable outer lock is projecting from A shown in the illustration f Install the top of the shift cable to the shift lever assy g Connect the shift cable to the control cable bracket and install a new clip h Connect the shift cable to the transaxle and install the washer and clip 6 INSTALL AIR BAG SENSOR ASSY CENTER See page 60 56 7 INSTALL AIR CONDITIONING RADIATOR ASS...

Page 677: ... cable from the transaxle b Remove the clip and select cable from the control cable bracket c Turn the lock and separate the select cable from the shift lever retainer d Remove the clip and separate the top of the select cable from the shift lever assy e Remove the 2 retainer set bolts from the floor f Separate the retainer from the grommet g Remove the select cable from the grommet h Remove the s...

Page 678: ... to the shift lever assy and install the clip NOTICE The serrate part of the select cable point should face upward when the select cable point is connected the clip should be inserted to the direction shown in the illustration g Connect the top of the select cable to the shift lever assy and install the clip h Connect the select cable to the control cable bracket and install a new clip i Connect t...

Page 679: ...22 2 REMOVE FRONT DRIVE SHAFT ASSY RH See page 30 8 3 REMOVE FRONT DRIVE SHAFT ASSY LH See page 30 8 4 DISCONNECT WIRE HARNESS a Disconnect the wire harness clamp b Disconnect the back up lamp switch connector and start er connector 5 REMOVE ENGINE WIRE NO 3 a Remove the bolt and engine wire No 3 6 REMOVE WIRE HARNESS CLAMP a Remove the 2 bolts and 2 wire harness clamps 7 REMOVE STARTER ASSY a Rem...

Page 680: ...Remove the 2 bolts and manual transmission case pro tector 10 REMOVE EXHAUST PIPE SUPPORT BRACKET NO 1 a Remove the 2 bolts and exhaust pipe support bracket No 1 11 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR a Remove the 4 bolts and engine mounting insulator 12 REMOVE MANUAL TRANSAXLE ASSY a Remove the 10 bolts b Separate and remove the transaxle from the engine 13 INSTALL MANUAL TRANSAXLE...

Page 681: ... the engine mounting insulator with the 4 bolts Torque 64 N m 653 kgf cm 47 ft lbf HINT Tighten them in the order A B C and D 15 INSTALL EXHAUST PIPE SUPPORT BRACKET NO 1 a Install the exhaust pipe support bracket No 1 with the 2 bolts Torque 8 0 N m 82 kgf cm 71 in lbf 16 INSTALL MANUAL TRANSMISSION CASE PROTECTOR a Install the manual transmission case protector with the 2 bolts Torque 18 N m 184...

Page 682: ...stall the wire harness clamps with the 2 bolts Torque 8 0 N m 82 kgf cm 71 in lbf 20 INSTALL ENGINE WIRE NO 3 a Install the engine wire No 3 with the bolt Torque 25 5 N m 260 kgf cm 19 ft lbf 21 CONNECT WIRE HARNESS a Connect the wire harness clamp b Connect the back up lamp switch connector and starter connector 22 INSTALL FRONT DRIVE SHAFT ASSY LH See page 30 8 23 INSTALL FRONT DRIVE SHAFT ASSY ...

Page 683: ...BEARING ASSY a Remove the clutch release bearing assy and clutch release bearing hub clip from the clutch release fork sub assy 3 REMOVE RELEASE FORK SUPPORT a Remove the release fork support from the manual trans axle case 4 REMOVE CLUTCH RELEASE FORK BOOT a Remove the clutch release fork boot from the manual transaxle case 5 REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB ASSY a Remove the bolt and spe...

Page 684: ...the nut and spring washer b Using a brass bar and hammer remove the shift outer lock pin c Remove the control shift lever 8 REMOVE CONTROL SHAFT COVER a Remove the 4 bolts and control shaft cover from the manual transmission case 9 FIX MANUAL TRANSAXLE ASSY a Using wooden blocks fix the manual transaxle assy 10 REMOVE LOCK BALL ASSY NO 1 a Remove the lock ball assy No 1 from the manual trans missi...

Page 685: ...SELECT LEVER SHAFT ASSY a Remove the shift select lever shaft assy from the manu al transmission case 13 REMOVE BACK UP LAMP SWITCH ASSY a Remove the back up lamp switch assy and gasket from the manual transmission case 14 REMOVE MANUAL TRANSMISSION FILLER PLUG a Remove the manual transmission filler plug and gasket from the manual transmission case 15 REMOVE DRAIN MTM PLUG SUB ASSY a Remove the d...

Page 686: ...VE MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT a Engage the gear to the double meshing b Using SST and a hammer loosen the staked part of the manual transmission output shaft rear set nut SST 09930 00010 c Using SST remove the manual transmission output shaft rear set nut from the output shaft SST 09229 55010 d Disengage the double meshing of the gear 18 INSPECT 5TH GEAR THRUST CLEARANCE a Using...

Page 687: ...t gear needle roller bearing 20 REMOVE TRANSMISSION CLUTCH HUB NO 3 a Using 2 screwdrivers and hammer remove the transmis sion clutch hub No 3 shaft snap ring from the input shaft HINT Using a waste to prevent the snap ring from being scattered b Remove the gear shift fork bolt from the gear shift fork No 3 c Using SST remove the transmission clutch hub No 3 and gear shift fork No 3 from the input...

Page 688: ...put shaft SST 09950 30012 09951 03010 09953 03010 09954 03010 09957 04010 09950 60010 09951 00180 09955 03011 09950 50013 24 REMOVE BEARING RETAINER REAR MTM a Using a torx socket wrench T45 remove the 7 torx screws and bearing retainer rear MTM from the manual transmission case 25 REMOVE OUTPUT SHAFT REAR BEARING SHIM a Remove the output shaft rear bearing shim from the out put shaft 26 REMOVE IN...

Page 689: ... a waste to prevent the snap ring from being scattered b Using 2 screw drivers and a hammer remove the shift fork shaft shaft snap ring from the gear shift fork shaft No 2 HINT Using a waste to prevent the snap ring from being scattered 28 REMOVE REVERSE IDLER GEAR SHAFT BOLT a Remove the reverse idler gear shaft bolt and gasket 29 REMOVE CLUTCH TUBE BRACKET NO 1 a Remove the 3 bolts and remove th...

Page 690: ...IPE NO 2 MTM a Remove the bolt and oil receiver pipe No 2 MTM from the manual transmission case NOTICE Do not damage the pipe 32 REMOVE OIL RECEIVER PIPE NO 1 MTM a Remove the bolt and oil receiver pipe No 1 MTM from the manual transmission case NOTICE Do not damage the pipe 33 REMOVE REVERSE RESTRICT PIN ASSY a Using a hexagon wrench 6 mm remove the reverse re strict pin plug from the manual tran...

Page 691: ...s axle case 35 REMOVE REVERSE IDLER GEAR SUB ASSY a Remove the reverse idler gear sub assy from the manual transaxle case b Remove the reverse gear and reverse idler thrust washer from the reverse idler gear shaft 36 REMOVE REVERSE SHIFT ARM BRACKET ASSY a Remove the 2 bolts and reverse shift arm bracket from the manual transaxle case 37 REMOVE GEAR SHIFT FORK SHAFT NO 1 a Remove the shift fork bo...

Page 692: ... a hammer remove the shift fork shaft snap ring from the gear shift fork shaft No 1 NOTICE Using a waste to prevent the snap ring from being scat tered 38 REMOVE REVERSE SHIFT FORK ROLLER a Using a magnetic finger remove the reverse shift fork roll er from the reverse shift fork 39 REMOVE GEAR SHIFT FORK SHAFT NO 2 a Remove the 2 shift fork bolts from the gear shift fork No 2 and gear shift head N...

Page 693: ...FT NO 3 a Remove the gear shift fork shaft No 3 from the manual transaxle case b Using 2 screwdriver and a hammer remove the 2 shift fork shaft snap rings from the gear shift fork shaft No 3 c Remove the reverse shift fork from the gear shift fork shaft No 3 42 REMOVE GEAR SHIFT FORK NO 2 a Remove the gear shift fork No 2 from the input shaft assy 43 REMOVE INPUT SHAFT ASSY a Incline the output sh...

Page 694: ...case assy from the manual trans axle case 46 REMOVE MANUAL TRANSAXLE CASE RECEIVER a Remove the 3 bolts and manual transaxle case receiver from the manual transaxle case 47 REMOVE INPUT SHAFT FRONT BEARING a Using SST remove the input shaft front bearing outer race from the manual transaxle case SST 09612 65014 09612 01040 09612 01050 48 REMOVE FRONT TRANSAXLE CASE OIL SEAL a Using SST remove the ...

Page 695: ...MTM COVER a Remove the output shaft MTM cover from the manual transaxle case 51 REMOVE OUTPUT SHAFT REAR BEARING a Using SST remove the output shaft rear bearing from the manual transmission case outer race SST 09950 60010 09951 00680 09950 70010 09951 07100 52 REMOVE TRANSMISSION CASE OIL SEAL a Using SST remove the transmission case oil seal from the manual transmission case SST 09308 00010 53 R...

Page 696: ...T 09950 00020 09950 00030 09950 40011 09957 04010 09950 60010 09951 00560 55 REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING a Using SST and hammer remove the FR differential case front tapered roller bearing outer race and FR differen tial case rear shim from the manual transmission case SST 09950 60020 09951 00790 09950 70010 09951 07100 b Using SST remove the FR differential case front...

Page 697: ...uter diameter mm in Standard outer diameter Minimum outer diameter 19 984 20 000 0 7868 0 7874 19 984 0 7868 If the outer diameter is less than the minimum replace the re verse idler gear shaft 58 REMOVE TRANSMISSION HUB SLEEVE NO 3 a Remove the transmission hub sleeve No 3 from the trans mission clutch hub No 3 59 REMOVE SYNCHROMESH SHIFTING KEY SPRING NO 3 a Push the synchromesh shifting key spr...

Page 698: ...gear shift fork No 3 and calculate the clearance Standard clearance 0 15 0 35 mm 0 0059 0 0138 in A B If the clearance is out of the specification replace the transmis sion hub sleeve No 3 and gear shift fork No 3 with the new one 63 INSPECT 5TH GEAR a Using a calipers gauge measure the inside diameter of the 5th gear Inside diameter mm in Standard inside diameter Maximum inside diameter 34 981 34...

Page 699: ...to the transmission clutch hub No 3 NOTICE Align the projection of the shifting key spring with the hole of the clutch hub No 3 and install them b Install the synchronizer ring set and synchromesh shifting key spring No 3 to the transmission clutch hub No 3 NOTICE Engage the shifting key spring claw to the center of the teeth of the synchronizer ring Align the projection of the shifting key spring...

Page 700: ...R TAPERED ROLLER BEARING a Using SST and a hammer install the FR differential case rear tapered roller bearing outer race to the front trans axle case SST 09950 60020 09951 00910 09950 70010 09951 07100 b Using SST and press install the FR differential case rear tapered roller bearing inner race to the front differential case SST 09950 70010 09951 07100 09951 07150 09608 10010 70 INSTALL FR DIFFER...

Page 701: ...depth 3 5 0 5 mm 0 138 0 020 in b Coat the lip of transmission case oil seal with MP grease 72 INSTALL OUTPUT SHAFT REAR BEARING a Using SST and a hammer install the output shaft rear bearing outer race to the manual transmission case SST 09950 60020 09951 00680 09950 70010 09951 07100 Clearance 3 8 4 4 mm 0 150 0 173 in 73 INSTALL OUTPUT SHAFT MTM COVER a Coat the output shaft MTM cover with MP g...

Page 702: ...ts to the manual transaxle case Torque 29 N m 296 kgf cm 21 ft lbf c Install the 3 bolts to the manual transaxle side Torque 30 N m 306 kgf cm 22 ft lbf d Install the output shaft rear bearing shim to the output shaft HINT Install the same thickness of case shim as the removed one e Using a torx socket wrench T45 install the bearing re tainer RR with 7 screws to the manual transmission case Torque...

Page 703: ...9001 1 30 0 0512 0 90564 59002 1 35 0 0531 1 90564 59003 1 40 0 0551 2 90564 59004 1 45 0 0571 3 90564 59005 1 50 0 0591 4 90564 59006 1 55 0 0610 5 90564 59007 1 60 0 0630 6 90564 59008 1 65 0 0650 7 90564 59009 1 70 0 0669 8 90564 59010 1 75 0 0689 9 90564 5901 1 1 80 0 0709 A 90564 59012 1 85 0 0728 B 90564 59013 1 90 0 0748 C 90564 59014 1 95 0 0768 D 90564 59015 2 00 0 0787 E 90564 59016 2 05...

Page 704: ...81U l Remove the output shaft rear bearing shim from the out put shaft m Remove the 3 bolts n Remove the 14 bolts and manual transmission case from the manual transaxle case o Remove the output shaft assy from the front manual transaxle case 76 ADJUST TAPERED POLLER BEARING PRELOAD a Install differential case assy to the manual transaxle case ...

Page 705: ...0 8 1 6 8 16 16 32 7 1 14 2 Used 0 5 1 0 5 10 10 2 4 4 8 9 If the preload is out of the specification select the front differen tial case shim RR and adjust it HINT The preload of the front differential case shim RR varies in torque from about 0 04 to 0 06 N m is one size Shim mm in Part No Thickness Mark 90564 56055 2 00 0 0787 0 90564 56056 2 05 0 0807 1 90564 56057 2 10 0 0827 2 90564 56058 2 1...

Page 706: ... Remove the 14 bolts and manual transmission case to the manual transaxle case h Remove the differential case assy from the manual trans axle case 77 INSTALL FRONT TRANSAXLE CASE OIL SEAL a Using SST and a hammer install the front transaxle case oil seal No 1 to the manual transaxle case SST 09950 60010 09951 00420 09950 70010 09951 07150 b Coat the lip of front transaxle case oil seal No 1 with M...

Page 707: ...ual transaxle case receiver to the manual transaxle case Torque 7 0 N m 71 kgf cm 62 in lbf 80 INSTALL DIFFERENTIAL CASE ASSY a Coat the differential case taper roller bearing with gear oil install the differential case assy to the manual transaxle case 81 INSTALL OUTPUT SHAFT ASSY a Apply gear oil to each sliding part of the output shaft assy b Lift the differential case assy up with the output s...

Page 708: ...fork No 3 to the gear shift fork shaft No 3 b Using a brass bar and hammer install the 2 shift fork shaft snap rings to the gear shift fork shaft c Apply gear oil to each sliding part of the gear shift fork shaft No 3 install it to the manual transaxle case 85 INSTALL GEAR SHIFT FORK NO 1 a Apply gear oil to each sliding part of the gear shift fork No 1 install it to the output shaft assy 86 INSTA...

Page 709: ...45 kgf cm 18 ft lbf 87 INSTALL REVERSE SHIFT FORK ROLLER a Using a magnetic finger install the reverse shift fork roller to the reverse shift fork 88 INSTALL GEAR SHIFT FORK SHAFT NO 1 a Using a brass bar and hammer install the shift fork shaft snap ring to the shift fork shaft No 1 b Install the gear shift fork shaft No 1 to the manual trans axle case c Install the shift fork bolt to the gear shi...

Page 710: ...LER GEAR SUB ASSY a Coat the reverse idler gear and reverse idler thrust wash er with MP grease install them to the reverse idler gear shaft b Install the reverse idler gear to the manual transaxle case HINT Align the mark of the reverse idler gear shaft with the hole of the bolt 91 INSTALL TRANSMISSION MAGNET a Clean the transmission magnet install it to the manual transaxle case 92 INSTALL REVER...

Page 711: ... kgf cm 13 ft lbf HINT Tighten the oil receiver pipe No 1 with the bolt 94 INSTALL OIL RECEIVER PIPE NO 2 MTM a Install the bolt and oil receiver pipe No 2 MTM to the manual transmission case Torque 17 N m 173 kgf cm 13 ft lbf HINT Tighten the oil receiver pipe No 2 MTM with the bolt while manual transmission case is being put 95 INSTALL MANUAL TRANSMISSION CASE a Apply FIPG bead condition sequent...

Page 712: ... 17 N m 173 kgf cm 13 ft lbf 97 INSTALL REVERSE IDLER GEAR SHAFT BOLT a Coat the bolt with sealant install new gasket to the manu al transmission case with the bolt Torque 30 N m 306 kgf cm 22 ft lbf Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent 98 INSTALL SHIFT FORK SHAFT SHAFT SNAP RING a Using a brass bar and hammer install the shift fork shaft snap ring to the gear shif...

Page 713: ... rear bearing shim to the output shaft HINT Install the same thickness of the case shim as the remove one 101 INSTALL BEARING RETAINER REAR MTM a Coat the bearing retainer rear MTM with sealant install it with a torx wrench T45 Torque 42 N m 428 kgf cm 31 ft lbf 102 INSTALL 5TH DRIVEN GEAR a Using SST install the 5th driven gear to the output shaft SST 09950 30012 09951 03010 09953 03010 09954 030...

Page 714: ...projection of the synchronizer ring with the hole of the 5th gear and install them b Install the transmission hub sleeve No 3 and gear shift fork No 3 to the transmission clutch hub No 3 c Coat the shift fork bolt with sealant install the gear shift fork No 3 Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 24 N m 245 kgf cm 18 ft lbf d Select a snap ring that will allo...

Page 715: ...20 27068 2 10 2 15 0 0827 0 0846 h 90520 27069 2 15 2 20 0 0846 0 0866 j 106 INSPECT 5TH GEAR RADIAL CLEARANCE a Using a dial indicator inspect the 5th gear radial clear ance Standard clearance 0 009 0 050 mm 0 0004 0 0020 in If the clearance is out of the specification replace 1st gear needle roller bearing 107 INSPECT 5TH GEAR THRUST CLEARANCE a Using a dial indicator inspect the 5th gear thrust...

Page 716: ...shaft rear set nut 109 INSTALL MANUAL TRANSMISSION CASE COVER SUB ASSY a Apply FIPG to the transaxle case cover sub assy as shown in the installation FIPG Part No 08826 00090 THREE BOND 1281 NOTICE Install the parts within 10 minutes after applying the pack ing material FIPG b Install the transmission case cover sub assy with 10 bolts to the manual transaxle case 110 INSTALL DRAIN MTM PLUG SUB ASS...

Page 717: ...a Coat the shift select lever shaft assy with gear oil install it to the manual transmission case 113 INSTALL BACK UP LAMP SWITCH ASSY a Install back up lamp switch assy to the manual transmis sion case Torque 40 N m 408 kgf cm 30 ft lbf 114 INSTALL MANUAL TRANSMISSION BREATHER PLUG a Install the new gasket with manual transmission breather plug to the manual transmission case Torque 49 N m 500 kg...

Page 718: ...tall the spring washer with nat Torque 6 4 N m 65 kgf cm 57 in lbf 118 INSTALL SELECTING BELL CRANK ASSY a Coat the 2 bolts with sealant install it with selecting bell crank assy to the manual transmission case Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 20 N m 204 kgf cm 15 ft lbf 119 INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB ASSY a Install the bolt and speedomete...

Page 719: ...SE BEARING ASSY a Coat the clutch release bearing assy with release hub grease install it to the clutch release fork sub assy Sealant Part No 08887 01806 RELEASE HUB GREASE or equivalent b Apply clutch spline grease to the input shaft spline 123 INSTALL CLUTCH RELEASE FORK SUB ASSY a Install the clutch release fork sub assy to the input shaft ...

Page 720: ...ce 0 10 0 57 mm 0 0039 0 0224 in 2 INSPECT 3RD GEAR THRUST CLEARANCE a Using a dial indicator measure the 3rd gear thrust clear ance Standard clearance 0 10 0 35 mm 0 0039 0 0138 in 3 INSPECT 4TH GEAR RADIAL CLEARANCE a Using a dial indicator measure the 4th gear radial clear ance Standard clearance mm in Bearing Standard clearance KOYO made 0 009 0 053 0 0004 0 0021 NSK made 0 009 0 051 0 0004 0 ...

Page 721: ...If the clearance exceeds the maximum replace the 3rd gear needle roller bearing 5 REMOVE 4TH GEAR a Hold the input shaft assy and soft jaws with a vise b Using a 2 screwdrivers and a hammer remove the input shaft rear bearing shaft snap ring from the input shaft NOTICE Using a waste to prevent the snap ring from being scat tered c Using SST and a press remove the input shaft rear bear ing and 4th ...

Page 722: ...h gear bearing spacer from the transmis sion clutch hub No 2 9 REMOVE 3RD GEAR a Using 2 screwdrivers and a hammer remove the clutch hub No 2 setting shaft snap ring from the input shaft NOTICE Using a waste to prevent the snap ring from being scat tered b Using SST and a press remove the transmission clutch hub No 2 and 3rd gear from the input shaft SST 09950 00020 NOTICE Do not tighten SST exces...

Page 723: ...eys and 3 synchromesh shifting key springs from the transmission clutch hub No 2 NOTICE Using a waste to prevent the shifting key and shifting key spring from being scattered 13 REMOVE INPUT SHAFT FRONT BEARING a Using SST and a press remove the input shaft bearing front inner race from the input shaft SST 09950 00020 NOTICE Do not tighten SST excessively 14 INSPECT INPUT SHAFT a Using V block and...

Page 724: ...r is less than the minimum replace the input shaft 15 INSPECT 4TH GEAR a Using a cylinder gauge measure the inside diameter of the 4th gear Inside diameter mm in Standard inside diameter Maximum inside diameter 42 009 42 025 1 6539 1 6545 42 025 1 6545 16 INSPECT 3RD GEAR a Using a cylinder gauge measure the inside diameter of the 3rd gear Inside diameter mm in Standard inside diameter Maximum ins...

Page 725: ... Coat the 3rd gear cone with gear oil Turn the synchroniz er outer ring in one direction while pushing it to the 3rd gear cone Check that the ring locks b Using a feeler gauge measure the clearance between the synchronizer ring No 3 back and 3rd gear spline end Standard clearance 0 65 1 75 mm 0 0256 0 0689 in If the standard clearance is out of specification replace the syn chronizer ring No 3 19 ...

Page 726: ...d gear shift fork No 2 with the new one 20 INSTALL INPUT SHAFT FRONT BEARING a Using SST and a press install the input shaft front bear ing inner race SST 09608 00071 21 INSTALL TRANSMISSION HUB SLEEVE NO 2 a Coat the transmission hub sleeve No 2 with gear oil b Install the 3 synchromesh key springs with transmission hub sleeve No 2 NOTICE Do not install the transmission clutch hub sleeve No 2 and...

Page 727: ...gn the claw of clutch hub No 2 with notch of syn chronizer ring No 3 and install them Make sure that the 3rd gear should rotate b Select a snap ring so that clearance between the trans mission clutch hub No 2 and the clutch hub No 2 shaft snap ring will be the standard clearance Using a brass bar and a hammer install the snap ring Standard clearance 0 1 mm or less 0 0039 or less Snap ring thicknes...

Page 728: ...h hub No 2 NOTICE Align the claw of the clutch hub No 2 with the notch of the 2nd synchronizer outer ring and assemble 28 INSTALL 4TH GEAR NEEDLE ROLLER BEARING a Coat the 4th gear needle roller bearing with gear oil install it to the input shaft 29 INSTALL 4TH GEAR a Coat the 4th gear with gear oil install it to the input shaft 30 INSTALL INPUT SHAFT REAR RADIAL BALL BEARING a Using SST and a pre...

Page 729: ...ark 90520 30008 2 35 2 40 0 0925 0 0945 1 90520 30009 2 40 2 45 0 0945 0 0965 2 90520 30010 2 45 2 50 0 0965 0 0984 3 90520 3001 1 2 50 2 55 0 0984 0 1004 4 90520 30012 2 55 2 60 0 1004 0 1024 5 90520 30013 2 60 2 65 0 1024 0 1043 6 90520 30021 2 65 2 70 0 1043 0 1063 7 90520 30022 2 70 2 75 0 1063 0 1083 8 31 INSPECT 3RD GEAR RADIAL CLEARANCE a Using a dial indicator measure the 3rd gear radial c...

Page 730: ...andard clearance KOYO made 0 009 0 053 0 0004 0 0021 NSK made 0 009 0 051 0 0004 0 0020 If the clearance exceeds the maximum replace the 4th gear needle roller bearing 33 INSPECT 3RD GEAR THRUST CLEARANCE a Using a dial indicator measure the 3rd gear thrust clear ance Standard clearance 0 10 0 35 mm 0 0039 0 0138 in 34 INSPECT 4TH GEAR THRUST CLEARANCE a Using a feeler gauge measure the 4th gear t...

Page 731: ...0 25 0 40 mm 0 0098 0 0157 in 2 INSPECT 2ND GEAR THRUST CLEARANCE a Using a dial indicator measure the 2nd gear thrust clear ance Standard clearance 0 10 0 35 mm 0 0039 0 0138 in 3 INSPECT 1ST GEAR RADIAL CLEARANCE a Using a dial indicator measure the 1st gear radial clear ance Standard clearance mm in Bearing Standard clearance KOYO made 0 009 0 053 0 0004 0 0021 NSK made 0 009 0 051 0 0004 0 002...

Page 732: ...e KOYO made 0 009 0 053 0 0004 0 0021 NSK made 0 009 0 051 0 0004 0 0020 If the clearance is out of the specification replace the 2nd gear needle roller bearing 5 REMOVE 4TH DRIVEN GEAR a Using SST and a press remove the output shaft bearing rear inner race and 4th driven gear SST 09950 00020 6 REMOVE OUTPUT GEAR SPACER a Remove the output gear spacer from the output shaft 7 REMOVE 2ND GEAR a Usin...

Page 733: ... from the transmis sion clutch hub No 1 9 REMOVE 2ND GEAR NEEDLE ROLLER BEARING a Remove the 2nd gear needle roller bearing from the out put shaft 10 REMOVE 2ND GEAR BEARING SPACER a Remove the 2nd gear bearing spacer from the output shaft 11 REMOVE 2ND GEAR BUSH a Remove the 2nd gear bush from the output shaft 12 REMOVE 2ND GEAR BUSH BALL a Using a magnetic finger remove the 2nd gear bush ball fr...

Page 734: ...nchronizer ring set No 1 from the 1st gear 15 REMOVE 1ST GEAR NEEDLE ROLLER BEARING a Remove the 1st gear needle roller bearing from the output shaft 16 REMOVE OUTPUT SHAFT FRONT BEARING a Using SST and a press remove the output shaft front bearing inner race from the output shaft SST 09950 00020 09950 60010 09951 00320 09950 70010 09951 07150 NOTICE Do not tighten SST excessively 17 REMOVE REVERS...

Page 735: ...r diameter is less than the minimum replace the input shaft 19 INSPECT 2ND GEAR a Using a cylinder gauge measure the inside diameter of the 2nd gear Inside diameter mm in Standard inside diameter Maximum inside diameter 50 009 50 025 1 9689 1 9695 50 025 1 9695 If the inside diameter exceeds the maximum replace the 2nd gear 20 INSPECT 1ST GEAR a Using a cylinder gauge measure the inside diameter o...

Page 736: ...niz er ring set No 1 in one direction while pushing it to the 1st gear cone Check that the ring locks b Check the clearance between the synchronizer ring set No 1 and 1st gear while pushing it to the cone of synchro nizer ring set No 1 Standard clearance 0 70 1 45 mm 0 0276 0 0571 in If the standard clearance is out of the specification replace the synchronizer ring set No 1 with a new one 23 INSP...

Page 737: ...erse gear NOTICE Do not set the reverse gear and the transmission clutch hub No 1 in the incorrect direction c Using a screwdriver install the synchromesh sifting key No 1 to the reverse gear 26 INSTALL OUTPUT SHAFT FRONT BEARING a Using SST and a press install the output shaft front bear ing inner race to the output shaft SST 09950 60010 09951 00430 09950 70010 09951 07150 27 INSTALL SYNCHRONIZER...

Page 738: ...b No 1 to the output shaft SST 09316 60011 09316 00031 09950 60010 09951 00320 09950 70010 09951 07100 NOTICE Align the synchronizer ring No 1 with synchromesh shifting key No 1 and install Make sure that the 1st gear rotates 31 INSTALL 2ND GEAR BUSH BALL a Coat the gear bush with MP grease install it to the output shaft 32 INSTALL 2ND GEAR BUSH a Coat the 2nd gear bush with gear oil install it to...

Page 739: ...t the synchronizer ring set No 2 with gear oil install it to the transmission clutch hub No 1 NOTICE Align the key groove on the synchronizer ring set No 2 with the synchromesh shifting key No 1 36 INSTALL 2ND GEAR a Coat the 2nd gear with gear oil install it to the output shaft 37 INSTALL 3RD DRIVEN GEAR a Using SST and a press install the 3rd driven gear to the output shaft SST 09608 00071 09950...

Page 740: ...50 60010 09951 00320 09950 70010 09951 07100 41 INSPECT 2ND GEAR RADIAL CLEARANCE a Using a dial indicator measure the 2nd gear radial clear ance Standard clearance mm in Bearing Standard clearance KOYO made 0 009 0 053 0 0004 0 0021 NSK made 0 009 0 051 0 0004 0 0020 If the clearance is out of the specification replace the 2nd gear needle roller bearing 42 INSPECT 1ST GEAR RADIAL CLEARANCE a Usin...

Page 741: ...NUAL RM881U 43 INSPECT 2ND GEAR THRUST CLEARANCE a Using a dial indicator measure the 2nd gear thrust clear ance Standard clearance 0 10 0 35 mm 0 0039 0 0138 in 44 INSPECT 1ST GEAR THRUST CLEARANCE a Using a feeler gauge measure the 1st gear thrust clear ance Standard clearance 0 25 0 40 mm 0 0098 in 0 0157 in ...

Page 742: ...SH a Remove the control shift lever bush from the selecting bellcrank No 2 2 REMOVE SELECTING BELLCRANK DUST COVER NO 1 a Remove the selecting bellcrank dust cover No 1 from the selecting bellcrank No 2 3 REMOVE SELECTING BELLCRANK SUPPORT SUB ASSY a Remove the nut washer and selecting bellcrank No 2 plate washer from the selecting bellcrank No 2 b Remove the selecting bellcrank support sub assy f...

Page 743: ...lcrank No 2 6 REMOVE SHIFT LEVER INNER NO 2 a Hold the shift select lever on the vise through the soft jaw NOTICE Do not damage the shift select lever shaft b Using a pin punch φ 5 mm remove the shift select le ver inner slotted pin and oil baffle NOTICE Do not damage the shift select lever shaft c Apply the force to the select return spring No 1 and select return spring No 2 then hold it on the v...

Page 744: ... shift select lever shaft b Remove the shift lever assy select return spring No 1 and select spring seat from the shift select lever shaft 8 REMOVE SHIFT INTER LOCK PLATE COVER a Remove the shift inter lock plate cover from the shift inter lock plate 9 REMOVE SHIFT LEVER INNER NO 1 a Remove the shift lever inner No 1 from the shift inter lock plate 10 REMOVE SELECT SPRING NO 1 SEAT SHAFT SNAP RING...

Page 745: ...T 09319 60020 13 INSTALL CONTROL SHAFT COVER BIMETAL FORMED BUSH a Using SST and hammer install a new control shaft cover bimetal formed bush to the control shaft cover SST 09950 60010 09951 00210 09950 70010 09951 07100 Oil seal drive in depth 0 0 25 mm 0 0 010 in 14 INSTALL CONTROL SHAFT COVER OIL SEAL a Using SST and hammer install a new control shaft cover oil seal to the control shaft cover S...

Page 746: ...late 18 INSTALL SELECT SPRING SEAT NO 1 a Install the select spring seat No 1 select return spring No 1 and shift lever inner assy to the shift select lever shaft b Hold the shift select lever on the vise through the soft jaw c Using a pin punch φ 5 mm install the shift lever slotted pin to the shift select lever shaft Clearance 0 5 0 5 mm 0 0197 0 0197 in 19 INSTALL SHIFT LEVER INNER NO 2 a Insta...

Page 747: ...268 in 20 INSTALL SELECTING BELLCRANK NO 2 BUSH a Coat the 2 selecting bellcrank No 2 bushes with MP grease install it to the selecting bellcrank No 2 21 INSTALL SELECTING BELLCRANK DUST COVER NO 2 a Coat the selecting bellcrank dust cover No 2 with MP grease install it to the selecting bellcrank No 2 22 INSTALL SELECTING BELLCRANK SUPPORT SUB ASSY a Install the selecting bellcrank support sub ass...

Page 748: ...2210 Author Date 2002 CAMRY REPAIR MANUAL RM881U 23 INSTALL SELECTING BELLCRANK DUST COVER NO 1 a Install the selecting bellcrank dust cover No 1 to the se lecting bellcrank No 2 24 INSTALL CONTROL SHIFT LEVER BUSH a Install the control shift lever bush to the selecting bell crank No 2 ...

Page 749: ...ront dif ferential case assy 2 REMOVE FRONT DIFFERENTIAL RING GEAR a Place machmarks on the front differential ring gear and from the front differential case b Remove the 16 bolts Using a plastic hammer remove the front differential case 3 INSPECT FRONT DIFFERENTIAL SIDE GEAR BACKLASH a Fixing the front differential pinion to the front differential case side Using a dial indicator measure the fron...

Page 750: ...the front differential pinion shaft No 1 to the front differential case 6 REMOVE FRONT DIFFERENTIAL SIDE GEAR a Remove the 2 front differential pinions 2 front differential pinion thrust washers 2 front differential side gear and 2 front differential side gear thrust washers from the front differential case HINT Revolving front differential pinion remove the 2 pinion thrust washers and side gear t...

Page 751: ...ved one c Install the 2 front differential side gears 2 front differential pinions and 2 front differential side gear thrust washers to the front differential case HINT Revolving the front differential pinion install the 2 front differen tial pinions with front differential washers 10 INSTALL FRONT DIFFERENTIAL PINION SHAFT NO 1 a Coat the rotating surface of the front differential pinion shaft No...

Page 752: ... Standard backlash 0 05 0 2 mm 0 0020 0 0079 in b If the backlash is out of the specification select another front differential side gear thrust washer and adjust it Thrust washer mm in Part No Thickness Mark 41361 28230 1 00 0 0394 1 41361 28240 1 10 0 0433 2 41361 28250 1 20 0 0472 3 41361 28260 1 30 0 0512 4 13 INSTALL FRONT DIFFERENTIAL RING GEAR a Using a heater heat the front differential ri...

Page 753: ...TRANSMISSION TRANSAXLE DIFFERENTIAL CASE ASSY E351 41 85 2215 Author Date 2002 CAMRY REPAIR MANUAL RM881U 14 INSTALL SPEEDOMETER DRIVE MTM GEAR a Install the speedometer drive MTM gear to the front dif ferential case ...

Page 754: ...lutch pedal spongy 1 Clutch Line Air in line 2 Master cylinder cup Damaged 3 Release cylinder rubber Damaged 42 9 42 12 Clutch noisy 1 Release bearing Worn dirty or damaged 2 Clutch disc torsion rubber Damaged 42 14 42 14 Clutch slips 1 Clutch pedal Free play out of adjustment 2 Clutch disc Oily 3 Clutch disc Worn out 4 Diaphragm spring Damaged 5 Pressure plate Distortion 6 Flywheel Distortion 42 ...

Page 755: ...VE INSTRUMENT PNL INSERT SUB ASSY LWR LH See page 71 12 5 REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Remove the clip and hole pin 6 REMOVE CLUTCH PEDAL ASSY a Disconnect the clutch start switch clamp and connector b Remove the bolt 2 nuts and clutch pedal assy 7 REMOVE TURN OVER SPRING SEAT COMPRESSION SPRING a Using a small screwdriver remove the E ring b Remove the compression sp...

Page 756: ... Date 2002 CAMRY REPAIR MANUAL RM881U c Remove the bolt nut and clutch pedal sub assy from clutch pedal support 9 REMOVE CLUTCH PEDAL BUSH a Remove the 2 bushes from the clutch pedal sub assy 10 REMOVE CLUTCH PEDAL TURNOVER BUSH 11 REMOVE OVER CENTER SPRING CAP 12 REMOVE CLUTCH PEDAL PAD 13 REMOVE CLUTCH PEDAL NO 1 CUSHION ...

Page 757: ...TCH MASTER CYLINDER PUSH ROD CLEVIS BUSH a Apply MP grease to inside of a new bush b Install the clevis bush to the clutch pedal sub assy HINT Install the clevis bush from the right side of the vehicle 16 INSTALL CLUTCH PEDAL NO 1 CUSHION 17 INSTALL CLUTCH PEDAL PAD 18 INSTALL OVER CENTER SPRING CAP 19 INSTALL CLUTCH PEDAL TURNOVER BUSH a Apply MP grease to inside of a new bush b Install the bush ...

Page 758: ...SEAT COMPRESSION SPRING a Apply MP grease to the contact surface of the bush and spring b Install the compression spring c Using needle nose pliers install the E ring 23 INSTALL CLUTCH PEDAL ASSY a Install the clutch pedal assy with the bolt and 2 nuts Torque Bolt Nut b Connect the clutch start switch clamp and connector 24 INSTALL CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Apply MP greas...

Page 759: ...STRUMENT PNL INSERT SUB ASSY LWR LH 26 INSTALL INSTRUMENT PANEL SUB ASSY UPPER 27 INSTALL COMBINATION METER ASSEMBLY See page 71 25 28 INSTALL INSTRUMENT CLUSTER FINISH PANEL See page 71 12 29 INSPECT AND ADJUST CLUTCH PEDAL SUB ASSY See page 42 7 30 INSPECT CLUTCH START SWITCH ASSY See page 42 18 ...

Page 760: ...clutch resistance begin to be felt Pedal free play 5 0 15 0 mm 0 197 0591 in 2 Gently depress the pedal until the resistance begins to increase a little Push rod play at pedal top 1 0 5 0 mm 0 039 0 197 in e Adjust the pedal free play and push rod play 1 Remove the instrument panel sub assy upper 2 Remove the instrument panel insert sub assy low er LH 3 Disconnect the air duct 4 Loosen the lock nu...

Page 761: ... point that the gear noise stops release point up to the full stroke end position Standard distance 25 mm 0 98 in or more From pedal stroke end position to release point If the distance is not as specified perform the following opera tions Check pedal height Check push rod play and pedal free play Bleed the clutch line Check the clutch cover assy and disc assy ...

Page 762: ...tch the fluid 5 DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE a Using SST disconnect the flexible hose tube SST 09023 00100 HINT Use a container to catch the fluid 6 REMOVE CLUTCH MASTER CYLINDER PUSH ROD CLEVIS W HOLE PIN a Remove the clip and hole pin 7 REMOVE CLUTCH MASTER CYLINDER ASSY a Remove the 2 nuts and clutch master cylinder assy 8 REMOVE CLUTCH MASTER CYLINDER KIT a Using a p...

Page 763: ...ER CYLINDER KIT a Coat parts with lithium soap base glycol grease shown in the illustration b Install the piston with spring into the cylinder NOTICE Be careful not to damage the inside of the cylinder body c Install the stop plate to the push rod d Install the push rod to the cylinder body e While pushing the piston rod using snap ring pliers install the snap ring f Install the boot to the cylind...

Page 764: ... N m 155 kgf cm 11 ft lbf 13 CONNECT CLUTCH RESERVOIR TUBE a Connect the clutch reservoir tube with the clip to the clutch master cylinder assy NOTICE Connect the clutch reservoir tube so that it will not be twisted 14 INSTALL BRAKE BOOSTER ASSY See page 32 20 15 INSTALL BRAKE MASTER CYLINDER SUB ASSY See page 32 12 16 BLEED MASTER CYLINDER SST 09023 00100 17 BLEED BRAKE LINE See page 32 4 18 BLEE...

Page 765: ...er body c Remove the piston from the cylinder body NOTICE Be careful not to damage the inside of the cylinder body d Remove the spring from the cylinder body e Remove the bleeder plug cap from the bleeder plug 4 REMOVE RELEASE CYLINDER BLEEDER PLUG 5 INSTALL RELEASE CYLINDER BLEEDER PLUG Torque 8 3 N m 85 kgf cm 73 in lbf 6 INSTALL CLUTCH RELEASE CYLINDER KIT a Install the bleeder plug cap to the ...

Page 766: ... 2 bolts Torque 11 8 N m 120 kgf cm 9 ft lbf 8 CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE a Using SST connect the flexible hose tube SST 09023 00100 Torque 15 2 N m 155 kgf cm 11 ft lbf 9 BLEED CLUTCH PIPE LINE a Fill the brake reservoir tank with clutch fluid and bleed clutch system Torque 8 3 N m 85 kgf cm 73 in lbf 10 CHECK CLUTCH FLUID LEAKAGE 11 CHECK FLUID LEVEL IN RESERVOIR ...

Page 767: ...7 REMOVE CLUTCH COVER ASSY a Place the matchmarks on the clutch cover assy with the one on the flywheel sub assy b Loosen each set bolt one turn at a time until spring tension is released c Remove the set bolts and pull off the clutch cover assy NOTICE Do not drop the clutch disc assy 8 REMOVE CLUTCH DISC ASSY NOTICE Keep the lining part of the clutch disc assy the pressure plate and surface of th...

Page 768: ... COVER ASSY a Using vernier calipers inspect the diaphragm spring for depth and width of wear Maximum A Depth 0 5 mm 0 020 in B Width 6 0 mm 0 236 in If necessary replace clutch cover assy 11 INSPECT FLYWHEEL SUB ASSY a Using a dial indicator inspect the flywheel sub assy run out Maximum runout 0 1 mm 0 004 in If necessary replace the flywheel sub assy 12 INSPECT CLUTCH RELEASE BEARING ASSY a Turn...

Page 769: ...r the knock pin on the top Torque 19 1 N m 195 kgf cm 14 ft lbf HINT Following the order in the illustration tighten the bolts at a time evenly Move SST up and down right and left lightly after check ing that the disc is in the center tighten the bolts 15 INSPECT AND ADJUST CLUTCH COVER ASSY a Using a dial indicator with roller instrument check the dia phragm spring tip alignment Maximum non align...

Page 770: ...or equivalent b Install the release fork to the release bearing assy 19 INSTALL CLUTCH RELEASE BEARING ASSY a Apply the clutch spline grease to the input shaft spline Sealant Part No 08887 01706 CLUTCH SPLINE GREASE or equivalent b Install the the release fork with release bearing assy to the manual transaxle assy NOTICE After the installation move the folk forward and backward to check that the r...

Page 771: ...02 CAMRY REPAIR MANUAL RM881U CLUTCH START SWITCH ASSY ON VEHICLE INSPECTION 1 CHECK CLUTCH START SYSTEM a Check that the engine does not start when the clutch ped al is released b Check that the engine starts when the clutch pedal is fully depressed If necessary replace the clutch start switch assy ...

Page 772: ...TART SWITCH ASSY 42 19 2234 Author Date 2002 CAMRY REPAIR MANUAL RM881U INSPECTION 1 INSPECT CLUTCH START SWITCH ASSY a Check the continuity between terminals when the switch is ON and OFF Switch position Condition ON pushed Continuity OFF free No continuity ...

Page 773: ...a Disconnect the clutch start switch assy connector b Remove the nut and clutch start switch assy from the clutch pedal support 2 INSTALL CLUTCH START SWITCH ASSY a Install the clutch start switch assy with the nut Torque 15 68 N m 160 kgf cm 12 ft lbf b Connect the clutch start switch assy connector 3 INSPECT CLUTCH START SWITCH ASSY See page 42 18 ...

Page 774: ...zard 2 HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM a The CAMRY is equipped with SRS Supplemental Restraint System such as the driver airbag and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing including removal or installation of parts inspection or...

Page 775: ...nt Incorrect 5 Steering system joints Worn 6 Suspension arm ball joints Worn 7 Steering column Binding 8 Power steering vane pump 9 Power steering gear 28 1 51 3 14 5 14 140 26 5 26 17 51 8 51 17 51 29 Poor return 1 Tires Improperly inflated 2 Front wheel alignment Incorrect 3 Steering column Binding 4 Power steering gear 28 1 26 5 51 29 Excessive play 1 Steering system joints Worn 2 Suspension ar...

Page 776: ...0 3 2238 Author Date 2002 CAMRY REPAIR MANUAL RM881U ON VEHICLE INSPECTION 1 CHECK STEERING WHEEL FREEPLAY a Stop the vehicle and face the tires straight ahead b Rock the steering wheel gently up and down by your hand check the steering wheel freeplay Maximum freeplay 30 mm 1 18 in ...

Page 777: ...p center of the steering wheel and steering column upper cover 2 Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph 56 km h and hold the steering wheel to maintain the course 3 Draw a line on the masking tape as shown in the il lustration 4 Turn the steering wheel to its straight position HINT Refer to the upper surface of the steering wheel steering spoke and SRS ai...

Page 778: ...g a paper gauge measure the distance from RH and LH tie rod ends to the rack end screws HINT Measure the RH side and LH side Make a note of the measured values 3 Remove the RH and LH boot clips from the rack boots 4 Loosen the RH and LH lock nuts 5 Turn the RH and LH rack end by the same amount but in different directions according to the steering angle 1 turn 360 deg of rack end 1 5 mm 0 059 in h...

Page 779: ...ermediate Shaft Sub assy Instrument Panel Sub assy Upper Door Scuff Plate Cowl Side Trim Sub assy Clamp Instrument Cluster Finish panel Steering Column Cover Instrument PNL Insert Sub assy LWR LH Heater to Foot Duct No 3 20 6 210 15 Clip 50 510 37 35 3 360 26 35 3 360 26 20 6 210 15 Steering Wheel Assy Steering Wheel Cover Lower No 3 Horn button Assy Steering Wheel Cover Lower No 2 N m kgf cm ft l...

Page 780: ...ssy Steering Main Shaft Radial Ball Bearing Snap Ring Steering Column Tube Steering Column Upper w Switch Bracket Assy Ignition Switch Lock Cylinder Assy w Illuminated Entry System Key Cylinder Lamp Assy Steering Column Clamp Upper Non reusable part TMC Made STEERING COLUMN STEERING COLUMN 50 7 2242 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 781: ...Un lock Warning Switch Assy Steering Column Assy Steering Column Upper w Switch Bracket Assy Ignition Switch Lock Cylinder Assy W Illuminated Entry System Key Cylinder Lamp Assy Steering Column Clamp Upper TMMK Made 50 8 STEERING COLUMN STEERING COLUMN 2243 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 782: ...EEL See page 50 6 6 REMOVE STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY See page 50 6 7 INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD 8 REMOVE HORN BUTTON ASSY NOTICE If the airbag connector is disconnected with the ignition switch being at ON DTCs will be recorded a Using a torx socket wrench loosen the 2 torx screws until the groove along the screw circumference catches on the ...

Page 783: ...tchmarks on the steering wheel assy and main shaft assy d Using SST remove the steering wheel assy SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 10 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 71 12 11 REMOVE STEERING COLUMN COVER a Remove the 2 screws and steering column cover 12 DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Using a screwdriver disconnect the floor shift p...

Page 784: ...Y See page 71 12 19 REMOVE INSTRUMENT PANEL SUB ASSY UPPER See page 71 12 20 REMOVE INSTRUMENT PNL INSERT SUB ASSY LWR LH See page 71 12 21 REMOVE HEATER TO FOOT DUCT NO 3 See page 71 12 22 DISCONNECT STEERING INTERMEDIATE SHAFT SUB ASSY a Loosen the bolt A and remove the clamp from the steering column hole cover No 1 b Separate the steering column hole cover No 2 from the steering column hole cov...

Page 785: ...ering column assy 24 REMOVE STEERING INTERMEDIATE SHAFT SUB ASSY a Place matchmarks on the steering intermediate shaft sub assy and steering sliding yoke sub assy b Remove the bolt and steering intermediate shaft sub assy 25 REMOVE STEERING COLUMN HOLE COVER SUB ASSY NO 2 26 REMOVE STEERING SLIDING YOKE SUB ASSY a Place matchmarks on the steering sliding yoke sub assy and steering main shaft assy ...

Page 786: ...er key amplifier toward the rear of the vehicle with the claw open NOTICE Take care not to apply excessive force to prevent the case from being damaged 29 REMOVE KEY CYLINDER LAMP ASSY W ILLUMINATED ENTRY SYSTEM 30 REMOVE STEERING COLUMN UPPER W SWITCH BRACKET ASSY a Using a centering punch mark the center of the 2 lap ered head bolts b Using a 3 4 mm 0 12 0 16 in drill drill into the 2 bolts c Us...

Page 787: ...K CYLINDER ASSY a Place the ignition switch lock cylinder assy at the ACC position b Push down the stop pin with a screwdriver and pull out the cylinder assy 34 REMOVE UN LOCK WARNING SWITCH ASSY a Disconnect the un lock warning switch assy connector from the ignition or starter switch assy b Remove the un lock warning switch assy 35 REMOVE IGNITION OR STARTER SWITCH ASSY a Remove the 2 screws and...

Page 788: ...osition b Install the ignition switch lock cylinder assy 39 INSPECT STEERING LOCK OPERATION a Check that the steering lock mechanism is activated when removing the key b Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position 40 INSTALL STEERING MAIN SHAFT ASSY a Using a snap ring expander install a new steering main shaft snap ring inner side to...

Page 789: ...ead bolts until the bolt heads break off 43 INSTALL KEY CYLINDER LAMP ASSY W ILLUMINATED ENTRY SYSTEM 44 INSTALL TRANSPONDER KEY AMPLIFIER W ENGINE IMMOBILISER SYSTEM a Align the transponder key amplifier with the installation position of the upper bracket with the amplifier inclined b Push the trasponder key amplifier up and connect it to the upper bracket NOTICE Take care not to push the amplifi...

Page 790: ...mark with the one on the steering inter mediate shaft sub assy and steering main shaft assy b Temporarily install the steering intermediate shaft sub assy with the bolt 48 INSTALL STEERING COLUMN ASSY a Install the steering column assy with the 3 bolts Torque 20 6 N m 210 kgf cm 15 ft lbf b Connect the connectors and wire harness clamps 49 CONNECT STEERING INTERMEDIATE SHAFT SUB ASSY a Align the m...

Page 791: ...e windshield wiper switch assy and connect the connector 51 INSTALL HEADLAMP DIMMER SWITCH ASSY a Install the headlamp dimmer switch assy and connect the connector 52 PLACE FRONT WHEELS FACING STRAIGHT AHEAD 53 INSTALL SPIRAL CABLE SUB ASSY See page 60 25 54 CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Turn the ignition switch to ACC or ON b Connect the cable to the upper bracket 55 CHECK KEY INT...

Page 792: ... battery negative terminal is disconnected NOTICE Do not start the operation for 90 seconds after removing the terminal c Turn the cable counterclockwise by hand until it becomes harder to turn d Then rotate the cable clockwise about 2 5 turns to align the marks HINT The cable will rotate about 2 5 turns to both right and left of the center 65 INSTALL STEERING WHEEL ASSY a Align the matchmark with...

Page 793: ...n the case or connec tor replace the horn button assy with a new one When installing the horn button assy take care so that the wirings do not interfere with other parts and that they are not pinched between other parts a Connect the 2 airbag connectors b Connect the horn connector 4 Spoke steering wheel c Install the horn button assy after confirming that the cir cumference groove of the torx scr...

Page 794: ...MRY REPAIR MANUAL RM881U 70 INSTALL CONNECTOR COVER W STEERING PAD SWITCH 4 SPOKE STEERING WHEEL See page 50 6 71 INSTALL STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY See page 50 6 72 INSPECT STEERING WHEEL CENTER POINT 73 INSPECT SRS WARNING LIGHT See page 05 690 ...

Page 795: ...ERING WHEEL See page 50 6 6 REMOVE STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY See page 50 6 7 PLACE FRONT WHEELS FACING STRAIGHT AHEAD 8 REMOVE HORN BUTTON ASSY NOTICE If the airbag connector is disconnected with the ignition switch at ON DTCs will be recorded a Using a torx socket wrench loosen the 2 torx screws until the groove along the screw circumference catches on the screw ...

Page 796: ...emble the horn button assy 9 REMOVE STEERING WHEEL ASSY SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 10 REMOVE INSTRUMENT CLUSTER FINISH PANEL ASSY See page 71 12 11 REMOVE STEERING COLUMN COVER LWR a Remove the 2 screws and steering column cover upper 12 REMOVE STEERING COLUMN COVER UPR 13 DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Using a screwdriver disconnect the floor...

Page 797: ...page 71 12 18 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 19 REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH See page 71 12 20 REMOVE INSTRUMENT PNL INSERT SUB ASSY LWR LH See page 71 12 21 REMOVE HEATER TO FOOT DUCT NO 3 See page 71 12 22 DISCONNECT STEERING INTERMEDIATE SHAFT ASSY a Loosen the bolt A and remove the clamp from the steering column hole cover No 1 b Separate the steering column ...

Page 798: ...HAFT ASSY a Place matchmarks on the steering intermediate shaft sub assy and steering sliding yoke sub assy b Remove the bolt and steering intermediate shaft sub assy 25 REMOVE TRANSPONDER KEY AMPLIFIER W ENGINE IMMOBILISER SYSTEM a Disengage the claw hung on the upper bracket with a screwdriver b Pull the transponder key amplifier toward the rear of the vehicle with the claw open NOTICE Take care...

Page 799: ... UPPER 29 REMOVE IGNITION SWITCH LOCK CYLINDER ASSY a Place the ignition switch lock cylinder assy at the ACC position b Push down the stop pin with a screwdriver and pull out the cylinder assy 30 REMOVE UN LOCK WARNING SWITCH ASSY a Disconnect the un lock warning switch assy connector from the ignition or starter switch assy b Remove the un lock warning switch assy 31 REMOVE IGNITION OR STARTER S...

Page 800: ...b Check that the steering lock mechanism is deactivated when inserting the key and turning it to ACC position 36 INSTALL STEERING COLUMN UPPER W SWITCH BRACKET ASSY a Temporarily install the steering column upper w switch bracket assy and steering column upper clamp with 2 new tapered head bolts b Tighten the 2 tapered head bolts until the bolt heads break off 37 INSTALL KEY CYLINDER LAMP ASSY W I...

Page 801: ...rk with the one on the steering inter mediate shaft sub assy and steering main shaft assy b Temporarily install the steering intermediate shaft sub assy with the bolt 41 INSTALL STEERING COLUMN ASSY a Install the steering column assy with the 3 bolts Torque 20 6 N m 210 kgf cm 15 ft lbf b Connect the connectors and wire harness clamps 42 CONNECT STEERING INTERMEDIATE SHAFT ASSY a Align the matchma...

Page 802: ...ch assy and connect the connector 44 INSTALL WINDSHIELD WIPER SWITCH ASSY a Install the headlamp dimmer switch assy and connect the connector 45 PLACE FRONT WHEELS FACING STRAIGHT AHEAD 46 INSTALL SPIRAL CABLE SUB ASSY See page 60 25 47 CONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY a Turn the ignition switch to ACC or ON b Connect the cable to the upper bracket 48 CHECK KEY INTERLOCK OPERATION See p...

Page 803: ...erminal is disconnected NOTICE Do not start the operation for 90 seconds after removing the terminal c Turn the cable counterclockwise by hand until it becomes harder to turn d Then rotate the cable clockwise about 2 5 turns to align the marks HINT The cable will rotate about 2 5 turns to both right and left of the center 58 INSTALL STEERING WHEEL ASSY a Align the matchmark with the one on the ste...

Page 804: ...n the case or connec tor replace the horn button assy with a new one When installing the horn button assy take care so that the wirings do not interfere with other parts and that they are not pinched between other parts a Connect the 2 airbag connectors b Connect the horn connector 4 Spoke steering wheel c Install the horn button assy after confirming that the cir cumference groove of the torx scr...

Page 805: ...MRY REPAIR MANUAL RM881U 63 INSTALL CONNECTOR COVER W STEERING PAD SWITCH 4 SPOKE STEERING WHEEL See page 50 6 64 INSTALL STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY See page 50 6 65 INSPECT STEERING WHEEL CENTER POINT 66 INSPECT SRS WARNING LIGHT See page 05 690 ...

Page 806: ...p shaft See page 51 15 TYPE B VANE PUMP Vane pump pulley cannot be removed from the vane pump shaft See page 51 15 c Sport Grade indicates the follwing models See page 51 15 MCV30L AEPSKA MCV30L CEPSKA 2 HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM a The CAMRY is equipped with SRS Supplemental Restraint System such as the driver airbag and front passenger airbag Failure to carry out service operation...

Page 807: ...lignment Incorrect 5 Steering system joints Worn 6 Suspension arm ball joints Worn 7 Steering column Binding 8 Power steering vane pump 9 Power steering gear 28 1 51 3 14 5 14 140 26 5 26 17 51 8 51 17 51 29 Poor return 1 Tires Improperly inflated 2 Front wheel alignment Incorrect 3 Steering column Binding 4 Power steering gear 28 1 26 5 51 29 Excessive play 1 Steering system joints Worn 2 Suspens...

Page 808: ...l times d Lower the vehicle e Start the engine 1 Run the engine at idle for a few minutes f Turn the steering wheel 1 With the engine idling turn the wheel to left or right full lock position and keep it there for 2 3 seconds then turn the wheel to the opposite full lock position and keep it there for 2 3 seconds 2 Repeat 1 several times g Stop the engine h Check for forming or emulsification Espe...

Page 809: ... oil reservoir g Stop the engine h Wait a few minutes and remeasure the fluid level in the oil reservoir Maximum fluid level rise 5 mm 0 20 in If a problem is found bleed the power steering system i Check the fluid level 4 CHECK STEERING FLUID PRESSURE a Disconnect the pressure feed tube from the rack pinion power steering gear assy See page 51 29 b Connect SST as shown in the illustration SST 096...

Page 810: ...300 kPa 80 85 kgf cm2 1 138 1 209 psi NOTICE Do not keep the valve closed for more than 10 se conds Do not let the fluid temperature become too high g With the engine idling open the valve fully h Measure the fluid pressure at engine speeds of 1 000 rpm and 3 000 rpm Fluid pressure difference 490 kPa 5 kgf cm2 71 psi or less NOTICE Do not turn the steering wheel i With the engine idling and valve ...

Page 811: ...HECK STEERING EFFORT a Center the steering wheel assy b Remove the horn button assy See page 50 9 50 22 c Start the engine and run it at idle d Using a torque wrench measure the steering effort in both directions Steering effort Reference 6 N m 60 kgf cm 53 in lbf or less HINT Take the tire type pressure and contact surface into consider ation before making your diagnosis e Install the steering wh...

Page 812: ...reusable part N m kgf cm ft lbf Specified torque Power steering fluid Vane Pump Side Plate Front Vane Pump Cam Ring Vane Pump Shaft Snap Ring Vane Pump Plate Vane Pump Rotor O Ring Power Steering Oil Pressure Switch 21 214 15 Vane Pump Housing Rear 22 224 16 Vane Pump Housing Front X10 69 704 51 POWER STEERING VANE PUMP ASSY 2AZ FE 51 7 2274 Author Date 2002 CAMRY REPAIR MANUAL RM881U VANE PUMP AS...

Page 813: ...HOSE NO 1 a Remove the clip and disconnect the oil reservoir to pump hose No 1 NOTICE Take care not to spill fluid on the V belt 7 DISCONNECT PRESSURE FEED TUBE ASSY a Disconnect the connector from the power steering oil pressure switch b Using a spanner 27 mm to hold the pressure port union remove the union bolt and gasket 8 REMOVE VANE PUMP ASSY a Disconnect the connector from the oil pressure s...

Page 814: ...il pressure switch If the power steering oil pressure switch is dropped or strongly damaged replace it with a new one 15 REMOVE VANE PUMP HOUSING REAR a Remove the 4 bolts and vane pump housing rear from the vane pump housing front b Remove the O ring from the vane pump housing rear 16 REMOVE W PULLEY SHAFT SUB ASSY a Using a screwdriver remove the vane pump shaft snap ring from the w pulley shaft...

Page 815: ... clearance 0 009 0 031 mm 0 00035 0 00122 in Maximum clearance 0 07 mm 0 0028 in If it is more than the maximum replace the vane pump assy 22 INSPECT VANE PUMP ROTOR AND VANE PUMP PLATES a Using a micrometer measure the height thickness and length of the vane pump plates Minimum height 7 7 mm 0 303 in Minimum thickness 1 408 mm 0 05543 in Minimum length 11 993 mm 0 47216 in b Using a feeler gauge ...

Page 816: ...e flow control valve compression spring Minimum free length 35 8 mm 1 409 in If it is not within the specification replace the vane pump assy 25 INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage replace the vane pump assy 26 INSTALL VANE PUMP HOUSING OIL SEAL a Coat a new oil seal lip with power steering fluid b Using SST ...

Page 817: ...the vane pump side plate front NOTICE Make sure that the vane pump side plate front is installed facing in the correct direction 28 INSTALL VANE PUMP CAM RING a Align the dent of the vane pump cam ring with that of the vane pump side plate front and install the vane pump cam ring with the inscribed mark facing outward 29 INSTALL W PULLEY SHAFT SUB ASSY 30 INSTALL VANE PUMP ROTOR a Install the vane...

Page 818: ...ench check the vane pump rotating torque Rotating torque 0 27 N m 2 8 kgf cm 2 4 in lbf or less 33 INSTALL POWER STEERING OIL PRESSURE SWITCH a Coat a new O ring with power steering fluid and install it to the power steering oil pressure switch b Install the power steering oil pressure switch to the vane pump assy Torque 21 N m 214 kgf cm 15 ft lbf 34 INSTALL FLOW CONTROL VALVE COMPRESSION SPRING ...

Page 819: ...t the connector to the power steering oil pressure switch 39 CONNECT PRESSURE FEED TUBE ASSY a Install the pressure feed tube assy and gasket to the vane pump assy with the union bolt HINT Make sure the stopper of the pressure feed tube touches the pump housing front as shown in the illustration b Using a spanner 27 mm to hold the pressure port union torque the union bolt Torque 51 5 N m 525 kgf c...

Page 820: ...N m kgf cm ft lbf Specified torque Power steering fluid Vane Pump Shaft Snap Ring Vane Pump Shaft Vane Pump Housing Oil Seal Vane Pump Rotor Vane Pump Plate Vane Pump Cam Ring Vane Pump Side Plate Rear Wave Washer 24 245 18 24 245 18 Vane Pump Bracket Rear O Ring Gasket Vane Pump Housing Rear 13 133 10 Sport Grade Except Sport Grade X10 83 846 61 43 438 32 POWER STEERING VANE PUMP ASSY 1MZ FE 51 1...

Page 821: ...ap Ring W Pulley Shaft Sub assy Non reusable part N m kgf cm ft lbf Specified torque Power steering fluid Vane Pump Housing Oil Seal Vane Pump Rotor Vane Pump Plate Vane Pump Cam Ring Vane Pump Side Plate Rear Wave Washer 24 245 18 24 245 18 Vane Pump Bracket Rear Vane Pump Housing Rear 13 133 10 44 449 32 44 449 32 Except Sport Grade Sport Grade X10 83 846 61 51 16 POWER STEERING VANE PUMP ASSY 1...

Page 822: ...ect the oil reservoir to pump hose No 1 NOTICE Take care not to spill fluid on the V belt 6 REMOVE POWER STEERING OIL PRESSURE SWITCH a Disconnect the connector b Remove the power steering oil pressure switch from the union bolt NOTICE Be careful not to drop the power steering oil pressure switch If the power steering oil pressure switch is dropped or strongly damaged replace it with a new one 7 D...

Page 823: ...VE VANE PUMP BRACKET REAR TYPE A VANE PUMP a Remove the 2 bolts vane pump bracket rear from the vane pump assy 16 REMOVE VANE PUMP BRACKET REAR TYPE B VANE PUMP a Remove the 2 bolts and 2 nuts vane pump bracket rear from the vane pump assy 17 REMOVE VANE PUMP HOUSING REAR a Remove the 4 bolts and vane pump housing rear from the vane pump housing front b Remove the gasket c Remove the 2 O rings fro...

Page 824: ...lt pump bracket front from the vane pump housing front 24 REMOVE VANE PUMP HOUSING OIL SEAL a Using SST and a hammer tap out the vane pump housing oil seal from the vane pump housing front SST 09631 10030 NOTICE Be careful not to damage the bushing of the vane pump housing front 25 INSPECT OIL CLEARANCE a Using a micrometer and a caliper gauge measure the oil clearance Standard clearance 0 027 0 0...

Page 825: ...d length of the vane pump plates Minimum height 8 7 mm 0 343 in Minimum thickness 1 4 mm 0 055 in Minimum length 14 991 mm 0 59020 in b Using a feeler gauge measure the clearance between the vane pump rotor groove and vane pump plate Maximum clearance 0 03 mm 0 0012 in If it is more than the maximum replace the vane pump assy 27 INSPECT FLOW CONTROL VALVE a Coat the flow control valve with power s...

Page 826: ...LVE COMPRESSION SPRING a Using vernier calipers measure the free length of the flow control valve compression spring Minimum free length 32 24 mm 1 2693 in If it is not within the specification replace the vane pump assy 29 INSPECT PRESSURE PORT UNION If the union seat in the pressure port union is remarkably damaged and it may cause fluid leakage replace the vane pump assy 30 INSTALL VANE PUMP HO...

Page 827: ... from the pulley side NOTICE Do not damage the vane pump housing oil seal lip in the vane pump housing front 33 INSTALL W PULLEY SHAFT SUB ASSY TYPE B VANE PUMP a Coat inside bushing surface of the vane pump housing front with power steering fluid b Gradually insert the w pulley shaft sub assy from the pulley side NOTICE Do not damage the vane pump housing oil seal lip in the vane pump housing fro...

Page 828: ... of the vane pump side plate rear install the vane pump side plate rear c Install the wave washer so that its protrusions fit into the slots in the vane pump side plate rear 37 INSTALL VANE PUMP HOUSING REAR a Coat a new O ring with power steering fluid and install it to the vane pump housing rear b Install the vane pump housing rear with the 4 bolts Torque 24 N m 245 kgf cm 18 ft lbf 38 MEASURE P...

Page 829: ...que 44 N m 449 kgf cm 32 ft lbf 42 INSTALL FLOW CONTROL VALVE COMPRESSION SPRING a Coat the flow control valve compression spring with power steering fluid and install it 43 INSTALL FLOW CONTROL VALVE a Coat the flow control valve with power steering fluid b Install the flow control valve 44 INSTALL PRESSURE PORT UNION a Coat a new O ring with power steering fluid and install it to the pressure po...

Page 830: ...d tube assy with the union bolt and a new gasket Torque 51 5 N m 525 kgf cm 38 ft lbf HINT Make sure the stopper of the pressure feed tube touches the front bracket as shown in the illustration then install the union bolt 50 INSTALL POWER STEERING OIL PRESSURE SWITCH a Install the power steering oil pressure switch to the union bolt Torque 21 N m 214 kgf cm 15 ft lbf NOTICE Be careful not to preve...

Page 831: ...tabilizer Bracket No 1 LH Front Stabilizer Bracket No 1 RH Front Stabilizer Bar 24 5 250 18 22 5 229 17 19 194 14 1MZ FE Front Stabilizer Bar Bush No 1 Front Stabilizer Bar Bush No 1 49 500 36 9 8 100 86 in lbf 19 194 14 9 8 100 86 in lbf O Ring 24 5 250 18 22 5 229 17 35 3 360 26 49 500 36 74 755 55 74 755 55 51 26 POWER STEERING RACK PINION POWER STEERING GEAR ASSY 2293 Author Date 2002 CAMRY RE...

Page 832: ...Tube O Ring Dust Cover Control Valve Housing Power Steering Control Valve Upper Oil Seal Control Valve Upper Bearing Control Valve Ring Rack Guide Spring Cap Nut 68 5 699 51 48 489 35 Rack Guide Spring Cap Rack Guide Compression Spring RACK PINION POWER STEERING GEAR ASSY MP grease 12 5 127 9 11 5 117 8 21 214 15 Oil Seal 12 5 127 9 11 5 117 8 12 5 127 9 11 5 117 8 POWER STEERING RACK PINION POWER...

Page 833: ...Rack Bush Oil Seal Cylinder End Stopper Wire Claw Washer Steering Rack End Sub assy Steering Rack Boot No 2 Clamp Steering Rack Boot No 2 For use with SST Non reusable part N m kgf cm ft lbf Specified torque Molybdenum disulfide lithium base grease Power steering fluid Steering Rack Boot Clip Lock Nut 74 755 55 Tie Rod Assy RH RACK PINION GEAR POWER STEERING GEAR ASSY 74 755 55 83 5 851 62 58 5 59...

Page 834: ... 5 REMOVE FRONT WHEEL 6 REMOVE SPIRAL CABLE SUB ASSY See page 50 9 50 22 7 DISCONNECT TIE ROD ASSY LH a Remove the cotter pin and nut b Using SST remove the tie rod assy LH from the steering knuckle SST 09628 62011 8 DISCONNECT TIE ROD ASSY RH SST 09628 62011 HINT Remove the RH side by the same procedures with LH side 9 DISCONNECT STEERING INTERMEDIATE SHAFT SUB ASSY a Loosen the bolt and remove t...

Page 835: ...NNECT FRONT STABILIZER LINK ASSY RH HINT Remove the RH side by the same procedures with LH side 12 REMOVE FRONT STABILIZER BRACKET NO 1 LH a Remove the 2 bolts and disconnect the front stabilizer bracket No 1 LH 13 REMOVE FRONT STABILIZER BRACKET NO 1 RH HINT Remove the RH side by the same procedures with LH side 14 DISCONNECT PRESSURE FEED TUBE ASSY a Using SST disconnect the return tube assy fro...

Page 836: ...olts nuts and rack pinion power steer ing gear assy 16 REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR 1MZ FE ENGINE TYPE a Remove the power steering rack housing heat insulator 17 REMOVE STEERING LEFT TURN PRESSURE TUBE a Using SST renove the left turn pressure tube SST 09023 38200 b Remove the 2 O rings from the left turn pressure tube 18 REMOVE STEERING RIGHT TURN PRESSURE TUBE a Using SST re...

Page 837: ...H side by the same procedures with LH side 22 INSPECT TIE ROD ASSY LH a Secure the tie rod assy LH in a vise b Install the nut to the stud bolt c Flip the ball joint stud back and forth 5 times d Using a torque wrench turn the nut continuously at a rate of 3 5 seconds per 1 turn and take the torque reading of the 5th turn Turning torque 0 83 3 43 N m 8 5 35 0 kgf cm 7 3 30 4 in lbf 23 INSPECT TIE ...

Page 838: ...OVE STEERING RACK BOOT NO 2 a Remove the steering rack boot No 2 28 REMOVE STEERING RACK BOOT NO 1 HINT Remove the steering rack boot No 1 by the same procedures with the steering rack boot No 2 29 REMOVE STEERING RACK END SUB ASSY a Using a screwdriver and a hammer unstake the claw washer NOTICE Avoid any impact to the power steering rack b Using 2 SSTs remove the 2 steering rack ends sub assy an...

Page 839: ...0010 NOTICE Use SST 09922 10010 in the direction shown in the illustra tion b Using SST remove the rack guide spring cap SST 09631 10021 c Remove the compression spring and rack guide 31 REMOVE POWER STEERING CONTROL VALVE a Using a socket wrench 27 mm remove the rack housing cap b Using SST hold the control valve and remove the nut SST 09616 00011 c Wind vinyl tape around the serrated part of the...

Page 840: ...alve h Using a plastic hammer remove the control valve with oil seal from the control valve housing i Remove the oil seal from the control valve j Using a screwdriver remove the 4 control valve rings NOTICE Be careful not to damage the grooves for the control valve rings 32 REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL a Using SST and a press remove the control valve upper bearing and power s...

Page 841: ...der end stopper counterclockwise and remove the wire and cylin der end stopper 34 REMOVE POWER STEERING RACK 35 REMOVE POWER STEERING RACK BUSH a Remove the power steering rack bush from the power steering rack b Using SST remove the rack bush oil seal SST 09527 21011 09612 24014 09613 22011 c Using a screwdriver remove the O ring from the power steering rack bush 36 INSPECT POWER STEERING RACK a ...

Page 842: ... a screwdriver remove the rack steering piston ring and O ring NOTICE Be careful not to damage the grooves for rack steering pis ton ring 39 INSTALL RACK STEERING PISTON RING a Coat a new O ring with power steering fluid and install it to the power steering rack b Expand a new rack steering piston ring with your fingers NOTICE Be careful not to over expand the rack steering piston ring c Coat a ne...

Page 843: ...on Take care so that the power steering cylinder tube oil seal will not be reversed as you install it 41 INSTALL POWER STEERING RACK a Install SST to the power steering rack SST 09631 33010 HINT If necessary scrape the burrs off the power steering rack teeth end and burnish b Coat the SST with power steering fluid c Install the power steering rack into the rack housing d Remove the SST 42 INSTALL ...

Page 844: ...g a screwdriver turn the cylinder end stopper clock wise by 450 50 44 AIR TIGHTNESS TEST a Install SST to the rack housing SST 09631 12071 09633 00010 b Apply vacuum of 53 kPa 400 mmHg 15 75 in Hg for about 30 seconds c Check that there is no change in the vacuum If there is a change in the vacuum check the installation of the oil seals 45 INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL a Coat...

Page 845: ... valve rings e To prevent power steering control valve upper oil seal lip damage wind vinyl tape around the serrated part of the control valve f Coat the power steering control valve upper oil seal lip with power steering fluid g Install the control valve to the control valve housing NOTICE Be careful not to damage the control valve ring and power steering control valve upper oil seal lip h Coat a...

Page 846: ... rack housing cap Torque 58 5 N m 597 kgf cm 43 ft lbf q Using a punch and a hummer stake the rack housing cap and rack housing 47 INSTALL RACK GUIDE a Install the rack guide b Install the compression spring c Apply sealant to 2 or 3 threads of the rack guide spring cap Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent d Temporarily install the rack guide spring cap 48 ADJUST T...

Page 847: ... preload is within specification SST 09616 00011 09631 10021 Preload turning 1 2 1 5 N m 12 2 15 3 kgf cm 10 6 13 3 in lbf g Apply sealant to 2 or 3 threads of the rack guide spring cap nut Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent h Temporarily install the rack guide spring cap nut i Using SST hold the rack guide spring cap and using another SST torque the rack guide s...

Page 848: ...D SUB ASSY a Install a new 2 claw washers and temporarily install the 2 steering rack ends sub assy HINT Align the claws of the claw washer with the power steering rack grooves b Using 2 SSTs install the 2 steering rack ends sub assy SST 09922 10010 Torque 58 5 N m 597 kgf cm 43 ft lbf NOTICE Use SST 09922 10010 in the direction shown in the illustra tion HINT Using SST hold the power steering rac...

Page 849: ...STEERING RACK BOOT NO 2 CLAMP a Using SST tighten the steering rack boot No 2 clamp as shown in the illustration SST 09521 24010 Clearance 3 0 mm 0 118 in or less NOTICE Be careful not to damage the boot No 2 54 INSTALL STEERING RACK BOOT NO 1 CLAMP SST 09521 24010 NOTICE Be careful not to damage the boot No 1 HINT Install the steering rack boot No 1 clamp by the same proce dures with steering rac...

Page 850: ...rque wrench 59 INSTALL STEERING RIGHT TURN PRESSURE TUBE a Coat 2 new O rings with power steering fluid and install them to the right turn pressure tube b Using SST install the right turn pressure tube to the rack pinion power steering gear assy SST 09023 38200 Torque 11 5 N m 117 kgf cm 8 ft lbf HINT Use a torque wrench with a fulcrum length of 345 mm 13 58 in This torque value is effective in th...

Page 851: ...y SST 09023 12700 Torque 22 5 N m 229 kgf cm 17 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm 11 81 in This torque value is effective in the case that SST is paral lel to a torque wrench b Using SST connect the return tube assy to the rack pin ion power steering gear assy SST 09023 12700 Torque 22 5 N m 229 kgf cm 17 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm...

Page 852: ...he stabilizer bar with the nut Torque 74 N m 755 kgf cm 55 ft lbf HINT If the ball joint turns together with the nut use a hexagon wrench 6 mm to hold the stud 66 CONNECT FRONT STABILIZER LINK ASSY RH HINT Connect the RH side by the same procedures with LH side 67 CONNECT STEERING INTERMEDIATE SHAFT SUB ASSY a Align the matchmarks on the intermediate shaft sub assy and rack pinion power steering g...

Page 853: ... HINT Connect the RH side by the same procedures with LH side 70 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 71 ADD POWER STEERING FLUID 72 BLEED POWER STEERING FLUID 73 CHECK POWERSTEERING FLUID LEAKAGE 74 INSTALL SPIRAL CABLE SUB ASSY See page 50 9 50 22 75 CENTER SPIRAL CABLE See page 50 9 50 22 76 INSTALL STEERING WHEEL ASSY See page 50 9 50 22 77 INSTALL HORN BUTTON ASSY See pag...

Page 854: ...EVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lu brication will be insufficient and compressor burnout may occur so take care to avoid this necessary care should be taken 7 DO NOT OP...

Page 855: ... compressor assy 5 Pressure switch No 1 6 Air mix damper servo sub assy 7 Condenser fan 8 A C cotrol assy 9 Wire harness or connector 55 12 55 21 55 12 55 7 55 3 55 7 55 3 Temperature Control No warm air comes out 1 Engine coolant volume 2 Air mix damper servo sub assy 3 Cooler thermistor No 1 4 A C cotrol assy 5 Heater radiator unit sub assy 6 Wire harness or connector 55 7 55 7 55 3 Temperature ...

Page 856: ...control Inspect pressure switch operation 1 Set on the manifold gauge set 2 Connect the positive lead from the ohmmeter to terminal 4 and the negative lead to terminal 1 3 Check continuity between terminals when refriger ant pressure is changed as shown in the illustra tion If operation is not as specified replace the pressure switch b Cooling fan control Inspect pressure switch operation 1 Connec...

Page 857: ...y replacing the controller with a new one If the circuit is not as specified inspect the circuits connected to other parts b Connect the connector to heater controller and inspect wire harness side from the back side as shown in the chart below Symbols Terminal No Condition Specified condition E Body ground B1 Body ground Always Continuity LO E B3 B1 Blower switch OFF LO 0 Below 1 0 V M1 E B5 B1 I...

Page 858: ...w 1 0 V 10 14 V FACE GND A21 A32 Ignition switch ON Mode select Except FACE FACE Below 1 0 V 0 V DEF GND A17 A32 Ignition switch ON Mode select Except DEF DEF Below 1 0 V 0 V F D GND A18 A32 Ignition switch ON Mode select Except F D F D Below 1 0 V 0 V FOOT GND A19 A32 Ignition switch ON Mode select Except FOOT FOOT Below 1 0 V 0 V B L GND A20 A32 Ignition switch ON Mode select Except B L B L Belo...

Page 859: ... clutch OFF ON Pulse generation E2 Body ground E28 Body ground Always Continuity PR2 Body ground 1 C30 Body ground Start engine Refrigerant pressure Normally Less than 0 19 Mpa 2 0 kgf cm2 28 psi or more than 1 34 Mpa 32 kgf cm22 2 455 psi 0 Below 1 0 V 1 2AZ FE If circuit is as specified try replacing the amplifier with a new one If the circuit is not as specified inspect the circuits connected t...

Page 860: ...k that the magnetic clutch energized If operation is not as specified replace the magnet clutch assy c Measure resistance between terminals 2 and 4 Standard resistance 165 205 Ω at 20 C 68 F If resistance is not as specified replace the cooler compressor assy 2 MAGNET CLUTCH RELAY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continui...

Page 861: ...pecified replace the air mix servomo tor b Inspect position sensor resistance Measure resistance between terminals at servomotor arm each position as shown in the chart Tester connection Condition Specified condition 1 2 Constant 4 2 7 8 kΩ 1 3 Arm position at COLD 3 4 6 2 kΩ 1 3 Arm position at HOT 0 8 1 6 kΩ If resistance is not as specified replace the servomotor 4 MODE DAMPER SERVO SUB ASSY a ...

Page 862: ...motor operation 1 Connect the positive lead from the battery to ter minal 5 and negative lead to terminal 1 then check that the arm turns to REC side smoothly 2 Connect the positive lead from the battery to ter minal 5 and negative lead to terminal 2 then check that the arm turns to FRS side smoothly If operations are not as specified replace the mode damper servomotor ...

Page 863: ...ER THERMISTOR NO 1 a Check resistance between terminals 1 and 2 of Cooler thermistor No 1 at each temperature as shown in the chart Resistance If resistance value is not as specified replace the sensor 7 BLOWER W FAN MOTOR SUB ASSY a Connect the positive lead from the battery to terminal 2 and negative to terminal 1 then check that the motor operation smoothly If operation is not as specified repl...

Page 864: ...rt below Tester connection Specified condition 1 2 1 398 1 605 Ω 1 3 0 465 0 535 Ω 1 4 3 069 3 531 Ω If resistance is not as specified replace the blower resistor 9 HEATER BLOWER MOTOR RELAY ASSY Condition Tester connection Specified condition Constant 1 2 3 4 Continuity Apply B between termi nals 1 and 2 3 5 Continuity If continuity is not as specified replace the heater blower motor relay ...

Page 865: ...ppear 2 No bubbles present None insufficient or too much Refer 3 and 4 3 No temperature difference between com pressor inlet and outlet Empty or nearly empty 1 Check for gas leakage with gas leak de tector and repair if necessary 2 Add refrigerant until bubbles disappear 4 Considerable temperature difference be tween compressor inlet and outlet Correct or too much Refer to 5 and 6 5 Immediately af...

Page 866: ...sition A C switch ON Fully open doors 1 Normally functioning refrigeration system Gauge reading Low pressure side 0 15 0 25 MPa 1 5 2 5 kgf cm2 High pressure side 1 37 1 57 MPa 14 16 kgf cm2 2 Moisture present in refrigeration system Symptom Probable cause Diagnosis Remedy During operation pressure on low pressure side sometimes become a vacuum and sometime normal Moisture in refrigerating system ...

Page 867: ...ficient cooling performance Gas leakage in refrigeration sys tem Insufficient refrigerant Refrigerant leaking 1 Check for gas leakage and re pair if necessary 2 Supply proper amount of new refrigerant 3 If indicated pressure value is close to a 0 when connected to gauge create the vacuum after in specting and repairing location of leak 4 Poor circulation of refrigerant Symptom Probable cause Diagn...

Page 868: ...ion valve 2 Clean out dirt in expansion valve by air blowing 3 Replace condenser 4 Evaporate air and supply prop er amount of new refrigerant 5 For gas leakage from expan sion valve replace expansion valve 6 Refrigerant overcharged or insufficient cooling of condenser Symptom Probable cause Diagnosis Remedy Pressure too high on both low and high pressure sides No sir bubbles seen through the sight...

Page 869: ...h low and high pressure sides The low pressure piping too hot to the touch Bubbles seen through sight glass Air entered in refrigerating system Air present in refrigerating sys tem Insufficient vacuum purging 1 Check compressor oil to see if it is see if it is dirty or insufficient 2 Evacuate air and supply new refrigerant 8 Expansion valve improperly Symptom Probable cause Diagnosis Corrective Ac...

Page 870: ... 0 2 2 1 0 14 1 5 1 2 12 3 1 25 12 8 1 32 13 5 HEATER AIR CONDITIONER REFRIGERANT 55 17 2332 Author Date 2002 CAMRY REPAIR MANUAL RM881U 9 Defective compression compressor Symptom Probable cause Diagnosis Corrective Actions Pressure too high on low high pressure sides Pressure too low to on high pres sure side Internal leak in compressor Compression failure Leakage from valve damaged or broken sli...

Page 871: ...ine rpm of approx 1 000 for 5 to 6 min circulate the refrig erant and collect compressor oil remaining in each component into the cooler compressor as much as possible c Stop the engine d Let the refrigerant gas out SST 07110 58060 07117 58080 07117 58090 07117 78050 07117 88060 07117 88070 07117 88080 2 CHARGE REFRIGERANT a Using a vacuum pump perform a vacuum purping b Charge refrigerant HFC 134...

Page 872: ...No 1 Cooler Refrigerant Discharge Hose No 1 N m kgf cm ft lbf Specified torque 5 4 55 49 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf HEATER AIR CONDITIONER REFRIGERANT LINE 55 19 2334 Author Date 2002 CAMRY REPAIR MANUAL RM881U REFRIGERANT LINE COMPONENTS ...

Page 873: ...No 1 Cooler Refrigerant Discharge Hose No 1 N m kgf cm ft lbf Specified torque 5 4 55 49 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 55 20 HEATER AIR CONDITIONER REFRIGERANT LINE 2335 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 874: ...en the bolt B and remove the cooler V belt No 1 2 INSTALL V COOLER COMPRESSOR TO CRANKSHAFT PULLEY BELT NO 1 a Temporarily install the cooler V belt No 1 as illustrated 3 ADJUST V COOLER COMPRESSOR TO CRANKSHAFT PULLEY BELT NO 1 a Apply drive belt tension by turning the bolt B Drive belt tension New Belt 165 27 lbf Used belt 88 22 lbf HINT New belt refers to a belt which has been used less than 5 ...

Page 875: ...ULLEY BELT NO 1 2337 Author Date 2002 CAMRY REPAIR MANUAL RM881U Check that the drive belt fits properly in the ribbed grooves 4 FULLY TIGHTEN V COOLER COMPRESSOR TO CRANKSHAFT PULLEY BELT NO 1 a Tighten the bolt A Torque 17 5 N m 178 kgf cm 12 ft lbf b Tighten the bolt C Torque 58 N m 591 kgf cm 43 ft lbf ...

Page 876: ... Housing Sub assy Air Conditioning Control Bulb Heater Control Base Sub assy HEATER AIR CONDITIONER AIR CONDITIONER CONTROL ASSEMBLY 55 23 2338 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR CONDITIONER CONTROL ASSEMBLY COMPONENTS ...

Page 877: ...e 4 fitting claws remove the 5 screws b Disconnect the connector remove the heater control housing sub assy 3 REMOVE AIR CONDITIONING CONTROL BULB a Remove the air conditioning control bulb from the heater control base sub assy 4 REMOVE HEATER CONTROL BASE SUB ASSY a Remove the 9 screws and heater control base sub assy 5 INSTALL AIR CONDITIONING CONTROL BULB a Install the air conditioning control ...

Page 878: ...550BY 01 I31579 Heater Control Housing HEATER AIR CONDITIONER AIR CONDITIONING PANEL SUB ASSY 55 25 2340 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR CONDITIONING PANEL SUB ASSY COMPONENTS ...

Page 879: ...EL SUB ASSY 2341 Author Date 2002 CAMRY REPAIR MANUAL RM881U OVERHAUL HINT COMPONENTS See page 55 25 1 REMOVE AIR CONDITIONING PANEL SUB ASSY See page 71 12 2 REMOVE HEATER CONTROL HOUSING a Remove the 2 screws b Release the 10 fitting claws remove the heater control housing ...

Page 880: ...Piping Clamp O Ring Blower Assy Heater To Foot Duct No 1 Air Conditioning Radiator Assy Heater To Foot Duct No 3 Compressor Oil ND OIL 8 or equivalent Non reusable part N m kgf cm ft lbf Specified torque 1 5 15 12 in lbf Auto A C Model 1 5 15 12 in lbf O Ring A X Models Only 9 8 100 87 in lbf 1 5 15 12 in lbf 1 5 15 12 in lbf HEATER AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY 55 27 2342 Author ...

Page 881: ...ub assy Piping Clamp Air Duct Sub assy Auto A C Model Mode Damper Servo Sub assy Air Mix Damper Servo Sub assy Cooler Thermistor No 1 Cooler Evaporator Sub assy No 1 Packing Air Conditioning Tube Assy Cooler Expansion Valve O Ring 55 28 HEATER AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY 2343 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 882: ...p SST 09870 00015 HINT Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label b Push down SST and release the clamp lock NOTICE Be careful not to deform the tube when pushing SST c Pull SST slightly and push the release lever then remove the piping clamp with SST d Disconnect the cooler refrigerant suction hose No 1 NOTICE Do not use tools like s...

Page 883: ...hose 6 REMOVE INSTRUMENT PANEL SAFETY PAD SUB ASSY See page 71 12 HINT Refer to the instructions for removal of the instrument panel safety pad sub assy 7 REMOVE AIR DUCT REAR NO 1 a Remove the 2 screws bolt and nut b Remove the air duct rear No 1 8 REMOVE AIR DUCT REAR NO 2 a Remove the bolt and nut b A X models Remove the 2 screws air duct rear No 2 and console box mounting bracket No 1 c M X mo...

Page 884: ...HIFT PARKING LOCK CABLE ASSY 11 REMOVE WINDSHIELD WIPER RELAY ASSY 12 REMOVE INSTRUMENT PANEL BRACE SUB ASSY NO 1 a Remove the 2 bolts and 2 earth wires b Release the 2 clamps c Remove the bolt and screw d Remove the nut and instrument panel brace sub assy No 1 13 REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER a Remove the 2 bolts and instrument finish retainer lower ...

Page 885: ...Y REPAIR MANUAL RM881U 14 REMOVE INSTRUMENT PANEL BRACE SUB ASSY NO 2 a Remove the clamp nut and passenger side junction block b Remove the bolt and earth wire c Remove the nut and clamp d Remove the 2 nuts bolt and instrument panel brace sub assy No 2 15 REMOVE HEATER TO FOOT DUCT NO 3 a Remove the clip and heater to foot duct No 3 ...

Page 886: ...Y REPAIR MANUAL RM881U 16 REMOVE HEATER TO FOOT DUCT NO 1 a Remove the clip and heater to foot duct No 1 17 DISCONNECT STEERING COLUMN ASSY a Remove the 3 nuts and driver side junction block b Remove the 2 nuts and steering side connector block c Release the 2 clamps d Remove the 3 bolts disconnect the steering column assy ...

Page 887: ...ER AIR CONDITIONER AIR CONDITIONING RADIATOR ASSY 2349 Author Date 2002 CAMRY REPAIR MANUAL RM881U 18 REMOVE INSTRUMENT PANEL REINFORCEMENT a Disconnect the 7 clamps and the wire harness b Remove the 3 nuts disconnect the 3 earth wires ...

Page 888: ...350 Author Date 2002 CAMRY REPAIR MANUAL RM881U c Remove the 3 caps 7 bolts and instrument panel rein forcement 19 REMOVE BLOWER ASSY a Disconnect the connectors b Remove the screw clamp and blower connector holder c Disconnect the 6 clamps and the wire harness d Remove the 2 screws 2 nuts and blower assy ...

Page 889: ...ING RADIATOR ASSY a Disconnect the connectors b Remove the 2 nuts and air conditioning radiator assy 22 REMOVE MODE DAMPER SERVO SUB ASSY a Remove the 3 screws and mode damper servo sub assy 23 REMOVE HEATER RADIATOR UNIT SUB ASSY a Release the 2 fitting claws remove the piping clamp b Remove the heater radiator unit sub assy NOTICE Prepare a support plate and waste to catch the leaked cool ant 24...

Page 890: ...exagon wrench 4 mm 0 16 in remove the 2 hexagon bolts and air conditioning tube assy c Remove the 2 O rings from the air conditioning tube assy 26 REMOVE COOLER EXPANSION VALVE a Remove the cooler expansion valve from the cooler evap orator sub assy No 1 27 REMOVE COOLER THERMISTOR NO 1 28 REMOVE COOLER EVAPORATOR SUB ASSY NO 1 a Auto A C model Release the fitting claw remove the 3 screws and air ...

Page 891: ...ter case RH d Remove the 2 O rings from the cooler evaporator sub assy No 1 29 INSTALL COOLER EVAPORATOR SUB ASSY NO 1 a Apply compressor oil to the contact surfaces of 2 new O rings and the cooler expansion valve and install them Compressor oil ND OIL 8 or equivalent b Install the cooler evaporator sub assy No 1 to the heater case RH c Install the heater case LH with the 12 screws d Auto A C mode...

Page 892: ...Compressor oil ND OIL 8 or equivalent b Using a hexagon wrench 4 mm 0 16 in install the air conditioner tube assy and 2 hexagon bolts to the cooler evaporator sub assy No 1 Torque 3 5 N m 35 kgf cm 30 in lbf c Install the packing HINT Securely attach so that the gap in the packing will not be mode 32 INSTALL AIR CONDITIONING RADIATOR ASSY a Install the air conditioning radiator assy with the 2 nut...

Page 893: ...STALL BLOWER ASSY a Install the blower assy with the 2 screws and 2 nuts Torque 1 5 N m 15 kgf cm 12 in lbf b Install the 6 clamps connect the wire harness c Install the blower connector holder with the screw and clamp d Connect the connectors 35 INSTALL INSTRUMENT PANEL REINFORCEMENT a Install the instrument panel reinforcement with the 7 bolts and 3 caps ...

Page 894: ...IONING RADIATOR ASSY 55 41 2356 Author Date 2002 CAMRY REPAIR MANUAL RM881U b Install the 3 earth wires with the 3 nuts c Install the 7 clamps connect the wire harness 36 INSTALL STEERING COLUMN ASSY a Install the steering column assy with the 3 bolts b Install the 2 clamps ...

Page 895: ... steering side connector block with the 2 nuts Torque 8 4 N m 85 kgf cm 73 in lbf d Install the driver side junction block with the 3 nuts Torque 8 4 N m 85 kgf cm 73 in lbf 37 INSTALL INSTRUMENT PANEL BRACE SUB ASSY NO 2 a Install the instrument panel brace sub assy No 2 with the 2 nuts and bolt b Install the nut and clamp c Install the earth wire with the bolt ...

Page 896: ... and clamp Torque 8 4 N m 85 kgf cm 73 in lbf 38 INSTALL INSTRUMENT FINISH PANEL RETAINER LOWER a Install the instrument finish panel retainer lower with the 2 bolts 39 INSTALL INSTRUMENT PANEL BRACE SUB ASSY NO 1 a Install the instrument panel brace sub assy No 1 with the nut b Install the bolt and screw Torque 9 8 N m 100 kgf cm 87 in lbf Screw c Install the 2 clamps d Install the 2 earth wires ...

Page 897: ...hose No 1 and piping clamp HINT After connection check the fitting for claw of the piping clamp 42 INSTALL COOLER REFRIGERANT LIQUID PIPE A HINT Install in the same way as the cooler refrigerant suction hose No 1 43 ADD COOLANT 1MZ FE See page 16 20 2AZ FE See page 16 6 44 CHARGE REFRIGERANT See page 55 18 SST 07110 58060 07117 58060 07117 58070 07117 58080 07117 58090 07117 78050 07117 88060 0711...

Page 898: ...ervo Sub assy Air Refiner Element Cowl Wire No 2 Heater To Foot Duct No 1 Blower Resistor Blower w fan Motor Sub assy Instrument Panel Wire No 3 Auto A C Model Blower Motor Control Instrument Panel Wire No 3 HEATER AIR CONDITIONER BLOWER ASSY 55 45 2360 Author Date 2002 CAMRY REPAIR MANUAL RM881U BLOWER ASSY COMPONENTS ...

Page 899: ...ge 55 45 1 REMOVE INSTRUMENT PANEL SAFETY PAD SUB ASSY See page 71 12 2 REMOVE HEATER TO FOOT DUCT NO 1 See page 55 29 3 REMOVE BLOWER ASSY See page 55 29 4 REMOVE AIR REFINER ELEMENT 5 REMOVE COWL WIRE NO 2 a Remove the clamp and cowl wire No 2 6 REMOVE RECIRCULATION DAMPER SERVO SUB ASSY a Remove the 3 screws and recirculation damper servo sub assy ...

Page 900: ...nect the connectors remove the 3 clamps and instrument panel wire No 3 b Auto A C model Disconnect the connectors remove the 2 clamps and instrument panel wire No 3 8 REMOVE BLOWER RESISTOR MANUAL AIR CONDITIONER a Remove the 2 screws and blower resistor 9 REMOVE BLOWER MOTOR CONTROL AUTO AIR CONDITIONER a Remove the 2 screws and blower motor control 10 REMOVE BLOWER W FAN MOTOR SUB ASSY a Remove ...

Page 901: ...55 48 HEATER AIR CONDITIONER BLOWER ASSY 2363 Author Date 2002 CAMRY REPAIR MANUAL RM881U 11 INSTALL BLOWER ASSY See page 55 29 12 INSTALL INSTRUMENT PANEL SAFETY PAD SUB ASSY See page 71 12 ...

Page 902: ...fied torque Magnet Clutch Washer Snap Ring Magnet Clutch Assy Cooler Compressor Assy Snap Ring Cooler Compressor Bracket HEATER AIR CONDITIONER COOLER COMPRESSOR ASSY 1MZ FE 55 49 2364 Author Date 2002 CAMRY REPAIR MANUAL RM881U COOLER COMPRESSOR ASSY 1MZ FE COMPONENTS ...

Page 903: ... Remove the nut and disconnect the cooler refrigerant dis charge hose No 1 b Remove the O ring from the cooler refrigerant discharge hose No 1 NOTICE Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering 5 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO 1 a Remove the nut and disconnect the cooler refrigerant suction hose No 1 b Remove the O...

Page 904: ...E COOLER COMPRESSOR BRACKET a Remove the screw earth wire and cooler compressor bracket 8 REMOVE MAGNET CLUTCH ASSY a Remove the bolt and bracket b Place the compressor and magnetic clutch in vise c Using a vise pliers hold the magnet clutch hub d Remove the bolt magnet clutch hub and magnet clutch washer e Using a snap ring expander remove the snap ring and magnet clutch rotor f Disconnect the co...

Page 905: ...UTCH ASSY a Matching the parts shown in the illustration install the magnet clutch starter b Using a snap ring expander install a new snap ring with the chamfered side facing up c Connect the connector d Using a snap ring expander install the magnet clutch ro tor and a new snap ring with the chamfered side facing up e Install the magnet clutch washer and magnet clutch hub NOTICE Do not change the ...

Page 906: ...rminal 3 of mag net clutch connector and the negative lead to the earth wire Turn on and off the magnet clutch and measure the clearance Standard clearance 0 35 0 60 mm 0 014 0 024 in If the measured value is out of the standard range remove the magnet clutch hub and adjust it with magnet clutch washers NOTICE Adjustment shall be performed with 3 or less magnet clutch washers c Remove the compress...

Page 907: ...emoval instal lation Because compressor oil remains in the pipes of the vehicle if a new compressor and magnetic clutch is installed without removing some oil inside the oil amount becomes too much pre venting heat exchange in the refrigerant cycle and causing refrigerant failure If the remaining oil in the removed compressor and magnetic clutch is too small in volume check for oil leakage Be sure...

Page 908: ... clutch with the nut Torque 9 8 N m 100 kgf cm 87 in lbf 17 INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO 1 a Remove the attached vinyl tape from the hose b Sufficiently apply compressor oil to the new O ring and fit surface of the compressor and magnetic clutch Compressor oil ND OIL 8 or equivalent c Install a O ring to the cooler refrigerant discharge hose No 1 d Install the cooler refrigerant di...

Page 909: ...ssy Snap Ring Magnet Clutch Washer Non reusable part N m kgf cm ft lbf Snap Ring 18 184 13 Specified torque 55 56 HEATER AIR CONDITIONER COOLER COMPRESSOR ASSY 2AZ FE 2371 Author Date 2002 CAMRY REPAIR MANUAL RM881U COOLER COMPRESSOR ASSY 2AZ FE COMPONENTS ...

Page 910: ...CHARGE HOSE NO 1 a Remove the nut and disconnect the cooler refrigerant dis charge hose No 1 b Remove the O ring from the cooler refrigerant discharge hose No 1 NOTICE Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering 5 DISCONNECT COOLER REFRIGERANT SUCTION HOSE NO 1 a Remove the nut and disconnect the cooler refrigerant suction hose N...

Page 911: ... the bolt d Remove the 3 bolts and compressor and magnetic clutch 7 REMOVE MAGNET CLUTCH ASSY a Remove the bolt and bracket b Place the compressor and magnetic clutch in vise c Using a vise pliers hold the magnet clutch hub d Remove the bolt magnet clutch hub and magnet clutch washer e Using a snap ring expander remove the snap ring and magnet clutch rotor f Disconnect the connector ...

Page 912: ...UTCH ASSY a Matching the parts shown in the illustration install the magnet clutch starter b Using a snap ring expander install a new snap ring with the chamfered side facing up c Connect the connector d Using a snap ring expander install the magnet clutch ro tor and a new snap ring with the chamfered side facing up e Install the magnet clutch washer and magnet clutch hub NOTICE Do not change the ...

Page 913: ... hub b Connect the battery positive lead to the terminal 3 of mag net clutch connector and the negative lead to the earth wire Turn on and off the magnet clutch and measure the clearance Standard clearance 0 35 0 60 mm 0 014 0 024 in If the measured value is out of the standard range remove the magnet clutch hub and adjust it with magnet clutch washers NOTICE Adjustment shall be performed with 3 o...

Page 914: ...s too much pre venting heat exchange in the refrigerant cycle and causing refrigerant failure If the remaining oil in the removed compressor and magnetic clutch is too small in volume check for oil leakage Be sure to use ND OIL8 for compressor oil 12 TEMPORARY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH a Temporarily the compressor and magnetic clutch with the 3 bolts 13 FULLY TIGHTEN COMPRESSOR AND MA...

Page 915: ...compressor and magnetic clutch Compressor oil ND OIL 8 or equivalent c Install a O ring to the cooler refrigerant discharge hose No 1 d Install the cooler refrigerant discharge hose No 1 to the compressor and magnetic clutch with the nut Torque 9 8 N m 100 kgf cm 87 in lbf 16 INSTALL GENERATOR ASSY See page 19 13 17 INSTALL FAN AND GENERATOR V BELT See page 14 5 SST 09249 63010 18 CHARGE REFRIGERA...

Page 916: ... cooler condenser assy is dirty clean it with water and dry it with compressor air NOTICE Do not damage the fin of the condenser assy b If a fin of the condenser assy is bent make it straight using a screwdriver or pliers 2 INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT a Using a halogen leak detector check pipe joints for gas leakage b If gas leakage is detected in a joint check the torque of the j...

Page 917: ...ompressor oil ND OIL 8 or equivalent 9 8 100 85 in lbf O ring 5 4 55 47 in lbf O ring 12 125 9 1MZ FE Air Cleaner Inlet No 1 1MZ FE Air Cleaner Inlet Assy Air Cleaner Inlet Assy 2AZ FE N m kgf cm ft lbf Specified torque 9 8 100 85 in lbf 55 64 HEATER AIR CONDITIONER COOLER CONDENSER ASSY 2379 Author Date 2002 CAMRY REPAIR MANUAL RM881U COMPONENTS ...

Page 918: ...er refrigerant discharge hose No 1 NOTICE Seat the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering 3 DISCONNECT COOLER REFRIGERANT LIQUID PIPE A a Remove the bolt and disconnect the cooler refrigerant liq uid pipe A from the cooler condenser assy b Remove the O ring from the cooler refrigerant liquid pipe A NOTICE Seal the opening of the disc...

Page 919: ...remove the cap and filter from the modulator b Remove the 2 O rings from the cap c Using a needle nose pliers remove the cooler dryer 8 INSTALL COOLER DRYER a Using a needle nose pliers install the cooler dryer b Install 2 new O rings to the cap c Sufficiently apply compressor oil to the fit surfaces of the O ring and the cap Compressor oil ND OIL 8 or equivalent d Using hexagon wrench 10 mm 0 39 ...

Page 920: ...the new O ring and pipe joint Compressor oil ND OIL 8 or equivalent c Install a O ring to the cooler refrigerant liquid pipe A d Connect the cooler refrigerant liquid pipe A to the cooler condenser assy with the bolt Torque 5 4 N m 55 kgf cm 47 in lbf 12 INSTALL COOLER REFRIGERANT DISCHARGE HOSE NO 1 a Remove the attached vinyl tape from the tube and con necting part of the cooler condenser assy b...

Page 921: ...Y REPAIR MANUAL RM881U 13 CHARGE REFRIGERANT See page 55 18 SST 07110 58060 07117 58060 07117 58070 07117 58080 07117 58090 07117 78050 07117 88060 07117 88070 07117 88080 Specified amount 550 50 g 19 37 1 76 oz 14 WARM UP ENGINE 15 INSPECT LEAKAGE OF REFRIGERANT See page 55 18 ...

Page 922: ...button assy instr pnl pass l door airbag assy airbag sensor assy center airbag front sensor front seat airbag assy side airbag sensor assy curtain shield airbag assy airbag sensor rear and seat position airbag sensor should be inspected See page 60 9 Before repairs remove the airbag sensor if shocks are likely to be applied to the sensor during repairs Never use SRS parts from another vehicle When...

Page 923: ...ion Airbag Sensor Spiral Cable Sub Assy Horn Button Assy Squib Instr Pnl Pass L Door Airbag Assy Squib Curtain Shield Airbag Assy RH Squib Seat Belt Pretensioner RH Front Seat Airbag Assy RH Squib Front Seat Airbag Assy LH Squib Seat Belt Pretensioner LH Curtain Shield Airbag Assy LH Squib 60 2 SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 2385 Author Date 1 SRS CONNECTORS ...

Page 924: ...8 10 14 23 5 Connector Lock Mechanism Connectors 19 21 25 27 a All connectors in the SRS are colored in yellow to distin guish them from other connectors Connectors having special functions and specifically designed for the SRS are used in the locations shown on the previous page to ensure high reliability These connectors use durable gold plated terminals 1 Terminal twin lock mechanism Each conne...

Page 925: ...diagram on the previous page 3 Electrical connection check mechanism This mechanism electrically checks that connectors are connected correctly and completely The electri cal connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector hous ing lock is locked HINT The connectors shown in this illustration are connectors 1 2...

Page 926: ...ned to go on at a smaller decelera tion rate than the airbag sensor As illustrated in Fig 2 ignition is caused when current flows to the squib which happens when a safing sensor and the deceleration sen sor go on simultaneously When a deceleration force acts on the sensors 2 squibs in the driver airbag and front pas senger airbag ignite and generate gas The gas discharg ing into the driver airbag ...

Page 927: ...AT AIRBAG ASSY a Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration fit in them without rubbing b Be sure to insert until they are locked After fitting in pull them slightly to check that they are locked When locked make sure that the outer returns to its original position and sound at the time of fitting in can be heard HINT As ...

Page 928: ...NNECTION OF AIRBAG FRONT SENSOR SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR CON NECTOR a While holding both flank sides of the outer slide the outer to the direction shown by an arrow b Lock of the connectors is released then disconnect the connectors HINT Be sure to hold both flank sides of the outer If holding the top and bottom sides it will obstruct disconnection ...

Page 929: ...eturns to its original position again If fitting stops half way connectors will separate c Be sure to insert until they are locked After fitting in pull them slightly to check that they are locked When locked make sure that the outer returns to its original position and sound at the time of fitting in can be heard HINT Do not fit in while holding the outer When fitting in the outer slides Do not t...

Page 930: ...isual check which includes the following items with the horn button assy with airbag removed from the ve hicle Check cuts minute cracks or marked discoloration on the horn button assy top surface and in the grooved portion Check cuts and cracks in wire harness and chip ping in connectors Check the deformation on the steering wheel Check the deformation on the horn button contact plate of the horn ...

Page 931: ... the following item with the instr pnl pass l door airbag assy installed in the ve hicle Check cuts minute cracks or marked discoloration on the instr pnl pass l door airbag assy and instrument panel 5 INSTR PNL PASS L DOOR AIRBAG ASSY VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a Do a diagnostic system check See page 05 690 b Do a visual check which includes the following items with ...

Page 932: ...e front passenger airbag assy and instrument panel 8 FRONT SEAT AIRBAG ASSY VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED a Do a diagnostic system check See page 05 690 b Do a visual check which includes the following items with the front seat airbag assy removed from the vehicle Check cuts minute cracks or marked discoloration on the front seat airbag assy Check cuts and cracks in wire...

Page 933: ...ront sensor which includes the following items even if the airbag was not deployed Cracks dents or chips in the case Cracks dents chipping and scratches in the con nector Peeling off of the label or damage to the serial num ber 16 SIDE AIRBAG SENSOR ASSY VEHICLE NOT INVOLVED IN COLLISION a Do a diagnostic system check See page 05 690 17 SIDE AIRBAG SENSOR ASSY VEHICLE INVOLVED IN COLLISION AND AIR...

Page 934: ...he airbag was not deployed Cracks dents or chips in the case Cracks dents chipping and scratches in the connector 24 WIRE HARNESS AND CONNECTOR VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check See page 05 690 25 WIRE HARNESS AND CONNECTOR VEHICLE INVOLVED IN COLLISION a Do a diagnostic system check See page 05 690 b Check breaks in all wires of the SRS wire harness and exposed conduc...

Page 935: ... Cover Spiral Cable Sub Assy Steering Column Cover Steering Wheel Cover Lower No 2 8 8 90 78 in lbf 8 8 90 78 in lbf 50 510 37 N m kgf cm ft lbf Specified torque Steering Wheel Cover Lower No 3 4 Spoke Steering Wheel Assy 3 Spoke Steering Wheel Assy 60 14 SUPPLEMENTAL RESTRAINT SYSTEM HORN BUTTON ASSY 2397 Author Date 2002 CAMRY REPAIR MANUAL RM881U HORN BUTTON ASSY COMPONENTS ...

Page 936: ...STEERING PAD SWITCH 4 SPOKE STEERING WHEEL 5 REMOVE STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY 6 REMOVE CONNECTOR COVER W STEERING PAD SWITCH 4 SPOKE STEERING WHEEL 7 REMOVE HORN BUTTON ASSY a Place the front wheels facing straight ahead b Using a torx socket wrench T30 loosen the 2 torx screws until the groove along the screw circumference catches on the screw case c Pull out the...

Page 937: ... 60 9 9 INSTALL HORN BUTTON ASSY a Connect the airbag connectors and horn connector b Install the horn button after confirming that the circumference groove of the torx screws is caught on the screw case c Using a torx socket wrench T 30 install the 2 screws Torque 8 8 N m 90 kgf cm 78 in lbf 10 INSPECT SRS WARNING LIGHT See page 05 690 ...

Page 938: ...esidents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise When deploying an airbag perform the operation at least 10 m 33 ft away from the horn button assy The horn button assy is very hot when the airbag is deployed so leave it alone for at least 30 minutes af ter deployment Use gloves and safety glasses...

Page 939: ...up when the activation switch is not being pressed SST malfunction is probable so definitely do not use the SST 3 Disconnect the SST from the battery b Install the SST CAUTION Check that there is no looseness in the steering wheel and horn button assy 1 While turning the steering wheel right left remove the 2 screws and column lower cover 2 Disconnect the airbag connector of the spiral cable 3 Con...

Page 940: ... hands with water after completing the operation HINT When scrapping a vehicle deploy the airbag and scrap the ve hicle with the horn button assy still installed 2 DISPOSE HORN BUTTON ASSY WHEN DISPOSING OF AIRBAG ASSEMBLY DEPLOYMENT METHOD NOTICE When disposing of the horn button assy with airbag only never use the customers vehicle to deploy the airbag Be sure to follow the procedure given below...

Page 941: ...d wire harness section Square 3 14 x Diameter 2 divided by 4 1 Install the 2 bolts with washers in the 2 bolt holes in the horn button assy Bolt L 35 0 mm 1 387 in M 6 0 mm 0 236 in Pitch 1 0 mm 0 039 in NOTICE Tighten the bolts by hand until the bolts become diffi cult to turn Do not tighten the bolts too much 2 Connect the connectors of the SST to the horn but ton assy connectors SST 09082 00801...

Page 942: ... bag is deployed This is highly dangerous 4 Face the upper surface of the horn button assy up ward Separately tie the left and right sides of the horn button assy to the disc wheel through the hub nut holes Position the horn button assy connector so that it hangs downward through a hub hole in the disc wheel CAUTION Make sure that the wire harness is tight It is very dan gerous when looseness in t...

Page 943: ...wire harness do not lock the secondary lock of the twin lock Also se cure some slack for the SST wire harness inside the disc wheel 2 Move the SST to at least 10 m 33 ft away from the horn button assy tied down on the disc wheel e Cover the horn button assy with a cardboard box or tires Covering method using a cardboard box Cover the horn button assy with the cardboard box and weight the cardboard...

Page 944: ... red clip to the battery positive terminal and the black clip to the battery negative terminal 2 Check that no one is within 10 m 33 ft area around the disc wheel which the horn button assy is tied to 3 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up g Dispose of the horn button assy with airbag CAUTIO...

Page 945: ...6007H 01 60 24 SUPPLEMENTAL RESTRAINT SYSTEM SPIRAL CABLE SUB ASSY 2407 Author Date 2002 CAMRY REPAIR MANUAL RM881U SPIRAL CABLE SUB ASSY COMPONENTS See page 60 14 ...

Page 946: ...EERING WHEEL 8 REMOVE HORN BUTTON ASSY See page 60 15 9 REMOVE STEERING WHEEL ASSY See page 50 9 SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 10 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 71 12 11 REMOVE STEERING COLUMN COVER 12 REMOVE SPIRAL CABLE SUB ASSY a Disconnect the airbag connector and connector from the spiral cable sub assy b Release the 3 claws and remove the sp...

Page 947: ...d Install the steering column cover with the 2 screws 16 CENTER SPIRAL CABLE a Check that the ignition switch is OFF b Check that the battery negative terminal is disconnected NOTICE Do not start the operation for 90 seconds after removing the terminal c Turn the cable counterclockwise by hand until it becomes harder to turn d Then rotate the cable clockwise about 2 5 turns to align the marks HINT...

Page 948: ...sh Tray Instrument Panel Ash Receptacle Assy Instrument Panel Upper Rear Instrument Panel Cup Holder Tray Console Panel Upper Console Panel Upper Console Box Front Console Box Carpet w o Steering Pad Switch Steering Wheel Cover Lower No 2 Steering Wheel Cover Lower No 2 Foot Parking Brake Instrument Panel Finish Panel Lower Center Clock Assy Front Pillar Garnish LH Front Pillar Garnish LH w o Curt...

Page 949: ...rument Panel Upper Rear Instrument Panel Cup Holder Tray Console Panel Upper Console Panel Upper Console Box Front Console Box Carpet w o Steering Pad Switch Steering Wheel Cover Lower No 2 Steering Wheel Cover Lower No 2 Foot Parking Brake Instrument Panel Finish Panel Lower Center Clock Assy Front Pillar Garnish LH Front Pillar Garnish LH w o Curtain Shield Airbag Front Pillar Garnish RH w o Cur...

Page 950: ...ide Defroster Nozzle Duct No 1 Side Defroster Nozzle Duct No 2 Instr Pnl Pass L Door Airbag Assy 20 200 14 Instrument Panel Safety Pad Sub Assy Instrument Panel Register Assy No 1 Instrument Panel Register Assy No 2 N m kgf cm ft lbf Specified torque SUPPLEMENTAL RESTRAINT SYSTEM INSTR PNL PASS L DOOR AIR BAG ASSY 60 29 2412 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 951: ...STEERING WHEEL ASSY See page 50 9 10 REMOVE STEERING COLUMN COVER 11 REMOVE HEADLAMP DIMMER SWITCH ASSY See page 50 9 12 REMOVE WINDSHIELD WIPER SWITCH ASSY See page 50 9 13 REMOVE COMBINATION METER ASSY See page 71 12 14 REMOVE FRONT DOOR SCUFF PLATE LH See page 71 12 15 REMOVE FRONT DOOR SCUFF PLATE RH See page 71 12 16 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 17 REMOVE COWL SIDE TRIM SU...

Page 952: ...12 33 REMOVE CONSOLE PANEL UPPER See page 71 12 34 REMOVE CONSOLE BOX FRONT See page 71 12 35 REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER See page 71 12 36 REMOVE FRONT PILLAR GARNISH LH W O CURTAIN SHIELD AIR BAG See page 71 12 37 REMOVE FRONT PILLAR GARNISH LH W CURTAIN SHIELD AIR BAG See page 71 12 38 REMOVE FRONT PILLAR GARNISH RH W O CURTAIN SHIELD AIR BAG See page 71 12 39 REMOVE FRONT...

Page 953: ...s b Release the rear side wall of the airbag door from the hook by slightly deflecting it and roll the instr pnl pass l door airbag assy forward c Release the front side wall of the airbag door from the oth er hook and remove the instr pnl pass l door airbag assy 53 INSPECT INSTR PNL PASS L DOOR AIR BAG ASSY See page 60 9 54 INSTALL INSTR PNL PASS L DOOR AIR BAG ASSY 55 INSTALL FRONT PILLAR GARNIS...

Page 954: ...SYSTEM INSTR PNL PASS L DOOR AIR BAG ASSY 60 33 2416 Author Date 2002 CAMRY REPAIR MANUAL RM881U 61 INSTALL HORN BUTTON ASSY See page 60 15 62 INSPECT HORN BUTTON ASSY See page 60 9 63 INSPECT SRS WARNING LIGHT See page 05 690 ...

Page 955: ...ance to nearby residents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise When deploying an airbag perform the operation at least 10 m 33 ft away from the instr pnl pass l door airbag assy The instr pnl pass l door airbag assy is very hot when the airbag is deployed so leave it alone for at least 30 minut...

Page 956: ...the 3 SST to the instr pnl pass l door airbag assy connectors SST 09082 00700 09082 00801 09082 10801 09082 30801 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 2 Move the SST to at least 10 m 33 ft away from the front of the vehicle 3 Close all the doors and windows of the vehicle NOTICE Take care not to damage the SST wire harness 4 Co...

Page 957: ...BAG ASSEMBLY DEPLOYMENT METHOD NOTICE When disposing of the instr pnl pass l door airbag assy only never use the customer s vehicle to deploy the airbag Be sure to follow the procedure given below when de ploying the airbag HINT Have a battery ready as the power source to deploy the airbag a Remove the instr pnl pass l door airbag assy See page 60 30 CAUTION When removing the instr pnl pass l door...

Page 958: ...e airbag deployment side facing inside Tire size Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION Make sure that the wire harness is tight It is very dan gerous if looseness in the wire harness results in the instr pnl pass l door airbag assy coming free due to the shock from the airbag deploying Always tie down the instr pnl pass l door airbag assy ...

Page 959: ...op tire should have the wheel installed 3 Tie the tires together with 2 wire harness CAUTION Make sure that the wire harness is tight It is very danger ous if looseness in the wire harness result in the tires com ing free due to the shock from the airbag deploying HINT Place the SST connector and wire harness inside tires Secure at least 1 m 3 ft of slack for the wire harness e Install the SST Con...

Page 960: ...ST ac tivation switch lights up g Dispose of the instr pnl pass l door airbag assy CAUTION The instr pnl pass l door airbag assy is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety glasses when handling a instr pnl pass l door airbag assy with the deployed airbag Always wash your hands with water after completing the operation Do...

Page 961: ... 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf 9 8 100 87 in lbf N m kgf cm ft lbf Specified torque 60 40 SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIR BAG ASSY LH 2423 Author Date 2002 CAMRY REPAIR MANUAL RM881U CURTAIN SHIELD AIR BAG ASSY LH COMPONENTS ...

Page 962: ...L UPPER REAR See page 71 12 12 REMOVE RR CONSOLE BOX See page 71 12 13 REMOVE CONSOLE PANEL UPPER See page 71 12 14 REMOVE CONSOLE BOX FRONT See page 72 7 15 REMOVE AIR DUCT REAR NO 1 See page 55 29 16 REMOVE AIR DUCT REAR NO 2 See page 55 29 17 REMOVE CONSOLE BOX DUCT NO 1 See page 55 29 18 REMOVE FLOOR SHIFT ASSY 19 REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP RH See page 76 20 20 REMOVE FRONT DO...

Page 963: ...ge 76 20 30 REMOVE FRONT PILLAR GARNISH LH See page 76 20 31 REMOVE ASSIST GRIP SUB ASSY See page 76 20 32 REMOVE RH VISOR ASSY See page 76 20 33 REMOVE LH VISOR ASSY See page 76 20 34 REMOVE INNER REAR VIEW MIRROR ASSY See page 76 20 35 REMOVE ROOF CONSOLE BOX ASSY See page 76 20 36 REMOVE ROOM LAMP ASSY NO 1 See page 76 20 37 REMOVE VISOR HOLDER See page 76 20 38 REMOVE ROOF HEADLINING ASSY See ...

Page 964: ...HIELD AIR BAG ASSY LH See page 60 9 41 INSTALL CURTAIN SHIELD AIR BAG ASSY LH a Install the curtain shield airbag assy LH with the 9 bolts Torque 9 8 N m 100 kgf cm 87 in lbf HINT Install the bolts from rear side of the vehicle in order b Connect the curtain shield airbag assy LH connector 42 INSTALL ROOF HEADLINING ASSY See page 76 20 43 INSTALL REAR SEAT BACK ASSY See page 72 34 44 INSTALL REAR ...

Page 965: ...bag Deployment Tool Perform the op eration in a place away from electrical noise When deploying an airbag perform the operation at least 10 m 33 ft away from the curtain shield airbag assy The curtain shield airbag assy is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety glasses when handling a cur tain shield airbag assy with th...

Page 966: ...e airbag 1 Confirm that no one is inside the vehicle or within 10 m 33 ft area around the vehicle 2 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up e Dispose of the curtain shield airbag assy LH CAUTION The curtain shield airbag assy is very hot when the airbag is deployed so leave it alone for at leas...

Page 967: ...he customer s vehicle to deploy the airbag Be sure to follow the procedure given below when de ploying the airbag HINT Have a battery ready as the power source to deploy the airbag a Remove the curtain shield airbag assy See page 60 41 CAUTION When removing the curtain shield airbag assy work must be started 90 seconds after the ignition switch is turned to the LOCK position and the negative termi...

Page 968: ...arness which is at least 1 25 mm2 0 0019 in 2 HINT To calculate the square of the stripped wire harness section Square 3 14 X Diameter 2 divided by 4 Position the curtain shield airbag assy LH inside the tire with the airbag deployment side facing inside Tire size Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION Make sure that the wire harness is tig...

Page 969: ... which the curtain shield airbag assy is tied The top tire should have the wheel installed 3 Tie the tires together with 2 wire harness CAUTION Make sure that the wire harness is tight It is very danger ous if looseness in the wire harness result in the tires com ing free due to the shock from the airbag deploying HINT Place the SST connector and wire harness inside tires Secure at least 1 m 3 ft ...

Page 970: ...he LED of the SST ac tivation switch lights up h Dispose of the curtain shield airbag assy CAUTION The curtain shield airbag assy is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety glasses when handling a cur tain shield airbag assy with the deployed airbag Always wash your hands with water after completing the operation Do not ...

Page 971: ...ble exploding sound when it deploys so perform the operation out of doors and where it will not create a nuisance to nearby residents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool perform the operation in a place away from electrical noise When deploying an airbag perform the operation at least 10 m 33 ft away from the airbag assy The front seat airbag assy is v...

Page 972: ...wire harness 4 Connect the red clip of the SST to the battery posi tive terminal and the black clip of the SST to the battery negative terminal e Deploy the airbag 1 Confirm that no one is inside the vehicle or within 10 m 33 ft area around the vehicle 2 Press the activation switch of the SST and deploy the airbag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch ligh...

Page 973: ...source to deploy the airbag a Remove the front seat airbag assy 1 Remove the 2 nuts and front seat airbag assy from the seatback assembly CAUTION Store the front seat airbag assy with the airbag deployment side facing upward b Using a service purpose wire harness tie down the front seat airbag assy Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more HINT To calculate the...

Page 974: ...m 14 17 in CAUTION Make sure the wire harness is tight It is very danger ous if looseness in the wire harness results in the front seat airbag assy coming free due to the shock from the airbag deploying Always tie down the front seat airbag assy with the airbag door facing inside NOTICE The tire will be marked by the airbag deployment so use the redundant tire c Check functioning of the SST See st...

Page 975: ...rness inside the tire f Deploy the airbag 1 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal 2 Check that no one is within 10 m 33 ft area around the tire which the front seat airbag assy is tied to 3 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lig...

Page 976: ... Holder Tray Console Box Front Console Box Carpet Console Panel Upper Rear RR Console Box Air Duct Rear No 1 Air Duct Rear No 2 Console Box Duct No 1 Auto A C Model Airbag Sensor Assy Center 17 5 178 13 N m kgf cm ft lbf Specified torque SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG SENSOR ASSY CENTER 60 55 2438 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR BAG SENSOR ASSY CENTER COMPONENTS ...

Page 977: ...IR DUCT REAR NO 2 See page 55 29 12 REMOVE CONSOLE BOX DUCT NO 1 AUTO AIR CONDITIONER See page 55 29 13 REMOVE AIR BAG SENSOR ASSY CENTER a Disconnect the 3 connectors from the airbag sensor assy center b Remove the 3 bolts and air bag sensor assy center 14 INSPECT AIR BAG SENSOR ASSY CENTER See page 60 9 15 INSTALL AIR BAG SENSOR ASSY CENTER a Check that the ignition switch turn OFF b Check that ...

Page 978: ...Front LH 17 5 178 13 17 5 178 13 N m kgf cm ft lbf Specified torque Engine Under Cover RH Engine Under Cover LH SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG FRONT RH SENSOR 60 57 2440 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR BAG FRONT RH SENSOR COMPONENTS ...

Page 979: ...r RH HINT Insert a screw driver in any of the three opening sections of the sensor and slide the sensor to disconnect it from the connector 5 INSPECT AIR BAG FRONT RH SENSOR See page 60 9 6 INSTALL AIR BAG FRONT RH SENSOR a Check that the ignition switch trun OFF b Check that the battery negative terminal is disconnected NOTICE Do not start the operation for 90 seconds after removing the terminal ...

Page 980: ...6007U 01 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG SENSOR FRONT LH 60 59 2442 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR BAG SENSOR FRONT LH COMPONENTS See page 60 57 ...

Page 981: ...or LH HINT Insert a screw driver in any of the three opening sections of the sensor and slide the sensor to disconnect it from the connector 5 INSPECT AIR BAG SENSOR FRONT LH See page 60 9 6 INSTALL AIR BAG SENSOR FRONT LH a Check that the ignition switch is OFF b Check that the battery negative terminal is disconnected NOTICE Do not start the operation for 90 seconds after removing the terminal c...

Page 982: ...r RH Rear Door Opening Trim Weatherstrip RH Front Seat Outer Belt Assy RH Side Airbag Sensor Assy RH 20 204 15 20 204 15 8 5 87 75 in lbf 42 420 31 N m kgf cm ft lbf Specified torque SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIR BAG SENSOR ASSY RH 60 61 2444 Author Date 2002 CAMRY REPAIR MANUAL RM881U SIDE AIR BAG SENSOR ASSY RH COMPONENTS ...

Page 983: ...tor from the side airbag sensor assy RH b Remove the 3 bolts and side airbag sensor assy RH 10 INSPECT SIDE AIR BAG SENSOR ASSY RH See page 60 9 11 INSTALL SIDE AIR BAG SENSOR ASSY RH a Install the 3 bolts and side airbag sensor assy RH Torque 20 N m 204 kgf cm 15 ft lbf b Connect the side airbag sensor connector NOTICE Installation of the connector is done with the sensor assembly installed Make ...

Page 984: ...AG SENSOR ASSY RH 60 63 2446 Author Date 2002 CAMRY REPAIR MANUAL RM881U 12 INSTALL FRONT SEAT OUTER BELT ASSY RH Torque Upper bolt 8 5 N m 87 kgf cm 75 in lbf Lower bolt 42 N m 420 kgf cm 31 ft lbf 13 INSPECT SRS WARNING LIGHT See page 05 690 ...

Page 985: ... Airbag Sensor Rear LH 17 5 178 13 N m kgf cm ft lbf Specified torque 18 184 13 Property Class 8T Property Class 6T 20 200 14 60 64 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG SENSOR REAR LH 2447 Author Date 2002 CAMRY REPAIR MANUAL RM881U AIR BAG SENSOR REAR LH COMPONENTS ...

Page 986: ...operty class 6T 17 5 N m 178 kgf cm 13 ft lbf Property class 8T 20 N m 200 kgf cm 14 ft lbf c Connect the connector of the airbag sensor rear LH NOTICE Installation of the connector is done with the sensor assembly installed Make sure the sensor assembly is installed with the specified torque If the sensor assembly has been dropped or there are cracks dents or other defects in the case bracket or ...

Page 987: ...N m kgf cm ft lbf Specified torque Front Seat Track Cover LH Rear Inner Power Seat Manual Seat Seat Track Cover Upper Rear Seat Track Upper Rail Cover RH Power Seat Manual Seat 60 66 SUPPLEMENTAL RESTRAINT SYSTEM SEAT POSITION AIR BAG SENSOR 2449 Author Date 2002 CAMRY REPAIR MANUAL RM881U SEAT POSITION AIR BAG SENSOR COMPONENTS ...

Page 988: ...at position sensor 9 INSTALL SEAT POSITION AIR BAG SENSOR a Using a torx socket wrench T30 install the seat position sensor with the torx screw Torque 8 0 N m 82 kgf cm 71 in lbf b Connect the connector of the seat position sensor NOTICE Installation of the connector is done with the sensor assembly installed Make sure the sensor assembly is installed with the specified torque If the sensor assemb...

Page 989: ...ner Belt Assy LH Clock Assy Passenger s Seat Belt Warning Lamp Seat Belt Warning Sensor Combination Meter Driver s Seat Belt Warning Lamp SEAT BELT SEAT BELT WARNING SYSTEM 61 1 2451 Author Date 2002 CAMRY REPAIR MANUAL RM881U SEAT BELT WARNING SYSTEM LOCATION ...

Page 990: ... See page Driver seat belt warning lamp does not light up 1 GAUGE 10 A Fuse 2 Combination meter 3 Air bag sensor assembly center 4 Front seat inner belt assembly LH 5 Wire harness 71 25 05 687 61 3 Passenger seat belt warning lamp does not light up 1 GAUGE 10 A Fuse 2 Clock assembly 3 Front seat inner belt assembly RH 4 Wire harness 71 26 61 3 ...

Page 991: ...result is not as specified replace the front seat inner belt assembly Standard TMMK made Terminal No Specified condition 1 4 330 Ω If the result is not as specified replace the front seat inner belt assembly b When releasing the seat belt Buckle switch is OFF 1 Inspect the continuity and resistance between the terminals Standard TMC made Terminal No Specified condition 1 3 1 330Ω If the result is ...

Page 992: ...ntinuity If the result is not as specified replace the front seat inner belt assembly Standard TMMK made Terminal No Specified condition 1 3 No continuity If the result is not as specified replace the front seat inner belt assembly c When releasing the seat belt Buckle switch is OFF 1 Check the continuity between the connector termi nals of the warning switch Standard TMC made Terminal No Specifie...

Page 993: ...eplace the front seat inner belt assembly Standard TMMK made Terminal No Specified condition 5 4 No continuity 1 3 No continuity If the result is not as specified replace the front seat inner belt assembly f When releasing the seat belt Buckle switch is OFF 1 Check the continuity between the connector termi nals of the warning switch Standard TMC made Terminal No Specified condition 2 4 No continu...

Page 994: ...e RH Center Pillar Garnish Lower RH Lap Belt Outer Anchor Cover 42 420 31 Front Seat Assy RH Front Seat Outer Belt Assy RH Front Seat Inner Belt Assy RH 42 420 31 42 420 31 Front Seat Inner Belt Assy RH 42 420 31 TMMK Made Belt Guide N m kgf cm ft lbf Specified torque 61 6 SEAT BELT FRONT SEAT BELT 2456 Author Date 2002 CAMRY REPAIR MANUAL RM881U FRONT SEAT BELT COMPONENTS ...

Page 995: ...NOTICE Removal operation of the seat belt with pretensioner must be started in 90 seconds or more after the igni tion switch is turned OFF and the battery negative ter minal is disconnected Carefully read the notices for the pretensioner in the SRS airbag system and the front seat outer belt assembly a Remoe the 2 screws and belt guide b Remove the nut and the shoulder anchor c Disconnect the conn...

Page 996: ... RH a Check the degree of tilt when beginning to lock the ELR 1 Check the belt will not lock within 15 degrees of tilt in all the direction but the belt will lock over 45 de grees of tilt when moving the installed retractor gently NOTICE Do not disassemble the retractor b Install the retractor with the 2 bolts Torque 7 5 N m 80 kgf cm 66 in lbf Upper part of retractor 42 N m 420 kgf cm 31 ft lbf L...

Page 997: ...tivated pretensioner The seat belt pretensioner produces a sizeable ex ploding sound when it activates so perform the op eration out of door and where it will not create a nui sance to nearby residents When activating a front seat outer belt with seat belt pretensioner perform the operation at least 10 m 33 ft away from the front seat outer belt Use gloves and safety glasses when handling a front ...

Page 998: ...e SST activation switch and check that the LED of the SST activation switch lights up CAUTION If the LED lights up when the activation switch is not pressed the SST probably malfunctions so definitely do not use the SST b Disconnect the pretensioner connector 1 Remove the front door scuff plate RH See page 76 20 2 Remove the rear door scuff plate RH See page 76 20 3 Remove the front door opening t...

Page 999: ... activation switch lighting up e Dispose of the front seat outer belt with seat belt pretensioner CAUTION The rear outer belt is very hot when the seat belt pretensioner is activated so leave it alone for at least 30 minutes after activation Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pre tensioner Always wash your hands with water after completing ...

Page 1000: ...uter belt as shown in the illustration 3 Move the SST at least 10 m 33 ft away from the disc wheel NOTICE Take care not to damage the SST wire harness d Activate the seat belt pretensioner 1 Connect the SST red clip to the battery positive terminal and black clip to the battery negative terminal 2 Check that no one is within 10 m 33 ft area around the disc wheel 3 Press the SST activation switch a...

Page 1001: ...er LH Rear Seat Shoulder Belt Cover LH w Curtain Shield Airbag TMMK Made Rear Seat Cushion Assy Package Tray Trim Panel Assy Room Partition Board Center Stop Lamp Assy Rear Side Seat Back Assy LH Rear Side Seat Back Assy RH 42 420 31 42 420 31 42 420 31 42 420 31 18 183 13 18 183 13 Child Restraint Seat Tether Anchor Cover N m kgf cm ft lbf Specified torque SEAT BELT REAR SEAT BELT 61 13 2463 Auth...

Page 1002: ... SHOULDER BELT COVER RH a Using a screwdriver disengage the claws in the front side HINT Tape the screwdriver tip before use b Pull out the shoulder belt cover to the front side to disen gage the claws c Pull out the shoulder belt from the slit to remove the shoul der belt cover 6 REMOVE REAR SIDE SEAT BACK ASSY RH See page 72 33 7 REMOVE REAR SIDE SEAT BACK ASSY LH See page 72 33 8 REMOVE PACKAGE...

Page 1003: ...oor anchor with the bolt Torque 42 N m 420 kgf cm 31 ft lbf NOTICE Take care for the anchor not to run onto the protrusion part of the floor panel 13 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER a Install the retractor with the bolt Torque 42 N m 420 kgf cm 31 ft lbf b Install the anchor of the rear seat 3 point type belt assem bly outer RH with the bolt Torque 42 N m 420 kgf cm 31 ft lbf NOTICE...

Page 1004: ...hat the belt will lock when pulling out the belt quickly with the belt installed d Check the fastening function for child restraint system NOTICE Check should be done with the assembly installed 1 Check that the belt cannot be pulled out any more but can be rewound after the belt is fully pulled out 2 Check that the belt can be pulled out and rewound after the belt is fully rewound e Install the f...

Page 1005: ...wdriver disengage the claws in the front side HINT Tape the screwdriver tip before use b Pull out the shoulder belt cover to the front side to disen gage the claws c Pull out the shoulder belt from the slit to remove the shoul der belt cover 6 REMOVE REAR SIDE SEAT BACK ASSY RH See page 72 38 7 REMOVE REAR SIDE SEAT BACK ASSY LH See page 72 38 8 REMOVE ROOM PARTITION BOARD ASSY a Remove the 9 clip...

Page 1006: ...loor anchor with the bolt Torque 42 N m 420 kgf cm 31 ft lbf NOTICE Take care for the anchor not to run onto the protrusion part of the floor panel 14 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER a Install the retractor with the bolt Torque 42 N m 420 kgf cm 31 ft lbf b Install the anchor of the rear seat 3 point type belt assem bly outer RH with the bolt Torque 42 N m 420 kgf cm 31 ft lbf NOTIC...

Page 1007: ...hat the belt will lock when pulling out the belt quickly with the belt installed d Check the fastening function for child restraint system NOTICE Check should be done with the assembly installed 1 Check that the belt cannot be pulled out any more but can be rewound after the belt is fully pulled out 2 Check that the belt can be pulled out and rewound after the belt is fully rewound e Install the f...

Page 1008: ...b Since the internal pressure of a halogen lamp is high dropping hitting or damaging the bulb may cause the glass to scatter Therefore handle it with great care c When replacing bulbs do not remove until a new bulb is prepared Because if it is left being removed for a long period of time the lens may be covered with dirt or mois ture d For replacement be sure to use a bulb of the same watt e Firml...

Page 1009: ...Connect the connector to turn signal flasher and inspect the wire harness side connector from the back side as shown in the chart below Tester connection Condition Specified condition 2 Ground Hazard switch OFF ON 0V 10 14 V 60 to 120 time per minutes 2 Ground Turn signal switch right turn OFF ON 0V 10 14 V 60 to 120 time per minutes 3 Ground Hazard switch OFF ON 0V 10 14 V 60 to 120 time per minu...

Page 1010: ...nection Specified condition FLASH 7 8 16 Continuity LOW BEAM 16 17 Continuity HI BEAM 7 16 Continuity c Inspect turn signal switch continuity 1 Check that there is continuity between terminals at each switch position as shown in the chart Switch operation Tester connection Specified condition Right turn 2 3 Continuity Neutral No continuity Left turn 1 2 Continuity d Inspect front fog light switch ...

Page 1011: ...When ball is pressed Continuity 4 LUGGAGE COMPARTMENT DOOR LOCK ASSY a Inspect luggage compartment door courtesy lamp switch continuity 1 Check that there is continuity between terminal 2 and body ground when switch is operated Standard ON When shaft is pressed No continuity OFF When shaft is not pressed Continuity 5 FOG LAMP RELAY a Inspect relay continuity Condition Tester connection Specified c...

Page 1012: ...heck that there is continuity between terminals when switch is operated Standard ON When shaft is pressed No continuity OFF When shaft is not pressed Continuity 9 LUGGAGE COMPARTMENT LAMP ASSY NO 1 a Inspect luggage compartment lamp assy No 1 b Check that there is continuity between terminals when switch is operated Standard ON Continuity OFF No continuity 10 TAIL LAMP RELAY a Inspect relay contin...

Page 1013: ... SYSTEM 2475 Author Date 2002 CAMRY REPAIR MANUAL RM881U 12 RUNNING LIGHT RELAY a Inspect relay continuity Condition Tester connection Specified condition Constant 1 3 2 4 Continuity Apply B between terminal 1 and 3 4 5 Continuity ...

Page 1014: ...1 Headlight Protector Retainer UPPER LH Headlight Bulb No 1 Headlight Bulb No 2 Front Turn Signal Light Bulb LIGHTING LH HEADLAMP ASSY 65 7 2476 Author Date 2002 CAMRY REPAIR MANUAL RM881U LH HEADLAMP ASSY COMPONENTS ...

Page 1015: ...VE ENGINE UNDER COVER LH See Page 76 2 2 REMOVE ENGINE UNDER COVER RH See Page 76 2 3 REMOVE FRONT FENDER LINER RH See Page 76 2 4 REMOVE FRONT FENDER LINER LH See Page 76 2 5 REMOVE FRONT BUMPER COVER See Page 76 2 6 REMOVE LH HEADLAMP ASSY a Remove the 2 bolts b Disconnect the connectors c Pull out the headlight unit forward d Remove the headlight assy ...

Page 1016: ... retainer UPPER LH In this case however the head light unit assy LH itself should not be damaged a Cut off the part shaded in the illustration and sand smooth with sandpaper NOTICE After cutting off the part roughly place the headlight pro tector retainer UPPER LH against the bosses and gradually file any interfering part until the proper condition for instal lation is made b Install the headlight...

Page 1017: ...on 9 84 ft away from the headlights 3 Ensure that the center line of the vehicle and the paper face forms a 90 degree angle as shown in the illustration 4 Draw a horizontal line H line on the paper showing where the headlights should strike 5 Draw a vertical line V line to where the center line of the vehicle is to be 6 Draw 2 vertical lines to where the both headlights should strike V RH and V LH...

Page 1018: ...direction 1 High Beam Using adjusting bolt A adjust the headlight aim to be within the specified range 2 Low Beam Using adjusting bolt A adjust the headlight aim to be within the specified range HINT The optical aim moves upward when turning a screwdriver clockwise while it moves downward when turning a screwdriver counterclockwise ...

Page 1019: ...HTING FOG LAMP ASSY LH 2481 Author Date 2002 CAMRY REPAIR MANUAL RM881U FOG LAMP ASSY LH REPLACEMENT 1 REMOVE ENGINE UNDER COVER LH See Page76 2 2 REMOVE FOG LAMP ASSY LH a Detach clip and pull out the fog light assy LH forward ...

Page 1020: ...THESE CONDITIONS a Tire inflation pressure is in the specified value b Start the engine 2 ADJUST FOG LIGHT AIM a The fog light aim can be adjusted by turning the aiming screw in the vertical direction HINT The optical aim moves upward when turning a screwdriver clockwise while it moves downward when turning a screwdriver counterclockwise ...

Page 1021: ...RM881U REAR COMBINATION LAMP ASSY LH REPLACEMENT 1 REMOVE REAR COMBINATION LAMP ASSY LH a Remove the service hole cover b Remove the 3 nuts and disconnect the connector of rear combination light c Pull the rear combination light assy to the back of the ve hicle and remove the rear combination light assy ...

Page 1022: ...MP ASSY REPLACEMENT 1 REMOVE LUGGAGE COMPARTMENT DOOR COVER See Page 76 16 2 REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB ASSY OUTSIDE See Page 76 16 3 REMOVE LICENSE PLATE LAMP ASSY a Pull the license plate light assy to the side of vehicle as shown in the illustration and release the claw then dis connect the connector ...

Page 1023: ... LED a Pull out the center stop light assy shown in the illustration b Disconnect connector 2 REMOVE LUGGAGE COMPARTMENT DOOR COVER W REAR SPOILER LED See Page 76 6 3 REMOVE REAR SPOILER SUB ASSY W REAR SPOILER LED See Page 76 6 4 REMOVE CENTER STOP LAMP ASSY W REAR SPOILER LED a Remove the 2 screws and center stop light assy 5 INSTALL REAR SPOILER SUB ASSY W REAR SPOILER LED See Page 76 6 ...

Page 1024: ...DLAMP DIMMER SWITCH ASSY REPLACEMENT 1 REMOVE STEERING COLUMN COVER See Page 50 9 2 REMOVE HEADLAMP DIMMER SWITCH ASSY a Disconnect the connector b Using a screwdriver release the claw and pull out the headlight dimmer switch assy NOTICE Pressing the claw hard breaks the claw HINT Tape the screwdriver tip before use ...

Page 1025: ...ASHER NOZZLE ADJUSTMENT a Do not clean or adjust the washer nozzle with a safety pin etc because 1 the washer nozzle tip is made of resin and could be damaged 2 adjustment is not necessary because the washer nozzle is spray type b In case the washer nozzle is clogged with wax etc remove the objects and clean the nozzle hole with a soft resin brush etc ...

Page 1026: ...ront wipers do not operate in INT 1 Front Wiper Switch 2 Front Wiper Motor 3 Wire Harness 66 4 66 4 Front Washer motor does not operate 1 WIPER Fuse 2 Front Washer Switch 3 Front Washer Motor 4 Wire Harness 66 4 65 2 Front Wipers do not operate when washer switch in ON 1 Front Wiper Switch 2 Front Wiper Motor 3 Wire Harness 66 4 66 4 Washer fluid does not operate 1 Washer Hose and Nozzle When the ...

Page 1027: ...SPECTION 1 WASHER MOTOR a Operation Check 1 Pour the water into the washer jar with the washer motor and the pump installed to the washer jar assy 2 Connect the battery to terminal 2 of the washer motor and the pump the battery to terminal 1 of the washer motor and the pump Check that the wa ter comes out from the washer jar ...

Page 1028: ...uity INT 16 S 7 1 Continuity LO 7 1 17 B Continuity HI 17 B 8 2 Continuity Front Washer Switch Switch position Tester connection Specified condition OFF No continuity ON 11 WF 2 EW Continuity b Intermittent Operation Check 1 Connect the voltmeter terminal to terminal 7 1 of the connector the voltmeter terminal to termi nal 2 EW of the connector 2 Connect the battery to terminal 17 B of the connect...

Page 1029: ...EW 2 WINDSHIELD WIPER MOTOR ASSY a LO Operation Check 1 Connect the battery to terminal 1 1 of the con nector the battery to terminal 5 E of the con nector and check that the motor operates at low speed LO b HI Operation Check 1 Connect the battery to terminal 4 2 of the con nector the battery to terminal 5 E of the con nector and check that the motor operates at high speed HI c Automatic Stop Ope...

Page 1030: ...VE FR WIPER ARM RH 4 REMOVE COWL TOP VENTILATOR LOUVER SUB ASSY a Remove the 6 clips and cowl top ventilator louver sub assy 5 REMOVE WIPER LINK ASSY a Disconnect the connector b Remove the 4 bolts and wiper link assy 6 REMOVE WINDSHIELD WIPER MOTOR ASSY a Disengage the meshing of rod at the clank arm pivot of the windshield wiper motor assy b Remove the 3 bolts and windshield wiper motor assy fro...

Page 1031: ...ld wiper link assy Torque 5 4 N m 55 kgf cm 48 in lbf 8 INSTALL WIPER LINK ASSY a Install the windshield wiper link assy with the 4 bolts Torque 7 0 N m 71 kgf cm 62 in lbf b Connect the connector 9 INSTALL FR WIPER ARM RH a Operate the wiper and stop the windshield wiper motor assy at the automatic stop position b Scrape off the serration part of the wiper arm with a round file or equivalent c Cl...

Page 1032: ...H a Clean the wiper pivot serration with the wire brush b Align the FR wiper blade front tip with the mark and install the FR wiper arm LH with the nut Torque 20 1 N m 205 kgf cm 15 ft lbf c Operate the wiper while running the water or the washer fluid over the window and check the wiping condition and that the wiper does not hit against the vehicle body ...

Page 1033: ... LH from the FR wiper blade LH b Remove the 2 wiper rubber backing plates from the wiper rubber LH 3 INSTALL WIPER RUBBER LH a Install the 2 wiper rubber backing plates to the wiper rub ber LH NOTICE Be careful to observe and keep direction of curvature for correct replacement b Install the wiper rubber LH so that the head part Longer side of the wiper rubber faces the arm axle side NOTICE Push in...

Page 1034: ...INDSHIELD WIPER SWITCH ASSY REPLACEMENT 1 REMOVE STEERING COLUMN COVER See Page 50 9 2 REMOVE WINDSHIELD WIPER SWITCH ASSY a Disconnect the connector b Using a screwdriver release the claw and pull out the windshield wiper switch assy NOTICE Pressing the claw hard breaks the claw HINT Tape the screwdriver tip before use ...

Page 1035: ...onditioner Control Assembly Radio Bracket No 2 Radio Bracket No 1 Radio Receiver Assy TMMK Made Separate Type Amplifier Radio Receiver Switch Knob AUDIO VISUAL SYSTEM AUDIO VISUAL SYSTEM 67 1 2497 Author Date 2002 CAMRY REPAIR MANUAL RM881U AUDIO VISUAL SYSTEM COMPONENTS ...

Page 1036: ...arette Lighter Assy Antenna Cord Sub assy Power Point Socket Assy RR Power Outlet Socket Cover RR Front No 1 Speaker Assy Rear Speaker Assy Disc Player Bracket No 2 Navigation ECU Disc Player Bracket Navigation Antenna Assy 67 2 AUDIO VISUAL SYSTEM AUDIO VISUAL SYSTEM 2498 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1037: ...LACEMENT HINT COMPONENTS See page 67 1 1 REMOVE AIR CONDITIONER CONTROL ASSEMBLY See page 71 12 2 REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB ASSY CENTER See page 71 12 3 REMOVE RADIO RECEIVER ASSY a Insert a screwdriver at indicated point and remove the ra dio receiver assy from instrument cluster finish panel sub assy center 4 REMOVE RADIO BRACKET NO 1 a Remove the 4 screws and radio bracket No 1...

Page 1038: ...COMPONENTS See page 67 1 1 REMOVE AIR CONDITIONER CONTROL ASSEMBLY See page 71 12 2 REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB ASSY CENTER See page 71 12 3 REMOVE NAVIGATION RECEIVER ASSY a Insert a screwdriver at indicated point and remove the navigation receiver assy from instrument cluster finish panel sub assy 4 REMOVE RADIO RECEIVER BRACKET NO 1 a Remove the 4 screws and radio receiver bracke...

Page 1039: ...REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See page 75 8 3 REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See page 75 8 4 REMOVE FRONT DOOR TRIM BOARD SUB ASSY LH See page 75 8 5 REMOVE FRONT NO 1 SPEAKER ASSY a Disconnect the connector b Remove the 4 screws and front No 1 speaker assy 6 INSTALL FRONT NO 1 SPEAKER ASSY a Install the front No 1 speaker assy with the 4 screws NOTICE Install the...

Page 1040: ...RUMENT PANEL SPEAKER PANEL SUB ASSY NO 2 See page 71 12 2 REMOVE FRONT NO 2 SPEAKER ASSY a Remove the 2 bolts b Disconnect the connector and remove the front No 2 speaker assy 3 INSTALL FRONT NO 2 SPEAKER ASSY a Connect the connector b Align a claw with the notch of the instrument panel safety pad with 2 bolts and install the front No 2 speaker assy NOTICE Install them in the order shown in the il...

Page 1041: ...IDE SEAT BACK ASSY LH TMC MADE See page 72 34 6 REMOVE REAR SIDE SEAT BACK ASSY RH TMMK MADE See page 72 38 7 REMOVE REAR SIDE SEAT BACK ASSY LH TMMK MADE See page 72 38 8 REMOVE ROOF SIDE GARNISH INNER RH W O CURTAIN SHIELD AIR BAG See page 76 20 9 REMOVE ROOF SIDE GARNISH INNER LH W O CURTAIN SHIELD AIR BAG See page 76 20 10 REMOVE ROOF SIDE GARNISH INNER RH W CURTAIN SHIELD AIR BAG See page 76 ...

Page 1042: ... the package tray trim panel assy 15 REMOVE PACKAGE TRAY TRIM PANEL ASSY TMMK MADE See page 61 17 16 REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMC MADE See page 61 14 17 REMOVE REAR SEAT INNER W CENTER BELT ASSY RH TMC MADE See page 61 14 18 REMOVE REAR SEAT INNER W CENTER BELT ASSY LH TMC MADE See page 61 14 19 REMOVE REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMMK MADE See page 61 17 20 REMOVE R...

Page 1043: ...r 26 INSTALL REAR SEAT INNER W CENTER BELT ASSY RH TMC MADE See page 61 14 27 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMC MADE See page 61 14 28 INSTALL REAR SEAT INNER W CENTER BELT ASSY LH TMC MADE See page 61 14 29 INSTALL REAR SEAT INNER W CENTER BELT ASSY RH TMMK MADE See page 61 17 30 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMMK MADE See page 61 17 31 INSTALL REAR SEAT INNER W ...

Page 1044: ...10 AUDIO VISUAL SYSTEM REAR SPEAKER ASSY 2506 Author Date 2002 CAMRY REPAIR MANUAL RM881U 36 INSTALL REAR SEAT BACK ASSY RH See page 72 34 or 72 38 37 INSTALL REAR SEAT BACK ASSY LH See page 72 34 or 72 38 ...

Page 1045: ...1 REMOVE FRONT DOOR SCUFF PLATE RH See page 71 12 2 REMOVE COWL SIDE TRIM SUB ASSY RH See page 71 12 3 REMOVE INSTRUMENT PANEL UNDER COVER SUB ASSY NO 1 See page 71 12 4 REMOVE GLOVE COMPARTMENT DOOR PAD See page 71 12 5 REMOVE INSTRUMENT PANEL SUB ASSY LOWER See page 71 12 6 REMOVE STEREO COMPONENT AMPLIFIER ASSY a Disconnect the connectors b Remove the 2 nuts and stereo component amplifier assy ...

Page 1046: ...SH PANEL SUB ASSY CENTER See page 71 12 10 REMOVE INSTRUMENT PANEL UNDER COVER SUB ASSY NO 1 See page 71 12 11 REMOVE GLOVE COMPARTMENT DOOR PAD See page 71 12 12 REMOVE INSTRUMENT PANEL SUB ASSY LOWER See page 71 12 13 REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB ASSY M T TRANSAXLE See page 71 12 14 REMOVE CONSOLE PANEL UPPER REAR See page 71 12 15 REMOVE CONSOLE BOX CARPET 16 REMOVE RR CONSOLE BOX Se...

Page 1047: ... LH See page 72 34 or 72 38 37 REMOVE REAR SIDE SEAT BACK ASSY RH TMC MADE See page 72 34 38 REMOVE REAR SIDE SEAT BACK ASSY LH TMC MADE See page 72 34 39 REMOVE REAR SIDE SEAT BACK ASSY RH TMMK MADE See page 72 38 40 REMOVE REAR SIDE SEAT BACK ASSY LH TMMK MADE See page 72 38 41 REMOVE ROOF SIDE GARNISH INNER RH W O CURTAIN SHIELD AIR BAG See page 76 20 42 REMOVE ROOF SIDE GARNISH INNER LH W O CU...

Page 1048: ...SSY OUTER TMMK MADE See page 61 17 53 REMOVE REAR SEAT INNER W CENTER BELT ASSY RH TMMK MADE See page 61 17 54 REMOVE REAR SEAT INNER W CENTER BELT ASSY LH TMMK MADE See page 61 17 55 REMOVE ROOM PARTITION BOARD LH TMC MADE See page 67 7 56 REMOVE ROOM PARTITION BOARD RH TMC MADE See page 67 7 57 REMOVE AIR DUCT REAR NO 2 See page 55 29 ...

Page 1049: ...c Remove the 12 clamps and antenna cord sub assy 59 INSTALL REAR SEAT INNER W CENTER BELT ASSY RH TMC MADE See page 61 14 60 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMC MADE See page 61 14 61 INSTALL REAR SEAT INNER W CENTER BELT ASSY LH TMC MADE See page 61 14 62 INSTALL REAR SEAT INNER W CENTER BELT ASSY RH TMMK MADE See page 61 17 63 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMMK MA...

Page 1050: ... TMC MADE See page 72 34 67 INSTALL REAR SIDE SEAT BACK ASSY LH TMMK MADE See page 72 38 68 INSTALL REAR SIDE SEAT BACK ASSY RH TMMK MADE See page 72 38 69 INSTALL REAR SEAT BACK ASSY RH See page 72 34 70 INSTALL REAR SEAT BACK ASSY LH See page 72 34 71 INSTALL FRONT SEAT ASSY LH POWER SEAT See page 72 7 72 INSTALL FRONT SEAT ASSY LH MANUAL SEAT See page 72 20 73 INSTALL FRONT SEAT ASSY RH POWER S...

Page 1051: ... WHEEL COVER ASSY 3 REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB ASSY RH 4 REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO 1 See page 76 5 5 REMOVE REAR FLOOR FINISH PLATE See page 76 5 6 REMOVE LUGGAGE COMPARTMENT TRIM COVER INNER LH See page 76 5 7 REMOVE NAVIGATION ECU a Disconnect the connectors and remove the 2 clamps b Remove the nut and 2 bolts then remove the navigation ECU 8 REMOVE DISC PLAYER BRACK...

Page 1052: ...I31480 67 18 AUDIO VISUAL SYSTEM NAVIGATION ECU 2514 Author Date 2002 CAMRY REPAIR MANUAL RM881U 9 REMOVE DISC PLAYER BRACKET NO 2 a Remove the 2 screws and disc player bracket No 2 ...

Page 1053: ...1 REMOVE REAR SIDE SEAT BACK ASSY RH TMMK MADE See page 72 38 12 REMOVE REAR SIDE SEAT BACK ASSY LH TMMK MADE See page 72 38 13 REMOVE ROOF SIDE GARNISH INNER RH W O CURTAIN SHIELD AIR BAG See page 76 20 14 REMOVE ROOF SIDE GARNISH INNER LH W O CURTAIN SHIELD AIR BAG See page 76 20 15 REMOVE ROOF SIDE GARNISH INNER RH W CURTAIN SHIELD AIR BAG See page 76 20 16 REMOVE ROOF SIDE GARNISH INNER LH W C...

Page 1054: ... REMOVE REAR SEAT INNER W CENTER BELT ASSY RH TMMK MADE See page 61 17 26 REMOVE REAR SEAT INNER W CENTER BELT ASSY LH TMMK MADE See page 61 17 27 REMOVE ROOM PARTITION BOARD LH TMC MADE See page 67 7 28 REMOVE ROOM PARTITION BOARD RH TMC MADE See page 67 7 29 REMOVE NAVIGATION ANTENNA ASSY a Disconnect the connector b Tie the string at the tip of the cable of the navigation an tenna assy ...

Page 1055: ...he room side 30 INSTALL NAVIGATION ANTENNA ASSY a Detach the string put through the luggage room and the room side from the connector and attach it with a new navigation antenna assy b Using this string put the navigation antenna assy through the luggage room and the room side NOTICE To prevent the connector from being damaged wrap protective tape around the tip of connector of the navigation ante...

Page 1056: ...BELT ASSY RH TMMK MADE See page 61 17 35 INSTALL REAR SEAT 3 POINT TYPE BELT ASSY OUTER TMMK MADE See page 61 17 36 INSTALL REAR SEAT INNER W CENTER BELT ASSY LH TMMK MADE See page 61 17 37 INSTALL REAR SIDE SEAT BACK ASSY LH TMC MADE See page 72 34 38 INSTALL REAR SIDE SEAT BACK ASSY RH TMC MADE See page 72 34 39 INSTALL REAR SIDE SEAT BACK ASSY LH TMMK MADE See page 72 38 40 INSTALL REAR SIDE SE...

Page 1057: ...ENT PANEL ASH RECEPTACLE ASSY See page 71 12 2 REMOVE CIGARETTE LIGHTER ASSY a Rotate the ring nut counterclockwise to remove it b Remove the cigarette lighter assy from the instrument panel ash receptacle assy 3 INSTALL CIGARETTE LIGHTER ASSY a Properly position the socket at the cutout of the instrument panel ash receptacle assy and insert them b Install the socket cap c Rotate the ring nut cloc...

Page 1058: ...UMENT PANEL ASH RECEPTACLE ASSY W ASHTRAY See page 71 12 5 REMOVE CONSOLE PANEL UPPER See page 71 12 6 REMOVE POWER POINT SOCKET ASSY a Turn the socket in the circumference direction as shown the illustration disengage the claw between the socket and the power pint socket cover and push out the socket to the room side b Align the socket with the notch on the power point socket cover remove the pow...

Page 1059: ... RR CONSOLE BOX See page 71 12 5 REMOVE POWER POINT SOCKET ASSY RR a Remove the clamp b Turn the socket in the circumference direction as shown the illustration disengage the claw between the socket and the power outlet socket cover RR and push out the socket to the room side c Align the socket with the notch on the power outlet socket cover RR remove the power point socket assy RR to the room sid...

Page 1060: ... cleaners with abrasive ingredients When measuring voltage wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger as shown in the illustration a Inspect the continuity at the center of each antenna wire as shown in the illustration 2 REPAIR WINDOW GLASS ANTENNA WIRE a Clean the broken wire tips with a grease wax and silicone remover b Pla...

Page 1061: ...elay Block Engine Room Junction Block Assy ABS Relay Block Sub Assy Instrument Panel Junction Block Assy Turn Signal Flasher Assy w ABS WIRING POWER SOURCE 68 1 2523 Author Date 2002 CAMRY REPAIR MANUAL RM881U POWER SOURCE LOCATION ...

Page 1062: ... LH UPR 9 ETCS 10 HORN 11 IGN 12 HEAD RH UPR 13 HAZ RELAY FUSE 25 A 25 A 5 A 30 A 20 A 5 A 10 A 10 A 10 A 15 A 10 A 15 A 14 D C C 15 IG 2 16 ST 17 ADJ PDL 18 CDS 19 ABS No 2 20 MAIN 21 ABS No 3 22 HTR 23 RDI 30 A 10 A 5 A 30 A 30 A 40 A 40 A 40 A 50 A 30 A 68 2 WIRING POWER SOURCE 2524 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1063: ...AN No 3 I ADJ PDL J DRL No 4 1 ABS No 1 2 ALT 3 A C 4 DRL 5 HEAD RH LWR 6 HEAD LH LWR 7 SPARE 8 SPARE 9 SPARE 60 A 100 A 2AZ 120 A 1MZ 10 A 5 A 15 A 15 A 5 A 10 A 15 A ABS Relay Block Sub Assy RELAY FUSE A ABS MTR B ABS SOL 1 ABS No 4 7 5 A WIRING POWER SOURCE 68 3 2525 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1064: ...A 15 A 20 A 10 A 10 A 25 A 10 A 12 MIR HTR 13 AM 1 14 FOG 15 SUN SHADE 16 GAUGE 2 17 PANEL 18 TAIL 19 PWR No 4 20 PWR No 2 21 OBD 22 SEAT HTR 10 A 5 A 15 A 15 A 10 A 10 A 10 A 20 A 20 A 7 5 A 20 A 23 WASHER 24 FAN RLY 25 STOP 26 FUEL OPN 27 DOOR No 2 28 AMP 29 PWR No 3 30 PWR SEAT 31 PWR No 1 32 DEF 15 A 10 A 15 A 5 A 25 A 25 A 20 A 30 A 30 A 40 A 68 4 WIRING POWER SOURCE 2526 Author Date 2002 CAM...

Page 1065: ...6902K 03 B57706 Low Pitched Horn Assy High Pitched Horn Assy Steering Wheel Pad COMMUNICATION SYSTEM HORN SYSTEM 69 1 2527 Author Date 2002 CAMRY REPAIR MANUAL RM881U HORN SYSTEM LOCATION ...

Page 1066: ...TEM HORN SYSTEM 2528 Author Date 2002 CAMRY REPAIR MANUAL RM881U PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Horn does not sound 2 Horn button switch 3 High pitched horn 4 Low pitched horn 5 HORN relay 6 Wire harness 69 3 ...

Page 1067: ... RM881U INSPECTION 1 INSPECT HORN RELAY ASSY a Inspect the horn relay Marking HORN continuity Condition Tester connection Specified condition Constant 1 2 Continuity Constant 3 5 No continuity Apply B between terminals 1 and 2 3 5 Continuity If the continuity is not as specified replace the relay ...

Page 1068: ...MENT 1 REMOVE LOW PITCHED HORN ASSY a Disconnect the connector b Remove the bolt and the low pitched horn assembly 2 INSTALL LOW PITCHED HORN ASSY a Place the stay onto the baffle part in the radiator support upper and then install the low pitched horn assembly with the bolt Torque 16 23 N m 163 235 kgf cm 12 17 ft lbf b Connect the connector ...

Page 1069: ...f the original transmitter to register a code the system might operate When registering the transmitter codes such as for garage gate or something check that there is nobody around then register them a Press the switch for the item to be registered for 20 seconds HINT When transferring to the registration mode LED red blinks in 1 Hz cycle b In the condition of step a bring the original transmitter...

Page 1070: ...d Press the switch of the original transmitter repeatedly in the registration mode as some transmitters stop transmitting for 1 to 2 seconds This system is not applicable to the garage door opener which was made before 1982 2 CODE DELETION a Press the switches at both ends of the garage door opener simultaneously for 20 seconds HINT When transferring to the deletion mode LED red blinks in 6 Hz cyc...

Page 1071: ...he home link tester made by KENT MORE for this test Be cause it is necessary to register the code of the hand held transmitter the customer s code should be erased When the inspection is complete register the customer s code again a Check that the code of hand held transmitter for inspec tion can be registered HINT If the code can not be registered replace the garage door open er b Press the switc...

Page 1072: ...able switch is turned UP during the AUTO DOWN op eration However if the switch is kept in the UP side it will transfer to the manual operation e Check that the door glass stops when the applicable switch is turned DOWN during the AUTO UP op eration However if the switch is kept in the DOWN side it will transfer to the manual operation 3 CHECK JAM PROTECTION FUNCTION DRIVER S DOOR GLASS W JAM PROTE...

Page 1073: ...12 1 10 1 1 13 2 OFF 1 13 1 1 18 2 1 15 1 18 1 1 10 2 1 16 6 12 1 10 1 1 12 2 DOWN 6 15 1 13 1 1 18 2 6 16 1 18 1 1 10 2 6 10 1 6 13 2 1 12 Standard Window lock Switch position Passenger Side Terminal No Rear RH Terminal No Rear LH Terminal No UP 6 13 1 6 18 2 6 18 1 6 10 2 6 12 OFF 13 15 1 18 15 2 16 18 1 1 10 2 10 12 DOWN 6 15 6 16 6 10 1 6 13 2 1 w Jam protection 2 w o Jam protection If the con...

Page 1074: ...rm with the power window regulator and door glass installed to the vehicle 1 Set the DC 400 A probe to terminal 4 or 5 of the wire harness NOTICE Match the arrow mark of the probe with the current direction 2 Set the door glass at the fully closed position 3 When approximately 60 seconds have passed after fully closing the door glass check how long the current when pressing the power regulator swi...

Page 1075: ...tage to each connector terminal check that the motor operates smoothly Standard Measuring condition Operational direction Battery positive Terminal 5 Battery negative Terminal 4 Clockwise rotation toward driving axis Battery positive Terminal 4 Battery negative Terminal 5 Counterclockwise wind rotation toward driving axis b Check the PTC operation inside the power window regulator motor NOTICE Wor...

Page 1076: ... regulator and door glass installed to the vehicle 1 Set the DC 400 A probe to terminal 4 or 5 of the wire harness NOTICE Match the arrow mark of the probe with the current direction 2 Set the door glass at the fully closed position 3 When approximately 60 seconds have passed after fully closing the door glass check how long the current when pressing the power regulator switch UP again at initial ...

Page 1077: ...ssy RH Visor Assy LH Visor Holder Roof Console Box Visor Holder Front Pillar Garnish RH Front Door Opening Trim Weatherstrip RH Partial Windshield Glass Retainer Windshield Moulding OUT UPR Assist Grip Cover Assist Grip Sub assy Assist Grip Sub assy Roof Headlining Assy Partial Window Glass Adhesive Dam w Curtain Shield Airbag Front Pillar Garnish Cover w Erectro Chromic Inner Mirror Inner Rear Vi...

Page 1078: ...76 20 7 REMOVE FRONT PILLAR GARNISH LH W O CURTAIN SHIELD AIR BAG See page 76 20 8 REMOVE FRONT PILLAR GARNISH RH W CURTAIN SHIELD AIR BAG See page 76 20 9 REMOVE FRONT PILLAR GARNISH LH W CURTAIN SHIELD AIR BAG See page 76 20 10 REMOVE ROOF CONSOLE BOX ASSY See page 76 20 11 REMOVE RH VISOR ASSY See page 76 20 12 REMOVE LH VISOR ASSY See page 76 20 13 REMOVE VISOR HOLDER See page 76 20 14 REMOVE ...

Page 1079: ...n working around the curtain shield airbag be careful not to damage the airbag When separating the glass take care not to damage the paint and interior exterior ornaments To prevent the piano wire to be cut do not cross it d Cut the adhesive by pulling the piano wire around it e Using a suction rubber remove the glass NOTICE Leave as much adhesive on the body as possible when cut ting off the glas...

Page 1080: ... much primer b Install 2 new windshield glass stoppers No 2 onto the glass as shown in the illustration A 7 7 mm 0 303 in B 40 0 mm 1 575 in 21 INSTALL WINDSHIELD GLASS RETAINER a Install 2 new windshield glass retainers onto the glass as shown in the illustration 22 INSTALL WINDOW GLASS ADHESIVE DAM a Coat the installation part of the window glass adhesive dam with Primer G NOTICE Let the primer ...

Page 1081: ...eference mark s positions 4 Remove the glass c Coat the contact surface of the back door with Primer M d Using a bursh coat the exposed part of the contact surface on the vehicle side with Primer M NOTICE Dry the primer coating for 3 minutes or more Do not coat the adhesive with Primer M Do not apply too much Primer e Coat the contact surface of the glass with Primer G 1 Using a brush or sponge co...

Page 1082: ...ruding adhesive HINT Apply adhesive on the glass rim 24 INSTALL WINDSHIELD MOULDING OUTER UPPER a Install a new windshield moulding to the windshield glass before the adhesive has hardened b Hold the windshield glass in place securely with protective tape or equivalent until the adhesive has completely hardened c Using a scraper remove any excess or protruding adhesive before the adhesive has hard...

Page 1083: ...ip RH Partial Rear Door Opening Trim Weatherstrip LH Partial Roof Side Garnish Inner LH Roof Headlining Assy Partial Roof Side Garnish Inner RH w Curtain Shield Airbag Roof Side Garnish Inner Cover Assist Grip Sub assy Assist Grip Sub assy w Curtain Shield Airbag Roof Side Garnish Inner Cover N m kgf cm ft lbf Specified torque 42 420 31 42 420 31 42 420 31 70 12 WINDSHIELD WINDOWGLASS MIRROR BACK ...

Page 1084: ...NISH INNER LH W O CURTAIN SHIELD AIR BAG See page 76 20 7 REMOVE ROOF SIDE GARNISH INNER RH W CURTAIN SHIELD AIR BAG See page 76 20 8 REMOVE ROOF SIDE GARNISH INNER LH W CURTAIN SHIELD AIR BAG See page 76 20 9 REMOVE ROOF HEADLINING ASSY See page 76 20 10 REMOVE CENTER STOP LAMP ASSY See page 65 16 11 REMOVE PACKAGE TRAY TRIM PANEL ASSY See page 61 14 61 17 12 REMOVE BACK WINDOW MOULDING OUTSIDE a...

Page 1085: ...sing a suction rubber remove the glass NOTICE Leave as much adhesive on the body as possible when cut ting off the glass 14 CLEAN BACK WINDOW GLASS a Using a scraper remove the damaged spacers and clips dam and adhesive sticking to the glass b Clean the outer circumference of the glass with white gas oline NOTICE Do not touch the glass after cleaning it Be careful not to damage the body 15 INSTALL...

Page 1086: ...rim are perfectly even 3 Place reference marks between the glass and body NOTICE Check that the stoppers are attached to the body correctly HINT When reusing the glass check and correct the reference mark s positions 4 Remove the glass c Coat the contact surface of the back door with Primer M d Using a bursh coat Primer M to the exposed part of the contact surface on the vehicle side with Primer M...

Page 1087: ...mer coating for 3 minutes or more Check that the stoppers are attached to the body correctly Check the clearance between the body and glass 2 Lightly press the glass front surface for close contact 3 Using a scraper remove any excess or protruding adhesive HINT Apply adhesive on the glass rim 18 INSTALL BACK WINDOW MOULDING OUTSIDE a Install a new windshield moulding to the windshield glass before...

Page 1088: ...anel J B Defogger Wire Auto A C Manual A C Rear Window Defogger Switch ECM Heater Control Base Heater Control Housing WINDSHIELD WINDOWGLASS MIRROR WINDOW DEFOGGER SYSTEM 70 17 2550 Author Date 2002 CAMRY REPAIR MANUAL RM881U WINDOW DEFOGGER SYSTEM LOCATION ...

Page 1089: ...rate Indicator lamp on 1 DEF fuse Instrument panel J B 2 GAUGE 2 fuse Instrument panel J B 3 DEF relay Instrument panel J B 4 Rear window defogger wire 5 Wire harness 6 ECM 2AZ FE 7 ECM 1MZ FE 68 1 68 1 70 19 05 23 05 199 Rear window defogger does not operate Indicator lamp off 1 HTR fuse Instrument panel J B 2 Defogger switch Heater control housing 3 Wire harness 4 Heater control base 68 1 05 626...

Page 1090: ...R MANUAL RM881U INSPECTION 1 INSPECT DEFOGGER RELAY a Inspect the defogger relay marking DEF continuity Standard Terminal No Condition Specified condition 1 2 Constant Continuity 3 5 Constant No continuity 3 5 Apply B between terminals 1 and 2 Continuity If the continuity is not as specified replace the relay ...

Page 1091: ...Rear View Mirror Assy LH Outer Rear View Mirror Assy RH Mirror Heater Switch Defogger Switch ECM Heater Control Base Heater Control Housing 70 20 WINDSHIELD WINDOWGLASS MIRROR POWER MIRROR CONTROL SYSTEM 2553 Author Date 2002 CAMRY REPAIR MANUAL RM881U POWER MIRROR CONTROL SYSTEM LOCATION ...

Page 1092: ...002 CAMRY REPAIR MANUAL RM881U PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Mirror does not operate 1 ECU ACC fuse Instrument panel J B 2 Mirror switch 3 Mirror motor 4 Wire harness 68 1 70 22 70 22 Mirror operates abnormally 1 Mirror switch 2 Mirror motor 3 Wire harness 70 22 70 22 ...

Page 1093: ...inal No Switch position Specified condition OFF No continuity 4 8 6 7 UP Continuity 4 7 6 8 DOWN Continuity 5 8 6 7 LEFT Continuity 5 7 6 8 RIGHT Continuity If the continuity is not as specified replace the switch 2 Right side for left right adjustment switch Inspect the right side mirror switch continuity Standard Terminal No Switch position Specified condition OFF No continuity 3 8 6 7 UP Contin...

Page 1094: ...d Positive 2 Negative 6 Turn downward Positive 3 Negative 2 Turn left Positive 2 Negative 3 Turn right If the continuity is not as specified replace the outer rear view mirror assy LH 3 INSPECT OUTER REAR VIEW MIRROR ASSY RH W O OUTER MIRROR HEATER a Inspect the mirror motor operation Standard TMC Made Battery connection Mirror position Positive 1 Negative 2 Turn upward Positive 2 Negative 1 Turn ...

Page 1095: ...Ω 2 Check that the mirror is heated up when connecting the battery positive to terminal 4 and the battery negative to terminal 5 of the connector 5 INSPECT OUTER REAR VIEW MIRROR ASSY LH W OUTER MIRROR HEATER TMMK MADE a Inspect the mirror motor operation Standard Battery connection Mirror position Positive 6 Negative 2 Turn upward Positive 2 Negative 6 Turn downward Positive 3 Negative 2 Turn lef...

Page 1096: ...esistance 4 0 5 4 Ω 2 Check that the mirror is heated up when connecting the battery positive to terminal 4 and the battery negative to terminal 5 of the connector 7 INSPECT OUTER REAR VIEW MIRROR ASSY RH W OUTER MIRROR HEATER TMMK MADE a Inspect the mirror motor operation Standard Battery connection Mirror position Positive 6 Negative 2 Turn upward Positive 2 Negative 6 Turn downward Positive 3 N...

Page 1097: ...R REAR VIEW MIRROR ASSY REPLACEMENT HINT Installation is according to the reverse order of the removal 1 REMOVE INNER REAR VIEW MIRROR ASSY a Remove the screw b w Erectro chromic inner mirror Remove the inner rear view mirror cover c w Erectro chromic inner mirror Disconnect the connector d Remove the rear view inner mirror assembly ...

Page 1098: ...he magnetic condition differs according to the area where the vehicle is used it is necessary for each user to set the zone Refer to Compass Zone Map The zone setting can be changed using the comp switch of the inner mirror 3 PERFORMING CALIBRATION a Because each vehicle has its own magnetic field calibration should be performed for each vehicle This compass function is used when storing the recor...

Page 1099: ...t the zone number c Leave it untouched for several seconds after setting and check that the compass display shows an azimuthal direction N NE E SE S SW W or NW or C 7 CALIBRATION SETTING MODE a Pressing the comp switch for 6 seconds in the normal mode will also activate this mode b Drive the vehicle at a slow speed of 8 km h 5 MPH or less in the circular direction c Driving around the circle 1 to ...

Page 1100: ...ect the electro chromic inner mirror operation 1 Connect the positive lead from the battery to ter minal 1 and the negative lead to terminal 2 2 Attach a black colored tape to the forward sensor to prevent it from sensing 3 Light up the mirror with an electric light and check that the mirror surface changes from bright to dark If the operation is not as specified replace the inner mirror ...

Page 1101: ... OUTER REAR VIEW MIRROR SUB ASSY LH TMMK made a Tape the upper part of outer mirror body with protection tape b Using a roof mouding remover disengage the clips placed in the upper part of the mirror c Pull out the outer rear view mirror 3 INSTALL OUTER REAR VIEW MIRROR SUB ASSY LH TMC made a Insert the claws placed in the upper part of backside of the mirror into the actuator hole b Set the mirro...

Page 1102: ...ness or Connector 2 Front Door Courtesy Light 3 MPX Body ECU 4 Combination Meter Assy 05 897 Fuel Level warning light does not light up 1 Wire Harness or Connector 2 Fuel Level Warning Switch 3 Combination Meter Assy Low Oil Pressure warning light does not light up 1 Wire Harness or Connector 2 Low Oil Pressure Warning Switch 3 Combination Meter Assy Window washer level warning does not lights up ...

Page 1103: ... 05 448 SLIP indicator light does not light up 1 Wire Harness or Connector 2 Slip Indicator Circuit 3 Combination Meter Assy 05 448 Meter Gauges Symptom Suspect Area See page Tachometer Fuel Gauge and Water Temperature Gauge do not operate 1 Wire Harness or Connector 2 GAUGE Fuse 3 Combination Meter Assy Fuel Gauge does not operate or abnormal operation 1 Wire Harness or Connector 2 Fuel Receiver ...

Page 1104: ...0 km h 17 24 km h 40 km h 38 46 km h 60 km h 57 5 67 km h 80 km h 77 88 km h 100 km h 96 109 km h 120 km h 115 130 km h 140 km h 134 151 5 km h 160 km h 153 173 km h NOTICE Tire wear and tire over or under inflation will increase the indication error 2 Check the deflection width of the speed meter indicator Reference Below 0 5 km h 0 3 mph 2 INSPECT OUTPUT SIGNAL OF VEHICLE SPEED a Check for stand...

Page 1105: ...00 7 300 4 INSPECT FUEL RECEIVER GAUGE a Inspect the circuit 1 Disconnect the connector from the sender gauge 2 Turn the ignition switch ON then check the position of the receiver gauge needle Standard Needle position is EMPTY and FUEL warning light is ON 5 INSPECT FUEL LEVEL WARNING a Inspect the circuit 1 Disconnect the connector from the sender gauge 2 Turn the ignition switch to ON check the f...

Page 1106: ...on switch to ON and check that the warning light lights up b Inspect the brake fluid level warning light 1 Disconnect the connector from the brake fluid level warning switch and connect terminals on the wire harness side connector 2 Turn the ignition switch to ON and check that the warning light lights up 10 INSPECT BRAKE FLUID LEVEL WARNING SWITCH a Inspect the continuity 1 Remove the reservoir t...

Page 1107: ...stat connector terminals when operating the rheo stat volume knob Standard Switch Terminal No Symbol Continuity Turn the knob to maxi mum 1 TC 3 T Continuity Other conditions of the above 1 TC 3 T No continuity b Check resistance 1 Check the resistance between terminal 4 RV and terminal 3 T when operating the light control rheo stat volume knob Also check that the resistance changes continuously S...

Page 1108: ...Panel Ash Receptacle Assy Instrument Panel Upper Rear Instrument Panel Cup Holder Tray Console Panel Upper Console Panel Upper Console Box Front Console Box Carpet w o Steering Wheel Pad Switch Steering Wheel Cover Lower No 2 Steering Wheel Cover Lower No 3 Foot Parking Brake Instrument Panel Finish Panel Lower Center Clock Assy Front Pillar Garnish LH Front Pillar Garnish LH w o Curtain Shield Ai...

Page 1109: ...Panel Upper Rear Instrument Panel Cup Holder Tray Console Panel Upper Console Panel Upper Console Box Front Console Box Carpet w o Steering Wheel Pad Switch Steering Wheel Cover Lower No 2 Steering Wheel Cover Lower No 3 Foot Parking Brake Instrument Panel Finish Panel Lower Center Clock Assy Front Pillar Garnish LH Front Pillar Garnish LH w o Curtain Shield Air Bag Front Pillar Garnish RH w o Cur...

Page 1110: ...e Assy H H H H H H Side Defroster Nozzle Duct No 1 Side Defroster Nozzle Duct No 2 H Cooler Solar Solar Sensor Thermistor w Conlight Auto air conditioner Automatic Light Control Sensor Glove Box Lamp Assy Instrument Panel Register Assy No 1 Instrument Panel Register Assy No 3 Instrument Panel Passenger Air Bag Assy INSTRUMENT PANEL METER INSTRUMENT PANEL METER 71 9 2572 Author Date 2002 CAMRY REPA...

Page 1111: ...ster Nozzle Duct No 2 Cooler Solar Solar Sensor Thermistor w Conlight Auto air conditioner Automatic Light Control Sensor Glove Box Lamp Assy Instrument Panel Register Assy No 1 Instrument Panel Register Assy No 3 Instrument Panel Passenger Air Bag Assy G or I G or I G or I G or I G or I G or I G or I G or I G or I G or I G or I G or I G or I G or I 71 10 INSTRUMENT PANEL METER INSTRUMENT PANEL ME...

Page 1112: ...MANUAL RM881U INSTRUMENT PANEL SAFETY PAD SUB ASSY PRECAUTION 1 PRECAUTION FOR VEHICLE WITH SRS AIRBAG AND SEAT BELT PRETENSIONER a Some operations in this section may affect the SRS airbag Before performing the corresponding op erations please read the NOTICE of the SRS airbag to perform the proper operations ...

Page 1113: ...MRY REPAIR MANUAL RM881U REPLACEMENT HINT COMPONENTS See page 71 7 1 TABLE OF BOLT SCREW AND NUT HINT Indicate the bolts screws and nuts which are necessary for installation and removal of the instrument panel in the illustration and the text with alphabets 2 DISCONNECT BATTERY NEGATIVE TERMINAL See page 60 1 3 REMOVE STEERING WHEEL COVER LOWER NO 2 4 REMOVE STEERING WHEEL COVER LOWER NO 3 W O STE...

Page 1114: ... 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 10 REMOVE INSTRUMENT CLUSTER FINISH PANEL a Disengage the 4 clips and remove the instrument cluster finish panel 11 REMOVE STEERING COLUMN COVER See page 50 9 or 50 22 12 REMOVE HEADLAMP DIMMER SWITCH ASSY See page 65 17 13 REMOVE WINDSHIELD WIPER SWITCH ASSY See page 66 10 14 REMOVE COMBINATION METER ASSY a Remove the 2 screws and disen...

Page 1115: ... PLATE LH a Disengage the 7 claws 4 clips and remove the front door scuff plate LH 16 REMOVE FRONT DOOR SCUFF PLATE RH 17 REMOVE COWL SIDE TRIM SUB ASSY LH a Remove the clip b Disengage the 2 clips and remove the cowl side trim sub assy LH 18 REMOVE COWL SIDE TRIM SUB ASSY RH 19 REMOVE INSTRUMENT PANEL COIN BOX SUB ASSY a Disengage the claw and remove the instrument panel coin box sub assy ...

Page 1116: ...re use c TMC made Remove the bolt D and 2 screws J d TMMK made Remove the bolt C and 2 screws G e Disengage the 3 clips f Disconnect the connectors and remove the instrument panel sub assy upper 21 REMOVE INSTRUMENT PNL INSERT SUB ASSY LWR LH TMMK MADE a Remove the 4 bolts A b Disengage the 2 claws and remove the instrument panel insert sub assy LWR LH 22 REMOVE AIR CONDITIONER CONTROL ASSEMBLY a ...

Page 1117: ...y then disconnect the connectors 24 REMOVE INSTRUMENT PANEL UNDER COVER SUB ASSY NO 1 a Disengage the 3 claws and pin b Remove the instrument panel under cover sub assy No 1 25 REMOVE GLOVE COMPARTMENT DOOR PAD a Using a screwdriver remove the glove compartment door pad HINT Tape the screwdriver tip before use 26 REMOVE INSTRUMENT PANEL SUB ASSY LOWER a TMC made Remove the bolt D and 4 screws J b ...

Page 1118: ...T b Hand parking brake Disengage the clip and 2 claws then remove the console panel cup holder c Hand parking brake Using a moulding remover disengage the claw 8 clips and remove the console panel upper rear HINT Set the shift lever N range A T 29 REMOVE CONSOLE BOX CARPET 30 REMOVE RR CONSOLE BOX a TMC made Remove the 2 bolts B and 2 screws H b TMMK made Remove the 2 bolts B and 2 screws G c Dise...

Page 1119: ...ment panel ash receptacle assy 33 REMOVE CONSOLE PANEL UPPER a Using a moulding remover disengage the 4 clips and 2 claws b Disconnect the connectors and remove the console panel upper HINT Set the shift lever N range A T 34 REMOVE CONSOLE BOX FRONT a Remove the 2 nuts K b Disengage the 2 claws and remove the console box front 35 REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER a TMC made Remove ...

Page 1120: ...sing a moulding remover disengage the clip 2 claws and remove the front pillar garnish LH 38 REMOVE FRONT PILLAR GARNISH RH W O CURTAIN SHIELD AIR BAG 39 REMOVE FRONT PILLAR GARNISH RH W CURTAIN SHIELD AIR BAG 40 REMOVE INSTRUMENT PANEL SPEAKER PANEL SUB ASSY NO 2 a Using a screwdriver disengage the 2 clips and 2 claws HINT Tape the screwdriver tip before use b Remove the instrument panel speaker ...

Page 1121: ...FETY PAD SUB ASSY 2583 Author Date 2002 CAMRY REPAIR MANUAL RM881U 45 REMOVE INSTRUMENT PANEL SAFETY PAD SUB ASSY a TMC made Remove the 2 screws H F nut L and 4 bolts A E b TMMK made Remove the 2 screws G or I F nut K and 3 bolts A E c Disconnect the connectors d Disengage the 5 pins and remove the instrument panel safety pad sub assy ...

Page 1122: ...UTOMATIC LIGHT CONTROL SENSOR W CONLIGHT a Using a screwdriver remove the automatic light control sensor HINT Tape the screwdriver tip before use 50 REMOVE COOLER SOLAR SENSOR THERMISTOR AUTO AIR CONDITIONER a Remove the cooler solar sensor thermistor NOTICE Do not pry the cooler solar sensor thermistor off from the upper position 51 REMOVE SIDE DEFROSTER NOZZLE DUCT NO 2 a TMC made Remove the scr...

Page 1123: ...Remove the 2 screws H and heater to register duct No 3 b TMMK made Remove the 2 screws G or I and heater to register duct No 3 56 REMOVE HEATER TO REGISTER DUCT NO 2 a TMC made Remove the screw H and heater to register duct No 2 b TMMK made Remove the screw G or I and heater to register duct No 2 57 REMOVE DEFROSTER NOZZLE GARNISH NO 1 a Disengage the 5 clips and remove the defroster nozzle garnis...

Page 1124: ...te 2002 CAMRY REPAIR MANUAL RM881U 61 INSTALL INSTRUMENT PANEL SAFETY PAD SUB ASSY a Engage the 5 Pins b Connect the connectors c TMC made Install the instrument panel safety pad sub assy with 2 screws H F nut L 4 bolts A E d TMMK made Install the instrument panel safety pad sub assy with 2 screws G or I F nut K 3 bolts A E Torque Bolt E 20 N m 200 kgf cm 14 ft lbf ...

Page 1125: ...lip b Install the front pillar garnish with bolt Torque 7 5 20 N m 76 204 kgf cm 66 117 in lbf 63 INSTALL FRONT PILLAR GARNISH RH W CURTAIN SHIELD AIR BAG 64 CENTER SPIRAL CABLE See page 60 25 65 INSTALL STEERING WHEEL ASSY See page 50 9 or 50 22 66 INSPECT STEERING WHEEL CENTER POINT See page 50 9 or 50 22 67 INSTALL HORN BUTTON ASSY See page 60 15 68 INSPECT HORN BUTTON ASSY See page 60 15 69 IN...

Page 1126: ...NTS See page 71 7 1 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page 71 12 2 REMOVE COMBINATION METER ASSY a Remove the 2 screws and disengage the 2 clips b Disconnect the connectors and remove the combination meter assy 3 REMOVE COMBINATION METER GLASS a Reverse the combination meter and remove the 2 screws b Remove the tape c Disengage the 7 claws and remove the combination me ter glass ...

Page 1127: ...REPAIR MANUAL RM881U CLOCK ASSY REPLACEMENT HINT COMPONENTS See page 71 7 1 REMOVE AIR CONDITIONER CONTROL ASSEMBLY See page 71 12 2 REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB ASSY CENTER See page 71 12 3 REMOVE CLOCK ASSY a Remove the 2 screws b Disengage the claw and remove the clock assy ...

Page 1128: ...otor Assy Slide Front Up Down Power Seat Motor Assy Front Vertical Power Seat Motor Assy Reclining Power Seat Motor Assy Rear Vertical SEAT FRONT POWER SEAT CONTROL SYSTEM 72 1 2590 Author Date 2002 CAMRY REPAIR MANUAL RM881U FRONT POWER SEAT CONTROL SYSTEM LOCATION ...

Page 1129: ...ont slide power seat motor assy Slide 3 Wire harness 72 3 72 3 Front vertical of the power seat does not operate Driver s seat only 1 Front power seat switch 2 Front up down power seat motor assy Front vertical 3 Wire harness 72 3 72 3 Rear lifter of the power seat does not operate Driver s seat only 1 Front power seat switch 2 Power seat motor assy Rear vertical 3 Wire harness 72 3 72 3 Power sea...

Page 1130: ...ition 1 9 4 6 FRONT Continuity 6 4 9 OFF Continuity 4 9 1 6 REAR Continuity Standard Front vertical switch Terminal No Switch position Specified condition 1 10 4 5 UP Continuity 5 4 10 OFF Continuity 1 5 4 10 DOWN Continuity Standard Rear vertical switch Terminal No Switch position Specified condition 1 7 4 8 UP Continuity 7 4 8 OFF Continuity 1 8 4 7 DOWN Continuity Standard Reclining switch Term...

Page 1131: ...DOWN Continuity Standard Rear vertical switch Terminal No Switch position Specified condition 1 8 4 7 FRONT Continuity 7 4 8 OFF Continuity 1 7 4 8 REAR Continuity Standard Reclining switch Terminal No Switch position Specified condition 1 3 2 4 FRONT Continuity 2 4 3 OFF Continuity 1 2 3 4 REAR Continuity If the result is not as specified replace the front power seat switch 3 INSPECT FRONT UP DOW...

Page 1132: ...Y a Inspect the power seat motor operation 1 Check that the motor rotates smoothly when the battery is connected to the connector terminal Standard Tester Condition Specified Condition Battery positive voltage 1 Battery negative voltage 2 Counterclockwise Battery positive voltage 2 Battery negative voltage 1 Clockwise If the result is not as specified replace the power seat motor ...

Page 1133: ...t Seat Back Cover w Seat Heater Front Seat Cushion Heater Assy LH Reclining Adjuster Cover LH Reclining Adjuster Inside Cover LH Reclining Adjuster Inside Cover RH 43 1 440 32 Front Seat Track Cover LH Rear Inner Front Seat Track Cover LH Rear Outer Lumber Support Adjuster Assy LH Reclining Adjuster Knob Separate Type Front Seat Cushion Cover Separate Type Front Seat Cushion Pad Front Seat Back Sp...

Page 1134: ...emove the 4 bolts b Disconnect the connectors and then remove the front seat assembly LH 5 REMOVE FRONT SEAT HEADREST ASSY 6 REMOVE RECLINING POWER SEAT SWITCH KNOB 7 REMOVE SLIDE VERTICAL POWER SEAT SWITCH KNOB 8 REMOVE RECLINING ADJUSTER COVER LH a Remove the 4 screws b Disengage the claws and then remove the reclining ad juster cover LH 9 REMOVE FRONT POWER SEAT SWITCH LH a Disconnect the conne...

Page 1135: ... seat cushion cover 16 REMOVE FRONT SEAT BACK ASSY a Remove the hog rings at the lower portion of the front seat back cover b Remove the 4 bolts from the front seat back c Remove the 2 screws and reclining adjuster inside cover RH d w Side airbag Disconnect the wire harness of the side airbag from the inside cover LH e Remove the front seat back assembly f Remove the 2 screws and the reclining adj...

Page 1136: ...he 3 screws and the lumber support adjuster assembly LH 21 REMOVE POWER SEAT MOTOR a Remove the 2 screws each to remove the sliding motor reclining motor front vertical motor and rear lifter motor 22 INSTALL FRONT SEAT BACK HEATER ASSY LH W SEAT HEATER a Set the seat heater to the seat back cover b Install the front seat heater assembly to the seat back cover with the 8 tack pins NOTICE Do not sub...

Page 1137: ...e side airbag may not activate normally unless the seat back cover is se curely installed Check that the strap has no twist after installing the bracket 24 INSTALL FRONT SEAT BACK ASSY a Install the front seat back assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b As shown in the illustration attach a rubber with new hog rings c Using hog ring pliers install new hog rings NOTICE Be ca...

Page 1138: ...MANUAL RM881U 27 INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a Using hog ring pliers install the front seat cushion cover LH with new hog rings to the front seat cushion pad LH NOTICE Be careful not to damage the cover When installing the hog rings take care to prevent wrinkles as little as possible 28 INSTALL FRONT SEAT CUSHION ASSY a Install the front seat cushion assembly with the 4 bolts b ...

Page 1139: ...Y REPAIR MANUAL RM881U 30 INSTALL FRONT SEAT ASSY LH a Set the front seat assembly LH to the body NOTICE Be careful not to damage the cover b Install the front seat assembly LH with the 4 bolts Torque 36 8 N m 377 kgf cm 27 ft lbf NOTICE Check that the seat adjuster locked ...

Page 1140: ...ck Cover w Seat Heater Front Seat Cushion Heater Assy LH Reclining Adjuster Cover LH Reclining Adjuster Inside Cover LH Reclining Adjuster Inside Cover RH 43 1 440 32 Front Seat Track Braket Cover Inner LH Front Seat Track Cover LH Lumber Support Adjuster Assy Reclining Adjuster Knob Separate Type Front Seat Cushion Cover Separate Type Front Seat Cushion Pad Front Seat Back Spring Assy Front Seat ...

Page 1141: ... 4 bolts b Disconnect the connectors and then remove the front seat assembly LH 5 REMOVE FRONT SEAT HEADREST ASSY 6 REMOVE RECLINING POWER SEAT SWITCH KNOB 7 REMOVE SLIDE VERTICAL POWER SEAT SWITCH KNOB 8 REMOVE RECLINING ADJUSTER COVER LH a Remove the 4 screws b Disengage the claws and then remove the front seat cushion shield LH 9 REMOVE FRONT POWER SEAT SWITCH LH a Disconnect the connectors b R...

Page 1142: ...t cushion cover 16 REMOVE FRONT SEAT BACK ASSY a Remove the hog rings at the lower portion of the front seat back cover b Remove the 4 bolts from the front seat back assembly LH c Remove the 2 screws and reclining adjuster inside cover RH d w Side airbag Disconnect the wire harness of the side airbag from the inside cover LH e Remove the front seat back assembly LH f Remove the 2 screws and the re...

Page 1143: ... 3 screws and the No 3 seat reclining adjuster assembly LH 21 REMOVE POWER SEAT MOTOR a Remove the 2 screws each to remove the sliding motor reclining motor front vertical motor and rear lifter motor 22 INSTALL FRONT SEAT BACK HEATER ASSY LH W SEAT HEATER a Set the seat heater to the seat back cover b Install the front seat heater assembly to the seat back cover with the 8 tack pins NOTICE Do not ...

Page 1144: ...rbag may not activate normally unless the seat back cover is se curely installed Check that the strap has no twist after installing the bracket 24 INSTALL FRONT SEAT BACK ASSY a Install the front seat back assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b As shown in the illustration attach a rubber with new hog rings c Using hog ring pliers install new hog rings NOTICE Be careful not...

Page 1145: ...ing pliers install the front seat cushion cover LH and pad LH with new hog ring to the front seat frame LH NOTICE Be careful not to damage the cover When installing the hog rings take care to prevent wrinkles as little as possible 28 INSTALL FRONT SEAT CUSHION ASSY a Install the front seat cushion assembly with the 4 bolts b w Side airbag Install the wire harness clamps of the side airbag through ...

Page 1146: ...H Reclining Adjuster Inside Cover RH 36 8 377 27 43 1 440 32 Reclining Adjuster Knob Reclining Adjuster Release Handle LH Reclining Adjuster Cover LH Front Seat Cushion Shield Inner LH Separate Type Front Seat Cushion Cover Separate Type Front Seat Cushion Pad Lumber Support Adjuster Assy Front Seat Inner Belt Assy LH Front Seat Cushion Spring Assy Seat Track Upper Rail Cover RH Seat Track Cover U...

Page 1147: ...ove the front seat assembly LH 5 REMOVE FRONT SEAT HEADREST ASSY 6 REMOVE VERTICAL SEAT ADJUSTER KNOB a Using a cloth or something remove the snap rings and the vertical seat adjusting knob 7 REMOVE RECLINING ADJUSTER RELEASE HANDLE LH a Using a screwdriver remove the reclining adjuster re lease handle LH HINT Tape the screwdriver tip before use 8 REMOVE RECLINING ADJUSTER COVER LH a Remove the 2 ...

Page 1148: ...r and then remove the front seat back heater assembly LH from the cushion cover NOTICE Be careful not to damage the seat cushion cover 15 REMOVE SEPARATE TYPE FRONT SEAT CUSHION COVER a Disengage the hook and remove the front seat cushion cover together with the front cushion spring b Remove the hog ring and take away the front seat cushion cover from the front cushion pad 16 REMOVE FRONT SEAT CUS...

Page 1149: ...e 2002 CAMRY REPAIR MANUAL RM881U 20 INSTALL SEPARATE TYPE FRONT SEAT CUSHION COVER a Using hog ring pliers install the front seat cushion cover LH with new hog rings to the front seat cushion pad LH b Using hog ring pliers install the front seat cushion cover LH and pad LH with new hog ring to the front seat frame LH NOTICE Be careful not to damage the cover When installing the hog rings take car...

Page 1150: ...SEAT BACK COVER NOTICE For a vehicle with side airbag if the seat back cover has damage the side airbag may not acti vate normally and therefore it is necessary to replace the seat back cover For a vehicle with side airbag if the side airbag has damage replace the pad and the frame with new ones For a vehicle with side airbag the side airbag may not activate normally unless the seat back cover is ...

Page 1151: ... Install the front seat back assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b As shown in the illustration engage the rubber with a hole of the front seat back frame with new hog rings c w Side airbag Install the wire harness and clamps of the side airbag through the seat cushion cover end d Using hog ring pliers install new hog rings NOTICE Be careful not to damage the cover When in...

Page 1152: ...SSY LH a Set the front seat assembly LH to the vehicle NOTICE Be careful not to damage the cover b Install the front seat assembly LH with the 4 bolts Torque 36 8 N m 377 kgf cm 27 ft lbf c When sliding the seat check that the both sides of the adjuster will lock simultaneously NOTICE Check that the seat adjuster locked ...

Page 1153: ...over RH 43 1 440 32 Reclining Adjuster Knob Reclining Adjuster Cover LH Front Seat Cushion Shield Inner LH Separate Type Front Seat Cushion Cover Separate Type Front Seat Cushion Pad Lumber Support Adjuster Assy Front Seat Cushion Spring Assy 36 8 377 27 Hog Ring Vertical Seat Adjuster Knob Seat Track Upper Rail Cover RH Seat Track Cover Upper Rear Snap Ring Snap ring Front Seat Inner Belt Assy LH...

Page 1154: ...e the 4 bolts b Disconnect the connectors and then remove the front seat assembly LH 5 REMOVE FRONT SEAT HEADREST ASSY 6 REMOVE VERTICAL SEAT ADJUSTER KNOB a Using a cloth or something remove the snap rings and the vertical seat adjusting knob 7 REMOVE RECLINING ADJUSTER RELEASE HANDLE LH a Using a screwdriver remove the reclining adjuster re lease handle LH HINT Tape the screwdriver tip before us...

Page 1155: ...wdriver disengage the seat back cover bracket c Disengage the claws to remove the 2 headrest supports and then take away the front seat cover LH from the pad spring d Remove the hog rings and then take away the cover from the pad 14 REMOVE FRONT SEAT BACK HEATER ASSY LH W SEAT HEATER a Cut off the tack pins which fasten the seat heater and then remove the seat heater from the cushion cover NOTICE ...

Page 1156: ...AMRY REPAIR MANUAL RM881U 17 REMOVE RECLINING ADJUSTER INSIDE COVER LH a Remove the 2 screws and the reclining adjuster inside cover LH b Employ the same manner described above to the other side 18 REMOVE RECLINING ADJUSTER INSIDE COVER RH 19 INSTALL FRONT SEAT CUSHION HEATER ASSY LH W SEAT HEATER a Set the seat heater to the seat cushion cover b Install the seat heater to the seat cushion cover w...

Page 1157: ...H W SEAT HEATER a Set the seat heater to the seat back cover b Install the seat heater to the seat back cover with the 8 tack pins NOTICE Does not substitute other metal parts for tack pins 22 INSTALL SEPARATE TYPE FRONT SEAT BACK COVER NOTICE For a vehicle with side airbag if the seat back cover has damage the side airbag may not acti vate normally and therefore it is necessary to replace the sea...

Page 1158: ...se curely installed Check that the strap has no twist after installing the bracket 23 INSTALL FRONT SEAT BACK ASSY a Install the front seat back assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b As shown in the illustration engage the rubber with a hole of the front seat back frame with hog rings c Install the wire harness and clamps of the side airbag through the seat cushion cover e...

Page 1159: ...SSY LH a Set the front seat assembly LH to the vehicle NOTICE Be careful not to damage the cover b Install the front seat assembly LH with the 4 bolts Torque 36 8 N m 377 kgf cm 27 ft lbf c When sliding the seat check that the both sides of the adjuster will lock simultaneously NOTICE Check that the seat adjuster locked ...

Page 1160: ...Seat Back Hinge Sub assy Center Rear Seat Back Hinge Sub assy LH Bench Type Rear Seat Cushion Cover Separate Type Rear Seat Back Cover LH Rear Seat Armrest Assy Center Rear Seat Back Lock Control Bezel Rear Side Seat Back Assy LH Hog Ring Hog Ring Bench Type Rear Seat Cushion Pad 20 204 15 18 183 13 18 183 13 18 183 13 20 204 15 18 183 13 18 183 13 18 183 13 18 183 13 Rear Seat back Hinge Cover Re...

Page 1161: ...EAT HEADREST ASSY 3 REMOVE REAR SEAT HEADREST ASSY 4 REMOVE REAR SEAT BACK ASSY RH a Tilting the seat forward remove the 2 clips that are engaged with the floor b Remove the 2 bolts and the rear seat back assembly c Employ the same manner described above to the other side 5 REMOVE REAR SEAT BACK ASSY LH 6 REMOVE REAR SIDE SEAT BACK ASSY RH a Remove the bolt and pull it out in the illustrated direc...

Page 1162: ...gs and then take away the cover from the rear seat back pad 13 REMOVE SEPARATE TYPE REAR SEAT BACK COVER LH 14 REMOVE REAR SEAT BACK LOCK ASSY RH a Remove the 2 bolts and the rear seat back lock assembly RH b Employ the same manner described above to the other side 15 REMOVE REAR SEAT BACK LOCK ASSY LH 16 REMOVE BENCH TYPE REAR SEAT CUSHION COVER 17 INSTALL BENCH TYPE REAR SEAT CUSHION COVER a Usi...

Page 1163: ...r seat back hinges center with the 2 bolts Torque 18 N m 183 kgf cm 13 ft lbf 21 INSTALL REAR SEAT BACK HINGE SUB ASSY RH a Install the 2 rear seat back hinge with the 2 bolts Torque 18 N m 183 kgf cm 13 ft lbf 22 INSTALL REAR SIDE SEAT BACK ASSY LH Torque 18 N m 183 kgf cm 13 ft lbf 23 INSTALL REAR SIDE SEAT BACK ASSY RH a Install the rear side seat back assembly with the 2 bolts Torque 18 N m 18...

Page 1164: ...ype Rear Seat Back Cover RH Rear Seat Shoulder Beat Guide Center Rear Seat Back Lock Control Bezel Rear Seat Back Hinge Sub assy Center Separate Type Rear Seat Back Cover Pad LH Rear Seat Back Hinge Sub assy LH Bench Type Rear Seat Cushion Cover Separate Type Rear Seat Back Cover LH Rear Seat Armrest Assy Center Rear Seat Back Lock Control Bezel Rear Side Seat Back assy LH Hog Ring Hog Ring Bench ...

Page 1165: ...a Tilting the seat forward remove the 2 clips that are engaged with the floor b Remove the 2 bolts and the rear seat back assembly c Employ the same manner described above to the other side 5 REMOVE REAR SEAT BACK ASSY LH 6 REMOVE REAR SIDE SEAT BACK ASSY RH a Remove the bolt and pull it out in the illustrated direction to remove the side seat back assembly b Employ the same manner described above...

Page 1166: ...ay the cover from the rear seat back pad 13 REMOVE SEPARATE TYPE REAR SEAT BACK COVER LH 14 REMOVE REAR SEAT BACK LOCK SUB ASSY RH a Remove the 2 bolts and the rear seat back lock assembly RH b Employ the same manner described above to the other side 15 REMOVE REAR SEAT BACK LOCK SUB ASSY LH REMOVE REAR SEAT BACK LOCK ASSY LH 16 REMOVE BENCH TYPE REAR SEAT CUSHION COVER 17 INSTALL BENCH TYPE REAR ...

Page 1167: ...s Torque 18 N m 183 kgf cm 13 ft lbf 21 INSTALL REAR SEAT BACK HINGE SUB ASSY RH a Install the 2 rear seat back hinge with the 2 bolts Torque 18 N m 183 kgf cm 13 ft lbf 22 INSTALL REAR SIDE SEAT BACK ASSY LH Torque 18 N m 183 kgf cm 13 ft lbf 23 INSTALL REAR SIDE SEAT BACK ASSY RH a Install the rear side seat back assembly with the 2 bolts Torque 18 N m 183 kgf cm 13 ft lbf 24 INSTALL REAR SEAT B...

Page 1168: ...Cushion Heater Assy LH Front Seat Back Heater Assy LH Seat Heater Switch Passenger s Side Front Seat Cushion Heater Assy RH Front Seat Back Heater Assy RH SEAT SEAT HEATER SYSTEM 72 41 2630 Author Date 2002 CAMRY REPAIR MANUAL RM881U SEAT HEATER SYSTEM LOCATION ...

Page 1169: ...M SYMPTOMS TABLE Symptom Suspected Area See page Seat heaters do not operate 1 SEAT HTR fuse 2 Front seat cushion heater assy LH 3 Front seat cushion heater assy RH 4 Front seat back heater assy LH 5 Front seat back heater assy RH 6 Seat heater switch 7 Wire harness 72 37 72 38 72 37 72 38 72 37 ...

Page 1170: ... heater switch passenger s side conti nuity Standard Terminal No Condition Specified condition 4 6 OFF Continuity 3 4 6 ON Continuity 3 4 6 ON Continuity 1 2 Illumination Continuity always If the continuity is not as specified replace the seat heater switch 2 INSPECT FRONT SEAT CUSHION HEATER ASSY LH a Inspect the seat cushion heater assembly LH continuity Standard Terminal No Condition Specified ...

Page 1171: ...with a beat light 3 Inspect the seat cushion heater continuity between the terminals Standard Terminal No Condition Specified condition 1 2 Seat heater temp below 25 35 C 77 95 F Continuity 1 2 Seat heater temp y Seat heater temp 25 35 C 77 95 F No continuity If the continuity is not as specified replace the seat heater cushion heater assembly 4 INSPECT FRONT SEAT CUSHION HEATER ASSY RH 5 INSPECT ...

Page 1172: ...d to the lock side 4 With the driver s door open lock the driver s door lock by holding the driver s door lock knob in the lock side for 2 seconds or more and then close the driver s door Then check that all doors will unlock c Check the security function 1 Close all doors with the driver s door glass open so that the door control switch can be operated outside the vehicle 2 Pull out the ignition ...

Page 1173: ...ation function 1 Move the map light switch in the DOOR position 2 Check that the map light will be on simultaneously with all doors unlocking operation when the driver s door of all the closing doors is turned unlock by the key operation 3 Map light will be off in approximately 15 seconds if a door has not been opened for a while ...

Page 1174: ...tery negative Terminal 4 Unlock If the operation is not as specified replace the door lock assem bly b Inspect the position switch continuity Standard Terminal No Door lock position Specification 7 8 Lock No continuity 7 8 Unlock Continuity If the continuity is not as specified replace the door lock assem bly 2 INSPECT FRONT DOOR W MOTOR LOCK ASSY LH a Inspect the door lock assembly continuity Sta...

Page 1175: ...nal No Door lock position Specification 7 8 Lock No continuity 7 8 Unlock Continuity If the continuity is not as specified replace the door lock assem bly 3 INSPECT REAR DOOR W MOTOR LOCK ASSY RH a Inspect the door lock motor operation Standard Measuring condition Operation Battery positive Terminal 4 Battery negative Terminal 1 Lock Battery positive Terminal 1 Battery negative Terminal 4 Unlock I...

Page 1176: ...tery negative Terminal 4 Unlock If the operation is not as specified replace the door lock assem bly b Inspect the position switch continuity Standard Terminal No Door lock position Specification 6 9 Lock No continuity 6 9 Unlock Continuity If the continuity is not as specified replace the door lock assem bly 5 LUGGAGE COMPARTMENT DOOR LOCK ASSY a Inspect the door lock motor operation Standard Mea...

Page 1177: ...l automatically lock as long as any of the doors has not been opened or all doors have not been locked within approximately 30 seconds after all doors are unlocked by pressing the switch 2 Under the above condition the automatic locking function will not work if any of the doors has been opened or all doors have been locked within approximately 30 seconds d Check the switch operation fail safe fun...

Page 1178: ...eck that the connector on the wire harness side b Check the voltage and continuity of each terminal of the wire harness side connector Standard Symbols Terminal No Wiring color Condition Specification GND D13 1 Body ground W B Constant Continuity B D13 5 Body ground R Constant 10 14 V HINT If the value is not as specified the wire harness side may be de fective c Using an oscilloscope connect the ...

Page 1179: ...e is used to erase all the registered codes and cancels the wireless door lock func tion Use this mode when the transmitter is lost The confirmation mode is for confirming how many recognition codes have already been registered before an additional registration of a recognition code a The vehicle should be in the following conditions 1 The key is not inserted in the ignition key cylinder 2 Driver ...

Page 1180: ...t the MPX body ECU automatically performs the LOCK UNLOCK operation within 3 seconds to inform the operator of a selected mode HINT In the confirmation mode as shown in the illustration when the LOCK UNLOCK operation is performed twice it means that 2 types of recognition codes are registered NOTICE In the confirmation mode if the number of the registration code is 0 the ON LOCK operation is auto ...

Page 1181: ...nds the LOCK UNLOCK operation will be automatically performed once if the reg istration of the recognition code of the transmitter has been completed correctly If the LOCK UNLOCK operation is performed twice the registration of the recognition code has failed Per form the registration procedure from the beginning once again 4 When continuing the registration register the next transmitter within 40...

Page 1182: ...ssy Combination Meter Warning Buzzer Front Door Courtesy Lamp Switch Instrument Panel J B Body ECU THEFT DETERRENT DOOR LOCK KEY UNLOCK WARNING SYSTEM 73 11 2644 Author Date 2002 CAMRY REPAIR MANUAL RM881U KEY UNLOCK WARNING SYSTEM LOCATION ...

Page 1183: ...or front door courtesy lamp switch assembly is off 3 Turn the ignition switch ON 4 Pull out the key from the ignition switch lock cylinder 2 CHECK INSTRUMENT PANEL JUNCTION BLOCK ASSY BODY ECU LEFT SIDE a Disconnect the B6 body ECU connector b Check the connector terminal continuity Standard Symbols Terminal No Wiring color Condition Specified condition KSW B6 19 Body ground L Body ground No key i...

Page 1184: ...UMENT PANEL JUNCTION BLOCK ASSY BODY ECU REAR SIDE a Disconnect the 2F and 2G connectors b Check the voltage and continuity between the connector terminals Standard Symbols Terminal No Wiring color Condition Specified condition B 2F 7 Body ground R Body ground Constant 10 14 V BDR1 2G 14 Body ground L W Body ground Constant 10 14 V GND 2R 8 Body ground W B Body ground Constant Continuity HINT If t...

Page 1185: ...or Date 2002 CAMRY REPAIR MANUAL RM881U PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Key unlock warning buzzer does not sound 1 Unlock warning switch 2 Front door courtesy lamp switch 3 Instrument panel J B Body ECU 4 Combination meter 5 Wire harness 73 15 73 15 73 12 ...

Page 1186: ...ntinuity Standard Terminal No Condition Specification 1 2 Switch pressed in Continuity 1 2 Switch not pressed in No continuity If the continuity is not as specified replace the switch 2 INSPECT COURTESY LAMP SWITCH a Check the switch continuity Standard Terminal No Condition Specification 1 Switch body FREE Continuity 1 Switch body PUSH No continuity If the continuity is not as specified replace t...

Page 1187: ...condition alarming functions when any of the following conditions is sa tisfied 1 Any of the doors or hood is open 2 Any of the doors is unlocked by any ways except the wireless operation 3 The hood is open 4 The battery is reconnected 5 The ignition terminal is short circuited 6 The self power siren sounds at the same time when the battery is disconnected d Alarming arming condition Disarming con...

Page 1188: ...thout the key 1 The battery terminal is disconnected and reconnected The system receives a panic signal from remote keyless entry 2 1 Only active arming mode 2 When the ignition key is not inserted in the key cylinder There are 4 conditions in this system which are disarming condition disarming preparation condition arming condition and alarming condition a Disarming condition 1 When a user is nea...

Page 1189: ...ed doors using the wireless remote function Unlock the locked doors using the key Insert the key into the ignition key cylinder and turn the ignition key ON Any of the following conditions is met Either of closed doors opens Either of locked doors is unlocked by any way other than key or wireless remote function The closed engine hood is opened The battery is reconnected Ignition switch is turned ...

Page 1190: ...ondition ON HINT Even in the disarming condition the indicator light flashes due to a signal output from immobilizer system The indicator always flashes by receiving a signal from the immobilizer system at any time in the arming condition Flashing frequency 0 2 seconds ON 1 8 seconds OFF 6 PASSIVE ARMING MODE This mode can be switched by the specified operation All initially set modes when shipped...

Page 1191: ...with all the doors and hood closed Perform any of the followings and the system will return to Disarmed state A Push the unlock switch on the wireless remote Put the key in the lock on the driver s or the passenger door or the luggage door and turn it towards the unlock Put the key in the ignition and turn it ON Armed state Perform any of the followings and the system will go on to Alarm sounding ...

Page 1192: ...nd the system will return to Disarmed state A Push the unlock switch on the wireless remote Put the key in the lock on the driver s or the passenger door or the luggage door and turn it towards the unlock Put the key in the ignition and turn it ON THEFT DETERRENT DOOR LOCK THEFT DETERRENT SYSTEM 73 21 2654 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1193: ...ition ON HINT Even in the disarming condition the indicator light flashes due to the signal output from immobilizer system The indicator always flashes by receiving the signal from the immobilizer system at any time in the arming condition Flashing frequency 0 2 seconds ON 1 8 seconds OFF Transfer to active mode In each passive mode when disarming condition of active mode disarming preparation tra...

Page 1194: ...is locked and unlocked The system starts force lock at once after 2 secs PASSIVE MODE OFF Driver s side door is closed and opened 3 to 5 times Driver s side knob for door lock is locked and unlocked The system starts force lock at once after 2 sec PASSIVE MODE ON Within 30 sec Within 20 sec HINT Initial mode is PASSIVE MODE OFF If there is a different signal in the middle of changing It is invalid...

Page 1195: ...til removing the key And after removing the key the indicator blinks 73 24 THEFT DETERRENT DOOR LOCK ENGINE IMMOBILISER SYSTEM 2657 Author Date 2002 CAMRY REPAIR MANUAL RM881U ENGINE IMMOBILISER SYSTEM REGISTRATION 1 KEY REGISTRATION IN AUTOMATIC REGISTRATION a Registration of a new transponder key This must be done when you install a new ECM The new ECM is in the automatic key code registration m...

Page 1196: ...ration could not be performed in the automatic registration mode code 2 1 is output from the security indicator And when inserting the already registered key code 2 2 is output b Automatic registration mode completion If finishing the mode forcibly after registering more than 1 key codes in the automatic registration mode perform the following procedures After 1 more key code has been registered w...

Page 1197: ...9 Author Date 2002 CAMRY REPAIR MANUAL RM881U 2 REGISTRATION OF ADDITIONAL KEY There are 2 ways for registration of additional master key one way is depressing the brake pedal and accel eration pedal and the other way is using the hand held tester HINT It is possible to register up to 7 master key codes including the already registered key code When any operation time described below is over regis...

Page 1198: ...master key registration is complete Security indicator OFF Within 20 sec Within 10 sec The registration mode is complete when pulling out the key and depressing and releasing the brake pedal once or more within 10 sec after in dicator has been off or 10 sec have passed HINT Follow the screen of the hand held tester for more detailed procedure THEFT DETERRENT DOOR LOCK ENGINE IMMOBILISER SYSTEM 73 ...

Page 1199: ...nd releasing the brake pedal once or more within 10 sec after in dicator has been off or 10 sec have passed 73 28 THEFT DETERRENT DOOR LOCK ENGINE IMMOBILISER SYSTEM 2661 Author Date 2002 CAMRY REPAIR MANUAL RM881U 3 REGISTRATION OF KEY NUMBER There are 2 ways for registration of additional sub key one way is depressing the brake pedal and accelera tion pedal and the other way is using hand held t...

Page 1200: ...sub key registration is complete Security indicator OFF Within 20 sec Within 10 sec The registration mode is complete when pulling out the key and depressing and releasing the brake pedal once or more within 10 sec after in dicator has been off or 10 sec have passed HINT Follow the screen of the hand held tester for more detailed procedure THEFT DETERRENT DOOR LOCK ENGINE IMMOBILISER SYSTEM 73 29 ...

Page 1201: ...1U 4 ERASURE OF KEY CODE There are 2 ways for erasure of transponder key codes one way is depressing the brake pedal and accelera tion pedal and the other way is using hand held tester HINT Delete all the other master and sub key codes than a master key code to use the erasing operation When using the key which was used for deletion it is necessary to register the code again When any operation tim...

Page 1202: ...inks 3 Remove the master key HINT When the key cannot be pulled out in step 3 key code deletion is canceled Security indicator is OFF Follow the screen of the hand held tester for more detailed procedure END Key code erased Within 10 sec THEFT DETERRENT DOOR LOCK ENGINE IMMOBILISER SYSTEM 73 31 2664 Author Date 2002 CAMRY REPAIR MANUAL RM881U 2 Using the hand held tester ...

Page 1203: ... Motor Switch Slide Roof Housing Sub assy Slide Roof Drive Gear Sub assy Sliding Roof Control Relay SLIDING ROOF CONVERTIBLE SLIDING ROOF SYSTEM 74 1 2665 Author Date 2002 CAMRY REPAIR MANUAL RM881U SLIDING ROOF SYSTEM LOCATION ...

Page 1204: ... d Check the automatic tilting DOWN operation 1 Turn the ignition switch ON 2 Check that the roof glass will tilt down by pressing the sliding roof switch DOWN when the roof glass is up e Check the operation function after key OFF 1 After turning the ignition switch from ON to OFF check that the roof glass can be operated via the sliding roof switch however the operation will be impossible after t...

Page 1205: ...m the sliding roof relay and inspect the connector on the wire harness side Standard Terminal No Wiring color Condition Specified condition 5 Body ground W B Body ground Constant Continuity 7 5 L W W B Constant 10 14 V 3 5 R L W B Ignition switch OFF ON 0 V 10 14 V 1 5 R W W B Sliding roof switch OPEN or DOWN No continuity Continuity 2 5 R Y W B Sliding roof switch CLOSE or UP No continuity Contin...

Page 1206: ... 0 V 10 14 V DWN 9 E 7 R W W B Sliding roof switch OPEN or DOWN No continuity Continuity UP 10 E 7 R Y W B Sliding roof switch CLOSE or UP No continuity Continuity If the value is not as specified there way be a malfunction in the wire harness side 3 Connect the connector and inspect the voltage and continuity between each terminal of connec tor and body ground Standard Symbols Terminal No Wiring ...

Page 1207: ...e 2 Sliding roof motor switch 3 Sliding roof drive gear 4 Wire harness 5 Faulty sliding of sliding roof 74 6 74 2 74 2 Sliding roof operation is abnormal 1 Sliding roof motor switch 2 Sliding roof drive gear 3 Wire harness 74 6 74 2 Sliding roof system stops operation half way No foreign object is in the motor 1 Sliding roof motor switch 2 Sliding roof drive gear 3 Wire harness 4 sliding roof rela...

Page 1208: ... 2002 CAMRY REPAIR MANUAL RM881U INSPECTION 1 INSPECT SLIDE ROOF MOTOR SWITCH a Check the slide roof motor switch continuity Standard Terminal No Switch position Specified condition 2 4 CLOSE UP Continuity 2 3 OPEN DOWN Continuity If continuity is not as specified replace the switch ...

Page 1209: ...hold the switch on the TILT UP side until the sliding roof tilts all the way up and down a little automatically 2 Confirm one touch side open and close and one touch tilt up and down functions by pushing the switch briefly to the SLIDE OPEN and TILT UP sides b Reset B 1 Push and hold the switch on the TILT UP CLOSE side until the sliding roof stops 2 Continue to push and hold the switch on the TIL...

Page 1210: ...rm RH Sliding Roof Lift Arm LH Sliding Roof Drive Cable RH Sliding Roof Drive Cable LH Roof Drip Channel Guide RH Roof Drip Channel Guide LH Roof Wind Deflector Spring Sliding Roof Housing Drain End Cap RH Sliding Roof Housing Drain End Cap LH Sliding Roof Housing Bracket No 1 Removable Roof Hinge RH Removable Roof Hinge LH Roof Wind Deflector Spring 74 8 SLIDING ROOF CONVERTIBLE SLIDING ROOF TMMK...

Page 1211: ...GLASS SUB ASSY a Disengage the claws and turn the sliding roof side garnish as shown in the illustration b Using a torx wrench T25 remove the 4 screws and slid ing roof glass 2 REMOVE SLIDING ROOF WEATHERSTRIP 3 REMOVE SLIDING ROOF DRIVE GEAR SUB ASSY a Using a torx wrench T25 remove the 3 screws and sliding roof drive gear 4 REMOVE SLIDE ROOF RAIL SUB ASSY a Disconnect the 4 drain hoses from the ...

Page 1212: ...ROOF HOUSING DRAIN END CAP LH 10 REMOVE SUNSHADE TRIM SUB ASSY a Pull out the sunshade trim in the vehicle s rear direction 11 REMOVE ROOF DRIP CHANNEL GUIDE RH a Disengage the roof drip channel guide and sliding roof lift arm and then pull out the roof drip channel guide in the vehicle s rear direction b Employ the same manner described above to the other side 12 REMOVE ROOF DRIP CHANNEL GUIDE LH...

Page 1213: ...and push cut remaining fragment with the drill 20 REMOVE ROOF WIND DEFLECTOR PANEL SUB ASSY 21 REMOVE SLIDING ROOF HOUSING BRACKET NO 1 a Remove the 4 bolts and 4 sliding roof housing bracket 22 INSTALL ROOF WIND DEFLECTOR SPRING a Using an air riveter or hand riveter with nose piece strike rivets into the body panel NOTICE If the rivet is not positioned perpendicularly it will bend the mandrel Wh...

Page 1214: ...of panel 1 Using a torx driver T25 loosen a screw to adjust the sliding roof panel position When the adjustment has done tighten the screw there 24 RESET THE SLIDING ROOF POSITION See page74 7 25 INSPECT FOR LEAK a Adjusting the sliding roof check there is no water leak b In case of water leak readjust the sliding roof ...

Page 1215: ...H Sliding Roof Side Garnish LH Sliding Roof Glass Sub assy Sliding Roof Weatherstrip Sliding Roof Drive Gear Sub assy Sliding Roof Housing Sub assy Sunshade Trim Sub assy SLIDING ROOF CONVERTIBLE SLIDING ROOF TMC Made 74 13 2677 Author Date 2002 CAMRY REPAIR MANUAL RM881U SLIDING ROOF TMC Made COMPONENTS ...

Page 1216: ...he same manner described above to the other side 3 REMOVE ROOF SIDE RAIL GARNISH PAD LH W O CURTAIN SHIELD AIR BAG 4 REMOVE SLIDING ROOF SIDE GARNISH RH a Using a screwdriver remove the sliding roof side garnish HINT Tape the screwdriver tip before use b Employ the same manner described above to the other side 5 REMOVE SLIDING ROOF SIDE GARNISH LH 6 REMOVE SLIDING ROOF GLASS SUB ASSY a Using a tor...

Page 1217: ... airbag Remove the 6 nuts and 4 bolts then remove the housing as shown in the illustration c w curtain shield airbag Remove the 6 nuts and 8 bolts then remove the housing as shown in the illustration 10 REMOVE SUNSHADE TRIM SUB ASSY a Remove the screw and stopper b Remove the sunshade trim c Employ the same manner described above to the other side 11 ADJUST THE FULLY CLOSED POSITION a By using a s...

Page 1218: ... 059 in b Check for a difference in level between the sliding roof glass and roof panel NOTICE The clearance should be thoroughly even c Adjustment the roof panel 1 Using a torque driver T25 loosen a screw to adjust the sliding roof panel position When the adjustment has done tighten the screw there 13 RESET THE SLIDING ROOF POSITION See page74 7 14 INSPECT FOR LEAK a Adjusting the sliding roof ch...

Page 1219: ...881U HOOD ADJUSTMENT HINT Since the centering bolt is used as a hood hinge set bolt and hood lock set bolt the hood and hood lock can not be adjusted with it on Substitute a bolt with washer for the centering bolt 1 INSPECT HOOD SUB ASSY a Check that the clearance is within the standard value 2 ADJUST HOOD SUB ASSY a Adjust the hood by loosening the hood side hinge bolts Torque 26 N m 265 kgf cm 1...

Page 1220: ...the hood by turning the cushions c Using a screwdriver remove the hood lock release lever cover HINT Tape the screwdriver tip before use NOTICE Removing the protector damages the clips inside the pro tector and therefore the use of a new protector is neces sary on installation d Adjust the lock by loosening the bolts ...

Page 1221: ...g a screwdriver to hold the left spring disengage the upper and lower parts of the support rod and then re move the hood support rod NOTICE Removal should be done while the hood is being held up 2 INSTALL HOOD SUPPORT ROD NOTICE Install a metal socket onto the hood except a resinous one onto the body After the installation make sure that the socket is securely attached ...

Page 1222: ...assembly with the piston rod pulled out on a vise b With protection glasses on cut a part between A and B as shown in the illustration with a metal saw to release the gas NOTICE Although the gas inside the hood stay assembly is color less odorless and harmless there is a possibility that cut ting tips of the metal saw would jump around therefore cover it with clothes or something ...

Page 1223: ...or Sub assy Power Window Regulator Motor Assy Front Door Glass Run Front Door Glass Run No 2 Front Door Window Front Bar Sub assy Front Door Frame Sub assy Rear Lower Front Door Outside Handle Cover Front Door w Motor Lock Assy Front Door Handle Assy Outside Door Outside Handle Sub assy Front Door Weatherstrip Outer Rear View Mirror Assy Front Door Belt Moulding Assy Non reusable part ENGINE HOOD ...

Page 1224: ... RH side work in the same procedure as in the LH side HINT Since the centering bolt is used as a door hinge set bolt the door can not be adjusted with it on Substitute a bolt with washer for the centering bolt 1 INSPECT FRONT DOOR PANEL SUB ASSY LH a Check that the clearance is within the standard value 2 ADJUST FRONT DOOR PANEL SUB ASSY LH a Using SST adjust the door by loosening the body side hi...

Page 1225: ...b Adjust the door by loosening the door side hinge bolts Torque 26 N m 265 kgf cm 19 ft lbf c Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer d Tighten the striker mounting screws again Torque 23 N m 235 kgf cm 17 ft lbf ...

Page 1226: ...tor master switch assembly then disconnect the connector HINT Tape the screwdriver tip before use 2 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH a Using a screwdriver remove the front door lower frame bracket garnish HINT Tape the screwdriver tip before use 3 REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH a Using a screwdriver remove the front door inside handle bezel plug HINT Tape the screwdr...

Page 1227: ... bolts and door glass NOTICE Do not damage the door glass HINT Pull the glass upward to remove it 8 REMOVE FRONT DOOR WINDOW REGULATOR SUB ASSY LH a Disconnect the connector b Loosen the temporarily installed bolt NOTICE When the temporarily installed bolt is removed the front door window regulator might drop and be deformed c Remove the 5 bolts and front door window regulator 9 REMOVE POWER WINDO...

Page 1228: ...ushing the outside handle in the arrow mark direction in the illustration remove the front door outside handle 17 REMOVE DOOR OUTSIDE HANDLE SUB ASSY LH a Using a torx wrench T30 loosen the screw b Using pliers disengage the clips and remove the front door outside handle as shown in the illustration NOTICE Be sure to remove the outside handle together with the clips because the clips will be damag...

Page 1229: ...crews 23 INSTALL FRONT DOOR OUTSIDE HANDLE COVER LH a Using a torx wrench T30 install the front door outside handle cover with the screw 24 INSTALL POWER WINDOW REGULATOR MOTOR ASSY LH W JAM PROTECTION a Apply MP grease to the sliding and rotating parts of the regulator assembly b If the jam protection dose not function properly perform the following procedure HINT It is necessary to reset the pow...

Page 1230: ...oint of the front door glass does not match adjust the regulator position by manual operation 1 Connect the power window switch to the wire harness and turn the ignition switch ON 2 Repeat UP and DOWN operation several times manually 3 Check if AUTO UP AUTO DOWN operates in the automatic operation HINT Note that the jam protection function does not operate just after resetting Reset the regulator ...

Page 1231: ... Door Window Division Bar Sub assy Rear Door Quarter Window Glass Rear Door Glass Sub assy Rear Door Quarter Window Weatherstrip Rear Door Window Regulator Sub assy Power Window Regulator Motor Assy Rear Door w Motor Lock Assy Rear Door Outside Handle Cover Rear Door Outside Handle Assy Rear Door Outside Handle Frame Sub assy Non reusable part Rear Door Lower Frame Plate ENGINE HOOD DOOR REAR DOOR...

Page 1232: ...ork in the same procedure as in the LH side HINT Since the centering bolt is used as a door hinge set bolt the door can not be adjusted with it on Substitute a bolt with washer for the centering bolt 1 INSPECT REAR DOOR PANEL SUB ASSY LH a Check that the clearance is within the standard value 2 REMOVE FRONT DOOR SCUFF PLATE LH See page 76 20 3 REMOVE REAR DOOR SCUFF PLATE LH See page 76 20 4 REMOV...

Page 1233: ...osening the body side hinge nuts Torque 26 N m 265 kgf cm 19 ft lbf b Adjust the door by loosening the door side hinge bolts Torque 26 N m 265 kgf cm 19 ft lbf c Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a brass bar and hammer d Tighten the striker mounting screws again Torque 23 N m 235 kgf cm 17 ft lbf ...

Page 1234: ... 2 REMOVE REAR DOOR INSIDE HANDLE BEZEL PLUG LH a Using a screwdriver remove the rear door inside handle bezel plug HINT Tape the screwdriver tip before use 3 REMOVE REAR DOOR TRIM BOARD SUB ASSY LH a Remove the 4 screws b Using a screwdriver remove the clip c Using a screwdriver remove the rear door trim board HINT Tape the screwdriver tip before use d Remove the inside handle then disconnect the...

Page 1235: ...ass and disconnect the roller of the regulator from the channel to remove the door glass NOTICE Do not damage the door glass HINT Pull the glass upward to remove it 13 REMOVE REAR DOOR WINDOW REGULATOR SUB ASSY LH a Disconnect the connector b Loosen the temporarily installed bolt NOTICE When the temporarily installed bolt is removed the rear door window regulator might drop and be deformed c Remov...

Page 1236: ...new door lock wire harness packing NOTICE If reusing the removed lock with rear door motor the packing in the connecting part should be replaced with a new one Be careful that grease and dirt will not stick to the packing surface in the connecting part Reusing the removed packing or using a damaged packing will cause water to penetrate through the connecting part and it will result in a malfunctio...

Page 1237: ...LE COVER LH a Install a new service hole cover to the door panel HINT When installing the service hole cover pull out the links and connectors through the service hole cover There should be no wrinkles or folds on the service hole cover after attaching it After attaching the service hole cover sealing condition should be confirmed ...

Page 1238: ...AGE COMPARTMENT DOOR COVER See page 76 6 3 REMOVE LUGGAGE COMPARTMENT FLOOR MAT See page 76 5 4 REMOVE SPARE WHEEL COVER ASSY See page 76 5 5 REMOVE LUGGAGE COMPARTMENT SIDE COVER SUB ASSY RH See page 76 5 6 REMOVE LUGGAGE COMPARTMENT TRIM HOOK NO 1 See page 76 5 7 REMOVE REAR FLOOR FINISH PLATE See page 76 5 8 ADJUST LUGGAGE COMPARTMENT DOOR PANEL SUB ASSY a For forward rearward and right left ad...

Page 1239: ...B50796 ENGINE HOOD DOOR LUGGAGE COMPARTMENT DOOR 75 21 2701 Author Date 2002 CAMRY REPAIR MANUAL 185W RM881U c Using a hammer and a brass bar tap the striker to adjust it ...

Page 1240: ...R INNER LH See page 76 4 6 REMOVE LUGGAGE DOOR HINGE TORSION BAR LH a Remove the torsion bar RH from the clip placed in the center of the upper back panel b Remove the tip of the torsion bar by hand from the roof side inner panel c Take out the hinge arm from the torsion bar in the rear direction d Pull the torsion bar to your side in order to remove the U shaped part from the hinge support 7 REMO...

Page 1241: ...maged adjustment should be done in the upper hole If the return force is little adjust one of the torsion bars If the return force is still little adjust both of the torsion bars 9 INSTALL LUGGAGE DOOR HINGE TORSION BAR RH a Check the paint mark of the torsion bar When installing a new one HINT White paint for a vehicle without rear spoiler Red paint for a vehicle with rear spoiler ...

Page 1242: ...t Bumper Hole Cover RH Fog Lamp Assy LH Fog Lamp Assy RH Engine Under Cover LH Engine Under Cover RH Front Bumper Reinforcement Sub assy Upper Front Bumper Cover Lower Front Bumper Extention Mounting Bracket TMC Made TMC Made N m kgf cm ft lbf Specified torque 34 350 25 34 350 25 EXTERIOR INTERIOR TRIM FRONT BUMPER 76 1 2704 Author Date 2002 CAMRY REPAIR MANUAL RM881U FRONT BUMPER COMPONENTS ...

Page 1243: ... front bumper cover can be removed 4 REMOVE FRONT FENDER LINER RH 5 REMOVE FRONT BUMPER COVER a Remove the 2 screws and 2 bolts b Using a clip remover remove the clip c Disengage the hooks and remove the front bumper cover d Disconnect the fog lamp connectors on the fog lamp op tion only 6 REMOVE FRONT BUMPER ENERGY ABSORBER 7 REMOVE FRONT BUMPER REINFORCEMENT SUB ASSY a Disconnect the cooler ther...

Page 1244: ...UAL RM881U 14 REMOVE FRONT BUMPER HOLE COVER RH a Disengage the hooks and remove the front bumper hole cover 15 REMOVE FRONT BUMPER HOLE COVER LH 16 INSTALL FRONT BUMPER REINFORCEMENT SUB ASSY a Install the front bumper reinforcement with 6 bolts Torque 34 N m 350 kgf cm 25 ft lbf ...

Page 1245: ...loor Finish Plate Rear Bumper Energy Absorber Rear Bumper Reinforcement Sub assy Rear Bumper Cover Luggage Compartment Side Cover Sub assy RH Rear Bumper Side Retainer LH Rear Bumper Retainer Upper RH Rear Bumper Retainer Upper LH Rear Bumper Side Retainer RH 34 350 25 34 350 25 N m kgf cm ft lbf Specified torque 76 4 EXTERIOR INTERIOR TRIM REAR BUMPER 2707 Author Date 2002 CAMRY REPAIR MANUAL RM8...

Page 1246: ...UGGAGE COMPARTMENT TRIM COVER INNER LH 8 REMOVE REAR BUMPER COVER a Remove the 8 nuts 4 bolts and 4 clips b Remove the 2 screws and rear bumper cover c Disengage the rear bumper seal bracket and remove the rear bumper cover 9 REMOVE REAR BUMPER SIDE RETAINER RH a Remove the clip and rear bumper side retainer Only TMC made b Remove the rivet and rear bumper side retainer Only TMMK made 10 REMOVE RE...

Page 1247: ...a heat light heat the spoiler 40 60 C 104 140 F NOTICE Do not heat the spoiler excessively d Tie both piano wire ends to wooden blocks or similar ob jects 1 Scrape the adhesive tape off by pulling the piano wire as shown in the illustration 2 If reusing the rear spoiler take care not to damage the rear spoiler NOTICE Do not damage the body e Disconnect the connector f Remove the 2 clips and rear s...

Page 1248: ...the rear spoiler to 40 60 C 104 140 F NOTICE Do not heat the spoiler excessively 2 Remove the adhesive tape from the rear spoiler 3 Wipe off the stains with cleaner 4 Install new adhesive tape to the rear spoiler as shown in the illustration e Using a heat light heat the body and moulding HINT Body 40 60 C 104 140 F Moulding 20 30 C 68 86 F f Install the rear spoiler with 2 nuts ...

Page 1249: ...rt ment Door Outs End Luggage Door Line End Garnish Luggage Compartment Door Outs End Garnish Luggage Compartment Door Outs End Luggage Door Line Luggage Door Line End Luggage Door Line Luggage Door Line End PLATE LUGGAGE COMPARTMENT DOOR NAME NO 2 PLATE LUGGAGE COMPARTMENT DOOR NO 3 mm in 76 8 EXTERIOR INTERIOR TRIM NAME PLATE 2711 Author Date 2002 CAMRY REPAIR MANUAL RM881U NAME PLATE REPLACEMEN...

Page 1250: ...ocedure as in the LH side 1 REMOVE POWER WINDOW REGULATOR MASTER SWITCH ASSY See page 75 8 2 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH LH See page 75 8 3 REMOVE FRONT DOOR INSIDE HANDLE BEZEL PLUG LH See page 75 8 4 REMOVE FRONT DOOR TRIM BOARD SUB ASSY LH See page 75 8 5 REMOVE OUTER REAR VIEW MIRROR ASSY LH See page 75 8 6 REMOVE FRONT DOOR BELT MOULDING ASSY LH a Put protective tape under t...

Page 1251: ...NT HINT Installation is in the reverse order of the removal But the installation is indicated only when it has a point In the RH side work in the same procedure as in the LH side 1 REMOVE REAR DOOR BELT MOULDING ASSY LH a Put protective tape under the rear door belt moulding b Using a moulding remover or scraper remove the rear door belt moulding HINT Tape the scraper tip before use ...

Page 1252: ...d then remove the roof drip side finish moulding NOTICE Do not remove the clips If the clips are damaged or removed accidentally ex change them for supplied ones 2 INSTALL ROOF DRIP SIDE FINISH MOULDING CLIP NO 1 NOTICE Only when exchanging the clips a Remove the adhesive tape that remains on the mounting surface of the body and then clean the sur face with white gasoline b Heat up the clip instal...

Page 1253: ...B56186 2 5 mm 0 098 in 1 7 mm 0 067 in Front Side Rear Side 76 12 EXTERIOR INTERIOR TRIM ROOF DRIP SIDE FINISH MOULDING CENTER LH 2715 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1254: ...e both piano wire ends to wooden block or similar ob ject c Scrape the adhesive tape off by pulling the piano wire as shown in the illustration NOTICE If reusing the moulding take care not to damage the moulding Do not damage the body 2 INSTALL OUT SIDE MOULDING a Using a heat light heat the body mounting surface to 40 60 C 104 140 F NOTICE Do not heat the body excessively b Remove the protective ...

Page 1255: ...g HINT Body 40 60 C 104 140 F Moulding 20 30 C 68 86 F NOTICE Do not heat the body excessively f Lift the moulding release sheet from the face moulding NOTICE When the moulding release sheet is removed take care that no dirt or no dust can get onto the uncoated area Do not apply excessive force onto the moulding but steady pressure with your thumbs ...

Page 1256: ...L MOULDING LH 76 15 2718 Author Date 2002 CAMRY REPAIR MANUAL RM881U ROCKER PANEL MOULDING LH REPLACEMENT 1 REMOVE ROCKER PANEL MOULDING LH a Remove the 6 screws b Using a screwdriver remove the rocker panel moulding HINT Tape the screwdriver tip before use ...

Page 1257: ...GGAGE COMPARTMENT DOOR GARNISH SUB ASSY OUTSIDE REPLACEMENT 1 REMOVE LUGGAGE COMPARTMENT DOOR COVER a Remove the 15 screws and luggage compartment door cover 2 REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB ASSY OUTSIDE a Remove the 4 screws b Using a screwdriver remove the luggage compartment door garnish outside HINT Tape the screwdriver tip before use ...

Page 1258: ...nt floor footrest HINT Tape the screwdriver tip before use NOTICE Warm the inside of the vehicle well before removal b Disengage the foot rest clips and then remove the 2 clips from the front floor footrest 2 INSTALL FRONT FLOOR FOOTREST a Install the footrest clips by engaging the claws with the front floor footrest b Before installation check that the part to be engaged with the clips of front f...

Page 1259: ...e RH w Curtain Shield Airbag w Curtain Shield Airbag 42 420 31 w Curtain Shield Airbag Front Pillar Garnish LH Front Door Opening Trim Weatherstrip LH Front Door Scuff Plate LH Rear Door Scuff Plate LH Lap Belt Outer Anchor Cover Center Pillar Garnish LH Rear Door Opening Trim Weatherstrip LH Center Pillar Garnish Lower LH 42 420 31 N m kgf cm ft lbf Specified torque 76 18 EXTERIOR INTERIOR TRIM R...

Page 1260: ...ssy LH Visor Holder Visor Bracket Cover Assist Grip Sub assy Assist Grip Sub assy Assist Grip Sub assy Assist Grip Cover Assist Grip Cover w Sunshade Sunshade Trim Holder Roof Headlining Assy w Sunshade Sunshade Trim Holder Lens Sun Roof Opening Trim Moulding Assist Grip Sub assy Assist Grip Cover EXTERIOR INTERIOR TRIM ROOF HEADLINING ASSY 76 19 2722 Author Date 2002 CAMRY REPAIR MANUAL RM881U ...

Page 1261: ...e 72 34 72 38 5 REMOVE REAR SIDE SEAT BACK ASSY LH See page 72 34 72 38 6 REMOVE REAR SEAT BACK ASSY See page 72 34 72 38 7 REMOVE CONSOLE PANEL UPPER REAR See page 71 12 8 REMOVE RR CONSOLE BOX See page 71 12 9 REMOVE CONSOLE PANEL UPPER See page 71 12 10 REMOVE CONSOLE BOX ASSY REAR See page 71 12 11 REMOVE CONSOLE BOX DUCT NO 1 See page 55 29 12 REMOVE AIR DUCT REAR NO 1 See page 55 29 13 REMOV...

Page 1262: ...ING TRIM WEATHERSTRIP RH 20 REMOVE FRONT DOOR OPENING TRIM WEATHERSTRIP LH 21 REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP RH 22 REMOVE REAR DOOR OPENING TRIM WEATHERSTRIP LH 23 REMOVE CENTER PILLAR GARNISH LOWER RH a Pull the center pillar lower garnish upward to remove it b Employ the same manner described above to the other side 24 REMOVE CENTER PILLAR GARNISH LOWER LH 25 REMOVE CENTER PILLAR GAR...

Page 1263: ...r tip before use b Employ the same manner described above to the other side 28 REMOVE ROOF SIDE GARNISH INNER LH W O CURTAIN SHIELD AIR BAG 29 REMOVE ROOF SIDE GARNISH INNER RH W CURTAIN SHIELD AIR BAG a Using a screwdriver remove the roof side garnish inner cover HINT Tape the screwdriver tip before use b Remove the bolt c Using a screwdriver remove the roof side garnish inner HINT Tape the screw...

Page 1264: ...r remove the front pillar garnish HINT Tape the screwdriver tip before use d Protect the curtain shield airbag NOTICE Cover the curtain shield airbag with the protection cover as soon as the front pillar garnish is removed 1 Cover the airbag with cloth or nylon of 700 mm 27 56 in 120 mm 4 72 in and fix the ends of the cover with tape as shown in the illustration e Employ the same manner described ...

Page 1265: ...screwdriver tip before use b Remove the 2 screws and assist grip 37 REMOVE LH VISOR ASSY 38 REMOVE ROOF CONSOLE BOX ASSY a Using a screwdriver remove the roof console box then disconnect the connector HINT Tape the screwdriver tip before use 39 REMOVE ROOM LAMP ASSY NO 1 a Using a screwdriver remove the lens b Using a screwdriver remove the room lamp assembly No 1 then disconnect the connector HIN...

Page 1266: ...lder of the sun visor by turning it to the left 41 REMOVE SUN ROOF OPENING TRIM MOULDING W SLIDING ROOF 42 REMOVE ROOF HEADLINING ASSY a Remove the 2 sunshade trim holders b w Erectro chromic inner mirror Remove the inner rear view mirror cover c Tear off the tape on the adhered part of the wire harness d Remove the headlining assembly from the passenger s door ...

Page 1267: ...ape HINT Be careful for dirt or foreign objects not to stick to the adhered part when peeling the double stick tape b Attach the roof wire harness across the adhered part NOTICE Roof wire harness should be attached securely 44 INSTALL FRONT SEAT ASSEMBLY LH Power Seat Type See page 72 7 72 14 Manual Seat Type See page 72 20 72 27 45 INSTALL FRONT SEAT ASSEMBLY RH Power Seat Type See page 72 7 72 1...

Page 1268: ...Y REPAIR MANUAL RM881U IGNITION OR STARTER SWITCH ASSY REPLACEMENT 1 REMOVE INSTRUMENT PANEL SUB ASSY LOWER See page 71 12 2 REMOVE IGNITION OR STARTER SWITCH ASSY a Disconnect the ignition switch connector and unlock warning switch connector b Remove the clamp c Remove the 2 screws and ignition switch ...

Page 1269: ...RM881U INSPECTION 1 INSPECT IGNITION OR STARTER SWITCH ASSY a Inspect the ignition switch continuity Standard Switch position Tester connection Specified condition LOCK No continuity ACC 2 3 Continuity ON 2 3 4 Continuity ON 2 3 4 6 7 Continuity START 1 2 4 Continuity START 1 2 4 6 7 8 Continuity If the continuity is not as specified replace the switch ...

Page 1270: ...ge 82 5 5 REMOVE STEERING WHEEL COVER LOWER NO 3 3 SPOKE STEERING WHEEL ASSY 6 INSPECT PLACE FRONT WHEELS FACING STRAIGHT AHEAD 7 REMOVE HORN BUTTON ASSY See page 60 15 8 REMOVE STEERING WHEEL ASSY SST 09950 50013 09951 05010 09952 05010 09953 05020 09954 05021 9 REMOVE STEERING PAD SWITCH W STEERING PAD SWITCH 4 SPOKE STEERING WHEEL See page 82 5 10 REMOVE CRUISE CONTROL MAIN SWITCH ASSY a 4 spok...

Page 1271: ...steering wheel assy Remove the 3 screws f 3 spoke steering wheel assy Reverse the steering wheel remove the 3 screws and cruise control main switch assy g Disengage the wiring pins other than the cruise control main switch assy from the connector and pull them out 11 CENTER SPIRAL CABLE See page 60 25 12 INSTALL STEERING WHEEL ASSY See page 50 9 or 50 22 13 INSPECT STEERING WHEEL CENTER POINT See ...

Page 1272: ... CRUISE CONTROL CRUISE CONTROL MAIN SWITCH ASSY 82 3 2734 Author Date 2002 CAMRY REPAIR MANUAL RM881U 16 INSPECT SRS WARNING LIGHT ...

Page 1273: ... 1 REMOVE FRONT DOOR SCUFF PLATE LH See page 71 12 2 REMOVE COWL SIDE TRIM SUB ASSY LH See page 71 12 3 REMOVE INSTRUMENT PANEL SUB ASSY UPPER See page 71 12 4 REMOVE INSTRUMENT PNL INSERT SUB ASSY LWR LH TMMK MADE See page 71 12 5 REMOVE CLUTCH SWITCH ASSY a Disconnect the connector b Loosen the nut and remove the clutch switch assy ...

Page 1274: ...See page 60 1 2 REMOVE STEERING WHEEL COVER LOWER NO 2 3 REMOVE CONNECTOR COVER a Using a screwdriver disengage the claw A HINT Tape the screwdriver tip before use b Disengage the claw B and remove the connector cover 4 REMOVE HORN BUTTON ASSY See page 60 15 5 REMOVE STEERING PAD SWITCH a Disconnect the connector b Remove the 2 screws and steering pad switch c Disengage the wiring 2 pins from the ...

Page 1275: ...82 6 CRUISE CONTROL STEERING PAD SWITCH 2737 Author Date 2002 CAMRY REPAIR MANUAL RM881U 6 INSTALL HORN BUTTON ASSY See page 60 15 7 INSPECT HORN BUTTON ASSY See page 60 15 8 INSPECT SRS WARNING LIGHT ...

Page 1276: ...er reading miles or the time interval months Maintenance service after the last period should be performed at the same interval as before unless noted Failure to do even one of the items can cause the engine to run poorly and increase the exhaust emis sions 2 TIRES a Check the pressure with a gauge If necessary make adjustment b Check for cuts damage or excessive wear 3 WHEEL NUTS a When checking ...

Page 1277: ...s sions 2 LIGHTS a Check that the headlights stop lights taillights turn signal lights and other lights are all working b Check the headlight aiming 3 WARNING LIGHTS AND BUZZERS a Check that all the warning lights and buzzers function properly 4 HORN a Check that the horn works normally 5 WINDSHIELD GLASS a Check for scratches pits or abrasions 6 WINDSHIELD WIPER AND WASHER a Check the operation o...

Page 1278: ...hat the pedal has the proper freeplay 15 BRAKE PEDAL See page 32 6 a Check the pedal for smooth operation b Check that the pedal has the proper reserve distance and freeplay c Check the brake booster function 16 BRAKES a At a safe place check that the brakes do not pull to one side when applied 17 PARKING BRAKE See page 33 2 a Check that the lever has the proper travel b On a safe incline check th...

Page 1279: ...CTROLYTE LEVEL a Check that the electrolyte level of all the battery cells is between the upper and lower level lines on the case 6 BRAKE FLUID LEVEL a Check that the brake fluid levels are near the upper level line on the see through reservoirs 7 ENGINE DRIVE BELT a Check the drive belt for fraying cracks wear or oiliness 8 ENGINE OIL LEVEL a Check the level on the dipstick with the engine turned...

Page 1280: ...nside thoroughly and then blow from the outside of the filter d Reinstall the air filter 5 REPLACE AIR FILTER a Replace the air filter with a new one 6 REPLACE ENGINE OIL AND OIL FILTER 2AZ FE See page 17 7 1MZ FE See page 17 22 7 REPLACE ENGINE COOLANT 2AZ FE See page 16 6 1MZ FE See page 16 20 8 INSPECT GASKET IN FUEL TANK CAP 2AZ FE See page 12 1 1MZ FE See page 12 11 9 INSPECT FUEL LINES AND C...

Page 1281: ...brake lines and hoses for Damage Wear Deformation Cracks Corrosion Leaks Bends Twists b Check all the clamps for tightness and connections for leakage c Check that the hoses and lines are clear of sharp edges moving parts and the exhaust system d Check that the lines install in grommets pass through the center of the grommets 2 INSPECT FRONT BRAKE PADS AND DISCS See page 32 25 3 INSPECT REAR BRAKE...

Page 1282: ...cessive looseness 1 Jack up the front of the vehicle and place wooden blocks with a height of 180 200 mm 7 09 7 87 in under the front tires 2 Lower the jack until there becomes about half a load on the front coil spring Place stands under the vehicle for safety 3 Check that the front wheels are pointing straight ahead and block them with chocks 4 Using a lever pry up the end of the lower arm and c...

Page 1283: ...ain Rear axle and suspension Brake system Engine mounting etc b Where necessary tighten all the parts of the body Seat belt system Seats Doors and hood Body mountings Fuel tank Exhaust pipe system etc 2 REPLACE AIR CONDITIONING FILTER a Remove the glove compartment assembly b Remove the filter case from the filter outlet c Remove the filter from the filter case d Replace the filter with a new one ...

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Toyota 2002 Camry, Service Manual

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