Page 1 All information contained herein is the most up-to-date at the time of publication. We reserve the right to make changes without prior notice. 2000 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro- duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Aug. 30, 2000 01-000830-00...
Page 2 CAMRY - OUTLINE OF NEW FEATURES CAMRY OUTLINE OF NEW FEATURES The Camry is a high-quality family sedan with advanced technology and sporty performance. The following changes are made for the 2001 model year. 1. 5S-FE Engine The 5S-FE engine that are equipped on the ’00 California specification models, which comply with the U- LEV (Ultra-Low Emission Vehicle) requirements, have now been provided on the all models.
Page 3: Model Code
CAMRY - MODEL CODE & MODEL LINE-UP MODEL CODE MCV20 L - C E P G K A BASIC MODEL CODE GEAR SHIFT TYPE SXV20 : With 5S-FE Engine M : 5-Speed Manual, Floor SXV23 : With 5S-FNE Engine P : 4-Speed Automatic, Floor...
Page 4 CAMRY - MAJOR TECHNICAL SPECIFICATIONS MAJOR TECHNICAL SPECIFICATIONS Area U.S.A. Item Body Type 4-Door Sedan Vehicle Grade Model Code SXV20L-CEMDKA SXV20L-CEPDKA SXV20L-A(C)EPNKA SXV20L-A(C)EPGKA Length mm (in.) 4790 (188.6) 1780 (70.1) 1785 (70.3) Overall Width mm (in.) Height* mm (in.) 1415 (55.7) Wheel Base mm (in.)
Page 5 CAMRY - MAJOR TECHNICAL SPECIFICATIONS U.S.A. Canada 4-Door Sedan MCV20L-CEMNKA MCV20L-A(C)EPNKA MCV20L-A(C)EPGKA SXV20L-AEMDKK SXV20L-AEPDKK SXV20L-AEPNKK 1780 (70.1) 1785 (70.3) 1780 (70.1) 1420 (55.9) 1415 (55.7) 135 (5.3) 130 (5.1) 880 (1940) 920 (2028)* , 920 (2028)* 920 (2028)* , 925 (2039)*...
Page 6 CAMRY - MAJOR TECHNICAL SPECIFICATIONS Area Canada U.S.A. Item Body Type 4-Door Sedan Vehicle Grade Model Code MCV20L-AEPDKK MCV20L-AEPGKK SXV23L-AEPNCA 4790 (188.6) Length mm (in.) Overall Width mm (in.) 1780 (70.1) 1785 (70.3) 1780 (70.1) Height* mm (in.) 1420 (55.9) 2670 (105.1)
Page 7 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U–22 GENERAL INFORMATION INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page.
Page 8 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 9: Identification Information
IN–3 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0CN–03 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label B01453 ENGINE SERIAL NUMBER...
Page 10: Repair Instructions
IN–4 INTRODUCTION – REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO–04 GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Installation and removal of battery terminal: FI1066 Before performing electrical work, disconnect the negative (–) terminal cable from the battery.
Page 11 IN–5 INTRODUCTION – REPAIR INSTRUCTIONS Precoated parts are indicated in the component il- lustrations by the ”D” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair.
Page 12 IN–6 INTRODUCTION – REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the prop- er locations (See page IN–8). Cancel the parking brake on the level place and shift the transmission in Neutral (or N position).
Page 13 IN–7 INTRODUCTION – REPAIR INSTRUCTIONS Installation and removal of vacuum hose: Example When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout.
Page 14 IN–8 INTRODUCTION – REPAIR INSTRUCTIONS IN0CP–03 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front..... Front crossmember Rear..... Rear axle beam CAUTION : When jacking–up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift ...........
Page 15 IN–9 INTRODUCTION – REPAIR INSTRUCTIONS PLATE TYPE LIFT Attachment HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position D Align the cushion gum ends of the plate with the attachment lower ends (A, C). D Align the attachment upper end (B) with the front jack supporting point (L).
Page 16: For All Of Vehicles
PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The 1999 CAMRY is equipped with an SRS (Supplemen- tal Restraint System), such as the driver airbag, front pas- senger airbag assembly, side airbag assembly and seat belt pretensioner.
Page 17 IN–11 INTRODUCTION – FOR ALL OF VEHICLES Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front pas- senger airbag assembly, side airbag assembly and seat belt pretensioner should be inspected (See page RS–16, RS–29, and BO–127).
Page 18 IN–12 INTRODUCTION – FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin–lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be dam- aged.
Page 19 IN–13 INTRODUCTION – FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY Always store a removed or new front passenger air- bag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag inflates.
Page 20 IN–14 INTRODUCTION – FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY Always store a removed or new side airbag assem- bly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag deploys.
Page 21 IN–15 INTRODUCTION – FOR ALL OF VEHICLES SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pre- tensioner. (This may cause the seat belt pretension- er to activate, which is very dangerous.) Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner in another vehicle.
Page 22 IN–16 INTRODUCTION – FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. The connectors to the airbag sensor assembly should be connected or disconnected with the sen- sor mounted on the floor.
Page 23 IN–17 INTRODUCTION – FOR ALL OF VEHICLES FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline.
Page 24 TOYOTA hand–held tester’s operator manual should be read thoroughly. Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand– held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Page 25 IN–19 INTRODUCTION – FOR ALL OF VEHICLES Press the TRAC cut switch to turn the TRAC to the operative mode and check that the TRAC OFF indi- cator light goes off. HINT: The SLIP indicator light blinks when the TRAC system in opera- tion.
Page 26 IN05Y–07 GENERAL INFORMATION A large number of ECU controlled systems are used in the 1999 CAMRY. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshoot- ing of these systems is not complex.
Page 27 IN–21 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05W–08 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit.
Page 28 IN–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Page 29 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the 1999 CAMRY fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting.
Page 30 IN–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshoot- ing using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnos- tic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table.
Page 31 IN–25 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle.
Page 32 IN–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs.
Page 33 IN–27 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble- shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed.
Page 34 IN–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring.
Page 35 IN–29 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item D Circuit Description The major role and operation, etc. of the circuit and its component parts are explained.
Page 36 IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS D Indicates the position of the ignition switch during the check. Inspection Procedure Use the inspection procedure to determine if LOCK Ignition Switch ON the circuit is normal or abnormal, and, if it is Ignition Switch LOCK (OFF) abnormal, use it to determine whether the START...
Page 37 IN–31 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05X–05 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
Page 38 IN–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals.
Page 39 IN–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.
Page 40 IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. Sensor As shown in Fig.
Page 41 IN–35 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector ”B” and measure the resis- Fig. 7 tance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. Between terminal 1 of connector ”A” and body Sensor ground No continuity...
Page 42 IN–36 INTRODUCTION – TERMS TERMS IN04Q–03 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air–Fuel Ratio Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna...
Page 43 IN–37 INTRODUCTION – TERMS Direct Current Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Distributorless Ignition DOHC Double Over Head Cam Dash Pot Dead Soak Digital Signal Processor ECAM Engine Control And Measurement System Electronic Controlled Diesel ECDY Eddy Current Dynamometer Electronic Control Unit...
Page 44 IN–38 INTRODUCTION – TERMS High Intensity Discharge (Head Lamp) Housing Hard Top Heated Windshield System Idle Air Control Integrated circuit Indirect Diesel Injection Independent Front Suspension Ignition Integrated Ignition Assembly Intake (Manifold, Valve) Intermittent Instrument Panel Independent Rear Suspension Junction Block Junction Connector Kick–Down Local Area Network...
Page 45 Special Service Materials Special Service Tools Standard Cold–Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS TOYOTA Computer–Controlled System Timing Control Valve Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Author : Date :...
Page 46 IN–40 INTRODUCTION – TERMS Total Information System For Vehicle Development Transmission TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge Underdrive Undersize Vacuum Control Valve VENT Ventilator Vehicle Identification Number Variable Power Steering Vehicle Skid Control Vehicle Stability Control...
Page 47 – TERMS IN0CI–01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their TOYOTA equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS...
Page 48 IN–42 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel–Shutoff – Idle Speed Control –...
Page 49 IN–43 INTRODUCTION – TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range – Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalytic (TWC) Three–Way Catalytic Converter Manifold Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow...
Page 50 SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT SS0ZS–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431 Author : Date :...
Page 51 SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZT–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class Class N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 – –...
Page 52 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 7N (5T) 10N (7T)
Page 53 SS–4 SERVICE SPECIFICATIONS – MAINTENANCE MAINTENANCE SS074–01 SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm (0 in.) Author : Date :...
Page 54 SS–5 SERVICE SPECIFICATIONS – MAINTENANCE SS075–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat mount bolts Front suspension member x Body 1,850 Rear suspension member x Body Author : Date :...
Page 55 SS–6 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) ENGINE MECHANICAL (5S–FE) SS0AD–03 SERVICE DATA Compression at 250 rpm STD 1,226 kPa (12.5 kgf/cm , 178 psi) or more pressure Minimum 981 kPa (10.0 kgf/cm , 142 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm , 14 psi) or less Valve...
Page 56 SS–7 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) Valve lifter Lifter diameter 30.966 – 30.976 mm (1.2191 – 1.2195 in.) Lifter bore diameter 31.000 – 31.018 mm (1.2205 – 1.2212 in.) Oil clearance 0.024 – 0.052 mm (0.0009 – 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Manifold...
Page 57 SS–8 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) Crankshaft Thrust clearance 0.020 – 0.220 mm (0.0008 – 0.0087 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 2.440 – 2.490 mm (0.0961 – 0.0980 in.) Main journal oil clearance STD No.3 STD 0.025 –...
Page 58 SS–9 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) SS0AE–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pump pulley x Oil pump drive shaft No.2 idler pulley x Oil pump Crankshaft pulley x Crankshaft 1,100 Camshaft timing pulley x Camshaft for use with SST No.1 idler pulley x Cylinder head Cylinder head x Cylinder block Turn 90°...
Page 59 SS–10 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) LH stiffener plate x Transaxle No.2 RH engine mounting bracket x Cylinder block No.2 RH engine mounting bracket x Generator bracket Rear engine mounting insulator x Cylinder block Front engine mounting insulator x Cylinder block Engine moving control rod x No.2 RH engine mounting bracket Engine moving control rod x Body Front engine mounting insulator x Front frame...
Page 60 SS–11 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) ENGINE MECHANICAL (1MZ–FE) SS076–02 SERVICE DATA Compression at 250 rpm STD 1,500 kPa (15.3 kgf/cm , 218 psi) pressure Minimum 1,000 kPa (10.2 kgf/cm , 145 psi) Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm , 15 psi) or less Valve...
Page 61 SS–12 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) Valve spring Deviation Maximum 2.0 mm (0.079 in.) Free length 45.50 mm (1.7913 in.) Installed tension at 33.8 mm (1.331 in.) 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) Valve lifter Lifter diameter 30.966 –...
Page 62 SS–13 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) Connecting Thrust clearance 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum 0.35 mm (0.0138 in.) Connecting rod thickness 20.80 – 20.85 mm (0.8189 – 0.8209 in.) Connecting rod bearing center wall thickness Reference Mark 1 1.484 –...
Page 63 SS–14 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) SS077–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Timing belt plate x Oil pump 69 in.·lbf No.1 idler pulley x Oil pump No.2 idler pulley x No.2 idler pulley bracket Camshaft timing pulley x Camshaft 1,300 for SST Timing belt tensioner x Oil pump...
Page 64 SS–15 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) No.2 RH engine mounting stay x No.2 Generator bracket RH engine mounting stay x Water outlet RH engine mounting stay x Engine moving control rod RH engine mounting stay x No.2 RH engine mounting bracket Front engine mounting insulator x Front frame TMC made TMMK made...
Page 65 SS–16 SERVICE SPECIFICATIONS – EMISSION CONTROL (5S–FE) EMISSION CONTROL (5S–FE) SS0AF–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf EGR valve x Intake manifold 13.3 EGR valve x EGR pipe Exhaust manifold x Cylinder head Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe Author : Date :...
Page 66 SS–17 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) EMISSION CONTROL (1MZ–FE) SS078–01 SERVICE DATA EGR valve Resistance (VC – E2) 1.5 – 4.3 kΩ position Power source voltage (VC– E2) 4.5 – 5.5 V sensor Power output voltage (EGLS – E2) at vacuum (17.3 kPa, 130 mmHg, 5.1 in.Hg) 3.2 –...
Page 67 SS–18 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) SS079–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf EGR valve position sensor x EGR valve 17 in.·lbf EGR pipe x EGR valve EGR pipe x EGR cooler EGR valve x Air intake chamber EGR gas temperature sensor x EGR valve Front exhaust pipe x Exhaust manifold Front exhaust pipe x Center exhaust pipe...
Page 68 SS–19 SERVICE SPECIFICATIONS – SFI (5S–FE) SFI (5S–FE) SS0AG–03 SERVICE DATA Fuel pressure Fuel pressure at no vacuum 301 – 347 kPa (3.1 – 3.5 kgf/cm , 44 – 50 psi) regulator at 20°C (68°F) 0.2 – 3.0 Ω Fuel pump Resistance 13.4 –...
Page 69 SS–20 SERVICE SPECIFICATIONS – SFI (5S–FE) SS0AH–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fuel line Union bolt type Flare nut type for use with SST Fuel pump assembly x Fuel tank 35 in.·lbf Fuel filter x Fuel pump bracket 17 in.·lbf Fuel pressure regulator x Fuel pump bracket 17 in.·lbf...
Page 70 SS–21 SERVICE SPECIFICATIONS – SFI (1MZ–FE) SFI (1MZ–FE) SS109–02 SERVICE DATA Fuel pressure Fuel pressure at no vacuum 301 – 347 kPa (3.1 – 3.5 kgf/cm , 44 – 50 psi) regulator at 20°C (68°F) 0.2 – 3.0 Ω Fuel pump Resistance 13.4 −...
Page 71 SS–22 SERVICE SPECIFICATIONS – SFI (1MZ–FE) SS10A–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Fuel line (Union bolt type) Fuel line (Flare nut type) using SST Fuel pump assembly x Fuel tank 35 in.·lbf Fuel filter x Fuel pump bracket 17 in.·lbf Fuel pressure regulator x Fuel pump bracket 17 in.·lbf...
Page 72 SS–23 SERVICE SPECIFICATIONS – COOLING (5S–FE) COOLING (5S–FE) SS0AI–03 SERVICE DATA Thermostat Valve opening temperature 80 – 84°C (176 – 183°F) Valve lift at 95°C (203°F) 8 mm (0.31 in.) or more Radiator cap Relief valve opening pressure 74 – 103 kPa (0.75 – 1.05 kgf/cm , 10.7 –...
Page 73 SS–24 SERVICE SPECIFICATIONS – COOLING (5S–FE) SS0AJ–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Cylinder block x Drain plug Water pump x Water pump cover, Cylinder block 78 in.·lbf Water bypass pipe x Water pump cover 82 in.·lbf Generator drive belt adjusting bar x Cylinder block Water inlet x Water pump cover 78 in.·lbf Oil cooler x Radiator lower tank...
Page 74 SS–25 SERVICE SPECIFICATIONS – COOLING (1MZ–FE) COOLING (1MZ–FE) SS07C–01 SERVICE DATA Thermostat Valve opening pressure 80 – 84°C (176 – 183°F) Valve lift at 95°C (203°F) 10.0 mm (0.394 in.) or more Radiator cap Relief valve opening pressure 83 – 113 kPa (0.85 – 1.15 kgf/cm , 12.1 –...
Page 75 SS–26 SERVICE SPECIFICATIONS – COOLING (1MZ–FE) SS07D–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf RH engine drain plug x EGR cooler 61 in.·lbf LH engine drain plug x Union on cylinder block Water pump x Cylinder block 69 in.·lbf Water inlet x Water inlet housing 69 in.·lbf Water inlet pipe x LH cylinder head 19.5...
Page 76 SS–27 SERVICE SPECIFICATIONS – LUBRICATION (5S–FE) LUBRICATION (5S–FE) SS0AK–03 SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf/cm , 4.3 psi) or more at 3,000 rpm 245 – 490 kPa (2.5 – 5.0 kgf/cm , 36 – 71 psi) Oil pump Body clearance 0.10 –...
Page 77 SS–28 SERVICE SPECIFICATIONS – LUBRICATION (5S–FE) SS0AL–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pan x Drain plug Oil pump body cover x Oil pump body 78 in.·lbf Oil pump x Cylinder block 78 in.·lbf Oil strainer x Engine balancer 48 in.·lbf Oil strainer x Oil pump 48 in.·lbf...
Page 78 SS–29 SERVICE SPECIFICATIONS – LUBRICATION (1MZ–FE) LUBRICATION (1MZ–FE) SS07E–01 SERVICE DATA Oil pressure at idle speed 29 kPa (0.3 kgf/cm , 43 psi) or more at 3,000 rpm 294 – 539 kPa (3.0 – 5.5 kgf/cm , 43 – 78 psi) Oil pump Side clearance 0.030 –...
Page 79 SS–30 SERVICE SPECIFICATIONS – LUBRICATION (1MZ–FE) SS07F–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pressure switch x Cylinder block No.2 oil pan x Drain plug Oil pump x Relief valve plug 36.8 Oil pump x Cylinder block 10 mm head 69 in.·lbf 12 mm head 19.5...
Page 80 SS–31 SERVICE SPECIFICATIONS – IGNITION (5S–FE) IGNITION (5S–FE) SS0AM–03 SERVICE DATA Firing order – 1 – 3 – 4 – 2 High–tension Resistance Maximum 25 kΩ per cord cord Spark plug Recommended spark plug DENSO made PK20TR11 NGK made BKR6EKPB11 Correct electrode gap for new spark plug 1.1 mm (0.043 in.) Maximum electrode gap for used spark plug...
Page 81 SS–32 SERVICE SPECIFICATIONS – IGNITION (5S–FE) SS0AN–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Ignition coil x No.2 intake manifold stay 87 in.·lbf No.2 intake manifold stay x Cylinder head No.2 intake manifold stay x Intake manifold Camshaft position sensor assembly x Cylinder head 84 in.·lbf Crankshaft position sensor x Oil pump...
Page 82 SS–33 SERVICE SPECIFICATIONS – IGNITION (1MZ–FE) IGNITION (1MZ–FE) SS07G–02 SERVICE DATA Firing order – 1 – 2 – 3 – 4 – 5 – 6 High–tension Resistance Maximum 25 kΩ per cord cord Spark plug Recommended spark plug DENSO made PK20TR11 NGK made BKR6EKPB11...
Page 83 SS–34 SERVICE SPECIFICATIONS – IGNITION (1MZ–FE) SS07H–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head Ignition coil x Cylinder head 69 in.·lbf Camshaft position sensor x Cylinder head 69 in.·lbf Crankshaft position sensor x Oil pump 69 in.·lbf Author : Date :...
Page 84 SS–35 SERVICE SPECIFICATIONS – STARTING (5S–FE) STARTING(5S–FE) SS0AO–01 SERVICE DATA Starter Rated voltage and output power 12 V 1.2 kW, 1.4 kW No–load characteristics Current 90 A or less at 11.5 V 3,000 rpm or more Brush length 15.5 mm (0.610 in.) Minimum 10.0 mm (0.394 in.) Spring installed load...
Page 85 SS–36 SERVICE SPECIFICATIONS – STARTING (5S–FE) SS0AP–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter mounting bolt End cover x Field frame 13 in.·lbf Starter housing x Magnetic switch 52 in.·lbf Field frame x Armature assembly 52 in.·lbf Lead wire x Terminal C of starter 52 in.·lbf Terminal nut x Terminal C of starter Terminal nut x Terminal 30 of starter...
Page 86 SS–37 SERVICE SPECIFICATIONS – STARTING (1MZ–FE) STARTING (1MZ–FE) SS07I–01 SERVICE DATA Starter Rated voltage and output power 12 V 1.4 kW No–load characteristics Current 90 A or less at 11.5 V 3,000 rpm or more Brush length 15.5 mm (0.610 in.) Minimum 10.0 mm (0.394 in.) Spring installed load...
Page 87 SS–38 SERVICE SPECIFICATIONS – STARTING (1MZ–FE) SS07J–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter mounting bolt End cover x Field frame 13 in.·lbf Starter housing x Magnetic switch 52 in.·lbf Field frame x Armature assembly 52 in.·lbf Lead wire x Terminal C of starter 52 in.·lbf Terminal nut x Terminal C of starter Terminal nut x Terminal 30 of starter...
Page 88 SS–39 SERVICE SPECIFICATIONS – CHARGING (5S–FE) CHARGING(5S–FE) SS0AQ–01 SERVICE DATA Battery Specific gravity (Except maintenance–free battery) at 20°C (68°F) 1.25 – 1.29 Voltage (Maintenance–free battery) at 20°C (68°F) 12.5 – 12.9 V 165 ± 25 lbf Drive belt Tension w/ A/C New belt 110 ±...
Page 89 SS–40 SERVICE SPECIFICATIONS – CHARGING (5S–FE) SS0AR–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 27 in.·lbf Rectifier end frame x Drive end frame 40 in.·lbf Wire clip x Rectifier end frame 48 in.·lbf Generator pulley x Rotor 110.5 1,125 Rectifier holder x Coil lead on rectifier end frame...
Page 90 SS–41 SERVICE SPECIFICATIONS – CHARGING (1MZ–FE) CHARGING (1MZ–FE) SS07K–01 SERVICE DATA Battery Voltage at 20°C (68°F) 12.5 – 12.9 V Drive belt Tension 175 ± 5 lbf New belt 115 ± 20 lbf Used belt Generator Rated output 12 V 80 A 2.1 –...
Page 91 SS–42 SERVICE SPECIFICATIONS – CHARGING (1MZ–FE) SS07L–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 27 in.·lbf Rectifier end frame x Drive end frame 40 in.·lbf Cord clip x Rectifier end frame 48 in.·lbf Generator pulley x Rotor 110.5 1,125 Rectifier holder x Coil lead on rectifier end frame...
Page 92 SS–43 SERVICE SPECIFICATIONS – CLUTCH CLUTCH SS09Q–01 SERVICE DATA Pedal height from asphalt sheet 1MZ–FE 161.8 – 171.8 mm (6.370 – 6.764 in.) Pedal height from asphalt sheet 5S–FE 156.8 – 166.8 mm (6.173 – 6.567 in.) Push rod play at pedal top 1.0 –...
Page 93 SS–44 SERVICE SPECIFICATIONS – CLUTCH SS09R–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder installation nut Clutch line Release cylinder installation bolt Bleeder plug 74 in.·lbf Cruise control actuator bracket x Body Starter x Transaxle Clutch accumulator installation bolt Clutch accumulator installation nut Release fork support 1MZ–FE...
Page 94 SS–45 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE (E153) SS09O–01 SERVICE DATA Input shaft 3rd & 4th gears journal diameter Min. 35.950 mm (1.4154 in.) 5th gear journal diameter Min. 27.950 mm (1.1004 in.) Runout Max. 0.05 mm (0.0020 in.) Output shaft 1st &...
Page 95 SS–46 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) Input shaft snap ring thickness Mark No.3 clutch hub 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0729 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0847 in.)
Page 96 SS–47 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) Output shaft bearing preload (at starting) New bearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) Reused bearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf) Output shaft rear bearing adjusting shim thickness Mark 1.30 mm (0.0512 in.)
Page 97 SS–48 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) SS09P–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transaxle x Engine 17 mm head 14 mm head A (See page MX–4) 14 mm head B Cruise control actuator x Body (w/ Cruise control) Starter x Transaxle Clutch release cylinder x Transaxle Clutch acummulator x Transaxle...
Page 98 SS–49 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) Transmission oil pump assembly x Transaxle case Transaxle case receiver x Transaxle case 65 in.·lbf Clutch release fork support Control lever housing support bracket x Transaxle case Vehicle speed sensor Clutch release line bracket x Transaxle case Back–up light switch Filler and drain plug No.1 and No.2 oil receiver pipe x Transmission case...
Page 99 SS–50 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE (S51) SS09M–01 SERVICE DATA Input shaft roller bearing journal diameter Min. 29.970 mm (1.799 in.) Input shaft 3rd gear journal diameter Min. 33.090 mm (1.3028 in.) Input shaft 4th gear journal diameter Min.
Page 100 SS–51 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) Input shaft snap ring thickness Input shaft snap ring thickness No.2 clutch hub No.2 clutch hub Mark 1 1.95 – 2.00 mm (0.0768 – 0.0787 in.) Mark 1 1.95 2.00 mm (0.0768 0.0787 in.) Mark 2 2.00 –...
Page 101 SS–52 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) SS09N–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transaxle x Engine Transaxle x Engine 17 mm head 17 mm head 14 mm head Cruise control actuator x Body (w/ Cruise control) Starter x Transaxle Clutch release cylinder x Transaxle Clutch line bracket x Transaxle Clutch line bracket x Transaxle...
Page 102 SS–53 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) Engine mount bracket x Transaxle Reverse shift arm bracket No.3 shift fork x Shift fork shaft Lock ball assembly Filler and Drain plugs Back–up light switch Differential side bearing retainer Release bearing retainer 65 in.·lbf Straight screw plug Vehicle speed sensor driven gear...
Page 103 SS–54 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE (A140E) SS0AS–01 SERVICE DATA Line pressure (Wheel locked) Engine idling D position 363 – 422 kPa (3.7 – 4.3 kgf/cm , 53 – 61 psi) R position 618 – 794 kPa (6.3 – 8.1 kgf/cm , 90 –...
Page 104 SS–55 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A140E) SS0AT–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transaxle x Starter Transaxle x Rear end plate Transaxle x No.1 exhaust pipe support bracket Transaxle x Engine Torque converter clutch x Drive plate Body x Front lower brace Bolt 1,850 Body x Rear lower brace...
Page 105 SS–56 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) AUTOMATIC TRANSAXLE (A541E) SS0BL–01 SERVICE DATA Line pressure (wheel locked) Engine idling D position 401 – 461 kPa (4.1 – 4.7 kgf/cm , 58 – 66 psi) R position 804 – 882 kPa (8.2 – 9.0 kgf/cm , 117 –...
Page 106 SS–57 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) SS0BM–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front engine front mounting insulator x Front frame assembly TMC: TMMK: Green color bolt Silver color bolt Rear engine mounting insulator x Front frame assembly LH transaxle mounting insulator x Transaxle Engine mounting absorber x Front frame assembly Transaxle x Engine...
Page 107 SS–58 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) Front wheel nut 1,050 Exhaust front pipe support bracket x Body PS reseroir pipe x Front frame Engine hood x Hood hinge Author : Date :...
Page 108 SS–59 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SUSPENSION AND AXLE SS04W–01 SERVICE DATA Front, Rear* 210 kPa (2.1 kgf/cm , 30 psi) P195/70R14 90S P195/70R14 90S Cold tire inflation Front, Rear* 210 kPa (2.1 kgf/cm , 30 psi) pressure Front, Rear* 220 kPa (2.2 kgf/cm , 32 psi) (Normal driving)
Page 109 SS–60 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE Axle bearing backlash 0.05 mm (0.0020 in.) Front axle Axle hub deviation 0.05 mm (0.0020 in.) Drive shaft standard length 609.2 ± 2.0 mm (23.984 ± 0.079 in.) 5S – FE 867.3 ± 2.0 mm (34.146 ± 0.079 in.) 601.5 ±...
Page 110 SS–61 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SS04X–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT: Hub nut 1,050 Tie rod end lock nut Steering knuckle x Shock absorber 2,150 Steering knuckle x Brake caliper 1,090 Steering knuckle x Tie rod end Axle hub x Drive shaft 3,000 Lower ball joint x Lower suspension arm...
Page 111 SS–62 SERVICE SPECIFICATIONS – BRAKE BRAKE SS09X–01 SERVICE DATA Brake pedal height (from asphalt sheet) 152.0 – 162.0 mm (5.984 – 6.378 in.) Brake pedal freeplay 1 – 6 mm (0.04 – 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) More than 70 mm (2.76 in.) Brake booster push rod to piston clearance (w/SST) 0 mm (0 in.)
Page 112 SS–63 SERVICE SPECIFICATIONS – BRAKE SS09Y–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder x Piston stopper bolt Master cylinder x Reservoir 16 in.·lbf Master cylinder x Brake booster Brake line union nut 10 mm nut 12 mm nut Brake booster clevis lock nut Brake booster x Pedal bracket Brake pedal x Pedal bracket...
Page 113 SS–64 SERVICE SPECIFICATIONS – STEERING STEERING SS06L–03 SERVICE DATA ON–VEHICLE INSPECTION Steering wheel freeplay Maximum 30 mm (1.18 in.) 5S–FE Engine : Drive belt tension New belt 95 – 145 lbf Drive belt tension Used belt 60 – 100 lbf 1MZ–FE Engine : Drive belt tension New belt 150 –...
Page 114 SS–65 SERVICE SPECIFICATIONS – STEERING SS06M–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf STEERING COLUMN Steering wheel pad set screw (Torx screw) 63 in.·lbf Steering wheel set nut Intermediate shaft assembly x Control valve shaft Steering column assembly x Intermediate shaft assembly Steering column assembly set nut Turn signal bracket x Column tube 61 in.·lbf...
Page 115 SS–66 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS061–17 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel Steering wheel pad 63 in.·lbf Front passenger airbag assembly x Instrument panel reinforcement Front seat installation bolt Seatback frame set bolt Bolt A (See page RS–49) Bolt B...
Page 116 SS–67 SERVICE SPECIFICATIONS – BODY ELECTRICAL BODY ELECTRICAL SS0B0–05 SERVICE DATA TURN SIGNAL FLASHER Flashes/ Minute 60 – 120 SPEEDOMETER (ON–VEHICLE) USA: Standard indication (mph) Allowable range (mph) 18 – 24 38 – 44 56 – 66 78 – 88 98 –...
Page 117 SS–68 SERVICE SPECIFICATIONS – BODY ELECTRICAL Approx. 229.7 Ω B – C ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature °C (°F) Resistance (Ω) 50 (122.0) 120 (248.0) 26.4 Author : Date :...
Page 118 SS–69 SERVICE SPECIFICATIONS – BODY BODY SS0BY–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT BUMPER – – – Front bumper cover x Body 49 in.·lbf Front bumper reinforcement x Body REAR BUMPER – – – Rear bumper cover x Body 43 in.·lbf Rear bumper reinforcement x Body HOOD...
Page 119 SS–70 SERVICE SPECIFICATIONS – BODY Front seat inner upper track x Seat cushion Side Airbag assembly x Seatback frame Seatback assembly x Seat cushion frame 53 in.·lbf Front Seat (Power Seat for TMMK Made) – – – Side airbag assembly x Seat cushion frame 53 in.·lbf Front Seat (Manual Seat for TMC Made) –...
Page 120 SS–71 SERVICE SPECIFICATIONS – AIR CONDITIONING AIR CONDITIONING SS05V–02 SERVICE DATA 800 ± 50 g (28.22 ± 1.76 oz.) Refrigerant charge volume Drive belt tension – New belt 165 ± 26 lbf Used belt 110 ± 11 lbf Idle–up speed –...
Page 121 SS–72 SERVICE SPECIFICATIONS – AIR CONDITIONING SS05W–06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Discharge hose Compressor x Suction hose Condenser x Disaharge hose Condenser x Liquid tube Receiver x Liquid tube 48 in.·lbf Expansion valve x Evaporator 48in.·lbf Compressor x Engine Compressor x Compressor bracket (1MZ–FE Only)
Page 122 Turn the control lever and dials left and right then check that click sound can be heard and recoil is felt. If click sound can not be heard or recoil is felt, adjust the control cable or check control cable and heater control assembly. 2001 CAMRY (RM819U) Author : Date :...
Page 123 Scuff Plate Front Door Inside Scuff Plate Blower Speed Control Switch Mode Switch A/C Switch Air Intake Switch Defogger Switch Heater Control Name Sheet Heater Control Base Heater Control Knob I12253 I12254 I12260 2001 CAMRY (RM819U) Author : Date : 2582...
Page 124 When the air mix damper control cable is disconnected, should not bend the cable. Air Mix Damper Control Cable I12255 REMOVE A/C CONTROL ASSEMBLY Remove the 4 screws and pull out the A/C control assembly, then disconnect the connector. I12256 2001 CAMRY (RM819U) Author : Date : 2583...
Page 125 Remove the 2 screws and pull out the switch. REMOVE HEATER CONTROL NAME SHEET Remove the 2 screws. Using a screwdriver, release the 4 claws and heater control name sheet. HINT: Tape the screwdriver tip before use. 2001 CAMRY (RM819U) Author : Date : 2584...
Page 126 Push the Air Intake button, then the indicator lights up. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. I12283 2001 CAMRY (RM819U) Author : Date : 2585...
Page 127 1 – 5 Continuity FOOT 1 – 4 Continuity FOOT/DEF. 1 – 3 Continuity 1 – 2 DEF. Continuity 7 – 8 N20257 If continuity is not as specified, replace the switch. 2001 CAMRY (RM819U) Author : Date : 2586...
Page 128 If circuit is as specified, try replacing the air intake switch with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. INSPECT REAR DEFOGGER SWITCH OPERATION (See page BE–57) 2001 CAMRY (RM819U) Author : Date : 2587...
Page 129 A/C unit and clamp the cable outer on condition. NOTICE: Don’t bend the cable on setting the cable. Clamp Don’t move the air mix nob before finishing on clamp- ing the cable outer. N20239 2001 CAMRY (RM819U) Author : Date : 2589...
Page 130: Air Conditioning System
AC–1 AIR CONDITIONING – AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM AC0LG–02 PRECAUTION DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR WEAR EYE PROTECTION ALWAYS WEAR EYE PROTECTION AC2810 BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin.
Page 131 – AIR CONDITIONING SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The CAMRY is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and passenger airbag. Fail- ure to carry out service operations the correct sequence could cause the SRS to unexpectedly deployed during servicing, pos- sible the SRS may fail to operate when required.
Page 132 AC–3 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LI–02 ON–VEHICLE INSPECTION Sight Glass INSPECT REFRIGERANT VOLUME Observe the sight glass on the liquid tube. Test conditions: Running engine at 1,500 rpm Blower speed control switch at ”HI” position A/C switch ON Temperature control dial at ”COOL”...
Page 133 AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT REFRIGERANT PRESSURE WITH MAN- IFOLD GAUGE SET This is a method in which the trouble is located by using a man- ifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30 –...
Page 134 AC–5 AIR CONDITIONING – AIR CONDITIONING SYSTEM Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I01387 Symptom seen in Probable cause Diagnosis Remedy refrigeration system z Drier oversaturated state Moisture entered in refrigeration (1) Replace receiver z Moisture in refrigeration system During operation, pressure on low system freezes at expansion valve...
Page 135 AC–6 AIR CONDITIONING – AIR CONDITIONING SYSTEM Poor circulation of refrigerant Condition: Insufficient cooling I01389 Symptom seen in Probable cause Diagnosis Remedy refrigeration system z Pressure low in both low and high pressure sides Refrigerant flow obstructed by dirt Receiver clogged Replace receiver z Frost on tube from receiver to in receiver...
Page 136 AC–7 AIR CONDITIONING – AIR CONDITIONING SYSTEM Refrigerant overcharged or insufficient cooling of condenser Condition: Insufficient cooling I01390 Symptom seen in Probable cause Diagnosis Remedy refrigeration system (1) Clean condenser z Pressure too high on both low z Excessive refrigerant in (2) Check condenser fan motor z Unable to develop sufficient per- and high pressure sides...
Page 137 AC–8 AIR CONDITIONING – AIR CONDITIONING SYSTEM Expansion valve improperly Condition: Insufficient cooling I01450 Symptom seen in Probable cause Diagnosis Remedy refrigeration system z Pressure too high on both low z Excessive refrigerant in low and high pressure sides pressure piping Check expansion valve Trouble in expansion valve z Frost or large amount of dew on...
Page 138 AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT IDLE–UP SPEED Warm up engine. Inspect idle–up speed when the these conditions are es- tablished. Warm up engine Blower speed control switch at ”HI” position A/C switch ON Temperature control dial at ”COOL” position Magnetic clutch condition Idle–up speed 700 ±...
Page 139 AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LJ–03 EVACUATING CONNECT QUICK DISCONNECT ADAPTER TO Quick Disconnect Adapter CHARGING HOSES Charging REMOVE CAPS FROM SERVICE VALVES ON RE- Hose FRIGERANT LINES SET ON MANIFOLD GAUGE SET Close both hand valves of manifold gauge set. Service Valve Connect the quick disconnect adapters to the service valves.
Page 140 AC–11 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC21S–01 CHARGING INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the direc- Push tions given in the instruction manual. Charge the proper amount of refrigerant into the charging cylinder. Connect the center hose to the charging cylinder. Low Pressure CAUTION: Service Valve...
Page 141 AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHARGE REFRIGERANT INTO REFRIGERANT SYS- If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system. CAUTION: Never run the engine when charging the system through the high pressure side. Do not open the low pressure hand valve when the system is being charged with liquid refrigerant.
Page 142 AC–13 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LL–02 LOCATION 1MZ–FE engine: 1MZ–FE engine: No. 1 Engine Coolant Temperature No. 2 Engine Coolant Temperature (ECT) Switch (ECT) Switch Compressor Engine Room Relay Block No. 1 z Magnetic Clutch Relay Condenser Fan (Marking: MG CLT) z Fan Motor z Heater Main Relay...
Page 143 AC–14 AIR CONDITIONING – TROUBLESHOOTING TROUBLESHOOTING AC21T–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The 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...
Page 144 AC–15 AIR CONDITIONING – TROUBLESHOOTING 1. Refrigerant volume AC–3 2. Drive belt AC–16 3. Magnetic clutch AC–16 4. Compressor AC–39 5. Condenser AC–52 6. Condenser fan AC–74 7. Receiver AC–49 Cool air comes out only at high engine rpm 8. Expansion valve AC–59 9.
Page 145 AC–16 AIR CONDITIONING – DRIVE BELT DRIVE BELT AC0LM–02 ON–VEHICLE INSPECTION INSPECT DRIVE BELT’S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. Correct Wrong CH0086 INSPECT DRIVE BELT TENSION Generator Using a belt tension gauge, check the drive belt tension. Drive belt tension: Crankshaft Pulley New belt: 165 ±...
Page 146 AC–17 AIR CONDITIONING – DRIVE BELT AC0LN–02 REMOVAL 5S–FE: Pivot Bolt REMOVE DRIVE BELT Loosen the pivot bolt and adjusting lock bolt. Torque: Adjusting Bolt 5S–FE: Pivot bolt: 52 N·m (530 kgf·cm, 38 ft·lbf) Adjusting Lock Adjusting lock bolt: 18 N·m (185 kgf·cm, 13 ft·lbf) Bolt Drive Belt 1MZ–FE:...
Page 147 AC–18 AIR CONDITIONING – DRIVE BELT AC0LO–01 INSTALLATION Installation is in the reverse order of removal (See page AC–17). Author : Date : 2500...
Page 148: Manifold Gauge Set
AC–19 AIR CONDITIONING – MANIFOLD GAUGE SET MANIFOLD GAUGE SET AC0LP–02 SET ON CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE REMOVE CAPS FROM SERVICE VALVES ON RE- FRIGERANT LINE...
Page 149 AC–20 AIR CONDITIONING – MANIFOLD GAUGE SET AC0LQ–02 SET OFF CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to un- lock the adapter and remove it from the service valve. INSTALL CAPS TO SERVICE VALVES ON REFRIGER- N06553 ANT LINE...
Page 150: Refrigerant Line
AC–21 AIR CONDITIONING – REFRIGERANT LINE REFRIGERANT LINE AC0LR–01 ON–VEHICLE INSPECTION INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Author : Date : 2503...
Page 151 AC–22 AIR CONDITIONING – REFRIGERANT LINE AC0LS–02 LOCATION Liquid Tube Suction Tube Piping Clamp 32 (330, 24) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) Liquid Tube 10 (100, 7) 14 (140, 10) 10 (100, 7) Suction Hose Discharge Hose 10 (100, 7)
Page 152 AC–23 AIR CONDITIONING – REFRIGERANT LINE AC0LT–03 REPLACEMENT DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torque.
Page 153 AC–24 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT AC21U–01 ON–VEHICLE INSPECTION INSPECT FOR LEAKAGE OF REFRIGERANT Remove glove compartment (See page BO–75). Remove the blower resistor. Disconnect the connector. Remove the 2 screws and blower resistor. Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints or check the evaporator.
Page 154 AC–25 AIR CONDITIONING – AIR CONDITIONING UNIT AC21V–01 COMPONENTS Instrument Panel Reinforcement No. 1 Brace No. 2 Brace Water Hose Piping Clamp Suction Tube Liquid Tube A/C Unit Piping Clamp z O–ring z O–ring Blower Motor Air Duct (Foot) Air Duct (Rear Foot) z Non–reusable part Connector Bracket I07050...
Page 155 AC–26 AIR CONDITIONING – AIR CONDITIONING UNIT Heater Protector Heater Radiator Pipe z Packing z O–ring z O–ring Heater Radiator Grommet Heater Case z Packing Plate Tube and Accessory 5.4 (55, 48) Expansion Valve z O–ring Air Outlet Servomotor z Water Seal z O–ring 5.4 (55, 48) Thermistor...
Page 156 AC–27 AIR CONDITIONING – AIR CONDITIONING UNIT AC21W–01 REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrig- erant.
Page 157 AC–28 AIR CONDITIONING – AIR CONDITIONING UNIT Inert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. I03838 Push down SST and release the clamp lock. Pull NOTICE: Push...
Page 158 AC–29 AIR CONDITIONING – AIR CONDITIONING UNIT AC21X–01 DISASSEMBLY REMOVE AIR OUTLET SERVOMOTOR Release the claw and pull out the plate. Remove the 3 screws and servomotor. REMOVE HEATER RADIATOR Remove the 3 screws and 3 plates. Remove the 2 clips and heater radiator pipes. Pull out the heater radiator.
Page 159 AC–30 AIR CONDITIONING – AIR CONDITIONING UNIT AC21Y–01 INSPECTION CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. CHECK FITTING FOR CRACKS OR SCRATCHES Repair as necessary. INSPECT THERMISTOR RESISTANCE Thermometer Place the thermistor in cold water, and while changing the...
Page 160 AC–31 AIR CONDITIONING – AIR CONDITIONING UNIT AC0LX–02 REASSEMBLY INSTALL THERMISTOR TO EVAPORATOR INSTALL EVAPORATOR Install the plate to the evaporator. Install the evaporator on the insulator. Connect the heater case with the 13 screws. NOTICE: The packing for water seal should be replaced, with a new one when the A/C unit is reassembled.
Page 161 AC–32 AIR CONDITIONING – AIR CONDITIONING UNIT Lubricate 2 new O–rings with compressor oil and install the expansion valve. Install the expansion valve with the tubes to evaporator with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator.
Page 162 AC–33 AIR CONDITIONING – AIR CONDITIONING UNIT AC0LY–01 INSTALLATION Installation is in the reverse order of removal (See page AC–27). Author : Date : 2515...
Page 163: Blower Unit
AC–34 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT AC0LZ–02 COMPONENTS Connector Bracket Glove Compartment Air Inlet Damper Cowl Side Trim Blower Unit Control Cable 1MZ–FE engine: A/C Amplifier Foot Air Duct Front Door No.2 Lower Cover Inside Scuff Plate Blower Resistor Blower Motor Connector Connecter Blower Unit Case...
Page 164 AC–35 AIR CONDITIONING – BLOWER UNIT AC0M0–02 REMOVAL REMOVE COWL SIDE TRIM REMOVE FRONT DOOR INSIDE PLATE LH REMOVE NO. 2 LOWER COVER REMOVE GLOVE COMPARTMENT REMOVE ECM Disconnect the connectors. Remove the 2 nuts and ECM. DISCONNECT AIR INLET DAMPER CONTROL CABLE HINT: At the in time of installation, please refer to following item.
Page 165 AC–36 AIR CONDITIONING – BLOWER UNIT AC0M1–01 DISASSEMBLY REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. Author : Date : 2518...
Page 166 AC–37 AIR CONDITIONING – BLOWER UNIT AC0M2–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–36). Author : Date : 2519...
Page 167 AC–38 AIR CONDITIONING – BLOWER UNIT AC0M3–01 INSTALLATION Installation is in the reverse order of removal (See page AC–35). Author : Date : 2520...
Page 168 AC–39 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH AC0M4–02 ON–VEHICLE INSPECTION INSPECT COMPRESSOR FOR METALLIC SOUND Start engine. Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound is heard, replace the compressor assembly. INSPECT REFRIGERANT PRESSURE See ”ON–VEHICLE INSPECTION”...
Page 169 AC–40 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M5–02 COMPONENTS 5S–FE engine : z O–Ring 10 (100, 7) Suction Hose 10 (100, 7) Discharge Hose z O–Ring 25 (250, 18) Compressor 1MZ–FE engine : 56 (570, 41) Generator Drive Belt z O–Ring 10 (100, 7) Discharge Hose...
Page 170 AC–41 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M6–02 REMOVAL RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX.10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REMOVE DRIVE BELT (See page AC–17) 1MZ–FE engine models: REMOVE SUCTION HOSE Remove the suction hose clamping bolt.
Page 171 AC–42 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH 5S–FE engine models: 5S–FE DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect both hoses. NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. N20261 5S–FE engine models: 5S–FE...
Page 172 AC–43 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M7–02 DISASSEMBLY REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. 07112–76060 Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) AC0943 Install SST on the pressure plate. 07112–66040 AC0944 Using SST and socket wrench, remove the pressure plate.
Page 173 AC–44 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH NOTICE: At the time of reassembly, please refer to the following Snap Ring item. The snap ring should be installed so that beveled side faces up. R–Shape Rotor Compressor N20013 Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the ro- tor.
Page 174 AC–45 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH Remove the stator. Stator AC0951 Author : Date : 2527...
Page 175 AC–46 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M8–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–43). AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the pressure plate of the magnetic clutch. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.
Page 176 AC–47 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M9–02 INSTALLATION 5S–FE engine models: INSTALL COMPRESSOR Install the compressor with 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the connector. 1MZ–FE engine models: INSTALL COMPRESSOR Install the compressor with 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Install the drive belt adjusting bar bracket with 2 bolts and nut.
Page 177 AC–48 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH 1MZ–FE engine models: CONNECT DISCHARGE HOSE Connect the discharge hose with the bolt. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Hoses should be connected immediately after the caps have been removed. HINT: Lubricate a new O–ring with compressor oil and install the tube.
Page 178 AC–49 AIR CONDITIONING – RECEIVER RECEIVER AC0MA–01 ON–VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints. Author : Date : 2531...
Page 179 AC–50 AIR CONDITIONING – RECEIVER AC0MB–02 REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrig- erant. Specified amount: 800 ±...
Page 180 AC–51 AIR CONDITIONING – RECEIVER AC0MC–01 INSTALLATION Installation is in the reverse order of removal (See page AC–50). Author : Date : 2533...
Page 181 AC–52 AIR CONDITIONING – CONDENSER CONDENSER AC0MD–01 ON–VEHICLE INSPECTION INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant.
Page 182 AC–53 AIR CONDITIONING – CONDENSER AC0ME–02 REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrig- erant. Specified amount: 800 ±...
Page 183 AC–54 AIR CONDITIONING – CONDENSER REMOVE CONDENSER Remove the 2 nuts from condenser upper mountings. Push the radiator toward the engine. Push the condenser toward the radiator and pull it up- ward. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the compressor.
Page 184 AC–55 AIR CONDITIONING – CONDENSER AC0MF–01 INSTALLATION Installation is in the reverse order of removal (See page AC–53). Author : Date : 2537...
Page 185: Heater Radiator
AC–56 AIR CONDITIONING – HEATER RADIATOR HEATER RADIATOR AC21Z–01 REMOVAL DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. DISCONNECT WATER HOSES FROM A/C UNIT (See page AC–27) REMOVE NO. 1 LOWER INSTRUMENT PANEL REMOVE LH INSTRUMENT LOWER PANEL REMOVE HEATER RADIATOR Release the 3 claws and pull out the heater protector.
Page 186 AC–57 AIR CONDITIONING – HEATER RADIATOR AC0MK–01 INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Author : Date : 2539...
Page 187 AC–58 AIR CONDITIONING – HEATER RADIATOR AC0ML–01 INSTALLATION Installation is in the reverse order of removal (See page AC–56). Author : Date : 2540...
Page 188: Expansion Valve
AC–59 AIR CONDITIONING – EXPANSION VALVE EXPANSION VALVE AC0MM–02 ON–VEHICLE INSPECTION CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE SET ON MANIFOLD GAUGE SET (See page AC–19) RUN ENGINE Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 – 1.57 MPa (14 – 16 kgf/cm , 199 –...
Page 189 AC–60 AIR CONDITIONING – EXPANSION VALVE AC220–01 REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM DISCONNECT LIQUID AND SUCTION TUBES FROM A/C UNIT (See page AC–27) REMOVE BLOWER UNIT (See page AC–35) REMOVE EXPANSION VALVE Remove the piping clamp. Ply out the packing. HINT: Do not reuse the packing.
Page 190 AC–61 AIR CONDITIONING – EXPANSION VALVE AC0MO–02 INSTALLATION INSTALL LIQUID TUBE AND SUCTION TUBE TO EX- PANSION VALVE HINT: Lubricate 4 new O–rings with compressor oil and install the tubes. INSTALL NEW PACKING ON EXPANSION VALVE Cut off packing paper and peel off the packing paper, as shown in the illustration.
Page 191 AC–62 AIR CONDITIONING – EXPANSION VALVE INSTALL EXPANSION VALVE Install the expnaion valve with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator. HINT: Lubricate 2 new O–rings with compressor oil and install O–rings on the expansion valve.
Page 192: Blower Motor
AC–63 AIR CONDITIONING – BLOWER MOTOR BLOWER MOTOR AC221–01 INSPECTION REMOVE GLOVE COMPARTMENT (See page BO–75) REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and blower motor. N20295 INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, then check that the motor op- erations smoothly.
Page 193: Blower Resistor
AC–64 AIR CONDITIONING – BLOWER RESISTOR BLOWER RESISTOR AC222–01 INSPECTION REMOVE GLOVE COMPARTMENT (See page BO–75) REMOVE BLOWER RESISTOR Disconnect the connector. Remove the 2 screws and blower resistor. N20296 INSPECT BLOWER RESISTOR RESISTANCE Tester connection Condition Specified condition Approx. 0.38 Ω 2 –...
Page 194 AC–65 AIR CONDITIONING – AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AC223–01 INSPECTION REMOVE NO. 1 LOWER INSTRUMENT PANEL REMOVE LH INSTRUMENT LOWER PANEL (See page BO–75) REMOVE SERVOMOTOR Release the claw and pull out the plate. N20287 Disconnect the connector. Remove the 3 screws and servomotor.
Page 195 AC–66 AIR CONDITIONING – AIR OUTLET SERVOMOTOR INSTALL SERVOMOTOR Install servomotor with the 3 screws. Connect he connector. N20278 Install the plate, then restraint the claw. N20287 Insert the drain of plate to the lever pin. N20245 INSTALL LH INSTRUMENT LOWER PANEL INSTALL NO.
Page 196: Pressure Switch
AC–67 AIR CONDITIONING – PRESSURE SWITCH PRESSURE SWITCH AC0N2–02 ON–VEHICLE INSPECTION SET ON MANIFOLD GAUGE SET (See page AC–19) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 1,500 RPM N20291 Magnetic clutch control: Magnetic clutch control INSPECT PRESSURE SWITCH OPERATION Low pressure side High pressure side Connect the positive (+) lead from the ohmmeter to termi-...
Page 197 AC–68 AIR CONDITIONING – PRESSURE SWITCH AC0N3–02 REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrig- erant.
Page 198 AC–69 AIR CONDITIONING – PRESSURE SWITCH AC0N4–01 INSTALLATION Installation is in the reverse order of removal (See page AC–68). Author : Date : 2551...
Page 199 AC–70 AIR CONDITIONING – HEATER MAIN RELAY HEATER MAIN RELAY AC224–01 INSPECTION REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 Heater Main Relay I09189 INSPECT HEATER MAIN RELAY (Marking: HTR RLY) CONTINUITY Condition Tester connection Specified condition 1 –...
Page 200 AC–71 AIR CONDITIONING – MAGNETIC CLUTCH RELAY MAGNETIC CLUTCH RELAY AC225–01 INSPECTION REMOVE MAGNETIC CLUTCH RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 Magnetic Clutch Relay I09189 INSPECT HEATER MAIN RELAY (Marking: MG CLT RLY) CONTINUITY Condition Tester connection Specified condition Constant 1 –...
Page 201 AC–72 AIR CONDITIONING – COOLING FAN RELAY COOLING FAN RELAY AC226–01 INSPECTION REMOVE NO. 1 COOLING FAN RELAY FROM ENGINE ROOM JUNCTION BLOCK NO. 2 No. 1 Cooling Fan Relay S05390 REMOVE NO. 2 COOLING FAN RELAY FROM ENGINE No. 2 Cooling ROOM RELAY BLOCK NO.
Page 202 AC–73 AIR CONDITIONING – COOLING FAN RELAY INSPECT NO. 3 COOLING FAN RELAY (Marking: FAN RLY NO. 3) CONTINUITY Condition Tester connection Specified condition Constant 1 – 2 Continuity Apply B+ between 3 – 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay.
Page 203 AC–74 AIR CONDITIONING – CONDENSER FAN CONDENSER FAN AC0N6–02 ON–VEHICLE INSPECTION INSPECT CONDENSER FAN OPERATION Inspect the fan operation, as shown in the chart below. Test conditions: Ignition switch ON Blower speed control switch position ”HI” A/C switch ON Condition Fan operation (Fan speed) Engine coolant temperature Not rotate...
Page 204 AC–75 AIR CONDITIONING – CONDENSER FAN AC0N7–02 COMPONENTS Condenser Fan Connector Upper Radiator Hose Condenser Fan Fan Shroud Fan Motor z Clip z Non–reusable part Z19147 Author : Date : 2557...
Page 205 AC–76 AIR CONDITIONING – CONDENSER FAN AC0N8–02 REMOVAL 1MZ–FE engine models only: DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 1MZ–FE engine models only: DISCONNECT UPPER RADIATOR HOSE REMOVE CONDENSER FAN Disconnect the connector. Remove the 4 bolts and fan.
Page 206 AC–77 AIR CONDITIONING – CONDENSER FAN AC0N9–02 DISASSEMBLY Protrusion REMOVE FAN Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: Install a new clip from the side opposite the protrusion on the P19301...
Page 207 AC–78 AIR CONDITIONING – CONDENSER FAN AC0NA–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–77). Author : Date : 2560...
Page 208 AC–79 AIR CONDITIONING – CONDENSER FAN AC0NB–01 INSTALLATION Installation is in the reverse order of removal (See page AC–76). Author : Date : 2561...
Page 209 AC–80 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY AC0NC–01 ON–VEHICLE INSPECTION INSPECT A/C CONTROL DIAL AND LEVER OPERATION Move the control dial and lever left and right and check for stiffness and binding through the full range of the levers.
Page 210 AC–81 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0ND–02 COMPONENTS Center Cluster Finish Panel LH Lower Instrument Panel A/C Control Assembly No.1 Lower Finish Panel Glove Compartment Cowl Side Trim Cowl Side Trim Front Door Inside Scuff Plate Front Door Inside Scuff Plate Air Inlet Damper Control Cable Blower Speed Control Air Inlet Control Lever...
Page 211 AC–82 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NE–02 REMOVAL REMOVE COWL SIDE TRIM LH AND RH REMOVE FRONT DOOR INSIDE SCUFF PLATE LH AND RH REMOVE NO. 2 LOWER COVER REMOVE GLOVE COMPARTMENT REMOVE NO. 1 LOWER INSTRUMENT PANEL REMOVE LH LOWER INSTRUMENT PANEL REMOVE CENTER CLUSTER FINISH PANEL DISCONNECT A/C CONTROL CABLES...
Page 212 AC–83 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NF–02 DISASSEMBLY REMOVE A/C SWITCH AND DEFOGGER SWITCH Using a screwdriver, release the claw and pull out the switch backward. HINT: Tape the screwdriver tip before use. REMOVE HEATER CONTROL KNOBS REMOVE HEATER CONTROL CABLE REMOVE BLOWER SPEED CONTROL SWITCH Remove the 2 screws and pull out the switch.
Page 213 AC–84 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NG–02 INSPECTION INSPECT A/C INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1. Push the A/C button in and then check that the indicator lights up.
Page 214 AC–85 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY INSPECT MODE SWITCH CONTINUITY Switch position Tester connection Specified condition FACE 1 – 6 Continuity 1 – 5 Continuity FOOT 1 – 4 Continuity FOOT/DEF. 1 – 3 Continuity 1 – 2 DEF.
Page 215 AC–86 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NH–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–83). Author : Date : 2568...
Page 216 AC–87 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NI–02 INSTALLATION Installation is in the reverse order of removal (See page AC–82). AFTER INSTALLATION INSPECT A/C CONTROL LE- VER AND DIAL OPERATION Move the control dial and lever left and right and check fro stiff- ness and binding through the full range of the lever and dial.
Page 217: Air Conditioning Amplifier
AC–88 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER AC0NJ–02 ON–VEHICLE INSPECTION REMOVE GLOVE COMPARTMENT (See page BO–75) INSPECT AMPLIFIER CIRCUIT Wire harness side: Disconnect the amplifier connector and inspect the con- nector on wire harness side, as shown in the chart below. Test conditions: Ignition switch ON Blower speed switch HI...
Page 218 AC–89 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER Connect the connector to amplifier and inspect wire har- From back side: ness side connector from the back side, as shown in the chart below. Test conditions: Running engine at idle speed Blower speed switch HI A/C switch ON Temperature control lever Max Cool Set on manifold gauge set...
Page 219 AC–90 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC0NK–02 REMOVAL REMOVE GLOVE COMPARTMENT (See page BO–75) REMOVE A/C AMPLIFIER Disconnect the connector. Release the 2 claws and pull out the amplifier. N20285 Author : Date : 2572...
Page 220 AC–91 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC0NL–01 INSTALLATION Installation is in the reverse order of removal (See page AC–90). Author : Date : 2573...
Page 221 AC–92 AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH AC227–01 INSPECTION DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. REMOVE ECT SWITCHES 5S–FE: Disconnect the connector. Remove the ECT switch. ECT Switch P15233 1MZ–FE:...
Page 222 AC–93 AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH 1MZ–FE engine: INSPECT No. 2 SWITCH CONTINUITY Using an ohmmeter, check that no continuity exists be- tween the terminal and switch body when the coolant temperature is above 93°C (199°F). If continuity exists, replace the switch. Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below 83°C (181°F).
Page 223 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002–0W To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one.
Page 224 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 225 IN–3 INTRODUCTION – HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS: CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the compo- nents being repaired.
Page 226 IN–4 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS IN022–07 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect the negative (–) terminal cable from the battery.
Page 227 IN–5 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component il- lustrations by the ”S” symbol. When necessary, use a sealer on gaskets to prevent leaks.
Page 228 GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS IN016–02 This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS...
Page 229 IN–7 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection Inertia Fuel–Shutoff – Idle Speed Control –...
Page 230 IN–8 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) Three–Way Catalytic Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow Air Flow Meter...
Page 231 IN–9 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL IN01H–0R Automatic Transaxle Fluid Overdrive Brake Second coast Brake Second Brake First and Reverse Brake Overdrive Direct Clutch Forward Clutch Direct Clutch Disc Flange O/D One–way Clutch No.1 One–way Clutch No.2 One–way Clutch Multipurpose...
Page 232 IN–10 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS IN008–02...
Page 233 IN–11 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS...
Page 234 AX–12 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS AT06P–0C SERVICE DATE Oil Pump 0.07 – 0.15 mm Body clearance 0.0028 – 0.0059 in. 0.3 mm Maximum 0.012 in. 0.11 – 0.14 mm Tip clearance 0.0043 – 0.0055 in. 0.3 mm Maximum 0.012 in.
Page 235 AX–13 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 19.025 – 19.050 mm Ring gear bushing inside diameter Standard 0.7490 – 0.7500 in. 0.20 – 0.50 mm Planetary pinion gear thrust clearance Standard 0.0079 – 0.0197 in. Rear Planetary Gear 0.20 – 0.50 mm Planetary pinion gear thrust clearance Standard 0.0079 –...
Page 236 AX–14 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Valve Body Spring Free length and Coil outer Spring Total No. of coils and Color diameter mm (in.) Upper valve body 21.7 (0.854) Throttle modulator valve 9.5 (0.374) None 28.1 (0.105) 13.0 Accumulator control valve 10.6 (0.417) Yellow 21.6 (0.850)
Page 237 AX–15 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 1 – 2 shift valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) 2 – 3 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) 3 – 4 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) Lock–up signal valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126)
Page 238 AX–16 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Differential 1.0 – 1.6 N·m Drive pinion preload (at starting) New bearing 10 – 16 kgf·cm 8.7 – 13.9 in.·lbf Reused bearing 0.5 – 0.8 N·m 5 – 8 kgf·cm 4.3 – 6.9 in.·lbf Add drive pinion preload Total preload (at starting) 0.3 –...
Page 239 AX–17 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 1.90 mm 0.0748 in. 1.95 mm 0.0768 in. 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in. 2.20 mm 0.0866 in. 2.25 mm 0.0886 in. 2.30 mm 0.0906 in.
Page 240 AX–18 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS AT06Q–0C TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Stator shaft x Oil pump body Upper valve body x Lower valve body 48 <in.lbf> Ring gear x Differential case Side bearing cap x Transaxle case Bearing retainer x Transaxle case Counter drive gear x Drive pinion 1,750...
Page 241: General Description
AX–1 AUTOMATIC TRANSAXLE – GENERAL DESCRIPTION GENERAL DESCRIPTION AX0EP–02 The A140E automatic transaxle described in this AX section is a 4–speed lock–up automatic transaxle developed exclusively for use with a transversely–mounted engine.
Page 242 AX–2 AUTOMATIC TRANSAXLE – GENERAL DESCRIPTION General Specifications Type of Transaxle A140E Type of Engine 5S–FE Torque Converter Clutch Stall Torque Ratio 2.0 : 1 Lock–up Mechanism Equipped Gear Ratio 1st Gear 2.810 2nd Gear 1.549 3rd Gear 1.000 O/D Gear 0.706 Reverse Gear 2.296...
Page 243 AX–3 AUTOMATIC TRANSAXLE – OPERATION OPERATION AX0SW–01 OPERATION...
Page 244 AX–4 AUTOMATIC TRANSAXLE – OPERATION FUNCTION OF COMPONENTS FUNCTION OPERATION O/D Direct Clutch (C Connects overdrive sun gear and overdrive carrier Prevents overdrive sun gear from turning either clockwise or O/D Brake (B counterclockwise When transmission is being driven by engine, connects overdrive sun O/D One–way Clutch (F gear and overdrive carrier.
Page 245 AX–5 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
Page 246 AX–6 AUTOMATIC TRANSAXLE – OPERATION HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu- mulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect all of these components.
Page 247 AX–7 AUTOMATIC TRANSAXLE – OPERATION ELECTRONIC CONTROL SYSTEM The electronic control system for controlling the shift timing and the operation of the lock–up clutch is composed of the following 3 parts: (a) Sensors: These sense the vehicle speed and throttle position and send this data to the ECM in the form of electronic signals.
Page 248 PREPARATION PREPARATION AX0EQ–02 SST (SPECIAL SERVICE TOOLS) Wire Gauge Set 09240–00020 Companion Flange Holding Tool 09330–00021 09350–32014 TOYOTA Automatic Transmission Tool Set 09308–10010 Oil Seal Puller Stator Stopper (09351–32020) (09351–32032) Counter Driven Gear Holding Tool No.1 Piston Spring Compressor (09351–32040) (09351–32050)
Page 249 AX–9 AUTOMATIC TRANSAXLE – PREPARATION (09351–32111) Side Bearing Race Replacer Overdrive Bearing Replacer (09351–32120) (09351–32130) Handle Oil Seal Replacer (09351–32140) (09351–32150) Oil Seal Replacer Measure Terminal (09351–32190) (09351–32200) No.3 Piston Spring Compressor Differential Side Bearing Puller 09502–10012 09564–32011 Differential Preload Adaptor 09710–28020 Front Suspension Bushing Tool SetS...
Page 250 AX–10 AUTOMATIC TRANSAXLE – PREPARATION AX0ES–02 EQUIPMENT Feeler gauge Vernier calipers Dial indicator or dial indicator with magnetic base Straight edge Torque wrench AX0ET–02 LUBRICANT Liters Item Clacification US qts Imp qts Automatic Transaxle Fluid ATF DEXRON ® @@@@@: [g 2] (w/o Differential Fluid) Dry Fill Drain and Refill...
Page 251 AX–11 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL AX0GS–02 COMPONENTS...
Page 252 AX–12 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 253 AX–13 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 254 AX–14 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 255 AX–15 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0EW–02 SEPARATE BASIC SUBASSEMBLY REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the manual shift lever. (b) Pry off the lock washer and remove the manual valve shaft nut. (c) Remove the 2 bolts and pull out the park/neutral position switch.
Page 256 AX–16 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the cover. REMOVE OIL PAN AND GASKET (a) Remove the 15 bolts. (b) Remove the oil pan by lifting transaxle case. NOTICE: Do not turn the transaxle over as this will contami- nate the valve body with the foreign materials in the bottom of the oil pan.
Page 257 AX–17 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 11. REMOVE OIL TUBES Pry up both tube ends with a large screwdriver and re- move the 4 tubes. 12. REMOVE MANUAL DETENT SPRING 13. REMOVE MANUAL VALVE AND MANUAL VALVE BODY 14. REMOVE VALVE BODY (a) Remove the 12 bolts.
Page 258 AX–18 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 17. REMOVE ACCUMULATOR PISTON AND SPRINGS (a) Loosen the 5 bolts one turn at a time until the spring ten- sion is released. (b) Remove the cover and gasket. (c) Remove the piston and spring for C and C (d) Remove the O–rings.
Page 259 AX–19 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 19. REMOVE SECOND COAST BRAKE PISTON (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Remove the cover. (c) Remove the piston and outer return spring. (d) Remove the O–ring from the cover. 20.
Page 260 AX–20 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 22. REMOVE DIRECT CLUTCH FROM OIL PUMP 23. BE CAREFUL WHEN REMOVING RACE BEHIND OIL PUMP 24. REMOVE CLUTCH DRUM THRUST WASHER 25. REMOVE FORWARD CLUTCH 26. REMOVE BEARINGS AND RACES FROM FORWARD CLUTCH 27.
Page 261 AX–21 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 29. REMOVE BEARING RACES FROM FRONT PLAN- ETARY RING GEAR 30. REMOVE PLANETARY GEAR 31. REMOVE RACES AND BEARINGS FROM PLAN- ETARY GEAR 32. REMOVE SUN GEAR, SUN GEAR INPUT DRUM, SE- COND BRAKE HUB AND NO.1 ONE–WAY CLUTCH 33.
Page 262 AX–22 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 34. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE 35. REMOVE SECOND BRAKE DRUM If the brake drum is difficult to remove, lightly tap it with a wooden block. 36. REMOVE SECOND BRAKE PISTON RETURN SPRING 37.
Page 263 AX–23 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 39. REMOVE SNAP RING HOLDING NO.2 ONE–WAY CLUTCH OUTER RACE TO CASE 40. REMOVE NO.2 ONE–WAY CLUTCH AND REAR PLAN- ETARY GEAR 41. BE CAREFUL WHEN REMOVING THRUST WASHERS FROM BOTH SIDES OF PLANETARY CARRIER 42.
Page 264 AX–24 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 44. CHECK OPERATION OF FIRST AND REVERSE BRAKE PISTON Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassemble and inspect. 45. REMOVE SNAP RING HOLDING FLANGE TO CASE 46.
Page 265 AX–25 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (c) Remove the overdrive brake drum from the transaxle case. (d) Remove the overdrive planetary gear and counter gear if they remain in the transaxle. 50. REMOVE OVERDRIVE CLUTCH APPLY GASKET AND OVERDRIVE BRAKEAPPLY GASKET 51.
Page 266 AX–26 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 52. REMOVE FIRST AND REVERSE BRAKE PISTON (a) Apply compressed air into the passage of the case to re- move the piston. HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole.
Page 267 AX–27 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 55. REMOVE PIN, SPRING AND PARKING LOCK PAWL 56. REMOVE MANUAL VALVE SHAFT (a) Remove the retaining spring. (b) Using a hammer and chisel, pry and turn the collar. (c) Using a hammer and punch, drive out the pin. (d) Slide out the shaft and remove the manual valve lever from the case.
Page 268 AX–28 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0EX–02 DISASSEMBLY OF DIFFERENTIAL REMOVE CARRIER COVER MEASURE TOTAL PRELOAD Using a torque meter, measure the total preload, and note the measurement value. MEASURE BACKLASH OF SIDE GEAR Measure each side gear backlash while holding one pin- ion toward the case.
Page 269 AX–29 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL REMOVE DIFFERENTIAL CASE, OUTER RACE AND ADJUSTING SHIM Remove the differential case, the outer race and the ad- justing shim from the case. MEASURE DRIVE PINION PRELOAD Using a torque meter, measure the drive pinion preload. Preload (at starting): Reused bearing 0.5 –...
Page 270 AX–30 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Install SST onto the gear. SST 09350–32014 (09351–32032) (c) Using SST to hold the gear, remove the nut. SST 09330–00021 (d) Using SST, remove the gear and bearing. SST 09350–32014 (09351–32061) 10. REMOVE OUTER RACE FROM CASE Using SST, remove the outer race.
Page 271 AX–31 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 13. REMOVE ROTOR SENSOR 14. REMOVE DRIVE PINION (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Install a brass bar into case hole to tap out the drive pin- ion. (c) Tap the drive pinion and remove the bearing cage from the bore.
Page 272: Component Parts
AX–32 AUTOMATIC TRANSAXLE – COMPONENT PARTS COMPONENT PARTS AX0EY–02 GENERAL NOTES The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar–looking parts of different subassemblies being on your work- bench at the same time.
Page 273 AX–33 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE SECOND COAST BRAKE AX0EZ–02 COMPONENTS AX0F0–02 SECOND COAST BRAKE PISTON DISASSEMBLY REMOVE OIL SEAL RING Remove the oil seal ring from the piston. REMOVE PISTON ROD (a) Remove the E–ring while pushing the piston with needle– nose pliers.
Page 274 AX–34 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Remove the spring, washer and piston rod. AX0F1–02 SECOND COAST BRAKE INSPECTION INSPECT BRAKE BAND If the lining of the brake band is peeling off or discolored, or even if a part of the printed numbers are defaced, re- place the brake band.
Page 275 AX–35 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE INSTALL OIL SEAL RING (a) Apply ATF to the oil seal ring. (b) Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary.
Page 276 AX–36 AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP AX0F3–02 COMPONENTS AX0F4–02 OIL PUMP DISASSEMBLY REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the stator shaft back side. REMOVE THRUST WASHER FROM STATOR SHAFT BACK SIDE...
Page 277 AX–37 AUTOMATIC TRANSAXLE – OIL PUMP REMOVE STATOR SHAFT Remove the 11 bolts and stator shaft. Keep the gears in assembly order. REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AX0F5–02 OIL PUMP BUSHING INSPECTION CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body.
Page 278 AX–38 AUTOMATIC TRANSAXLE – OIL PUMP Drive and driven gear thickness Thickness Mark mm (in.) 9.440 – 9.456 (0.3717 – 0.3723) 9.456 – 9.474 (0.3723 – 0.3730) 9.474 – 9.490 (0.3730 – 0.3736) If the thickest gear cannot make the side clearance within standard specification, replace the oil pump body subas- sembly.
Page 279 AX–39 AUTOMATIC TRANSAXLE – OIL PUMP INSTALL STATOR SHAFT ONTO PUMP BODY Align the stator shaft with each bolt hole. TIGHTEN 11 STATOR SHAFT BOLTS Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollow of the pump body.
Page 280 AX–40 AUTOMATIC TRANSAXLE – DIRECT CLUTCH DIRECT CLUTCH AX0GT–02 COMPONENTS AX0F7–02 DIRECT CLUTCH DISASSEMBLY CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Set a dial indicator and measuring terminal (SST) togeth- er, measure the direct clutch piston stroke while applying and releasing compressed air (392 –...
Page 281 AX–41 AUTOMATIC TRANSAXLE – DIRECT CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a shop press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with the snap ring pliers. (c) Remove the piston return spring.
Page 282 AX–42 AUTOMATIC TRANSAXLE – DIRECT CLUTCH AX0F8–02 DIRECT CLUTCH INSPECTION INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying lowpres- sure compressed air. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
Page 283 AX–43 AUTOMATIC TRANSAXLE – DIRECT CLUTCH INSTALL PLATES, DISCS AND FLANGE (a) Install plates and discs. Install in order: P=Plate D=Disc P – D – P – D – P – D (b) Install the flange with the flat end facing downward. INSTALL SNAP RING Check that the end gap of the snap ring is not aligned with one of the cutouts.
Page 284 AX–44 AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH AX0FA–02 COMPONENTS AX0FB–02 FORWARD CLUTCH DISASSEMBLY CHECK PISTON STROKE OF FORWARD CLUTCH Set a dial indicator and measuring terminal (SST) togeth- er, measure the forward clutch piston stroke while apply- ing and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm , 57 –...
Page 285 AX–45 AUTOMATIC TRANSAXLE – FORWARD CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES REMOVE RETURN SPRINGS (a) Place SST on the spring retainer and compress the springs with a shop press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with the snap ring pliers. (c) Remove the piston return spring.
Page 286 AX–46 AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Remove the 2 O–rings from the piston. IF NECESSARY, REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the shaft. AX0FC–02 FORWARD CLUTCH INSPECTION INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying lowpres- sure compressed air.
Page 287 AX–47 AUTOMATIC TRANSAXLE – FORWARD CLUTCH INSTALL CLUTCH PISTON TO CLUTCH DRUM (a) Install the 2 new O–rings to the piston. (b) Coat the O–rings with ATF. (c) Press the piston into the drum with the cup side up, being careful not to damage the O–rings.
Page 288 AX–48 AUTOMATIC TRANSAXLE – FORWARD CLUTCH RECHECK PISTON STROKE OF FORWARD CLUTCH Set a dial indicator and measuring terminal (SST) togeth- er, measure the forward clutch piston stroke while apply- ing and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm , 57 –...
Page 289 AX–49 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR FRONT PLANETARY GEAR AX0FE–02 COMPONENTS AX0FF–02 ONE–WAY CLUTCH AND SUN GEAR DISASSEMBLY CHECK OPERATION OF ONE–WAY CLUTCH Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock counterclockwise. REMOVE SECOND BRAKE HUB AND ONE–WAY CLUTCH FRONT SUN GEAR While turning the hub clockwise, remove the one–way...
Page 290 AX–50 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR REMOVE THRUST WASHER FROM SUN GEAR INPUT DRUM REMOVE SUN GEAR FROM DRUM (a) Using snap ring pliers, remove the snap ring from the drum. (b) Remove the sun gear from the drum. REMOVE SHAFT SNAP RING Using snap ring pliers, remove the shaft snap ring from the sun gear.
Page 291 AX–51 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR INSTALL ONE–WAY CLUTCH AND SECOND BRAKE HUB ON SUN GEAR While turning the hub clockwise, slide the one–way clutch onto the sun gear. RECHECK OPERATION OF ONE–WAY CLUTCH AX0FH–02 PLANETARY RING GEAR INSPECTION INSPECT RING GEAR FLANGE BUSHING Using a dial indicator, measure the inside diameter of the flange bushing.
Page 292 AX–52 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR AX0FJ–02 FRONT PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.20 – 0.50 mm (0.0079 – 0.0197 in.)
Page 293 AX–53 AUTOMATIC TRANSAXLE – SECOND BRAKE SECOND BRAKE AX0FK–02 COMPONENTS AX0FL–02 SECOND BRAKE PISTON DISASSEMBLY REMOVE SECOND BRAKE PISTON (a) Apply compressed air to the oil hole to remove the piston. (b) Remove the 2 O–rings from the piston.
Page 294 AX–54 AUTOMATIC TRANSAXLE – SECOND BRAKE AX0FM–02 SECOND BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surface of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re- place all discs.
Page 295 AX–55 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REAR PLANETARY GEAR AX0FP–02 COMPONENTS AX0FQ–02 ONE–WAY CLUTCH DISASSEMBLY CHECK OPERATION OF ONE–WAY CLUTCH Hold the outer race and turn the hub. The hub should turn freely counterclockwise and should lock clockwise. SEPARATE ONE–WAY CLUTCH AND PLANETARY GEAR REMOVE THRUST WASHERS Remove the 2 thrust washers from both sides of the plan-...
Page 296 AX–56 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REMOVE ONE–WAY CLUTCH FROM OUTER RACE (a) Remove the 2 snap rings and retainers from both sides. (b) Remove the one–way clutch from the outer race. AX0FR–02 REAR PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Page 297 AX–57 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR CHECK OPERATION OF ONE–WAY CLUTCH INSTALL THRUST WASHERS (a) Coat the 2 thrust washers with petroleum jelly. (b) Align the tab of the washers with the hollow of the carrier. AX0FT–02 RING GEAR FLANGE REPLACEMENT REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring.
Page 298 AX–58 AUTOMATIC TRANSAXLE – FIRST AND REVERSE BRAKE FIRST AND REVERSE BRAKE AX0FU–02 COMPONENTS AX0FV–02 FIRST AND REVERSE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re-...
Page 299 AX–59 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT OVERDRIVE UNIT AX0FW–02 COMPONENTS...
Page 300 AX–60 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0FX–02 OVERDRIVE BRAKE DISASSEMBLY REMOVE PISTON RETURN SPRING (a) While pushing the return spring, remove the snap ring with a screwdriver. (b) Remove the piston return spring. REMOVE CUSHION PLATE, PLATES, DISCS AND FLANGE REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston.
Page 301 AX–61 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0FY–02 OVERDRIVE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re- place all discs.
Page 302 AX–62 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE REMOVE SNAP RING WITH SCREWDRIVER REMOVE FLANGES, DISCS AND PLATES REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the spring with a shop press.
Page 303 AX–63 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE PISTON FROM CLUTCH DRUM (a) Install the clutch drum of the case. (b) Apply compressed air to the pressure apply hole of the case. (c) Remove the piston from the clutch drum. If the piston does not come out completely, use needle– nose pliers to remove it.
Page 304 AX–64 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G1–02 OVERDRIVE DIRECT CLUTCH ASSEMBLY INSTALL CLUTCH PISTON (a) Install new O–rings to the piston. Coat the O–rings with ATF. (b) Press the piston into the drum with the cup side up, being careful not to damage the O–ring. INSTALL PISTON RETURN SPRING (a) Install the return spring and set snap ring in place.
Page 305 AX–65 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT INSTALL SNAP RING Be sure end gap of the snap ring is not aligned with the groove of the clutch drum. INSTALL BEARING AND RACE (a) Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum.
Page 306 AX–66 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G2–02 COUNTER DRIVE GEAR DISASSEMBLY CHECK OPERATION OF ONE–WAY CLUTCH (a) While turning the overdrive gear clockwise, install the ov- erdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft.
Page 307 AX–67 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE NO.3 OVERDRIVE PLANETARY THRUST WASHER REMOVE ONE–WAY CLUTCH FROM OUTER RACE Note the direction of the one–way clutch. REMOVE PLUGS FROM PLANETARY GEAR Remove the 4 plugs with a magnetic finger. HINT: Be careful not to lose them. REMOVE ADJUSTING NUT AND WASHER (a) Pry off the locking washer with chisel.
Page 308 AX–68 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE INTERMEDIATE SHAFT BEARING Using SST, press out the bearing from the shaft. SST 09950–00020 10. REMOVE COUNTER DRIVE GEAR AND FRONT BEARING Press out the gear and bearing together. 11. REMOVE REAR BEARING Using SST, press out the bearing.
Page 309 AX–69 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 14. REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring. AX0G3–02 OVERDRIVE PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Page 310 AX–70 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT INSTALL REAR BEARING Using SST, press in the bearing onto the shaft. SST 09350–32014 (09351–32120) HINT: Press in the bearing until the side surface of the in- ner race touches the shaft. INSTALL COUNTER DRIVE GEAR AND FRONT BEAR- (a) Install the gear onto the shaft, and mesh the ring gear with the planetary pinions.
Page 311 AX–71 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT ADJUST PRELOAD OF COUNTER DRIVE GEAR (a) Place SST onto the adjusting nut and hold the shaft in a vise with soft jaws. SST 09350–32014 (09351–32080) (b) Tighten the adjusting nut until the following gear starting load occurs with a tension gauge.
Page 312 AX–72 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 12. INSTALL OVERDRIVE ONE–WAY CLUTCH INTO HUB Be sure that the one–way clutch is installed in the correct direction. 13. INSTALL RETAINING PLATE (a) Place the retaining plate into the hub. (b) Install the snap ring with a screwdriver. 14.
Page 313 AX–73 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G4–02 OVERDRIVE CASE DISASSEMBLY REMOVE C ACCUMULATOR PISTON FROM OVER- DRIVE CASE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retaining plate and two springs. (c) Remove the accumulator piston. (d) Remove the O–ring from the piston.
Page 314 AX–74 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G5–02 OVERDRIVE CASE ASSEMBLY INSTALL OIL SEAL RINGS ON OVERDRIVE CASE Install the oil seal rings to the O/D case groove, then snug them down by squeezing their ends together. HINT: After installing the oil seal rings, check that they move smoothly.
Page 315 AX–75 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (b) Install the discs and plates. Install in order: P=Plate D=Disc Flange – D – P – P – D – P HINT: There are 2 different thickness plates, as shown in the illustration. (c) Install the cushion plate facing the rounded end upward.
Page 316 AX–76 AUTOMATIC TRANSAXLE – VALVE BODY VALVE BODY AX0G7–02 COMPONENTS AX0G8–02 VALVE BODY DISASSEMBLY NOTE THE NUMBERS OF ADJUSTING RINGS HINT: Count the number of adjusting rings before disas- sembly of the valve body because the throttle pressure is changed according to the number. (Some of the valve bo- dies do not have any adjusting rings).
Page 317 AX–77 AUTOMATIC TRANSAXLE – VALVE BODY REMOVE UPPER VALVE BODY COVER Remove the 9 bolts and upper valve body cover. REMOVE STRAINER GASKETS, PLATE AND SLEEVE STOPPER FROM UPPER VALVE BODY (a) Remove the strainer, 2 gaskets and plate. (b) Remove the sleeve stopper. REMOVE BOLTS FROM UPPER VALVE BODY Remove the 3 bolts from the upper valve body.
Page 318 AX–78 AUTOMATIC TRANSAXLE – VALVE BODY REMOVE BOLTS FROM LOWER VALVE BODY Remove the 3 bolts from lower valve body. LIFT OFF LOWER VALVE BODY AND PLATE AS SINGLE UNIT Hold the plate to the lower valve body and lift off the lower valve body.
Page 319 AX–79 AUTOMATIC TRANSAXLE – VALVE BODY PLACE LOWER VALVE BODY WITH PLATE AND GAS- KETS ON UPPER VALVE BODY HINT: Hold the lower valve body, gaskets and plate se- curely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate.
Page 320 AX–80 AUTOMATIC TRANSAXLE – VALVE BODY INSTALL UPPER VALVE BODY COVER GASKETS, PLATE AND THROTTLE MODULATOR OIL STRAINER (a) Position a new gasket and plate and then another new gasket. HINT: The gaskets are not identical, but can be installed in any order.
Page 321 AX–81 AUTOMATIC TRANSAXLE – UPPER VALVE BODY UPPER VALVE BODY AX0GA–02 COMPONENTS...
Page 322 AX–82 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GB–02 VALVE BODY SPRINGS SPECIFICATIONS HINT: During re–assembly please refer to the spring specifications below to help you to discriminate between the different springs. Free Length / Coil Outer Diameter Spring (Color) Number of Coils mm (in.) Throttle Modulator Spring (None) 21.70 / 9.50 (0.8543 / 0.3740)
Page 323 AX–83 AUTOMATIC TRANSAXLE – UPPER VALVE BODY Throttle Valve Spring (None) 30.70 / 9.20 (1.2087 / 0.3622) [c E] Second Coast Modulator Valve Spring 20.93 / 8.50 (0.8240 / 0.3364) 10.0 (Light Green) [c F] Lock–up Relay Valve spring (Green) 26.56 / 10.20 (1.0457 / 0.4016) 11.5 [c G]...
Page 324 AX–84 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GC–02 RETAINERS, PINS, VIBRATING STOPPER AND CHECK BALLS LOCATION Height / Width / Thickness Retainer mm (in.) @@@@@: [c H] Throttle Modulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126) @@@@@: [c I] Accumulator Control Valve 11.5 / 5.0 / 3.2 (0.453 / 0.197 / 0.126)
Page 325 AX–85 AUTOMATIC TRANSAXLE – LOWER VALVE BODY LOWER VALVE BODY AX0GV–02 COMPONENTS...
Page 326 AX–86 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0GD–02 VALVE BODY SPRINGS SPECIFICATIONS HINT: During re–assembly please refer to the spring specifications below to help you to discriminate between the different springs. Free length / Outer diameter Spring (Color) Number of Coils mm (in.) Secondary Regulator Valve Spring 43.60 / 10.90 (1.7165 / 0.4291)
Page 327 AX–87 AUTOMATIC TRANSAXLE – LOWER VALVE BODY 1–2 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5 [c D] 2–3 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5 [c E] Primary Regulator Valve Spring (None) 66.65 / 18.60 (2.6240 / 0.7323) 12.5 [c F]...
Page 328 AX–88 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0GE–02 RETAINER, STRAINER AND CHECK BALLS LOCATION Height / Width / Thickness Retainer mm (in.) @@@@@: [c I] Primary Regulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.128) @@@@@: [c J] 2–3 Shift Valve 8.0 / 6.0 / 3.2 (0.315 / 0.236 / 0.126) @@@@@: [c K]...
Page 329 AX–89 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY AX0GF–02 COMPONENTS...
Page 330 AX–90 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0GG–02 DIFFERENTIAL CASE DISASSEMBLY REMOVE RING GEAR (a) Loosen the staked part of the lock plate. (b) Remove the 8 bolts and locking plates. (c) Using a copper hammer, tap on the ring gear to remove it from the case.
Page 331 AX–91 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and 2 side gears with the 4 thrust washers. REMOVE LH OIL SEAL Using a hammer and screwdriver, remove the oil seal. REMOVE BEARING OUTER RACE FROM LH SIDE BEARING RETAINER Using SST, press out the outer race and shim.
Page 332 AX–92 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY INSTALL BEARING OUTER RACE TO LH SIDE BEAR- ING RETAINER (a) Place the shim onto the retainer. (b) Using SST, press a new outer race into the retainer. SST 09350–32014 (09351–32111, 09351–32130) HINT: Use the 2.60 mm (0.1024 in.) thick thim. INSTALL LH OIL SEAL (a) Using SST, drive in a new oil seal.
Page 333 AX–93 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (d) Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Referring to the table below, select thrust washers which will ensure that the backlash is within specification.
Page 334 AX–94 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (c) Using SST and a press, press in the LH side bearing onto the differential case. SST 09710–28020 (09710–08040) INSTALL RING GEAR (a) Clean the contact surface of the differential case. (b) Heat the ring gear to about 100 °C (212 °F) in an oil bath. (c) Carefully remove the ring gear from the water.
Page 335 AX–95 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY REMOVE OIL SEALS FROM CAGE Using SST, press out the two oil seals together. SST 09350–32014 (09351–32090) REMOVE SHAFT BEARING OUTER RACE FROM CAGE Using a hammer and brass bar, drive out the outer race from the cage.
Page 336 AX–96 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (b) Measure the oil seal press in depth. Oil seal press in depth: 4 mm (0.16 in.) (c) With the oil seal lip facing upward, use SST to press in a new oil seal until its end is flush with the surface of the cage.
Page 337 AX–97 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0GL–02 DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT PLACE OUTER RACE AND ADJUSTING SHIM ONTO RH SIDE BEARING Use the adjusting shim which was removed or one 2.40 mm (0.0945 in.) thick. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE Be sure to install the adjusting shim.
Page 338 AX–98 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY ADJUST SIDE BEARING PRELOAD Using SST and a torque meter, measure the preload of the ring gear. SST 09564–32011 Preload (at starting): New bearing 1.0 – 1.6 N·m (10 – 16 kgf·cm, 8.7 – 13.9 in.·lbf) Reused bearing 0.5 –...
Page 339 AX–99 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION AX0GW–02 COMPONENT PARTS INSTALLATION Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Page 340 AX–100 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION BEARING AND RACE DIAMETERS Front Bearing Race Thrust Bearing Race Rear Bearing Race (in.) Outer / Inner Diameter Outer / Inner Diameter Outer / Inner Diameter 43.0 / 30.5 (1.693 / 1.201) 42.0 / 28.9 (1.654 / 1.138) 42.0 / 27.1 (1.654 / 1.067) [c A]...
Page 341 AX–101 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.7 / 23.0 (1.406 / 0.906) [c B] 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.0 / 19.0 (1.378 / 0.748) [c C] 45.0 / 28.0 (1.772 / 1.102) 45.0 / 30.0 (1.772 / 1.181)
Page 342 AX–102 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL SNAP RING INTO CASE (a) Using SST, install the snap ring into the groove. SST 09350–32014 (09351–32050) (b) Slightly tap the drive pinion to fit the snap ring into the groove. INSTALL ROTOR SENSOR Install the rotor sensor, facing the magnet outward.
Page 343 AX–103 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL NEW SPACER Always use new spacer. Install the spacer with the small end first. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT (a) Place a bar at the drive pinion side and position the outer end of the bar against a vise or similar.
Page 344 AX–104 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION If the preload is greater than specified, replace the bearing spacer. If the preload is less than specified, retighten the nut 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the speci- fied preload is reached.
Page 345 AX–105 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equiva- lent (e) Temporarily tighten the bolts evenly and gradually while turning the ring gear. INSTALL RH SIDE BEARING CAP Tighten the bolts evenly and gradually while turning the ring gear.
Page 346 AX–106 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION STAKE COUNTER DRIVEN GEAR NUT INSTALL DRIVE PINION CAP INSTALL CARRIER COVER (a) Clean the threads of the bolts and case with white gaso- line. (b) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equiva- lent...
Page 347 AX–107 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (e) Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface. Match the collar hole to the lever calking hollow and calk the collar to the lever. (g) Install the retaining spring.
Page 348 AX–108 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL PARKING LOCK ROD INSTALL PARKING LOCK PAWL BRACKET Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) CHECK OPERATION OF PARKING LOCK PAWL Make sure the counter driven gear is locked when the manual valve lever is in the P position. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE (a) Coat a new O–rings with ATF.
Page 349 AX–109 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring on the piston. (b) Place SST, and compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040) (c) Install snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer.
Page 350 AX–110 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (e) Install the overdrive unit with overdrive case to the trans- axle case. Install and tighten the bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) CHECK INTERMEDIATE SHAFT END PLAY (a) Make sure that the intermediate shaft has thrust play. Thrust play: 0.49 –...
Page 351 AX–111 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL RING GEAR INTO CASE (a) Coat the races and bearing with petroleum jelly and install them onto the ring gear. Bearing and races mm (in.) Outer Diameter Inner Diameter Front Race 37.3 (1.469) 24.1 (0.949) Bearing...
Page 352 AX–112 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Coat the thrust washer with petroleum jelly and install it onto the planetary gear. 16. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise. 17.
Page 353 AX–113 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL PISTON RETURN SPRING Each spring end is installed onto the protrusion with the case. 21. INSTALL SECOND BRAKE DRUM INTO CASE Align the groove of the drum with the bolt and place it into the case.
Page 354 AX–114 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 25. INSTALL NO.1 ONE–WAY CLUTCH AND SECOND BRAKE HUB (a) Align the flukes of the discs in the second brake. (b) Align the spline of the hub with the flukes of the discs and install the hub to the second brake discs.
Page 355 AX–115 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Coat the race and bearing with petroleum jelly, and install them onto the planetary gear. Bearing and race mm (in.) Outer Diameter Inner Diameter Bearing 45.0 (1.772) 30.0 (1.181) Race 45.0 (1.772) 28.0 (1.102) (c) Install the planetary gear onto the ring gear.
Page 356 AX–116 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 30. INSTALL SECOND COAST BRAKE BAND (a) Place the band into the case. (b) Install the pin through the oil pump mounting bolt hole. 31. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH (a) Coat the races and bearing with petroleum jelly, and install them onto both sides of the clutch drum.
Page 357 AX–117 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Mesh the hub with the flukes of the direct clutch while turn- ing the clutch drum or forward clutch. (e) If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch.
Page 358 AX–118 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transaxle case. (d) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum.
Page 359 AX–119 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 33. MEASURE THRUST PLAY OF INPUT SHAFT Measure the thrust play with a dial gauge. Thrust play: 0.3 – 0.9 mm (0.012 – 0.035 in.) HINT: There are 2 thickness of races for the end of stator shaft.
Page 360 AX–120 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Using SST, install the snap ring while pressing the cover. SST 09350–32014 (09351–32050) (e) Check that the front end of the piston rod contacts the center of the second brake band depression. 37.
Page 361 AX–121 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 39. INSTALL NEW SECOND BRAKE APPLY GASKET 40. INSTALL THROTTLE CABLE IN CASE Push the cable through the case, being careful not to damage the O–ring. Check for full seating. NOTICE: In subsequent work, to avoid breaking the cable fitting do not roll the case over the cable.
Page 362 AX–122 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 44. INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length (mm, in.) is indicated in the illustra- tion. (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place.
Page 363 AX–123 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 48. CONNECT SOLENOID WIRING (a) Connect the No.1 solenoid connector. (white and shorter wire) (b) Connect the No.2 solenoid connector. (black and longer wire) 49. INSTALL 3 MAGNETS IN PLACE NOTICE: Make sure that the magnets do not interfere with the oil tubes.
Page 364 AX–124 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 53. INSTALL SOLENOID WIRING RETAINING PLATE 54. INSTALL THROTTLE CABLE RETAINING PLATE 55. INSTALL FILLER TUBE AND BRACKET 56. INSTALL SL SOLENOID (a) Coat the O–ring with ATF and push the tip of SL solenoid into the hole.
Page 365 AX–125 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 60. INSTALL MANUAL SHIFT LEVER...
Page 366 AX–1 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX034–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. Author : Date : 1894...
Page 367 AX–2 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM AX035–01 OPERATION 2nd Brake (B Planetary Gear Unit 1st & Reverse Brake (B 2nd Coast brake (B O/D Direct Forward One – Way clutch O/D Brake (B Clutch (C Clutch (C Direct Clutch (C No.2 (F One Way Clutch Counter...
Page 368 AX–3 AUTOMATIC TRANSAXLE (A140E) – VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR AX036–01 ON–VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT VEHICLE SPEED SENSOR CONNEC- REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Q00207 Remove the clip and speedometer driven gear from ve- hicle speed sensor.
Page 369 AX–4 AUTOMATIC TRANSAXLE (A140E) – PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AX037–01 ON–VEHICLE REPAIR REMOVE CONTROL SHAFT LEVER Remove the nut and control cable. Remove the nut, washer and control shaft lever. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR REMOVE PARK/NEUTRAL POSITION SWITCH Pry off the lock washer and remove the nut.
Page 370 AX–5 AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX038–01 ON–VEHICLE REPAIR DRAIN TRANSAXLE FLUID REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the oil pan bolts, and carefully remove the oil pan as- sembly.
Page 371 AX–6 AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY DISCONNECT SOLENOID CONNECTORS AT0493 Z10941 REMOVE OIL PIPES Pry up the both pipe ends with a large screwdriver and remove the 4 pipes. NOTICE: Be careful not to bend or damage the pipe. AT7868 REMOVE VALVE BODY Remove the 12 bolts.
Page 372 AX–7 AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY INSTALL SHIFT SOLENOID VALVE NO.1 AND NO.2 Coat 2 new O–rings with ATF. Install the 2 O–rings to the shift solenoid valve No.1 and No.2. Install the shift valve No.1 with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the shift valve No.2 with the bolt.
Page 373 AX–8 AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY INSTALL OIL STRAINER AND OIL PIPE BRACKET mm (in.) Install the 2 bolts and oil pipe bracket. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Install the 3 bolts and oil strainer. (0.78) Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (1.969) (1.772)
Page 374 AX–9 AUTOMATIC TRANSAXLE (A140E) – THROTTLE CABLE THROTTLE CABLE AX039–01 ON–VEHICLE REPAIR DISCONNECT THROTTLE CABLE Disconnect the cable from the throttle linkage. Disconnect the cable from the cable clamps in the engine compartment. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) REMOVE VALVE BODY (See page AX–5) REMOVE THROTTLE CABLE Remove the retaining bolt and plate.
Page 375 AX–10 AUTOMATIC TRANSAXLE (A140E) – SHIFT SOLENOID VALVE SL SHIFT SOLENOID VALVE SL AX03A–01 ON–VEHICLE REPAIR REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) DISCONNECT SHIFT SOLENOID VALVE SL CONNEC- REMOVE SHIFT SOLENOID VALVE SL Remove the 2 bolts and shift solenoid valve SL. Q10051 Remove the 2 O–rings from the shift solenoid valve SL.
Page 376 AX–11 AUTOMATIC TRANSAXLE (A140E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX03B–01 ON–VEHICLE REPAIR REMOVE LH AND RH DRIVE SHAFTS (See page SA–17) REMOVE SIDE GEAR SHAFT OIL SEAL Using SST, drive out the oil seals on both sides. 09308–00010 Q00394 INSTALL SIDE GEAR SHAFT OIL SEAL Using SST, drive in a new oil seal.
Page 377 AX–12 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made) SHIFT LOCK SYSTEM (TMC Made) AX03C–01 LOCATION Shift Lock Override Cover Shift Lock Override Button Stop Light Switch Key Interlock Solenoid Shift Lock Control Unit Assembly D00760 Author : Date : 1905...
Page 378 AX–13 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made) AX03D–01 INSPECTION 5 (IG) 1 (ACC) INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY 4 (KLS Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connec- 3 (E) tor.
Page 379 AX–14 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) SHIFT LOCK SYSTEM (TMMK Made) AX03E–01 LOCATION Shift Lock Override Cover Shift Lock Override Button Stop Light Switch Key Interlock Solenoid Shift Lock Solenoid Shift Lock Control Switch Shift Lock Control ECU D00759 Author : Date :...
Page 380 AX–15 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) AX03F–01 INSPECTION 3 (IG) 1 (ACC) 6 (STP) Back Side INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure voltage at each terminal. 1 (P) 4 (KLS HINT: – 5 (SLS 4 (P2) Do not disconnect the ECU connector.
Page 381 AX–16 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) INSPECT KEY INTERLOCK SOLENOID 1 (KLS Disconnect the solenoid connector. Using an ohmmeter, measure resistance between termi- nals. Standard resistance: 12.5 – 16.5 Ω 2 (E) If resistance value is not as specified, replace the solenoid. Q09456 Apply battery positive voltage between terminals.
Page 382 AX–17 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03G–01 COMPONENTS 14 (145, 10) Air Cleaner Assembly Engine Hood 14 (145, 10) Starter Hold Down Clamp Cruise Control Actuator RH Drive Shaft 66 (670, 48) 42 (430, 31) Torque Converter 39 (400, 29) Manifold Stay...
Page 383 AX–18 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT RH Fender Apron seal RR Engine Mounting Stabilizer Bar TMC Made : 80 (820, 59) 19 (195, 14) TMMK Made : Green Color Bolt : 66 (670, 48) Silver Color Bolt : 44 (450, 32) RH Rear 10 (100, 7) Lower Brace...
Page 384 AX–19 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03H–01 REMOVAL REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY DISCONNECT THROTTLE CABLE w/ CRUISE CONTROL: REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector. Remove the 3 bolts and disconnect cruise control actua- tor with the bracket. Q10055 DISCONNECT OIL COOLER HOSE DISCONNECT VEHICLE SPEED SENSOR CONNEC-...
Page 385 AX–20 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT REMOVE EXHAUST MANIFOLD STAY Remove the 2 bolts and exhaust manifold stay. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) REMOVE TRANSAXLE–TO–ENGINE BOLT Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) REMOVE ENGINE HOOD Disconnect the washer pipe.
Page 386 AX–21 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT REMOVE EXHAUST FRONT PIPE Remove the 2 nuts and exhaust front pipe clamp. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 2 bolts and exhaust pipe No.1 support brack- Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 3 nuts.
Page 387 AX–22 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT REMOVE STEERING GEAR HOUSING Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings. Torque:19 N·m (195 kgf·cm, 14 ft·lbf) Remove the front stabilizer bar. (See page SA–48) Remove the 2 steering gear housing mounting bolts and nuts.
Page 388 AX–23 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts and 4 nuts. Front Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) Remove the front frame assembly.
Page 389 AX–24 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT REMOVE TORQUE CONVERTER CLUTCH MOUNT- ING BOLT Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley set bolt by a wrench. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) HINT: At the time of installation, please refer to the following item.
Page 390 AX–25 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03I–01 INSTALLATION CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION Using a scale and a straight edge, measure to the distance from the installed surface to the transaxle housing. Correct distance: 13.0 mm (0.512 in.) or more TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX–19).
Page 391 AX–26 AUTOMATIC TRANSAXLE (A140E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX03J–01 INSPECTION INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. 09350–32014 (09351–32010) Install SST so that it fits in the notch of the converter hub AT0953 and outer race of the one–way clutch.
Page 392 AX–27 AUTOMATIC TRANSAXLE (A140E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 in.) If the runout is not within the specification, try to correct by reori- enting the installation of the torque converter clutch.
Page 393 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002–0W To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one.
Page 394 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 395 IN–3 INTRODUCTION – HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS: CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the compo- nents being repaired.
Page 396 IN–4 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS IN022–07 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect the negative (–) terminal cable from the battery.
Page 397 IN–5 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component il- lustrations by the ”S” symbol. When necessary, use a sealer on gaskets to prevent leaks.
Page 398 GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS IN016–02 This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS...
Page 399 IN–7 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module – Indirect Fuel Injection Indirect Injection Inertia Fuel–Shutoff – Idle Speed Control –...
Page 400 IN–8 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) Three–Way Catalytic Converter TWC+OC Three–Way + Oxidation Catalytic Converter + CCo Volume Air Flow Air Flow Meter...
Page 401 IN–9 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL IN01H–0R Automatic Transaxle Fluid Overdrive Brake Second coast Brake Second Brake First and Reverse Brake Overdrive Direct Clutch Forward Clutch Direct Clutch Disc Flange O/D One–way Clutch No.1 One–way Clutch No.2 One–way Clutch Multipurpose...
Page 402 IN–10 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS IN008–02...
Page 403 IN–11 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS...
Page 404 AX–1 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION AX0CH–05 GENERAL SPECIFICATIONS Type of Transaxle A541E Type of Engine 1MZ–FE Torque Converter Clutch Stall Torque Ratio 1.8 : 1 Torque Converter Clutch Lock–up Mechanism Equipped Gear Ratio 1st Gear 2.810 2nd Gear 1.549 3rd Gear 1.000 O/D Gear...
Page 405 AX–2 AUTOMATIC TRANSAXLE – OPERATION OPERATION AX0RF–01 MECHANICAL OPERATION...
Page 406 AX–3 AUTOMATIC TRANSAXLE – OPERATION AX019–03 FUNCTION OF COMPONENTS...
Page 407 AX–4 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
Page 408 AX–5 AUTOMATIC TRANSAXLE – OPERATION AX01A–0B HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accu- mulators, the clutches and brakes as well as the fluid passages which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hy- draulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the ve- hicle driving conditions.
Page 409 Wire Gauge Set 09240–00020 09316–20011 Transfer Bearing Replacer 09316–60011 Transmission & Transfer Bearing Replacer Replacer Pipe (09316–00011) 09350–32014 TOYOTA Automatic Transmission Tool Set Oil Seal Puller 09308–10010 Counter Driven Gear Holding Tool (09351–32032) No.1 Piston Spring Compressor (09351–32040) Snap Ring Expander (09351–32050) (09351–32061)
Page 410 AX–7 AUTOMATIC TRANSAXLE – PREPARATION (09351–32100) Drive Pinion Bearing Replacer Overdrive Bearing Replacer (09351–32120) (09351–32140) Oil Seal Replacer Oil Seal Replacer (09351–32150) (09351–32190) Measure Terminal No.3 Piston Spring Compressor (09351–32200) 09608–16011 Rear Hub Bearing Tool– Remove differential side bearing 09612–65014 Steering Worm Bearing Puller Remove pinion shaft bearing outer race...
Page 411 AX–8 AUTOMATIC TRANSAXLE – PREPARATION AX02N–02 EQUIPMENT Feeler gauge Check major clearance. Vernier calipers Check length of second coast brake piston rod. Dial indicator with magnetic base Check piston stroke and end play of the output shaft. Dial indicator Check inside diameter of major bushing.
Page 412 AX–9 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL AX02Q–02 COMPONENTS...
Page 413 AX–10 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 414 AX–11 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 415 AX–12 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL...
Page 416 AX–13 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0TT–02 SEPARATE BASIC SUBASSEMBLY REMOVE SHIFT CONTROL CABLE BRACKET REMOVE UNION AND ELBOW (a) Remove the manual shift lever. (b) Using a open end wrench, remove the union and elbow. (c) Remove the O–rings from the union and elbow. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Pry off the lock washer and remove the manual valve shaft nut.
Page 417 AX–14 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL REMOVE T/M REVOLUTION SENSOR (a) Remove the bolt and T/M revolution sensor. (b) Remove the O–ring from the T/M revolution sensor. REMOVE TRANSAXLE CASE UPPER COVER REMOVE OIL PAN AND GASKET (a) Remove the 17 bolts. (b) Remove the oil pan by lifting transaxle case.
Page 418 AX–15 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 10. REMOVE MANUAL VALVE BODY (a) Remove the 2 bolts and detent spring. (b) Remove the 5 bolts and manual valve body with the manual valve. (c) Remove the manual valve from the manual valve body. 11.
Page 419 AX–16 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 14. REMOVE B APPLY PIPE Pry up the pipe with a screwdriver and remove the pipe. 15. REMOVE VALVE BODY (a) Remove the 9 bolts. (b) Remove the wire harness clamp. (c) Disconnect the throttle cable from the cam, and remove the valve body.
Page 420 AX–17 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 17. REMOVE SOLENOID WIRING Remove the bolt and the solenoid wiring. 18. REMOVE SECOND BRAKE APPLY GASKET 19. REMOVE ACCUMULATOR PISTONS AND SPRINGS (a) Loosen the 4 bolts one turn at a time until the spring ten- sion is released.
Page 421 AX–18 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 20. MEASURE PISTON STROKE SECOND COAST BRAKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm 57–114 psi).
Page 422 AX–19 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 22. STAND TRANSAXLE ENGINE SIDE UPWARD 23. REMOVE OIL PUMP NOTICE: Before removing the oil pump, remove the se- cond coast brake piston. (a) Remove the 7 bolts. (b) Using SST, pull out the oil pump from the transaxle case. SST 09350–32014 24.
Page 423 AX–20 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 27. REMOVE BEARING FROM FORWARD CLUTCH 28. REMOVE SECOND COAST BRAKE BAND (a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting. (b) Remove the brake band. 29.
Page 424 AX–21 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 31. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM (a) Remove the sun gear and the sun gear input drum. (b) Remove the thrust washer from sun gear input drum. 32. CHECK OPERATION OF SECOND BRAKE PISTON Apply compressed air into the case passage and confirm that the piston moves.
Page 425 AX–22 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the second brake drum. 35. REMOVE SECOND BRAKE PISTON RETURN SPRING 36. REMOVE NO.1 ONE–WAY CLUTCH 37. REMOVE PLATES, DISCS AND FLANGE 38. REMOVE SECOND BRAKE DRUM GASKET Remove the gasket.
Page 426 AX–23 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 39. REMOVE NO.2 ONE–WAY CLUTCH AND REAR PLAN- ETARY GEAR (a) Remove the snap ring. (b) Remove the No.2 one–way clutch and rear planetary gear. (c) Remove the thrust washer from the rear planetary gear. 40.
Page 427 AX–24 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a filler gauge, check the pack clearance of the first and reverse brake. Clearance: 1.92–2.68 mm (0.0756–0.1055 in.) 42. REMOVE FLANGE, DISCS AND PLATES OF FIRST AND REVERSE BRAKE (a) Remove the snap ring. (b) Remove the flange, 6 discs and plates.
Page 428 AX–25 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (c) Remove the overdrive planetary gear from transaxle case. (d) Remove the overdrive brake drum from the transaxle case. (e) Remove the overdrive clutch apply gasket and overdrive brake apply gasket. 45. REMOVE FIRST AND REVERSE BRAKE PISTON (a) Remove the piston return spring.
Page 429 AX–26 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Apply compressed air into the passage of the case to re- move the piston. HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole. (c) If the piston does not pop out with compressed air, use needle–nose pliers to remove it.
Page 430 AX–27 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 47. REMOVE MANUAL VALVE SHAFT (a) Using a chisel and hammer, cut the collar. (b) Remove the retaining spring. (c) Using a pin punch and hammer, drive out the pin. (d) Slide out the shaft from the transaxle case and remove the manual valve lever and parking lock rod.
Page 431 AX–28 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 49. REMOVE PIN, SPRING AND PARKING LOCK PAWL AX02S–04 DIFFERENTIAL COMPONENT PARTS REMOVAL MEASURE DIFFERENTIAL TOTAL PRELOAD Using a small torque wrench, measure the total preload and make a note of it. REMOVE LH BEARING RETAINER (a) Remove the 6 bolts.
Page 432 AX–29 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a large screwdriver, remove the RH retainer. NOTICE: Wrap the screwdriver tip in a rag, etc. to avoid damaging the case and retainer. REMOVE CARRIER COVER (a) Remove the 10 bolts. (b) Tap the carrier cover with a plastic hammer to remove it.
Page 433 AX–30 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL REMOVE TRANSAXLE CAP (a) Remove the bolt. (b) Using pliers, pull out the drive pinion cap. (c) Remove the O–rings from the cap. MEASURE DRIVE PINION PRELOAD Using a small torque wrench, measure the drive pinion preload.
Page 434 AX–31 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (c) Using SST, remove the gear and bearing. SST 09350–32014 (09351–32061) REMOVE OUTER RACE, SPACER AND OIL SLINGER (a) Using SST, remove the outer race with oil slinger and spacer. SST 09350–32014 (09308–10010) (b) Using SST, remove the snap ring.
Page 435 AX–32 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (d) Remove the bearing cage from drive pinion. (e) Using SST, press out the bearing. SST 09950–00020...
Page 436 AX–33 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX02T–07 GENERAL NOTES The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar–looking parts of different subassemblies being on your work- bench at the same time.
Page 437 AX–34 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE SECOND COAST BRAKE AX02U–02 COMPONENTS AX02V–02 SECOND COAST BRAKE PISTON DISASSEMBLY REMOVE OIL SEAL RING Remove the oil seal ring from the piston. REMOVE PISTON ROD (a) Remove the E–ring while pushing the piston with needle– nose pliers.
Page 438 AX–35 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Remove the inner spring, plate washer and piston rod. AX02W–03 SECOND COAST BRAKE COMPONENT INSPECTION If the lining of the brake band is peeling off or discolored, or even part of the printed mark is defaced, replace the brake band.
Page 439 AX–36 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Install the E–ring while pushing the piston. INSTALL OIL SEAL RING (a) Apply ATF to the oil seal ring. (b) Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary.
Page 440 AX–37 AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP AX02Y–02 COMPONENTS AX02Z–02 OIL PUMP DISASSEMBLY REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the stator shaft back side. REMOVE THRUST WASHER FROM STATOR SHAFT BACK SIDE...
Page 441 AX–38 AUTOMATIC TRANSAXLE – OIL PUMP REMOVE STATOR SHAFT Remove the 11 bolts and stator shaft. HINT: Keep the gears in assembly order. REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AX030–06 OIL PUMP BUSHING INSPECTION CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body.
Page 442 AX–39 AUTOMATIC TRANSAXLE – OIL PUMP CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.002–0.005 mm (0.0008–0.0020 in.) Maximum side clearance: 0.100 mm (0.0039 in.) There are 3 different thicknesses for drive and driven gears.
Page 443 AX–40 AUTOMATIC TRANSAXLE – OIL PUMP INSTALL DRIVEN GEAR AND DRIVE GEAR Make sure the top of the gears are facing upward. INSTALL STATOR SHAFT TO PUMP BODY (a) Align the stator shaft with each bolt hole. (b) Torque the 11 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly.
Page 444 AX–41 AUTOMATIC TRANSAXLE – DIRECT CLUTCH DIRECT CLUTCH AX032–02 COMPONENTS AX033–05 DIRECT CLUTCH DISASSEMBLY CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Install a dial indicator and measuring terminal (SST) to- gether, measure the direct clutch piston stroke while ap- plying and releasing compressed air (392–785 kPa, 4–8 kg/cm , 57–114 psi).
Page 445 AX–42 AUTOMATIC TRANSAXLE – DIRECT CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with snap ring pliers. (c) Remove the piston return spring.
Page 446 AX–43 AUTOMATIC TRANSAXLE – DIRECT CLUTCH AX034–03 DIRECT CLUTCH INSPECTION INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pres- sure compressed air. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt.
Page 447 AX–44 AUTOMATIC TRANSAXLE – DIRECT CLUTCH (b) Place SST on the spring retainer, and compress the re- turn spring with a press. SST 09350–32014 (09351–32070) (c) Install the snap ring using snap ring pliers. Be sure the end gap of snap ring is aligned with the spring retainer claw.
Page 448 AX–45 AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH AX036–02 COMPONENTS AX037–04 FORWARD CLUTCH DISASSEMBLY CHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) to- gether, measure the forward clutch piston stroke while ap- plying and releasing compressed air (392–785 kPa, 4–8 kgf/cm , 57–114 psi).
Page 449 AX–46 AUTOMATIC TRANSAXLE – FORWARD CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES REMOVE RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Using snap ring pliers, remove the snap ring. (c) Remove the return spring.
Page 450 AX–47 AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Remove the 2 O–rings from the piston. IF NECESSARY, REMOVE OIL SEAL RINGS Remove the 3 oil seal rings from the shaft. AX038–03 FORWARD CLUTCH INSPECTION INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pres- sure compressed air.
Page 451 AX–48 AUTOMATIC TRANSAXLE – FORWARD CLUTCH INSTALL CLUTCH PISTON TO CLUTCH DRUM (a) Install the 2 new O–rings to the piston. (b) Coat the O–ring with ATF. (c) Press the piston into the drum with the cup side up, being careful not to damage the O–rings.
Page 452 AX–49 AUTOMATIC TRANSAXLE – FORWARD CLUTCH RECHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) to- gether, measure the forward clutch piston stroke while ap- plying and releasing compressed air (392–785 kPa, 4–8 kgf/cm , 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.79–2.21 mm (0.0704–0.0870 in.)
Page 453 AX–50 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR FRONT PLANETARY GEAR AX03A–02 COMPONENTS AX0TU–03 NO.1 ONE–WAY CLUTCH AND SUN GEAR DISASSEMBLY CHECK OPERATION OF NO.1 ONE–WAY CLUTCH Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock counterclockwise. REMOVE NO.1 ONE–WAY CLUTCH FROM SUN GEAR While turning the hub clockwise, remove the No.1 one–...
Page 454 AX–51 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR REMOVE SUN GEAR FROM DRUM (a) Using snap ring pliers, remove the snap ring from the drum. (b) Remove the sun gear from the drum. CHECK SUN GEAR BUSHINGS Using a dial indicator, measure the inside diameter of the sun gear bushings.
Page 455 AX–52 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. AX03E–03 FRONT PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST...
Page 456 AX–53 AUTOMATIC TRANSAXLE – SECOND BRAKE SECOND BRAKE AX03F–02 COMPONENTS AX03G–03 SECOND BRAKE PISTON DISASSEMBLY REMOVE SECOND BRAKE PISTON (a) Apply compressed air to the oil hole to remove the piston. (b) Remove the 2 O–rings from the piston.
Page 457 AX–54 AUTOMATIC TRANSAXLE – SECOND BRAKE AX03H–03 SECOND BRAKE COMPONENT INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re- place all discs.
Page 458 AX–55 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REAR PLANETARY GEAR AX03K–02 COMPONENTS AX03L–02 NO.2 ONE–WAY CLUTCH DISASSEMBLY CHECK OPERATION OF NO.2 ONE–WAY CLUTCH Hold the outer race and turn the rear planetary gear. The rear planetary gear should turn freely counterclockwise and should lock clockwise.
Page 459 AX–56 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REMOVE NO.2 ONE–WAY CLUTCH FROM OUTER RACE (a) Remove the 2 snap rings and retainers from both sides. (b) Remove the No.2 one–way clutch from the outer race. AX03M–03 REAR PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear...
Page 460 AX–57 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR INSTALL PLANETARY GEAR INTO NO.2 ONE–WAY CLUTCH Install the planetary gear into the No.2 one–way clutch, facing the inner race of the rear planetary gear toward the black side of the No.2 one–way clutch outer race. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly.
Page 461 AX–58 AUTOMATIC TRANSAXLE – FIRST AND REVERSE BRAKE FIRST AND REVERSE BRAKE AX03Q–02 COMPONENTS AX03R–03 FIRST AND REVERSE BRAKE COMPONENTS INSPECTION INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re-...
Page 462 AX–59 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT OVERDRIVE UNIT AX03S–02 COMPONENTS...
Page 463 AX–60 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03T–03 OVERDRIVE BRAKE DISASSEMBLY REMOVE PISTON RETURN SPRING (a) While pushing the return spring, remove the snap ring with a screwdriver. (b) Remove the piston return spring. REMOVE PLATES, DISCS AND FLANGE REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston.
Page 464 AX–61 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03U–03 OVERDRIVE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT: If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, re- place all discs.
Page 465 AX–62 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE SNAP RING WITH SCREWDRIVER REMOVE FLANGES, DISCS AND PLATES REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the spring with a press. SST 09350–32014 (09351–32070, 09351–32200) (b) Remove the snap ring. (c) Remove the piston return spring.
Page 466 AX–63 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE O–RINGS Remove the 2 O–rings from the piston. AX03W–03 OVERDRIVE DIRECT CLUTCH INSPECTION INSPECT OVERDRIVE DIRECT CLUTCH (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pres- sure compressed air.
Page 467 AX–64 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (b) Press the piston into the drum with the cup side up, being careful not to damage the O–ring. INSTALL PISTON RETURN SPRING (a) Install the return spring and seat snap ring in place. (b) Place SST on the spring retainer, and compress the spring with a press.
Page 468 AX–65 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT INSTALL BEARING AND RACE (a) Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum. Bearing outer diameter: 46.3 mm (1.823 in.) Bearing inner diameter: 26.2 mm (1.031 in.) (b) Coat the race with petroleum jelly and install it to the case.
Page 469 AX–66 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT CHECK COUNTER DRIVE GEAR PRELOAD (a) Hold the O/D planetary gear in a vise with soft jaws. HINT: Do not let the counter drive gear touch the vise. (b) Using a tension gauge, measure the preload. Preload (at starting): 9.2–15.3 N (940–1,560 g, 2.1–3.4 lb) HINT: Turn the counter drive gear right and left several...
Page 470 AX–67 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Remove the O/D one–way clutch from the outer race. HINT: Note the direction of the one–way clutch. REMOVE NO.3 PLANETARY THRUST WASHER REMOVE PLUGS FROM PLANETARY GEAR Remove the 4 plugs with a magnetic finger. NOTICE: Be careful not to lose them.
Page 471 AX–68 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE COUNTER DRIVE GEAR AND FRONT BEARING Press out the gear and bearing together. REMOVE REAR BEARING (a) Using SST, press out the bearing. SST 09950–00020 (b) Tag the bearings to show the location for reassembly. 10.
Page 472 AX–69 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 11. REMOVE OUTER RACES FROM COUNTER DRIVE GEAR (a) Drive out the 2 races with a brass bar and hammer. (b) Tag the races to show the location for reassembly. 12. REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring.
Page 473 AX–70 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX040–03 COUNTER DRIVE GEAR ASSEMBLY INSTALL SNAP RING INTO COUNTER GEAR Install the snap ring with a screwdriver. INSTALL OUTER RACES INTO COUNTER DRIVE GEAR Using SST, press in the 2 outer races to both sides of the gear.
Page 474 AX–71 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT INSTALL COUNTER DRIVE GEAR AND FRONT BEAR- (a) Install the gear onto the shaft, and mesh the ring gear with the planetary pinions. (b) Place the front bearing on to the shaft. (c) Using SST, press in the bearing until there is slight play between the bearings.
Page 475 AX–72 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT HINT: Turn the counter drive gear right and left several times before measuring the preload. (c) Lock the adjusting nut with one locking washer tab. Bend the locking washer tab until it is flat with the adjusting nut groove.
Page 476 AX–73 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Install the snap ring. 12. CHECK OPERATION OF O/D ONE–WAY CLUTCH (a) Install the overdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise.
Page 477 AX–74 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT REMOVE OIL SEAL RINGS AX042–02 OVERDRIVE CASE ASSEMBLY INSTALL OIL SEAL RINGS ON OVERDRIVE CASE Install the 2 oil seal rings to the overdrive case groove, then snug them down by squeezing their ends together. HINT: After installing the oil seal rings, check that they move smoothly.
Page 478 AX–75 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX043–05 OVERDRIVE BRAKE ASSEMBLY INSTALL PISTON INTO DRUM (a) Install new O–rings to the piston. Coat the new O–rings with ATF. (b) Press the piston into the drum, being careful not to dam- age the O–rings. INSTALL FLANGE, DISCS AND PLATES Install the flange, discs and plates.
Page 479 AX–76 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT INSTALL SNAP RING INTO CASE Be sure the end gap of the snap ring is not aligned with one of cutouts. INSTALL OVERDRIVE PLANETARY GEAR ONTO OV- ERDRIVE DIRECT CLUTCH While turning the overdrive planetary gear clockwise, install it onto the overdrive direct clutch.
Page 480 AX–77 AUTOMATIC TRANSAXLE – VALVE BODY VALVE BODY AX044–02 COMPONENTS AX0TW–01 VALVE BODY DISASSEMBLY NOTICE: When disassembling the valve body, be careful not to damage or deform the plate which overhangs the valve body. REMOVE SOLENOIDS (a) Remove No.1 and No.2 solenoids with the retainer. NOTICE: When removing the solenoid, do not use a screw- driver, etc.
Page 481 AX–78 AUTOMATIC TRANSAXLE – VALVE BODY REMOVE LOCK PLATE REMOVE B ACCUMULATOR ASSEMBLY (a) Remove the 3 bolts. (b) Remove the B accumulator assembly. DISASSEMBLE B ACCUMULATOR ASSEMBLY (a) Applying compressed air to the cylinder hole, remove the piston and spring. (b) Remove the 2 O–rings from the piston.
Page 482 AX–79 AUTOMATIC TRANSAXLE – VALVE BODY REMOVE OIL STRAINER, NO.1 LOWER VALVE BODY COVER GASKETS AND CHECK VALVE (a) Remove the 2 gaskets and plate from the lower valve body. (b) Remove the oil strainer, check valve and spring. REMOVE PRESSURE RELIEF VALVE REMOVE NO.2 LOWER VALVE BODY COVER, OIL STRAINER, CHECK BALLS AND VIBRATING STOP- Remove the 11 bolts and lower valve body cover.
Page 483 AX–80 AUTOMATIC TRANSAXLE – VALVE BODY 10. REMOVE NO.2 LOWER VALVE BODY COVER GAS- KETS AND CHECK BALLS (a) Remove the 2 screws from the lower valve body cover. (b) Remove the 2 gaskets and plate. (c) Remove the 3 check balls from the cover. 11.
Page 484 AX–81 AUTOMATIC TRANSAXLE – VALVE BODY 13. REMOVE 2 CHECK BALLS AND VIBRATING STOP- PER FROM UPPER VALVE BODY 14. REMOVE 2 OIL STRAINERS AND CHECK BALL FROM LOWER VALVE BODY AX0TX–01 VALVE BODY ASSEMBLY INSTALL 2 CHECK BALLS AND VIBRATING STOP- PER TO UPPER VALVE BODY INSTALL 2 OIL STRAINERS AND CHECK BALL TO LOWER VALVE BODY...
Page 485 AX–82 AUTOMATIC TRANSAXLE – VALVE BODY PLACE UPPER VALVE BODY WITH PLATE AND GAS- KETS ON LOWER VALVE BODY Hold the upper valve body, plate and gaskets securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate.
Page 486 AX–83 AUTOMATIC TRANSAXLE – VALVE BODY (b) Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. (c) Install the 2 screws. INSTALL NO.2 LOWER VALVE BODY COVER (a) Position the No.2 lower valve body cover. (b) Install and finger tighten the 11 bolts.
Page 487 AX–84 AUTOMATIC TRANSAXLE – VALVE BODY 10. INSTALL LOWER VALVE BODY COVER GASKETS AND NO.2 PLATE Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. 11. INSTALL LOWER VALVE BODY COVER (a) Position the lower valve body cover. (b) Install and finger tighten the 5 bolts.
Page 488 AX–85 AUTOMATIC TRANSAXLE – VALVE BODY (d) Install the B accumulator assembly. (e) Install the torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) 15. INSTALL LOCK PLATE 16. INSTALL SOLENOIDS (a) Coat new O–rings with ATF and install them to the sole- noids.
Page 489 AX–86 AUTOMATIC TRANSAXLE – UPPER VALVE BODY UPPER VALVE BODY AX047–03 COMPONENTS...
Page 490 AX–87 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX048–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Free Length / Outer Diameter Name (Color) Total No. of Coils mm (in.) Lock–Up Relay Valve (Yellow) 26.8 (1.055) / 10.2 (0.402)
Page 491 AX–88 AUTOMATIC TRANSAXLE – UPPER VALVE BODY Low Coast Modulator Valve (Purple) 20.2 (0.795) / 7.9 (0.311) 11.9 [c E]...
Page 492 AX–89 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GZ–02 RETAINERS, PIN, AND CHECK BALLS LOCATION PIN, RETAINERS Height / Width / Thickness Mark Name mm (in.) @@@@@: [c A] Orifice Control Valve 8.9 (0.350) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] Low Coast Modulator Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) CHECK BALLS...
Page 493 AX–90 AUTOMATIC TRANSAXLE – LOWER VALVE BODY LOWER VALVE BODY AX04A–03 COMPONENTS...
Page 494 AX–91 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX04B–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Free Length / Outer Diameter Name (Color) Total No. of Coils mm (in.) Accumulator Control Valve (Red) 25.1 (0.988) / 8.6 (0.339)
Page 495 AX–92 AUTOMATIC TRANSAXLE – LOWER VALVE BODY Cut–Back Valve (None) 21.8 (0.858) / 6.0 (0.236) 13.5 [c E] Primary Regulator Valve (None) 36.6 (1.441) / 16.1 (0.634) [c F] 3–4 Shift Valve (None) 28.0 (1.102) / 7.6 (0.299) 10.3 [c G] Second Lock Valve (None) 20.7 (0.815) / 7.4 (0.291) [c H]...
Page 496 AX–93 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0TY–01 RETAINERS AND CHECK BALLS LOCATION RETAINERS Mark Name Height / Width / Thickness mm (in.) @@@@@: [c A] Accumulator Control Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] 2–3 Shift Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c C]...
Page 497 AX–94 AUTOMATIC TRANSAXLE – LOWER VALVE BODY Lower Side...
Page 498 AX–95 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY AX04D–02 COMPONENTS...
Page 499 AX–96 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0TZ–02 DIFFERENTIAL CASE DISASSEMBLY REMOVE SIDE BEARING Using SST, remove the 2 side bearings. SST 09608–16011, 09550–40010 REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. (b) Remove the 12 bolts. (c) Using a plastic hammer, tap out the ring gear.
Page 500 AX–97 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DISASSEMBLE DIFFERENTIAL CASE (a) Drive out the pinion shaft lock pin from the side on which the ring gear is installed. (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and side gears with the 4 thrust washers.
Page 501 AX–98 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (d) Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 in.) Refering to the table below, select thrust washers which will ensure that the backlash is within specification.
Page 502 AX–99 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY INSTALL SIDE BEARING (a) Install the speedometer drive gear onto the differential case. (b) Using SST and a press, press in the RH side bearing onto the differential case. SST 09316–20011 (c) Using SST and a press, press in the LH side bearing onto the differential case.
Page 503 AX–100 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION AX04G–06 Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately.
Page 504 AX–101 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION Thrust Bearing Outside Diameter Thrust Bearing Inside Diameter Mark mm (in.) mm (in.) See page AX–118 27.7 (1.091) 47.6 (1.874) 31.4 (1.236) 45.5 (1.791) 30.1 (1.185) 45.5 (1.791) 30.1 (1.185) 38.7 (1.524) 22.6 (0.890) 46.3 (1.823) 28.6 (1.126)
Page 505 AX–102 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AX0U1–02 DIFFERENTIAL AND DRIVE PINION INSTALLATION INSTALL DRIVE PINION INTO TRANSAXLE CASE (a) Using SST, install the bearing to the drive pinion shaft. SST 09350–32014 (09351–32120) (b) Place the bearing cage onto the drive pinion shaft. NOTICE: Be careful not to damage the oil seals with the pinion shaft.
Page 506 AX–103 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION PLACE OIL SLINGER AND NEW SPACER HINT: Install the spacer with the small end downward. INSTALL OUTER RACE TO TRANSAXLE CASE Using SST, press in the outer race. SST 09350–32014 (09351–32100, 09351–32140) INSTALL COUNTER DRIVE GEAR (a) Place a brass bar into the transaxle hole to hold the drive pinion shaft.
Page 507 AX–104 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION If the preload is less then specified, retighten the nut 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the speci- fied preload is reached. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure.
Page 508 AX–105 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL CARRIER COVER (a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case. (b) Apply seal packing to the carrier cover. Seal packing: Part No.08826–00090, THREE BOND 1281 or equiva- lent...
Page 509 AX–106 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AT3700:Adjusting shim thickness mm (in.) Mark Thickness Mark Thickness 2.00 (0.0787) 2.45 (0.0965) 2.05 (0.0807) 2.50 (0.0984) 2.10 (0.0827) 2.55 (0.1004) 2.15 (0.0846) 2.60 (0.1024) 2.20 (0.0866) 2.65 (0.1043) 2.25 (0.0886) 2.70 (0.1063) 2.30 (0.0906) 2.75 (0.1083) 2.35 (0.0925)
Page 510 AX–107 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL NEW OIL SEAL (a) Place the oil baffle onto the LH bearing retainer. (b) Using SST, drive in a new oil seal unit its end is flush with surface of the LH bearing retainer. SST 09223–15010 13.
Page 511 AX–108 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 14. INSTALL DRIVE PINION CAP (a) Install a new O–ring to the cap. (b) Install the drive pinion cap to the transaxle case. AX0U2–03 4–SPEED GEAR UNIT INSTALLATION INSTALL PARKING LOCK PAWL (a) Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl.
Page 512 AX–109 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface. (g) Match the collar hole to the lever caulking hollow and caulk the collar to the lever. (h) Install the retaining spring.
Page 513 AX–110 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE (a) Coat the new O–rings with ATF. (b) Install the 2 O–rings on the piston. (c) Push the piston into the bore of the case, facing the spring seat upward.
Page 514 AX–111 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL OVERDRIVE UNIT (a) Install the overdrive brake apply gasket and overdrive clutch apply gasket. (b) Install the overdrive brake drum to the case. (c) Install the new case gasket to the case. (d) Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 in.).
Page 515 AX–112 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (g) Coat the threads of 23 mm (0.91 in.) bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equiva- lent (h) Install and tighten the 13 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 61 mm (2.402 in.) Bolt B 38 mm (1.496 in.)
Page 516 AX–113 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Install the rear planetary gear. 11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE (a) Install the 6 plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D–P–D–P–D (b) Install the flange, facing the flat end downward. (c) Install the snap ring.
Page 517 AX–114 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL NO.2 ONE–WAY CLUTCH INTO CASE (a) Place the No.2 one–way clutch with the shiny side of flange upward. (b) Install the one–way clutch while turning the planetary gear clockwise with SST. SST 09350–32014 (09351–32050) If the planetary gear cannot turn clockwise, check the installation of the one–way clutch.
Page 518 AX–115 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the No.1 one–way clutch onto the rear planetary gear. 16. INSTALL SECOND BRAKE (a) Install the flange, facing the flat end upward. (b) Install the 3 discs and plates. Install in order: P=Plate D=Disc D–P–D–P–D–P (c) Place the piston return spring into the case.
Page 519 AX–116 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL NEW SECOND BRAKE GASKET Install a new gasket until it makes contact with the second brake drum. 18. CHECK OPERATION OF SECOND BRAKE Apply compressed air into the second brake gasket and confirm that the piston moves.
Page 520 AX–117 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 21. INSTALL FRONT PLANETARY GEAR (a) Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear. Bearing outer diameter: 45.5 mm (1.791 in.) Bearing inner diameter: 30.1 mm (1.185 in.) (b) Install the planetary gear onto the sun gear.
Page 521 AX–118 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Coat the bearing with petroleum jelly and install it onto the front side of the forward clutch. HINT: There are 2 different thickness bearings for adjust- ment of the input shaft thrust play. Bearing thickness mm (in.) Thickness...
Page 522 AX–119 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case. NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum.
Page 523 AX–120 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm 57–114 psi). SST 09240–00020 Piston stroke: 2.0–3.5 mm (0.079–0.138 in.) If the stroke is more than specified, replace the piston rod with a longer one.
Page 524 AX–121 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION PLACE NEW SECOND BRAKE APPLY GASKET INSTALL SOLENOID WIRE INSTALL THROTTLE CABLE INSTALL VALVE BODY TO TRANSAXLE CASE (a) While holding the cam down with your hand, slip the cable end into the slot. (b) Lower the valve body into place.
Page 525 AX–122 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Install and tighten the 9 bolts. HINT: Each bolt length is indicated below. Hand tighten the 9 bolts first, then torque with a torque wrench. Bolt length: Bolt A: 30 mm (1.181 in.) Bolt B: 43 mm (1.693 in.) Bolt C: 48 mm (1.890 in.) Bolt D: 52 mm (2.047 in.)
Page 526 AX–123 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION INSTALL OIL PIPES Using a plastic hammer, install the pipes into the posi- tions. NOTICE: Be careful not to bend or damage the pipes. 10. INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length is indicated below. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 37 mm (1.457 in.)
Page 527 AX–124 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL MAGNETS IN PLACE NOTICE: Make sure that the magnets do not interfere with the oil pipes. 13. INSTALL OIL PAN WITH NEW GASKET (a) Install a new gasket and oil pan. (b) Install and torque the 17 bolts.
Page 528 AX–125 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch to the manual valve shaft. (b) Place the new locking plate and tighten the nut. (c) Stake the nut with locking plate. (d) Install the 2 bolts.
Page 529 AX–126 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL SHIFT CONTROL CABLE BRACKET...
Page 530 AX–127 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS AX0H1–06 SERVICE DATE Second Coast Brake 2.0 – 3.5 mm Piston stroke 0.079 – 0.138 in. 95.2 mm Piston rod length 3.748 in. 96.3 mm 3.791 in. Oil Pump 0.07 – 0.15 mm Body clearance 0.0028 –...
Page 531 AX–128 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Front Planetary Gear 22.59 mm Sun gear bushing inside diameter Maximum 0.8894 in. 30.08 mm Ring gear flange bushing inside diameter Maximum 1.1842 in. 0.61 mm Planetary pinion gear thrust clearance Maximum 0.024 in. Rear Planetary Gear 0.61 mm Planetary pinion gear thrust clearance...
Page 532 AX–129 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Valve Body Spring Free length / Coil outer diameter Spring Total No. of coils / Color mm (in.) Upper valve body Low coast modulator valve 20.2 (0.795) / 7.9 (0.311) 11.9 / Purple orifice control valve 24.8 (0.976) / 6.4 (0.252) 12.0 / White Down–shift plug...
Page 533 AX–130 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Accumulator Spring Spring Free length mm (in.) Color Inner 47.5 (1.870) White Outer 16.3 (0.642) None 73.6 (2.898) None 51.8 (2.039) Yellow / Purple 66.8 (2.630) Red / Yellow Inner 70.3 (2.767) None Outer 88.2 (3.473) None Differential Assembly...
Page 534 AX–131 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in. Side bearing adjusting shim thickness Mark 2.20 mm 0.0866 in. 2.25 mm 0.0886 in. 2.30 mm 0.0906 in. 2.35 mm 0.0925 in.
Page 535 AX–132 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS AX04N–03 TORQUE SPECIFICATIONS Part tightened N·m kgf·cm ft·lbf Oil cooler pipe union Oil pan 43 in.·lbf Valve body x Transaxle case Accumulator x Cover Oil pump x Transaxle case O/D case x Transaxle case Differential LH side bearing retainer Differential RH retainer Differential carrier cover...
Page 536 AX–1 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX03L–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN sec- tion. Author : Date : 1921...
Page 537 AX–2 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AX03M–01 OPERATION Planetary Gear Unit 1st and Reverse 2nd Coast Brake 2nd Brake (B O/D Direct Clutch (C Brake (B Forward Clutch O/D Brake (B One–Way Clutch Direct Clutch No.2 (F One–Way Clutch O/D One–Way Clutch No.1 (F Counter Drive...
Page 538 AX–3 AUTOMATIC TRANSAXLE (A541E) – VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR AX03N–01 ON–VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT VEHICLE SPEED SENSOR CONNEC- REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Q05725 Remove the clip and driven gear from the vehicle speed sensor.
Page 539 AX–4 AUTOMATIC TRANSAXLE (A541E) – DIRECT CLUTCH SPEED SENSOR DIRECT CLUTCH SPEED SENSOR AX03O–01 ON–VEHICLE REPAIR DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR REMOVE DIRECT CLUTCH SPEED SENSOR Remove the bolt and direct clutch speed sensor. Q05726 Remove the O–ring from direct clutch speed sensor. INSTALL DIRECT CLUTCH SPEED SENSOR O–Ring Coat a new O–ring with ATF and install it to the direct...
Page 540 AX–5 AUTOMATIC TRANSAXLE (A541E) – PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AX03P–01 ON–VEHICLE REPAIR DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR Q00229 REMOVE PARK/NEUTRAL POSITION SWITCH Remove the clip from the shift control cable. Remove the nut and control cable. Q06496 Remove the nut, washer and transaxle control shaft lever.
Page 541 AX–6 AUTOMATIC TRANSAXLE (A541E) – PARK/NEUTRAL POSITION (PNP) SWITCH Adjust the park/neutral position switch. Neutral (See page DI–438) Basic Line Groove Z10304 Install the transaxle control shaft lever and washer. Install and torque the nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Q04687 Install the control cable and nut.
Page 542 AX–7 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX03Q–02 ON–VEHICLE REPAIR DRAIN ATF Using a hexagon wrench, remove the drain plug and fluid into the suitable container. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove oil pan bolts, and carefully remove the pan assembly.
Page 543 AX–8 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY REMOVE DETENT SPRING AND OIL PIPE Remove the 2 bolts and detent spring. Remove the bolt. Pry up the pipe with a screwdriver and remove the pipe. D01020 REMOVE MANUAL VALVE BODY Remove the 5 bolts and manual valve body.
Page 544 AX–9 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY Disconnect the throttle cable from the cam and remove the valve body. REMOVE 2ND BRAKE APPLY GASKET OR0038 REMOVE SOLENOID VALVES Remove the 3 bolts, shift solenoid valve No.1 and No.2 with the retainer. NOTICE: When removing solenoid, do not use a screwdriver, etc.
Page 545 AX–10 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY Coat the 2 new O–rings with ATF and install it to the shift solenoid valve SLN. Install the shift solenoid valve SLN. Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Q05402 Coat the 2 new O–rings with ATF and install it to the shift solenoid valve No.1 and No.2.
Page 546 AX–11 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY INSTALL CONNECTOR CLAMP AND PIPE RETAINER Install the connector clamp and pipe retainer. Install and torque the 2 bolts. Bolt length: Bolt A: 48 mm (1.890 in.) Bolt B: 39 mm (1.535 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) D01059 INSTALL MANUAL VALVE BODY...
Page 547 AX–12 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY INSTALL OIL STRAINER AND APPLY PIPE BRACKET Install the oil strainer and apply pipe bracket. Install and torque the 6 bolts. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 53 mm (2.087 in.) Torque: Bolt A: 10 N·m (100 kgf·cm, 7 ft·lbf) Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf)
Page 548 AX–13 AUTOMATIC TRANSAXLE (A541E) – THROTTLE CABLE THROTTLE CABLE AX03R–01 ON–VEHICLE REPAIR REMOVE BATTERY w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Remove the 3 bolts and cruise control actuator. Q09982 DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–5) REMOVE VALVE BODY...
Page 549 AX–14 AUTOMATIC TRANSAXLE (A541E) – THROTTLE CABLE CONNECT THROTTLE CABLE TO ENGINE Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) ADJUST THROTTLE CABLE (See page DI–438) INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–5) Q00225 w/ Cruise Control: INSTALL CRUISE CONTROL ACTUATOR Install the cruise control actuator with the 3 bolts.
Page 550 AX–15 AUTOMATIC TRANSAXLE (A541E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX03S–01 ON–VEHICLE REPAIR REMOVE FRONT DRIVE SHAFT (See page SA–25) REMOVE SIDE GEAR SHAFT OIL SEAL Using SST, pull out the oil seal. 09308–00010 Q00394 INSTALL LEFT SIDE GEAR SHAFT OIL SEAL Using SST and a hammer, drive in a new oil seal.
Page 551 AX–16 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMC Made) SHIFT LOCK SYSTEM (TMC Made) AX03T–01 LOCATION Key Interlock Solenoid Shift Lock Override Cover Stop Light Switch Shift Lock Override Button Shift Lock Control Unit Assembly D01026 Author : Date : 1936...
Page 552 AX–17 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMC Made) AX03U–02 INSPECTION 5 (IG) INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY 1 (ACC) 4 (KLS+) Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connec- 3 (E) tor.
Page 553 AX–18 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) SHIFT LOCK SYSTEM (TMMK Made) AX03V–01 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Override Cover Shift Lock Override Button Shift Lock Solenoid Shift Lock Control Switch Shift Lock Control ECU D01027 Author : Date :...
Page 554 AX–19 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) AX03W–01 INSPECTION 3 (IG) 1 (ACC) 6 (STP) Back Side INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure voltage at each terminal. 1 (P) 5 (E) 4 (KLS+) HINT: 4 (P2) 5 (SLS–) Do not disconnect the ECU connector.
Page 555 AX–20 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) INSPECT KEY INTERLOCK SOLENOID 1 (KLS+) Disconnect the solenoid connector. Using an ohmmeter, measure resistance between termi- nals. Standard resistance: 12.5 – 16.5 Ω 2 (E) If resistance value is not as specified, replace the solenoid. Q09456 Apply battery positive voltage between terminals.
Page 556 AX–21 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03X–01 COMPONENTS Engine Hood Air Cleaner Assembly 26 (265, 19) 13 (130, 9) w/ Cruise Control : Cruise Control Actuator Shift Control Cable Clamp RH Drive Shaft Starter S Snap Ring 39 (400, 29) 32 (330, 24) 41 (420, 30)
Page 557 AX–22 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT Stabilizer Bar Link RH Fender Apron Seal Rear Side Engine Stabilizer Bar Mounting Insulator RH Rear Lower Brace 19 (195, 14) 36 (370, 27) 32 (330, 24) 80 (820, 59) Steering Return Pipe 10 (100, 7) 39 (400, 29) 181 (1,850, 134)
Page 558 AX–23 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AX03Y–01 REMOVAL REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY REMOVE THROTTLE CABLE FROM THROTTLE BODY Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Q00225 w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector. Remove the 3 bolts and disconnect cruise control actua- tor with the bracket.
Page 559 AX–24 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque: TMC Made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK Made: Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (440 kgf·cm, 32 ft·lbf) Q06478 REMOVE STARTER AND A/T SHIFT CABLE CLAMP Disconnect the connector and remove the nut.
Page 560 AX–25 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT REMOVE ENGINE UNDER FRONT COVER AND NO.4 CENTER ENGINE UNDER COVER REMOVE EXHAUST FRONT PIPE Remove the 2 bolts and exhaust front pipe support stay. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 4 nuts.
Page 561 AX–26 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT DISCONNECT 2 OIL COOLER HOSES Q10027 REMOVE REAR SIDE ENGINE MOUNTING NUT Remove the 2 grommets. Remove the 4 nuts. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) Q10071 REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT Remove the 2 grommets.
Page 562 AX–27 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT ATTACH ENGINE SLING DEVICE TO ENGINE HANG- Install the No.2 engine hanger in the correct direction. Part No.: Engine No.2 engine hanger: 12282–20020 Hanger Bolt: 91642–80825 Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Attach the engine chain hoist to the engine hangers.
Page 563 AX–28 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts and 4 nuts. Front Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) Remove the front frame assembly.
Page 564 AX–29 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AX03Z–01 INSTALLATION CHECK TORQUE CONVERTER CLUTCH INSTALLA- TION Using a scale and a straight edge, measure from the installed surface to the transaxle housing. Correct distance: 13.7 mm (0.539 in.) or more AT3412 TRANSAXLE INSTALLATION Installation is in the reverse order of removal.
Page 565 AX–30 AUTOMATIC TRANSAXLE (A541E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX040–01 INSPECTION INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. 09350–32014 (09351–32020) AT0952 Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch.
Page 566 AX–31 AUTOMATIC TRANSAXLE (A541E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque con- verter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 in.) If the runout is not within the specification, try to correct by reori- enting the installation of the converter.
Page 567 BO–1 BODY – CLIP CLIP BO0LJ–01 REPLACEMENT 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. Shape (Example) Removal/Installation Pliers...
Page 568 BO–2 BODY – CLIP Shape (Example) Removal/Installation Removal Installation Removal Installation V00012 Author : Date : 2350...
Page 569 BO0KU–01 PRECAUTION The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag, front passen- ger airbag, side airbag and seat belt pretensioner. Failure to carry out service operation in the correct se- quence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious acci- dent.
Page 570: Front Bumper
BO–4 BODY – FRONT BUMPER FRONT BUMPER BO0KV–01 COMPONENTS Turn Signal Light Assembly Turn Signal Light Assembly Upper Reinforcement Clip Sub–Assembly Fender Liner No.2 Reinforcement 34 (350, 25) 5.5 (55, 49 in.·lbf) Front Bumper Clip Reinforcement Emblem, 34 (350, 25) Fender Liner Radiator Grill Energy Absorber...
Page 571 BO–5 BODY – FRONT BUMPER BO0KW–01 REMOVAL REMOVE THESE PARTS: Engine under cover Fender liner Turn signal light assembly HINT: Remove the light assembly as shown. H01709 REMOVE BUMPER COVER Remove the 2 bolts and 3 clips. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) H01710 Remove the bolt holding the bumper end to the fender.
Page 572 BO–6 BODY – FRONT BUMPER BO0KX–01 INSTALLATION Installation is in the reverse order of removal (See page BO–5). Author : Date : 2354...
Page 573: Rear Bumper
BO–7 BODY – REAR BUMPER REAR BUMPER BO0KY–01 COMPONENTS Left Side Luggage Trim Right Side Luggage Trim Rear Bumper Reinforcement Rear Bumper Energy Absorber 34 (350, 25) Rear Bumper 5.0 (50, 43 in.·lbf) Side Retainer 5.0 (50, 43 in.·lbf) Quarter Air Duct Rear Bumper Side Retainer Rear Bumper Cover...
Page 574 BO–8 BODY – REAR BUMPER BO0KZ–01 REMOVAL REMOVE THESE PARTS: Right side luggage trim Left side luggage trim REMOVE REAR BUMPER COVER Remove the 7 clips, 2 bolts and 6 nuts from the bumper cover. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) H01714 Pull the bumper cover rearward to remove it.
Page 575 BO–9 BODY – REAR BUMPER BO0L0–01 INSTALLATION Installation is in the reverse order of removal (See page BO–8). Author : Date : 2357...
Page 576 BO–10 BODY – HOOD HOOD BO0L1–01 ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock can not be adjusted with it on. Substitute a bolt and washer for the centering bolt. Centering Bolt Bolt with Washer BO5235...
Page 577 BO–11 BODY – FRONT DOOR FRONT DOOR BO0L2–01 COMPONENTS Front Door Upper Moulding Front Door Belt Moulding Outside Door Lock Rear View Cylinder Mirror Outside Handle Door Glass 5.5 (55, 49 in.·lbf) Door Frame 5.0 (50, 43 in.·lbf) Door Glass Door Lock 5.5 (55, 49 in.·lbf) Service Hole Cover...
Page 578 BO–12 BODY – FRONT DOOR BO0L3–01 DISASSEMBLY w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. HINT: At the time of assembly, please refer to the following item. With the door window fully closed, install the plate and the regu- lator handle with the snap ring.
Page 579 BO–13 BODY – FRONT DOOR REMOVE DOOR GLASS Open the door glass until the bolt appears in the service hole. Remove the 2 bolts and the door glass. HINT: Pull the glass upward. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) REMOVE GLASS RUN HINT: N20970...
Page 580 BO–14 BODY – FRONT DOOR REMOVE WINDOW REGULATOR ASSEMBLY w/ Power Window: Remove the bolts and window regulator. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator rollers. w/ Power Window: REMOVE MOTOR FROM WINDOW REGULATOR Remove the 3 screws and motor.
Page 581 BO–15 BODY – FRONT DOOR BO0L4–01 ADJUSTMENT ADJUST DOOR IN FORWARD/REARWARD AND VER- TICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. 09812–00020 Torque: 31 N·m (310 kgf·cm, 22 ft·lbf) N20966 ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS To adjust, loosen the door side hinge.
Page 582 BO–16 BODY – FRONT DOOR BO0L5–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–12). Author : Date : 2364...
Page 583 BO–17 BODY – REAR DOOR REAR DOOR BO0L6–01 COMPONENTS Rear Door Upper w/o Power Door Moulding Lock: Door Belt Moulding Door Lock Door Glass Outside handle 7.0 (70, 61 in.·lbf) Door Glass Run Door Lock Door Lock Control Link Child Protector Lock Lever Cover 5.0 (50, 43 in.·lbf) 8.0 (80, 71 in.·lbf)
Page 584 BO–18 BODY – REAR DOOR BO0L8–01 DISASSEMBLY w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. HINT: At the time of reassembly, please refer to the following item. With the door window fully closed, install the plate and the regu- lator handle with the snap ring.
Page 585 BO–19 BODY – REAR DOOR REMOVE DOOR GLASS AND RUN Remove the bolt and nut holding the rear side frame to the door. Remove the 2 bolts holding the door glass to the window regulator. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) Remove the rear side frame and the rear section of the door glass run.
Page 586 BO–20 BODY – REAR DOOR REMOVE WINDOW REGULATOR ASSEMBLY w/ Power Window: Remove the bolts and window regulator assembly. Torque: 5.5 N·m (55 kgf·cm,49 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator rollers. w/ Power Window: REMOVE MOTOR FROM WINDOW REGULATOR Remove the 3 screws and motor.
Page 587 BO–21 BODY – REAR DOOR BO0L7–01 ADJUSTMENT ADJUST DOOR IN FORWARD/REARWARD AND VER- 3 Clips TICAL DIRECTION 2 Clips Remove the front part of the rear seat side garnish. Remove the rear part of the front door inside scuff plate. Remove the center pillar lower garnish.
Page 588 BO–22 BODY – REAR DOOR BO0L9–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–18). Author : Date : 2370...
Page 589 BO–23 BODY – OUTSIDE REAR VIEW MIRROR OUTSIDE REAR VIEW MIRROR BO0LA–01 COMPONENTS Outside Rear View Mirror Cover 5.5 (55, 49 in.·lbf) Door Trim N·m (kgf·cm, ft·lbf) : Specified Torque H01758 Author : Date : 2371...
Page 590 BO–24 BODY – OUTSIDE REAR VIEW MIRROR BO0LB–01 DISASSEMBLY IMI: IDENTIFY OUTSIDE REAR VIEW MIRROR Mirror w/ Power Rear View Mirror: UTA: Mirror Shell The mirror moves smoothly when pressing the end of the mirror inward. w/ Power Rear View Mirror: Gasket IMI: UTA:...
Page 591 BO–25 BODY – OUTSIDE REAR VIEW MIRROR TOKAIRIKA: Shop Towel DISASSEMBLE OUTSIDE REAR VIEW MIRROR Disconnect the battery. Slide a shop towel between the mirror and the mirror housing as shown. Pull the ends of the shop towel upward to disconnect the Mirror mirror from the housing.
Page 592 BO–26 BODY – OUTSIDE REAR VIEW MIRROR BO0LC–01 REASSEMBLY Gasket UTA: Mirror w/case ASSEMBLE OUTSIDE REAR VIEW MIRROR w/Heated Mirrors: Connect the heater wires. Install the wire retainer onto the mirror w/case assembly, then press the mirror firmly into place to engage the 6 lugs Wire Retainer Mirror Housing of the wire retainer.
Page 593 BO–27 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE LUGGAGE COMPARTMENT DOOR AND HINGE BO0LD–01 COMPONENTS Torsion Bar Luggage Compart- ment Door Hinge Luggage Compart- ment Door Hinge 8.0 (80, 71 in.·lbf) 8.0 (80, 71 in.·lbf) Luggage Compartment Door Luggage Compartment Door Trim Right Side Luggage Lock Cylinder...
Page 594 BO–28 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LE–01 REMOVAL REMOVE LUGGAGE COMPARTMENT DOOR TRIM REMOVE LUGGAGE COMPARTMENT DOOR Disconnect the connector. Using a clip remover, disconnect the clamps. Remove the 4 bolts and door. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) REMOVE THESE PARTS: Luggage compartment floor mat LH and RH rear floor finish side plates...
Page 595 BO–29 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE Install SST to the torsion bar on the hinge side. 09804–24010 BO4010 Push down on SST, and pull the luggage compartment door hinge from the torsion bar. BO4011 Slowly lift SST, and remove the torsion bar from the tor- sion bar bracket with SST.
Page 596 BO–30 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LF–01 DISASSEMBLY REMOVE DOOR LOCK Disconnect the control link. Remove the 2 bolts and lock. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) REMOVE REAR COMBINATION LIGHT Disconnect the connector. Remove the 10 nuts and rear combination lights. Author : Date : 2378...
Page 597 BO–31 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LG–01 ADJUSTMENT ADJUST LUGGAGE COMPARTMENT DOOR Remove the 11 clips and luggage compartment door trim. For forward/rearward and left/right adjustments loosen the bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) For vertical adjustment of the front end of the door, in- crease or decrease the number of washers between the hinge and the door.
Page 598 BO–32 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LH–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–30). Author : Date : 2380...
Page 599 BO–33 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LI–01 INSTALLATION INSTALL TORSION BAR Insert the torsion bar into the bracket. HINT: The center bracket opening is the nominal position of the tor- sion bar. If needed, move the torsion bar to the upper or lower hole to pro- vide the correct luggage door lift.
Page 600 BO–34 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE CHECK LUGGAGE DOOR LIFT Full Open Pop–up distance: 35 – 100 mm Pop– up to 1/2 open: Door should remain in any 1/2 Open position. Past 1/2 open: Door should open fully by itself.
Page 601: Front Wiper And Washer
BO–35 BODY – FRONT WIPER AND WASHER FRONT WIPER AND WASHER BO0LK–01 COMPONENTS Cowl Louver RH 24 (245, 18) Wiper Motor Wiper Arms Cowl Louver LH Weatherstrip Wiper Wiper Motor Link Assembly 5.5 (55, 49 in.·lbf) Window Washer Nozzle N·m (kgf·cm, ft·lbf) : Specified torque N21119 Author :...
Page 602 BO–36 BODY – FRONT WIPER AND WASHER BO0LL–01 REMOVAL REMOVE WIPER ARMS REMOVE WEATHERSTRIP AND COWL LOUVERS REMOVE WIPER MOTOR ASSEMBLY Disconnect the connector. Remove the 5 bolts and wiper motor assembly. REMOVE WIPER MOTOR Remove the 2 bolts, then separate the motor crank arm from the wiper links at the ball and socket joint.
Page 603 BO–37 BODY – FRONT WIPER AND WASHER BO0LM–01 ADJUSTMENT INSPECT WASHER NOZZLE While operating the washer, check that the washer fluid hits the windshield and the upsurge area within the shaded areas. U.S. mm (in.) Canada mm (in.), Approx. ”A” 280 (11) 600 (23.6) U.S.
Page 604 BO–38 BODY – FRONT WIPER AND WASHER BO0LN–01 INSTALLATION INSTALL WINDOW WASHER NOZZLE INSTALL WIPER LINK TO MOTOR INSTALL THESE PARTS: Wiper motor assembly Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) Cowl louvers and weatherstrip N20998 INSTALL WIPER ARMS Operate the wipers once and turn the wiper switch OFF, then install the wiper arms.
Page 605 BO–39 BODY – BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO0M8–01 COMPONENTS Front Door Rear Quarter Outside Moulding Outside Moulding Front Fender Front Quarter Outside Moulding Outside Moulding Rear Door Outside Moulding N22598 Author : Date : 2387...
Page 606 BO–40 BODY – BODY OUTSIDE MOULDING BO0M9–01 REMOVAL CAUTION: Store in a cool place, avoiding direct sunlight, high temperature and dust. The moulding is made of polyvinyl chloride. Do not al- low this material to come in contact with thinner or other solvents, open flame or boiling water.
Page 607 BO–41 BODY – BODY OUTSIDE MOULDING BO0MA–01 INSTALLATION HEAT BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface to 40 – 60 °C (104 – 140 °F). NOTICE: Do not heat body excessively. Remove the adhesive tape from the body. Wipe off stains with cleaner.
Page 608 BO–42 BODY – WINDSHIELD WINDSHIELD BO0LO–01 COMPONENTS Inside Rear View Mirror Map Light Assem- Sun Visor Weatherstrip Front Pillar Garnish Sun Visor Holder Windshield Glass Windshield Upper Moulding Stopper Weatherstrip Windshield Outside Moulding Wiper Arm Cowl Louver RH 24 (245, 18) Windshield Outside Cowl Louver LH...
Page 609 BO–43 BODY – WINDSHIELD BO0LP–01 REMOVAL REMOVE THESE PARTS: Inner rear view mirror Sun visors and holders Map light assembly Front pillar garnishes Hood Wiper arms Cowl louvers Weatherstrips REMOVE WEATHERSTRIP Remove the weatherstrip by pulling. HINT: Remove only the front half of weatherstrip. REMOVE WINDSHIELD OUTSIDE MOULDING Using a drill of less than ø...
Page 610 BO–44 BODY – WINDSHIELD NOTICE: When separating the glass, be careful not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad.
Page 611 BO–45 BODY – WINDSHIELD BO0LQ–01 INSTALLATION CLEAN AND SHAPE CONTACT SURFACE OF BODY Adhesive Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner.
Page 612 BO–46 BODY – WINDSHIELD INSTALL DAM Install the dam with double–stick tape as shown in the illustra- tion. NOTICE: Do not touch the glass face after cleaning it. A: 7 mm (0.276 in.) N21016 COAT CONTACT SURFACE OF BODY WITH PRIMER Primer ”M”...
Page 613 BO–47 BODY – WINDSHIELD INSTALL GLASS HINT: Adhesive Confirm that the dam is attached the body panel as shown in the illustration. N21019 Position the glass so that the reference marks are lined up, and press in gently along the rim. Using a spatula, apply adhesive on the glass rim.
Page 614 BO–48 BODY – WINDSHIELD INSTALL WINDSHIELD UPPER MOULDING Place the moulding onto the body and tap it in by hand. N22592 INSTALL WINDSHIELD OUTSIDE MOULDING Install the pawl of the outside moulding to the upper moulding to set the moulding to the body. Using an air riveter with nose piece, install the new 3 rivets and outside moulding.
Page 615 BO–49 BODY – BACK WINDOW GLASS BACK WINDOW GLASS BO0LR–01 COMPONENTS Back Window Moulding Back Window Glass z Dam Roof Side Rear Seatback 19 (185, 13) Inner Garnish Rear Side Seat Rear Side Seat Back LH Back RH 19 (185, 13) High–Mounted Stop Light 19 (185, 13)
Page 616 BO–50 BODY – BACK WINDOW GLASS BO0LS–01 REMOVAL REMOVE REAR SEAT CUSHION AND SEATBACKS REMOVE ROOF SIDE INNER GARNISHES Remove the clips. Pull the garnish to remove it. 3 Clips 1 Clip N21020 REMOVE HIGH–MOUNTED STOP LIGHT Push on the both side of the cover to release the claws by your hand and remove the cover as shown in the illustra- tion.
Page 617 BO–51 BODY – BACK WINDOW GLASS BO0LT–01 INSTALLATION HINT: Refer to the installation of windshield, install back window glass by the following operations. (See page BO–45) CLEAN AND SHAPE CONTACT SURFACE OF BODY CLEAN REMOVED GLASS REPLACE STOPPERS POSITION GLASS CLEAN CONTACT SURFACE OF GLASS INSTALL DAM Install the dam with double–stick tape as show in the illustration.
Page 618 BO–52 BODY – BACK WINDOW GLASS Room partition trims Seat belt lower side bolts Torque: 42 N·m (420 kgf·cm, 31 ft·lbf) High–mounted stop light Roof side inner garnish Rear seatbacks and seat cushion Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Author : Date : 2400...
Page 619 BO–53 BODY – SLIDING ROOF (TMC Made) SLIDING ROOF (TMC Made) BO0M1–01 ON–VEHICLE INSPECTION INSPECT SLIDING ROOF GLASS ALIGNMENT Start the engine and check the operation time of the slid- ing roof. Operation time: Approx. 6 secs. Check for abnormal noise or binding during operation. N10192 With the sliding roof fully closed, check for water leakage.
Page 620 BO–54 BODY – SLIDING ROOF (TMC Made) BO0M2–01 COMPONENTS Side Garnish Sliding Roof Glass Rear Roof Drip Channel Roof Window Deflector Panel Side Garnish Drive Cable Guide Block Guide Block Sliding Roof Housing Drive Gear Sunshade Trim Sliding Roof Guide Rail Stopper Panel Stopper Roof Rail Rear Frame...
Page 621 BO–55 BODY – SLIDING ROOF (TMC Made) BO0M3–01 REMOVAL REMOVE ROOF HEADLINING (See page BO–83) REMOVE SIDE GARNISH Using a screwdriver, remove the garnishes. HINT: Tape the screwdriver tip before use. REMOVE SLIDING ROOF GLASS ASSEMBLY Using a torx wrench, remove the 4 screws. Pull the glass upward to remove it.
Page 622 BO–56 BODY – SLIDING ROOF (TMC Made) REMOVE SLIDING ROOF HOUSING Disconnect the 4 drain hoses from the housing. Remove the 8 bolts and 4 brackets. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) Remove the 6 nuts, then remove the housing as shown on the following page.
Page 623 BO–57 BODY – SLIDING ROOF (TMC Made) BO0M4–01 DISASSEMBLY REMOVE SLIDING ROOF PANEL STOPPER Remove the 2 screws and 2 stoppers. REMOVE SUNSHADE TRIM N21523 REMOVE REAR ROOF DRIP CHANNEL Remove the rear roof drip channel as shown in the illustration. N21421 REMOVE REAR FRAME Remove the 4 screws and rear frame.
Page 624 BO–58 BODY – SLIDING ROOF (TMC Made) REMOVE GUIDE BLOCK Remove the 2 screws and guide block. N21420 REMOVE SLIDING ROOF HOUSING Remove the 6 screws and sliding roof housing. N21522 Author : Date : 2406...
Page 625 BO–59 BODY – SLIDING ROOF (TMC Made) BO0M5–01 ADJUSTMENT REMOVE SIDE GARNISH Before making adjustments, using a screwdriver, remove the side garnishes. HINT: Tape the screwdriver tip before use. After adjustment, reinstall the side garnishes. N21422 TO ADJUST FORWARD OR REARWARD Using a torx wrench, loosening the sliding roof glass installation screws.
Page 626 BO–60 BODY – SLIDING ROOF (TMC Made) BO0M6–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–57). Author : Date : 2408...
Page 627 BO–61 BODY – SLIDING ROOF (TMC Made) BO0M7–01 INSTALLATION Installation is in the reverse order of removal (See page BO–55). Author : Date : 2409...
Page 628 BO–62 BODY – SLIDING ROOF (TMMK Made) SLIDING ROOF (TMMK Made) BO0LU–01 ON–VEHICLE INSPECTION INSPECT SLIDING ROOF GLASS ALIGNMENT Start the engine and check the operation time of the slid- ing roof. Operation time: Approximately 6 sec. Check for abnormal noise or binding during operation. H01814 Check for water leakage with the sliding roof fully closed.
Page 629 BO–63 BODY – SLIDING ROOF (TMMK Made) BO0LV–01 COMPONENTS Sliding Roof Sliding Roof Glass Sunroof Opening Trim Headliner Assembly Room Light Map Light Assembly H01812 Author : Date : 2411...
Page 630 BO–64 BODY – SLIDING ROOF (TMMK Made) Wind deflector Roof Drip Channel Deflector Spring RH Lift Arm and Cable Assembly RH Roof Drip Channel Guide LH Roof Drip Channel Guide Sunshade Trim LH Lift Arm and Cable Assembly Drain Cap Drive Rail Assembly 5.5 (55, 49 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque...
Page 631 BO–65 BODY – SLIDING ROOF (TMMK Made) BO0LW–01 REMOVAL REMOVE ROOF HEADLINING (See page BO–83) REMOVE SIDE GARNISHES HINT: At the time of installation, please refer to the following item. Soak the garnishes in water to soften them before assembly. REMOVE GLASS PANEL ASSEMBLY Remove the 4 glass panel adjustment screws.
Page 632 BO–66 BODY – SLIDING ROOF (TMMK Made) BO0LX–01 DISASSEMBLY REMOVE SLIDING ROOF HOUSING DRAIN CAP Pull the drain cap rearward to remove it. HINT: At the time of reassembly, please refer to the following item. Apply seal packing to the drain cap. Seal packing: Part No.1 08826 –...
Page 633 BO–67 BODY – SLIDING ROOF (TMMK Made) REMOVE LH AND RH SIDING ROOF LIFT ARM AND CABLE ASSEMBLIES Using a drill, cut the flange portion of the stop pin (rivet) from each side rail. HINT: At the time of reassembly, please refer to the following item. Use two new rivets.
Page 634 BO–68 BODY – SLIDING ROOF (TMMK Made) BO0LY–01 ADJUSTMENT ALIGN THE MOTOR TO ”O” POSITION NOTICE: The ”O” position is the same as the sliding roof ”flush ” position (sliding roof closed). Use the vehicle sliding roof switch or a hex wrench to align the gear pointer with the motor housing pointer as shown.
Page 635 BO–69 BODY – SLIDING ROOF (TMMK Made) VERIFY CORRECT INSTALLATION TIMING Cycle the unit once (vent position closed, slide open, slide completely closed). HINT: After cycling the unit closed from the slide open position, verify the alignment holes in the cable arm and cam block are aligned and the motor pointers are in the ”O”...
Page 636 BO–70 BODY – SLIDING ROOF (TMMK Made) BO0LZ–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–66). Author : Date : 2418...
Page 637 BO–71 BODY – SLIDING ROOF (TMMK Made) BO0M0–01 INSTALLATION Installation is in the reverse order of removal (See page BO–65). NOTICE: Check and adjust the sliding roof after installation (See page BO–62). Author : Date : 2419...
Page 638 BO–72 BODY – INSTRUMENT PANEL INSTRUMENT PANEL BO0MB–01 COMPONENTS Instrument Panel Reinforcement No.2 Instrumental Panel Bracket No.1 Instrumental Panel Bracket No.2 Instrumental Panel Brace Instrument Panel Brace Mount No.1 Instrument Front Pillar Garnish Panel Brace Front 20 (200, 14) Front Pillar Passenger Garnish No.2 Side Defroster Nozzle...
Page 639 BO–73 BODY – INSTRUMENT PANEL Instrument Panel Wire Harness No.1 Defroster Nozzle Garnish Defroster Nozzle Assembly RH Side Defroster Duct Nozzle No.2 Heater Duct to Register No.1 No.3 Instrument Side Defroster Panel Register Duct Nozzle Assembly Instrument No.1 Heater Duct to Panel Center Register Bracket...
Page 640 BO–74 BODY – INSTRUMENT PANEL HINT: Screw shapes and size are indicated in the table below. The code (”A”–”P”) correspond to those indicated on the previous page. mm (in.) Code Shape Size Code Shape Size Code Shape Size ø = 5.2 (0.21) ø...
Page 641 BO–75 BODY – INSTRUMENT PANEL BO0MC–01 REMOVAL REMOVE THESE PARTS: HINT: Tape a screwdriver tip before use. Front door inside scuff plates Cowl side trims Front pillar garnishes Front door opening covers Lower finish plate REMOVE STEERING WHEEL (See page SR–11) REMOVE STEERING COLUMN COVERS Remove the steering tilt handle.
Page 642 BO–76 BODY – INSTRUMENT PANEL REMOVE GLOVE COMPARTMENT ASSEMBLY Using a screwdriver, remove the glove compartment door finish plate to the glove compartment box inside. NOTICE: When handling the airbag connector, be careful not to dam- age the airbag wire harness. HINT: Tape the screwdriver tip before use.
Page 643 BO–77 BODY – INSTRUMENT PANEL REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS–28) Remove the 2 bolts, 4 nuts and the front passenger airbag as- sembly. Torque: Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf) CAUTION: Store the front passenger airbag door facing upward (never downward).
Page 644 BO–78 BODY – INSTRUMENT PANEL Remove the bolt, nut, screw and the instrument panel as- sembly. N20994 REMOVE INSTRUMENT PANEL BRACES Remove the wire brackets and connector. Remove the bolt and connector from the No.1 instrument panel brace. w/ Wireless Control: Remove the nut and the wireless control unit from the No.1 instrument panel brace.
Page 645 BO–79 BODY – INSTRUMENT PANEL BO0MD–01 DISASSEMBLY REMOVE THESE PARTS: No.1 defroster nozzle garnish No.1 defroster nozzle RH side defroster duct nozzle No.1 side defroster duct nozzle No.1 heater duct to register No.2 heater duct to register No.2 register assembly No.3 register assembly No.1 register assembly REMOVE INSTRUMENT PANEL WIRE HARNESS...
Page 646 BO–80 BODY – INSTRUMENT PANEL BO0ME–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–79). Author : Date : 2428...
Page 647 BO–81 BODY – INSTRUMENT PANEL BO0MF–01 INSTALLATION Reassembly is in the reverse order of removal (See page BO–75). Author : Date : 2429...
Page 648 BO–82 BODY – ROOF HEADLINING ROOF HEADLINING BO0MG–01 COMPONENTS Assist Grip Roof Headlining Sun Visor Map Light Assembly Assist Grip Holder Cover Room Light Holder Sun Visor Center Pillar Garnish Front Pillar Garnish Roof Side Inner Garnish Rear Side Seat 42 (420, 31) Back RH Lower Center...
Page 649 BO–83 BODY – ROOF HEADLINING BO0MH–01 REMOVAL REMOVE THESE PARTS: Rear seat cushion Rear seatback and rear side seatbacks Front door scuff plates Front seat belt shoulder anchor bolts Sun visor and holders Assist grips Front pillar garnishes Rear door scuff plates Lower center pillar garnishes REMOVE ROOF SIDE INNER GARNISH (See page BO–28)
Page 650 BO–84 BODY – ROOF HEADLINING REMOVE ROOF HEADLINING 2 Clips Remove the 2 clips from the roof panel rear end. Remove the headlining. Bring out the headlining. N22971 Author : Date : 2432...
Page 651 BO–85 BODY – ROOF HEADLINING BO0MI–01 INSTALLATION Installation is in the reverse order of removal (See page BO–83). Author : Date : 2433...
Page 652 BO–85 BODY – ROOF HEADLINING BO0MI–01 INSTALLATION Installation is in the reverse order of removal (See page BO–83). Author : Date : 2433...
Page 653 BO–86 BODY – FRONT SEAT (Power Seat for TMC Made) FRONT SEAT (Power Seat for TMC Made) BO0MJ–01 COMPONENTS Headrest Seatback Frame Headrest Support z Hog Ring Hinge Cover 18 (185, 13) Seatback Cover 6.0 (61, 53 in.·lbf) w/ Side Airbag Assembly Side Airbag Assembly Seatback Pad 15 (150, 11)
Page 654 BO–87 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MK–01 REMOVAL REMOVE FRONT SEAT Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. Remove the 4 bolts. Disconnect the connector. Remove the front seat. NOTICE: Be careful not to damage the body.
Page 655 BO–88 BODY – FRONT SEAT (Power Seat for TMC Made) BO0ML–01 DISASSEMBLY REMOVE THESE PARTS: Headrest Switch knobs Seat cushion shield Lower seat cushion shield Power seat switch REMOVE SEATBACK ASSEMBLY Remove the 3 clips of the side airbag wire harness from the seat cushion frame.
Page 656 BO–89 BODY – FRONT SEAT (Power Seat for TMC Made) REMOVE REAR VERTICAL MOTOR Remove the 2 screws and front vertical motor. H01978 REMOVE SLIDE MOTOR Remove the 2 screws. Disconnect the No.1 drive cable, then remove the slide motor. H01979 REMOVE RECLINING MOTOR Remove the 2 screws.
Page 657 BO–90 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MM–01 REASSEMBLY INSTALL RECLINING MOTOR Connect the No.2 drive cable, then install the reclining motor with 2 screws. H01980 INSTALL SLIDE MOTOR Connect the No.1 drive cable, then install the slide motor with 2 screws.
Page 658 BO–91 BODY – FRONT SEAT (Power Seat for TMC Made) Hang the hook onto the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. INSTALL SEATBACK ASSEMBLY Install the seatback assembly with 4 bolts. Install the 2 clips of the side airbag wire harness to the seat cushion frame.
Page 659 BO–92 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MN–01 INSTALLATION Installation is in the reverse order of removal (See page BO–87). Author : Date : 2440...
Page 660 BO–93 BODY – FRONT SEAT (Power Seat for TMMK Made) FRONT SEAT (Power Seat for TMMK Made) BO0MU–01 COMPONENTS Front Seatback Cover Front Seatback Headrest Front Seat Cushion Cover Headrest Support z Hog Ring Front z Hog Ring Seatback Hinge Seatback Frame Cover Front Seat Cushion...
Page 661 BO–94 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MV–01 REMOVAL REMOVE FRONT SEAT Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. Remove the 4 bolts. w/ Side Airbag Assembly: Disconnect the connector. Disconnect the front power seat connector.
Page 662 BO–95 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MW–01 DISASSEMBLY REMOVE THESE PARTS: Switch knob Front seat cushion shield Front power seat switch Seat cushion lower shield w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY w/ Side Airbag Assembly: Remove the side airbag wire harness after removing...
Page 663 BO–96 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MX–01 REASSEMBLY INSTALL THESE PARTS: Front seat cushion inner shield Front seat cushion bracket Front seat cushion inner No.1 shield INSTALL SEAT CUSHION COVER Install the seat cushion cover to seat cushion pad. Install the seat cushion cover with pad to the seat cushion frame.
Page 664 BO–97 BODY – FRONT SEAT (Power Seat for TMMK Made) INSTALL SEATBACK ASSEMBLY Install the seatback assembly with 4 bolts. HINT: Tighten the 4 bolts temporarily, then from the bolt on the front right side tighten completely. Install Front Seatback hinge cover with bolts. Install a new hog rings.
Page 665 BO–98 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MY–01 INSTALLATION INSTALL FRONT SEAT Mount the seat to the vehicle. w/ Side Airbag: Connect the connector. Connect the front power seat connector. Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten completely. Slide the seat to the most rear position to install the bolts on the front side.
Page 666 BO–99 BODY – FRONT SEAT (Manual Seat for TMC Made) FRONT SEAT (Manual Seat for TMC Made) BO0MZ–01 COMPONENTS Headrest Seatback Pad z Hog Ring Headrest Support Seatback Cover Seatback Frame w/ Side Airbag: Seat Cushion Cover 6.0 (61, 53 in.·lbf) Side Airbag 18 (185, 13) Assembly...
Page 667 BO–100 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N0–01 REMOVAL REMOVE FRONT SEAT Using a screwdriver, remove the seat track outer cover. HINT: Tape the screwdriver tip before use. Remove the 4 bolts. w/ Side Airbag Assembly: Disconnect the connector. Remove the front seat.
Page 668 BO–101 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N1–01 DISASSEMBLY REMOVE THESE PARTS: Release handle Front seat cushion shield Vertical Seat Adjuster: Vertical adjuster knob Front seat cushion lower shield Seat cushion inner shield w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY...
Page 669 BO–102 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N2–01 INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF When reclining the seat, inspect that the outer and inner tracks are released at the same time. HINT: When the reclining lock positions slip off, disassemble the seat to adjust the position.
Page 670 BO–103 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N3–01 REASSEMBLY Vertical Seat Adjuster: INSTALL FRONT SEAT OUTER ADJUSTER Install front seat outer adjuster to front seat inner adjuster with E ring, nuts and bolts. w/o Vertical Seat Adjuster: INSTALL FRONT SEAT OUTER AND INNER AD- JUSTER Install the adjusters to the seat cushion frame.
Page 671 BO–104 BODY – FRONT SEAT (Manual Seat for TMC Made) w/ Side Airbag Assembly: Hang the hook on to the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. INSTALL SEATBACK ASSEMBLY Install the seatback assembly with bolts.
Page 672 BO–105 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N4–01 INSTALLATION INSTALL FRONT SEAT Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front positions slip off.
Page 673 BO–106 BODY – FRONT SEAT (Manual Seat for TMMK Made) FRONT SEAT (Manual Seat for TMMK Made) BO0MO–01 COMPONENTS Front Seatback Pad z Hog Ring Headrest Front Seatback Cover Front Seat Cushion Cover Headrest Support z Hog Ring Front Seatback Frame Front Seatback Hinge Cover...
Page 674 BO–107 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MP–01 REMOVAL REMOVE FRONT SEAT Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. Remove the 4 bolts. w/ Side Airbag Assembly: Disconnect the connector. Remove the front seat.
Page 675 BO–108 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MQ–01 DISASSEMBLY REMOVE THESE PARTS: Release handle Front seat cushion shield Vertical Seat Adjuster: Vertical adjuster knob Front seat cushion lower shield Front seatback hinge cover. w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY...
Page 676 BO–109 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MR–01 INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF When reclining the seat, inspect that the outer and inner tracks are released at the same time. HINT: When the reclining lock positions slip off, disassemble the seat to adjust the position.
Page 677 BO–110 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MS–01 REASSEMBLY INSTALL OUTER ADJUSTER SUB–ASSEMBLY Install the outer adjuster sub–assembly to the inner adjuster sub–assembly. INSTALL SEAT ADJUSTING HANDLE Install the seat track adjusting handle. INSTALL RECLINING CONNECTING PIPE Adjust the reclining lock positions of the seat adjusters.
Page 678 BO–111 BODY – FRONT SEAT (Manual Seat for TMMK Made) w/ Side Airbag Assembly: Hang the hook on to the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. INSTALL SEATBACK ASSEMBLY Install the seatback assembly with 4 bolts.
Page 679 BO–112 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MT–01 INSTALLATION INSTALL FRONT SEAT Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front positions slip off.
Page 680 BO–113 BODY – REAR SEAT (TMC Made) REAR SEAT (TMC Made) BO0NA–01 COMPONENTS Headrest Seatback Locking Knob Headrest Support Seatback Lock Knob Gromet Seatback Frame Rear Seatback Lock Control Seatback Pad Seatback Lock control Cable Rear Seatback lock Seatback Cover 17.5 (178, 12.5) Control Bezel Seat Belt Guide...
Page 681 BO–114 BODY – REAR SEAT (TMC Made) BO0NB–01 REMOVAL REMOVE LH SEATBACK ASSEMBLY Release lock to lean the seat back to front. Remove the clips. Remove the 2 bolts and LH seatback assembly. REMOVE RH SEAT BACK ASSEMBLY Release lock to lean the seatback to front. Remove the clips.
Page 682 BO–115 BODY – REAR SEAT (TMC Made) BO0NC–01 DISASSEMBLY REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. REMOVE THESE PARTS: HINT: Remove the clips to turn over the seatback cover before performing the following steps. Headrest Rear seatback lock control Bezel.
Page 683 BO–116 BODY – REAR SEAT (TMC Made) BO0ND–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–115). Author : Date : 2464...
Page 684 BO–117 BODY – REAR SEAT (TMC Made) BO0NE–01 INSTALLATION Installation is in the reverse order of removal (See page BO–114). Author : Date : 2465...
Page 685 BO–118 BODY – REAR SEAT (TMMK Made) REAR SEAT (TMMK Made) BO0N5–01 COMPONENTS Seatback Lock Knob Headrest Rear seatback Board Seatback Lock Knob Headres t Cover Support Rear Seatback Lock Rear Seatback frame Control Rear Seatback Pad Rear Seatback Cover 17.5 (178, 12.5) Rear Seatback Lock Control Cable...
Page 686 BO–119 BODY – REAR SEAT (TMMK Made) BO0N6–01 REMOVAL REMOVE SEAT CUSHION ASSEMBLY Remove the seat cushion assembly. HINT: Remove the rear seat inner with center belt from seat cushion slit to remove the seat cushion. Remove the 2 lock hooks. REMOVE LH SEATBACK ASSEMBLY Release lock to lean the seatback to front.
Page 687 BO–120 BODY – REAR SEAT (TMMK Made) BO0N7–01 DISASSEMBLY REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. REMOVE THESE PARTS: HINT: Remove the clips to turn over the seatback cover before performing the following steps. Headrest Rear seatback control Bezel Headrest supports...
Page 688 BO–121 BODY – REAR SEAT (TMMK Made) BO0N8–01 REASSEMBLY Reassembly is in the reverse order of disasssembly (See page BO–120). Author : Date : 2469...
Page 689 BO–122 BODY – REAR SEAT (TMMK Made) BO0N9–01 INSTALLATION Installation is in the reverse order of removal (See page BO–119). Author : Date : 2470...
Page 690: Seat Belt
BO–123 BODY – SEAT BELT SEAT BELT BO0NF–01 COMPONENTS Rear Seat Outer Belt 42 (420, 31) Center Belt 42 (420, 31) 42 (420, 31) Rear Seat Front Seat Outer Belt 42 (420, 31) Front Seat Front Seat Inner Belt 42 (420, 31) 42 (420, 31) Rear Seat Inner Belt 7.8 (79, 69 in.·lbf)
Page 691 BO–124 BODY – SEAT BELT BO0NG–01 INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill–bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious.
Page 692 BO–125 BODY – SEAT BELT Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. Tilt the retractor slowly. Full Belt Length Minus 200 mm (7.87 in.) N10070 Make sure that the belt can be pulled out at a tilt of 15 de- 15°...
Page 693: Seat Belt Pretensioner
BO–126 BODY – SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER BO0NH–01 REMOVAL NOTICE: If the wiring connector of the supplemental restraint system is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. Never use SRS parts from another vehicle. When re- placing parts, replace them with new parts.
Page 694 BO–127 BODY – SEAT BELT PRETENSIONER BO0NI–01 INSPECTION PRETENSIONER IS NOT ACTIVATED Perform a diagnostic system check. (See page DI–626) H00563 Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. Check for cuts and cracks in, or marked discolor- ation of the center pillar lower garnish.
Page 695 BO–128 BODY – SEAT BELT PRETENSIONER BO0NJ–01 DISPOSAL HINT: When scrapping vehicles equipped with a supplemental re- straint system or disposing of a front seat outer belt (with seat belt pretensioner) always first activate the seat belt pretension- er in accordance with the procedure described below. If any ab- normality occurs with the seat belt pretensioner operation, con- tact the SERVICE DEPT.
Page 696 BO–129 BODY – SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Battery Have a battery ready as the power source to deploy the airbag. AB0158 Check functioning of SST CAUTION: When deploying the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool.
Page 697 BO–130 BODY – SEAT BELT PRETENSIONER Connect the 2 SST, then connect them to the seat belt pretensioner. 09082–00700, 09082–00740 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of secondary lock of the twin lock.
Page 698 BO–131 BODY – SEAT BELT PRETENSIONER DEPLOYMENT WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTICE: When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer’s ve- hicle to deploy the seat belt pretensioner. Be sure to following the procedure given below when deploying the seat belt pretensioner.
Page 699 BO–132 BODY – SEAT BELT PRETENSIONER Deploy the seat belt pretensioner. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (–) terminal. Check that no one is within 10 m (33 ft) area around of the disc wheel.
Page 700 BO–133 BODY – SEAT BELT PRETENSIONER BO0NK–01 REPLACEMENT REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner. If the seat belt pretensioner has been activated. If the seat belt pretensioner has been found to be faulty in troubleshooting. If the front seat outer belt has been found to be faulty during the check in items 1–(b) or 2–(b).
Page 701 BO–134 BODY – SEAT BELT PRETENSIONER BO0NL–01 INSTALLATION NOTICE: Never use seat belt pretensioner from another vehicle. When replace parts, replace them with new parts. INSTALL FRONT SEAT OUTER BELT Install the front seat belt parts by following the reverse or- der of removal and torque the following bolts.
Page 702: Body Electrical System
SRS (SUPPLEMENTAL RESTRAINT SYSTEM) The CAMRY is equipped with an 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 replacement), be sure to read the precaution- ary notices in the RS section.
Page 703 BE–2 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BE09Z–03 PROBLEM SYMPTOMS TABLE POWER OUTLET Symptom Suspect Area See page 11.Battery – Electric power source cannot be taken out of the power outlet 12.POWER OUTLET Fuse (I/P J/B No.1) – 13.Wire Harness –...
Page 704 BE–3 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM (CANADA) Symptom Suspect Area See page Headlight does not light. 1. Wire Harness – (Taillight is normal) Headlight does not light. 1. Wire Harness – (Taillight does not light up) 1.
Page 705 BE–4 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. Integration Relay (I/P J/B No.1) BE–14 Taillight does not light. 2. Light Control Switch BE–24 (Headlight does not light) 3. Wire Harness – 1. TAIL Fuse (I/P J/B No.1) – 2. Taillight Control Relay (I/P J/B No.1) BE–24 Taillight does not light.
Page 706 BE–5 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. Bulb – Dome light does not light up. 2. Dome Light BE–32 3. Wire Harness – 1. Bulb – Map Light does not light up. 2. Map Light BE–32 3. Wire Harness –...
Page 707 BE–6 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM Washer fluid does not operate. 1. Washer Hose and Nozzle – D In wiper switch HI position, the wiper blade is in contact with 1. * Wiper Switch BE–40 the body. 2. Wire Harness –...
Page 708 BE–7 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. Bulb – 2. Seat Belt Buckle Switch BE–47 Seat Belt warning light does not light up. 3. Integration Relay (I/P J/B No.1) BE–47 4. Wire Harness – 1. IGN Fuse (I/P J/B No.1) –...
Page 709 BE–8 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. Bulb – 2. Meter Circuit Plate BE–46 Shift indicator lights do not light up. 3. Park/Neutral Position Switch (A140E) DI–424 (A541E) DI–479 4. Wire Harness – 1. Bulb – Only one shift indicator does not light up. 2.
Page 710 BE–9 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM ”Window Lock Illumination” does not light up. 1. Power Window Master Switch BE–60 1. GAUGE Fuse (I/P J/B No.1) – 2. Integration Relay (I/P J/B No.1) BE–60 Key–off power window does not operate. 3.
Page 711 BE–10 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM POWER SEAT CONTROL SYSTEM Symptom Suspect Area See page Power seat does not operate. 1. POWER M–Fuse (I/P J/B No.1) – (Door lock system does not operate) 2. Wire Harness – Power seat does not operate. 1.
Page 712: Power Source
BE–11 BODY ELECTRICAL – POWER SOURCE POWER SOURCE BE0A0–03 LOCATION Engine Room Relay Block No.1 Engine Room Junction Block No.2 Engine Room Relay Block No.2 Instrument Panel Junction Block No.1 Turn Signal Flasher Z19043 Author : Date : 2231...
Page 713 BE–12 BODY ELECTRICAL – POWER OUTLET POWER OUTLET BE0A1–03 LOCATION Power Outlet Instrument Panel J/B No.1 D PWR OUTLET Fuse N20688 Author : Date : 2232...
Page 714 BE–13 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A2–03 LOCATION Key Unlock Warning Switch Instrument Panel J/B No.1 D Integration Relay Ignition Switch N20687 Author : Date : 2233...
Page 715 BE–14 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A3–02 INSPECTION INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK LOCK – No continuity START 2 – 3 Continuity 2 – 3 – 4 Continuity 6 – 7 1 –...
Page 716 BE–15 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Connect the negative (–) lead from the battery to terminal Disconnect the negative (–) lead from the battery to termi- nal 5. Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. N20128 Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE B) OPERA-...
Page 717 BE–16 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Disconnect the negative (–) lead from the battery to termi- nal 6. Check that the buzzerr stops sounding. N20133 Connect the negative (–) lead from the battery to terminal Disconnect the negative (–) lead from the battery to termi- nal 5.
Page 718 BE–17 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Disconnect the connector from the integration relay and Wire harness side: inspect the connector on the wire harness side. 1 2 3 4 N20136 Tester connection Condition Specified condition 1 –...
Page 719 BE–18 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF (Door closed) No continuity 6 –...
Page 720 BE–19 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Passenger’s door courtesy switch ON (Door A6 – Ground Continuity opened) Passenger’s door unlock detection switch OFF A7 – Ground No continuity (Door locked) Passenger’s door unlock detection switch ON A7 –...
Page 721 BE–20 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Tester connection Condition Specified condition All door courtesy switches OFF (Except Driver’s 2 – Ground No continuity Door/ Door closed) One of the door courtesy switches ON (Except 2 – Ground Continuity Driver’s Door/ Door opened) Door courtesy switches except that of the driver’s...
Page 722 BE–21 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Tester connection Condition Specified condition A1 – Ground Door lock manual switch OFF or UNLOCK No continuity A1 – Ground Door lock manual switch LOCK Continuity A2 – Ground Door lock manual switch OFF or LOCK No continuity A2 –...
Page 723 BE–22 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE0A4–02 LOCATION E/G Room J/B No.2 Daytime Resister D HEAD LH Fuse (USA) D HEAD RH Fuse (USA) D HEAD LH (UPR) Fuse (CANADA) D HEAD RH (UPR) Fuse (CANADA) D DOME Fuse D ECU–B Fuse D Headlight Control Relay...
Page 724 BE–23 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A5–02 COMPONENTS Combination Switch D Light Control Switch D Headlight Dimmer Switch Switch Body Spiral Cable Combination Switch D Wiper and Washer Switch N18012 Author : Date : 2243...
Page 725 BE–24 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE10D–01 INSPECTION INSPECT LIGHT CONTROL SWITCH CONTINUITY Hi beam HEAD Switch position Tester connection Specified condition TAIL – No continuity TAIL 14 – 16 Continuity HEAD 13 – 14 – 16 Continuity Flash If continuity is not as specified, replace the switch.
Page 726 BE–25 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM INSPECT DAYTIME RUNNING LIGHT RELAY (MAIN) Wire harness side: CIRCUIT Disconnect the connector from the relay and inspect the con- nector on the wire harness side. I08219 Tester connection Condition Specified condition 2 –...
Page 727 BE–26 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY Condition Tester connection Specified condition Constant 3 – 4 Continuity Apply B+ between 1 – 2 Continuity terminals 3 and 4. If continuity is not as specified, replace the relay. Z08559 INSPECT DAYTIME RUNNING LIGHT RESISTER CON- TINUITY...
Page 728 BE–27 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM INSPECT AUTOMATIC LIGHT CONTROL SENSOR Wire harness side: CIRCUIT Connector disconnected: Disconnect the connector from the sensor and inspect the con- nector on the wire harness side, as shown in the table. I01254 Tester connection Condition...
Page 729 BE–28 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A7–02 ADJUSTMENT ADJUST HEADLIGHT AIMING For Adjustment in Vertical Direction For Adjustment in Horizontal Direction N20156 ADJUST SPIRAL CABLE (See page SR–16) Author : Date : 2248...
Page 730 BE–29 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A8–03 LOCATION E/G Room J/B No.2 D HORN Fuse Hazard Warning Switch Ignition Switch Turn Signal Light Instrument Panel J/B No.1 D TURN Fuse Turn Signal Flasher Combination Switch D Turn Signal Switch...
Page 731 BE–30 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A9–02 INSPECTION Right INSPECT TURN SIGNAL SWITCH CONTINUITY Switch position Tester connection Specified condition Left turn 1 – 2 Continuity Neutral – No continuity Right turn 2 – 3 Continuity Left If continuity is not as specified, replace the switch.
Page 732 BE–31 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE0AA–03 LOCATION E/G Room J/B No.2 D DOME Fuse Instrument Panel J/B No.1 D Integration Relay Map Light Dome Light Door Courtesy Switch Door Courtesy Switch Luggage Compartment Door Courtesy Switch Z19046 Author : Date :...
Page 733 BE–32 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM BE0AB–03 INSPECTION w/ Sliding roof: INSPECT MAP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition – No continuity 1 – 2 Continuity If continuity is not as specified, replace the light assembly or bulb.
Page 734 BE–33 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM INSPECT LUGGAGE COMPARTMENT DOOR COUR- TESY SWITCH CONTINUITY Check that continuity exists between terminal and switch body with the switch ON (switch pin released: opened door). Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in: closed door).
Page 735 BE–34 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BACK–UP LIGHT SYSTEM BE0AC–02 LOCATION Instrument Panel Ignition Switch J/B No.1 D GAUGE Fuse Back–up Light 1MZ–FE engine: 5S–FE engine: Back–up Light Switch Back–up Light Switch PNP Switch Z19047 Author : Date : 2254...
Page 736 BE–35 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BE0AD–02 INSPECTION INSPECT BACK–UP LIGHT SWITCH CONTINUITY Condition Tester connection Specified condition Free – No continuity Push 1 – 2 Continuity If continuity is not as specified, replace the switch. Push Free N14065 Author : Date : 2255...
Page 737 BE–36 BODY ELECTRICAL – STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE0AE–02 LOCATION Stop Light Switch Instrument Panel J/B No.1 D STOP Fuse Hi–Mounted Stop Light Stop Light Light Failure Sensor Z19048 Author : Date : 2256...
Page 738 BE–37 BODY ELECTRICAL – STOP LIGHT SYSTEM BE0AF–02 INSPECTION w/o Cruise control: w/o Cruise control: Pushed in Free INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition Switch pin free 1 – 2 Continuity Switch pin pushed in 1 –...
Page 739 BE–38 BODY ELECTRICAL – STOP LIGHT SYSTEM INSPECT LIGHT FAILURE RELAY CIRCUIT Wire harness side: Disconnect the connector from the relay and inspect the con- nector on the wire harness side, as shown. e–12–2–B N20209 Tester connection Condition Specified condition 1 –...
Page 740 BE–39 BODY ELECTRICAL – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE0AG–03 LOCATION Wiper Motor Washer Tank Washer Motor Wiper and Washer Switch Instrument Panel J/B No.1 D WIPER Fuse Z19049 Author : Date : 2259...
Page 741 BE–40 BODY ELECTRICAL – WIPER AND WASHER SYSTEM BE0AH–03 INSPECTION w/o Timer INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection Specified condition Washer ON 7 – 16 Continuity 7 – 16 Continuity 7 – 17 Continuity w/ Timer 8 –...
Page 742 BE–41 BODY ELECTRICAL – WIPER AND WASHER SYSTEM INSPECT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to termi- nal 7 and the negative (–) lead to terminal 2.
Page 743 BE–42 BODY ELECTRICAL – WIPER AND WASHER SYSTEM High speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 4, check that the motor oper- ates at high speed. If operation is not as specified, replace the motor.
Page 744 BE–43 BODY ELECTRICAL – WIPER AND WASHER SYSTEM Connect terminals 3 and 5. Connect the positive (+) lead from the battery to terminal 2 and negative (–) lead to terminal 4, check that the motor stops running in the stop position after the motor operates again.
Page 745: Combination Meter
BE–44 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE0AI–03 LOCATION Brake Fluid Level Warning Switch E/G Room J/B No.2 D ECU–B Fuse D DOME Fuse Washer Fluid Level Warning Switch Combination Meter D Bulb Check Relay ABS ECU Light Control Rheostat Instrument Panel J/B No.1 D GAUGE Fuse D TAIL Fuse...
Page 746 BE–45 BODY ELECTRICAL – COMBINATION METER Door Courtesy Switch PKB Switch Seat Belt Buckle Switch Door Courtesy Switch Fuel Sender Gauge DFuel Level Warning Switch Light Failure Sensor 5S–FE engine: 1MZ–FE engine: Low Oil Pressure Warning Switch Engine Coolant Temperature Gauge Engine Coolant Low Oil Pressure Temperature Gauge...
Page 747 BE–46 BODY ELECTRICAL – COMBINATION METER BE0AJ–03 CIRCUIT Connector ”A” Connector ”B” Connector ”C” 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 1213 1 2 3 4 5 6 7 8 9 10 11 12 13 J–13–1–A...
Page 748 BE–47 BODY ELECTRICAL – COMBINATION METER BE0AK–03 INSPECTION INSPECT SPEEDOMETER ON–VEHICLE Using a speedometer tester, inspect the speedometer for allow- able indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indica- tion error.
Page 749 BE–48 BODY ELECTRICAL – COMBINATION METER Compare the tester with tachometer indications. DC 13.5 V 25°C at (77 °F) Standard indication Allowable range 630 – 770 1,000 900 – 1,100 2,000 1,850 – 2,150 3,000 2,800 – 3,200 4,000 3,800 – 4,200 5,000 4,800 –...
Page 750 BE–49 BODY ELECTRICAL – COMBINATION METER INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3 for each float position. Float position mm (in.) Resistance (Ω) F: Approx. –91.1 (–3.587) Approx. 3.0 1/2: Approx. –34.2 (–1.346) Approx. 31.7 E: Approx.
Page 751 BE–50 BODY ELECTRICAL – COMBINATION METER Ground terminal on the wire harness side connector Engine coolant temperature gauge through a 3.4–W test bulb. Turn the ignition switch ON, and check that the bulb lights Ignition Test Bulb up and the receiver gauge needle moves to the hot side. Switch (3.4 W) If operation is as specified, replace the sender gauge.
Page 752 BE–51 BODY ELECTRICAL – COMBINATION METER INSPECT LOW OIL PRESSURE SWITCH Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm , 3.55 psi).
Page 753 BE–52 BODY ELECTRICAL – COMBINATION METER INSPECT WASHER FLUID LEVEL WARNING SWITCH Ohmmeter Check that no continuity exists between terminals with the switch OFF (float up). Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. N20217 INSPECT OPEN DOOR WARNING LIGHT Warning Light...
Page 754 BE–53 BODY ELECTRICAL – COMBINATION METER INSPECT INTEGRATION RELAY OF SEAT BELT Type A: WARNING SYSTEM OPERATION Connect the positive (+) lead from the battery to terminals 9 10 1 and 7. Connect the terminal 7 to terminal 9 through the 3.4–W test bulb.
Page 755 BE–54 BODY ELECTRICAL – COMBINATION METER INSPECT LIGHT CONTROL RHEOSTAT Connect the positive (+) lead from the battery to terminal 1 and negative lead (–) to terminal 3. Connect the positive (+) lead from the voltmeter to termi- nal 2 and negative lead to terminal 3. Turn the rheostat knob and check that the voltage changes.
Page 756 BE–55 BODY ELECTRICAL – DEFOGGER SYSTEM DEFOGGER SYSTEM BE0AL–03 LOCATION Defogger Switch Instrument Panel J/B No.1 D DEFOG M–Fuse D HTR Fuse D MIR–HTR Fuse D Defogger Relay Mirror Defogger Defogger Wire Z19051 Author : Date : 2275...
Page 757 BE–56 BODY ELECTRICAL – DEFOGGER SYSTEM BE0AM–03 INSPECTION Switch side: INSPECT DEFOGGER SWITCH CONTINUITY Check that is continuity exists between terminals 2 and 6. If continuity is not as specified, check the bulb. N20315 INSPECT DEFOGGER TIMER OPERATION Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 3.
Page 758 BE–57 BODY ELECTRICAL – DEFOGGER SYSTEM w/ Heater: INSPECT MIRROR DEFOGGER Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 6. Check that the mirror becomes warm. HINT: It takes short time for the mirror to become warm. N21371 INSPECT DEFOGGER WIRE NOTICE:...
Page 759 BE–58 BODY ELECTRICAL – DEFOGGER SYSTEM IF NECESSARY, REPAIR DEFOGGER WIRE Repair Point Clean the broken wire tips with grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Broken Thoroughly mix the repair agent (Dupont paste No. Wire 4817).
Page 760 BE–59 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE0AN–03 LOCATION Ignition Switch Instrument Panel J/B No.1 D POWER M–Fuse D GAUGE Fuse D Power Main Relay D Integration Relay Door Courtesy Switch Power Window Switch Power Window Switch Power Window Switch Power Window Master Switch Power Window Regulator...
Page 761 BE–60 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM BE0AO–02 INSPECTION INSPECT POWER WINDOW MASTER SWITCH CON- TINUITY Inspect the front driver’s switch. Window unlock: Switch position Tester connection Specified condition 3 – 8 – 9 Continuity 4 – 5 – 6 3 –...
Page 762 BE–61 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Window lock: Switch position Tester connection Specified condition 8 – 9 – 10 Continuity 10 – 12 Continuity DOWN 8 – 9 – 12 Continuity Inspect the rear right switch. Window unlock: Switch position Tester connection Specified condition...
Page 763 BE–62 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Using an ammeter: INSPECT ONE–TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to termi- nal 3 on the wire harness side connector and the negative (–) lead to negative terminal of the battery.
Page 764 BE–63 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM INSPECT POWER WINDOW MASTER SWITCH CIR- Wire harness side: CUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side, as shown in the follow- 1 2 3 4 5 6 ing page.
Page 765 BE–64 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Left side door: TMMK made: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. TMC made: N20555 Reverse the polarity, and check that the motor turns coun-...
Page 766 BE–65 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Right side door: TMMK made: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. TMC made: N20557 Reverse the polarity, and check that the motor turns coun-...
Page 767 BE–66 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Driver’s door: INSPECT POWER WINDOW MOTOR PTC THERM- ISTOR OPERATION Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to termi- nal 2 on the wire harness side connector and the negative (–) lead to negative terminal of the battery.
Page 768 BE–67 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the window begins to descend. If operation is not as specified, replace the motor. I21313 Rear Door: INSPECT POWER WINDOW MOTOR PTC THERM-...
Page 769 BE–68 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Turn the ignition switch ON and check that the meter Type B: needle indicates battery positive voltage again. If operation is not as specified, replace the relay. N20565 Key–off power window signal: Type C: (b) Close (c) Open...
Page 770 BE–69 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE0AP–02 LOCATION Instrument Panel J/B No.1 D POWER M–Fuse D CIG Fuse D DOOR Fuse D Integration Relay Door Key Lock and Unlock Switch Door Lock Assembly D Door Lock Motor Power Window Master Switch D Door Lock Control Switch...
Page 771 BE–70 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM BE0AQ–02 INSPECTION Master switch: INSPECT DRIVER’S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK 2 – 4 Continuity – No continuity UNLOCK 4 – 7 Continuity N21181 If continuity is not as specified, replace the switch.
Page 772 BE–71 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2, and check that the door lock link moves to UNLOCK position. Remove the polarity and check that the door lock link moves to LOCK position.
Page 773 BE–72 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM Door lock signal: Type B: Lock INSPECT INTEGRATION RELAY (Type B) OPERATION HINT: When the relay circuit is as specified, inspect the door lock sig- nal. Connect the positive (+) lead from the voltmeter to termi- nal A12 and the negative (–) lead to terminal A25.
Page 774 BE–73 BODY ELECTRICAL – SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE0AR–02 LOCATION E/G Room J/B No.2 D DOME Fuse Ignition Switch Instrument Panel J/B No.1 D POWER Fuse D GAUGE Fuse D Power Main Relay D Integration Relay Sliding Control Relay and Switch Sliding Roof Motor D Limit Switch Z19490...
Page 775 BE–74 BODY ELECTRICAL – SLIDING ROOF SYSTEM BE0AS–02 INSPECTION Wire harness side: INSPECT SLIDING ROOF CONTROL RELAY AND SWITCH CIRCUIT Disconnect the connector from the relay and switch and inspect the connector on the wire harness side, as shown in the table. 4 5 6 7 8 s–8–1 N21643...
Page 776 BE–75 BODY ELECTRICAL – SLIDING ROOF SYSTEM INSPECT SLIDING ROOF MOTOR OPERATION Webasto type: Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise (moves to the close and up side).
Page 777 BE–76 BODY ELECTRICAL – SLIDING ROOF SYSTEM With the sliding roof in fully opened position, hold the slid- ing roof switch in ”TILT UP” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. within 60 seconds N21645...
Page 778 BE–77 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM BE0AT–02 LOCATION Instrument Panel J/B No.1 D CIG Fuse Lifter Motor Reclining Motor Power Seat Switch Lifter Motor Sliding Motor Power Seat Switch Z19504 Author : Date : 2297...
Page 779 BE–78 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM BE0AU–02 INSPECTION Lifter Up TMC made: INSPECT DRIVER’S SEAT SWITCH CONTINUITY Inspect the slide switch. Switch position Tester connection Specified condition Down Reclining FRONT 4 – 6, 8 – 11 Continuity 4 – 6, 6 – 8 Continuity Forward Rear...
Page 780 BE–79 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM TMC made: Lifter Up INSPECT PASSENGER’S SEAT CONTINUITY Inspect the slide switch. Switch position Tester connection Specified condition FRONT 4 – 6, 8 – 11 Continuity Down 4 – 6, 6 – 8 Continuity Reclining BACK...
Page 781 BE–80 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM INSPECT SLIDE MOTOR PTC THERMISTOR OPERA- TION Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to the battery negative (–) terminal, then move the seat cushion to the front position.
Page 782 BE–81 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM INSPECT RECLINING MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. Reverse the polarity, check that the motor turns clock- wise.
Page 783 BE–82 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM BE0AV–03 LOCATION Mirror Control Switch Instrument Panel J/B No.1 D CIG Fuse RH Mirror D Mirror Motor LH Mirror D Mirror Motor Z19488 Author : Date : 2302...
Page 784 BE–83 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM BE0AW–03 INSPECTION Master switch left side: INSPECT MIRROR CONTROL SWITCH CONTINUITY MIRROR Switch position Tester connection Specified condition – No continuity 1 – 9, 6 – 10 Continuity DOWN 1 – 10, 6 – 9 Continuity RIGHT SIDE LEFT SIDE...
Page 785 BE–84 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM Reverse the polarity and check that the mirror turns to TMMK made right side. (w/o Heater) TMC made TMMK made (w/o Heater) (w/ Heater) N21185 TMMK made (w/o Heater): TMMK made Connect the positive (+) lead from the battery to terminal (w/o Heater) 3 and the negative (–) lead to terminal 2, check that the mirror turns upward.
Page 786 BE–85 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM Reverse the polarity, check that the mirror turns down- TMMK made ward. (w/o Heater) If operation is not as specified, replace the mirror assembly. TMC made TMMK made (w/o Heater) (w/ Heater) N21187 Author : Date :...
Page 787: Audio System
BE–86 BODY ELECTRICAL – AUDIO SYSTEM AUDIO SYSTEM BE0AX–03 DESCRIPTION RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: 30 kHz 300 kHz 3 MHz 30 MHz 300 MHz Frequency Designation Radio wave Modulation method Frequency modulation Amplitude modulation LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency...
Page 788 BE–87 BODY ELECTRICAL – AUDIO SYSTEM Multipath Multipath One type of interference caused by bouncing of ra- dio waves off obstructions is called ”multipath”. Mul- tipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is re- ceived directly.
Page 789 BE–88 BODY ELECTRICAL – AUDIO SYSTEM Matlers that require attention when checking: Noise coming into the radio usually has no harm for practical use as the noise protection is taken and it is hardly thinkable for an extremely loud noise to come in.
Page 790 BE–89 BODY ELECTRICAL – AUDIO SYSTEM Glass printed antenna: Antenna GROUNDING FOR THE ANTENNA CORD AND CHOKE Terminal COIL (Main) Plug (Main) HINT: During troubleshooting, in case that the antenna code continu- ity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustra- Antenna Plug (Sub)
Page 791 BE–90 BODY ELECTRICAL – AUDIO SYSTEM Fixed mast antenna: GROUNDING FOR THE ANTENNA CORD AND CHOKE COIL Antenna HINT: Terminal Plug During troubleshooting, in case that the antenna code continu- ity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustra- tions.
Page 792 BE–91 BODY ELECTRICAL – AUDIO SYSTEM BE0AY–05 TROUBLESHOOTING NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the re- placement part (spare part).
Page 793 BE–92 BODY ELECTRICAL – AUDIO SYSTEM Radio RADIO NOT OPERATING WHEN POWER SWITCH TURNED ’ON’ DRadio–CD Plater Unit (Built–in Power Amplifier) DRadio–Tape Plater Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Radio assembly faulty. Replace fuse. Check that RAD No.1 fuse is OK? ACC wire harness faulty.
Page 794 BE–93 BODY ELECTRICAL – AUDIO SYSTEM D Radio–Tape Player Unit (Separate Power Amplifier) D Radio–Tape Player–CD Player Unit (Separate Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) Does tape or CD player operate normally? Radio assembly faulty. Replace fuse. Check that RAD No.1 fuse is OK? ACC wire harness faulty.
Page 795 BE–94 BODY ELECTRICAL – AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED Radio ’ON’, BUT NO SOUND (INCLUDING ’NOISE’) IS PRODUCED D Radio–Tape Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Built–in Power Amplifier) Radio faulty. Does tape or CD player operate normally? Replace fuse.
Page 796 BE–95 BODY ELECTRICAL – AUDIO SYSTEM D Radio–Tape Player Unit (Separate Power Amplifier) D Radio–Tape Player–CD Player Unit (Separate Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? Check that RAD No.1 fuse is OK? Replace fuse.
Page 797 BE–96 BODY ELECTRICAL – AUDIO SYSTEM Radio NOISE PRESENT, BUT AM–FM NOT OPERATING Radio assembly faulty. Does tape player operate normally? Separate amplifier? Hiss noise from speaker? Power amplifier faulty. Radio assembly faulty. Radio ANY SPEAKER DOSE NOT WORK D Radio–Tape Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Radio assembly faulty.
Page 798 BE–97 BODY ELECTRICAL – AUDIO SYSTEM EITHER AM OR FM DOES NOT WORK, RECEPTION Radio POOR (VOLUME FAINT), FEWER STATION PRESETS D Radio–Tape Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Built–in Power Amplifier) Problem with radio wave signals or location? Poor signals, poor location.
Page 799 BE–98 BODY ELECTRICAL – AUDIO SYSTEM Radio POOR RECEPTION Is the condition bad in comparison with other vehicle? An electric wave environment. Does the condition get better if removing them? Is there any additional installation parts? (Sun shade film, telephone antenna etc.). Influence of additional installation parts.
Page 800 BE–99 BODY ELECTRICAL – AUDIO SYSTEM Radio SOUND QUALITY POOR D Radio–Tape Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Built–in Power Amplifier) Is sound quality bad in Poor signals, Is sound quality always bad? certain area only. poor location. Radio assembly faulty.
Page 801 BE–100 BODY ELECTRICAL – AUDIO SYSTEM PRESET MEMORY DISAPPEARS Radio D Radio–Tape Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Built–in Power Amplifier) Can cassette tape be inserted in tape player? Radio assembly faulty. Check that RAD No.1 fuse is OK? Replace fuse.
Page 802 BE–101 BODY ELECTRICAL – AUDIO SYSTEM Tape Player CASSETTE TAPE CANNOT BE INSERTED D Radio–Tape Player Unit (Built–in Power Amplifier) Is there a foreign object inside tape player? Remove foreign object. Does auto search button of radio operate normally? Radio assembly faulty. Check that RAD No.1 fuse is OK? Replace fuse.
Page 803 BE–102 BODY ELECTRICAL – AUDIO SYSTEM Tape Player CASSETTE TAPE IS INSERTED, BUT NO POWER D Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Radio assembly faulty. Check that RAD No.1 fuse is OK? Replace fuse. Is ACC applied to radio assembly? ACC wire harness faulty.
Page 804 BE–103 BODY ELECTRICAL – AUDIO SYSTEM Tape Player POWER COMING IN, BUT TAPE PLAYER NOT OPERATING D Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Cassette tape faulty. Radio assembly faulty. Does radio operate normally? Does continuity exist in speaker wire harness? Speaker wire harness faulty.
Page 805 BE–104 BODY ELECTRICAL – AUDIO SYSTEM Tape Player EITHER SPEAKER DOES NOT WORK D Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Radio assembly faulty. Is hiss noise produces by non–functioning speaker. Radio assembly faulty. Does continuity exist in speaker wire harness? Speaker wire harness faulty.
Page 806 BE–105 BODY ELECTRICAL – AUDIO SYSTEM Tape Player SOUND QUALITY POOR (VOLUME FAINT) D Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Cassette tape faulty. Head dirty. Operates normally after cleaning the heads? Does radio operate normally? Radio assembly faulty.
Page 807 BE–106 BODY ELECTRICAL – AUDIO SYSTEM Tape Player TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR AUTO–REVERSE Function OK if different tape (less than 120 mints.) inserted? Cassette tape faulty. Is there a foreign object inside tape player? Remove foreign object. Operates normally after cleaning the heads? Head dirty.
Page 808 BE–107 BODY ELECTRICAL – AUDIO SYSTEM CD Player CD CANNOT BE INSERTED D Radio–CD Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) D Radio–Tape Player – CD Player (Separate Power Amplifier) Is CD already inserted? Eject CD. Radio assembly Is auto search button of radio operating normally? Is +B applied to CD player?
Page 809 BE–108 BODY ELECTRICAL – AUDIO SYSTEM CD Player POWER COMING IN, BUT CD PLAYER NOT OPERATING D Radio–CD Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) D Radio–Tape Player – CD Player (Separate Power Amplifier) Is CD inserted with correct side up? Insert correctly.
Page 810 BE–109 BODY ELECTRICAL – AUDIO SYSTEM CD Player SOUND JUMPS D Radio–CD Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) D Radio–Tape Player – CD Player (Separate Power Amplifier) Jumping caused by vibration. Does sound jump only during strong vibration? Installed properly.
Page 811 BE–110 BODY ELECTRICAL – AUDIO SYSTEM CD Player EITHER SPEAKER DOES NOT WORK D Radio–CD Player Unit (Built–in Power Amplifier) D Radio–CD Player Unit (Separate Power Amplifier) D Radio–Tape Player – CD Player (Separate Power Amplifier) Does radio operate normally? CD player.
Page 812 BE–111 BODY ELECTRICAL – AUDIO SYSTEM Noise NOISE OCCURS Does the noise occur only in the radio? It occurs in the cassette CD. (Go to step 13 or 20) Does the noise occur in a particular place? An electric environment. Does the noise stop by removing it? Is there any additional installation part around the glass printed antenna? (Sunshade film, telephone antenna, etc.)
Page 813 BE–112 BODY ELECTRICAL – AUDIO SYSTEM Noise NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING Installed properly. Is speaker properly installed? Is speaker properly installed? With vehicle stationary lightly tap each system. Each system faulty. Is noise produced? Noise produced by static electricity accumulated in the vehicle body. I01474 Author : Date :...
Page 814 BE–113 BODY ELECTRICAL – AUDIO SYSTEM Noise NOISE PRODUCED WHEN ENGINE STARTS Generator noise. Whistling noise which becomes high–pitched when accelerator strongly depressed, disappears shortly after engine stops. Whining noise occurs when A/C is operating. A/C noise. Scratching noise occurs during sudden acceleration, Fuel gauge noise.
Page 815 BE–114 BODY ELECTRICAL – AUDIO SYSTEM BE0AZ–05 LOCATION Tweeter Speaker Tweeter Speaker Instrument Panel J/B No.1 D RADIO Fuse D DOME Fuse Glass Printed Front Speaker Antenna (MAIN) Diversity Only (SUB) Rear Speaker Z19489 Author : Date : 2334...
Page 816 Therefore, for the conti- nuity checking of the glass printed antenna on the main anten- na side of CAMRY, place one probe of the tester on the position beside the bus bar (position shown in the illustration) and check Matching by making the other probe of the tester move along.
Page 817 BE–116 BODY ELECTRICAL – AUDIO SYSTEM Using a fine tip brush, apply a small amount of the agent to the wire. After a few minutes, remove the masking tape. BE0151 Author : Date : 2336...
Page 818 BE–117 BODY ELECTRICAL – CLOCK CLOCK BE0B1–02 TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Clock will not operate Clock loses or gains time ± 1.5 seconds / day Ground Connector (Clock Side) (Wire Harness Side) Power Source (Illumination) Power Source 1 2 3...
Page 819 BE–118 BODY ELECTRICAL – CLOCK CLOCK LOSES OR GAINS TIME (a) Check that the battery positive voltage is 10 – 16 V. (Clock Side) If voltage is not as specified, replace the battery. (b) Inspect the error of the clock. Allowable error (per day): ±...
Page 820 BE–119 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM BE0B2–06 REGISTRATION PROCEDURE KEY REGISTRATION IN AUTOMATIC REGISTRATION MODE Registration of a new transponder key. HINT: This must be done when you have installed a new ECM. The new ECM is in the automatic key code registration mode. The already fixed number of key codes for this ECM can be registered.
Page 821 After 1 more key code have been registered with master key, perform step (1) or (2) without pulling the key out or inserting the already registered key. (1) Depress and release brake pedal 5 times or more within 15sec. (2) With the TOYOTA hand–held tester, require automatic registration mode completion. Author : Date :...
Page 822 REGISTRATION OF ADDITIONAL MASTER KEY There are 2 ways for registration of additional master key, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. HINT: It is possible to register up to 7 master key codes including the already registered key code.
Page 823 – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select master key reg- istration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder.
Page 824 REGISTRATION ADDITIONAL OF SUB–KEY There are 2 ways for registration of additional sub–key, one is depressing brake pedal and acceleration ped- al and the other is using TOYOTA hand–held tester. HINT: It is possible top register up to 3 sub–key codes including the already registered key code.
Page 825 – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select sub–key regis- tration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder.
Page 826 ERASURE OF TRANSPONDER KEY CODE There are 2 ways for erasure of transponder key code, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. NOTICE: All other master and sub–key codes are deleted leaving the master key code to use the operation.
Page 827 BE–126 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: 1. Insert master key in the key cylinder. Within 120 sec. 2. Require key code deletion from hand–held tester. (Security indicator blinks) Within 10 sec. 3. Remove the master key.
Page 828 BE–127 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B3–06 LOCATION Engine Room J/B No.2 D EFI Fuse Transponder Key Amplifier Transponder Key Coil Instrument Panel J/B D IGN Fuse I02682 Author : Date : 2347...
Page 829 BE–128 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B4–05 INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminal 1 and 2. If continuity is not as specified, replace the coil. I03099 Author : Date : 2348...
Page 830: Brake System
BR–1 BRAKE – BRAKE SYSTEM BRAKE SYSTEM BR0A9–01 PRECAUTION Care must be taken to replace each part properly 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.
Page 831 BR–2 BRAKE – TROUBLESHOOTING TROUBLESHOOTING BR0AA–03 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom CAUSE PAGE...
Page 832 BR–3 BRAKE – TROUBLESHOOTING 1. Fluid leaks for brake system DI–536 2. Air in brake system BR–4 3. Pad or lining (Worn) BR–21 BR–31 BR–36 4. Pad or lining (Cracked or distorted) BR–21 BR–31 BR–36 5. Rear brake shoe clearance (Out of adjustment) BR–35 Hard pedal but brake inefficient 6.
Page 833: Brake Fluid
BR–4 BRAKE – BRAKE FLUID BRAKE FLUID BR0AB–03 BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately.
Page 834 BR–5 BRAKE – BRAKE PEDAL BRAKE PEDAL Stop Light BR0YH–01 Switch ON–VEHICLE INSPECTION CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 152.0 – 162.0 mm (5.984 – 6.378 in.) IF NECESSARY, ADJUST PEDAL HEIGHT Disconnect the connector from the stop light switch. Push Rod Loosen the stop light switch lock nut and remove the stop light switch.
Page 835 BR–6 BRAKE – BRAKE PEDAL CHECK PEDAL RESERVE DISTANCE Pedal Reserve Distance Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 70 mm (2.76 in.) If the reserve distance is incorrect, troubleshoot the brake sys- tem.
Page 836 BR–7 BRAKE – BRAKE PEDAL BR0YI–01 COMPONENTS A/T: Lower Panel Insert Wave Washer No.1 Lower Panel Clevis Pin Brake Pedal Bracket Stop Light Switch Cruise Control ECU 13 (130, 9) Clip 5.0 (51, 44 in.·lbf) 13 (130, 9) S Bushing M/T: Front Opening Cover Return Spring...
Page 837: Parking Brake Lever
BR–8 BRAKE – PARKING BRAKE LEVER PARKING BRAKE LEVER BR0AD–03 ON–VEHICLE INSPECTION CHECK THAT PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the num- ber of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 5 –...
Page 838: Brake Master Cylinder
BR–9 BRAKE – BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR0AE–02 COMPONENTS w/o ABS Brake Booster Master Cylinder 15 (155, 11) w/ ABS (& TRAC) 2–way S Gasket 3–way 13 (130, 9) N·m (kgf·cm, ft·lbf) : Specified torque S Non–reusable part Z19120 w/ TRAC Strainer...
Page 839 BR–10 BRAKE – BRAKE MASTER CYLINDER w/o ABS Strainer Reservoir Reservoir Set Screw 1.7 (18, 16 in.·lbf) Snap Ring Grommet Grommet No. 2 Piston and Spring No. 1 Piston and Spring S Gasket Cylinder Body 10 (100, 7) Stopper Bolt w/ ABS Strainer Reservoir...
Page 840 BR–11 BRAKE – BRAKE MASTER CYLINDER BR0AF–03 REMOVAL DISCONNECT LEVEL WARNING SWITCH CONNEC- TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. DISCONNECT BRAKE LINES w/ ABS (& TRAC): W04697 Using SST, disconnect the 4 brake lines.
Page 841 BR–12 BRAKE – BRAKE MASTER CYLINDER BR0AG–02 DISASSEMBLY REMOVE RESERVOIR Remove the set screw and pull out the reservoir. Torque: 1.7 N·m (18 kgf·cm, 16 in.·lbf) Remove the cap and strainer from the reservoir. REMOVE 2 GROMMETS Except w/ TRAC: PLACE CYLINDER IN VISE w/o TRAC: Soft Jows...
Page 842 BR–13 BRAKE – BRAKE MASTER CYLINDER w/ TRAC: REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver, and remove the 2 straight pins by turning over the cylinder body. HINT: Tape the screwdriver tip before use. Remove the 2 pistons and springs by hand, pulling straight out, not at an angle.
Page 843 BR–14 BRAKE – BRAKE MASTER CYLINDER BR0AH–01 INSPECTION HINT: Clean the disassembled parts with compressed air. INSPECT CYLINDER BORE FOR RUST OR SCORING INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. Author : Date : 2037...
Page 844 BR–15 BRAKE – BRAKE MASTER CYLINDER BR0AI–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–12). NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR–9). Author : Date : 2038...
Page 845 BR–16 BRAKE – BRAKE MASTER CYLINDER BR0AJ–02 INSTALLATION Installation is in the reverse order of removal (See page BR–11). HINT: Before installation, adjust length of the brake booster push rod (See page BR–20). After installation, fill the brake reservoir with brake fluid, bleed the brake system and check for leaks (See page BR–4).
Page 846: Brake Booster Assembly
BR–17 BRAKE – BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY BR0AK–03 ON–VEHICLE INSPECTION OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.
Page 847 BR–18 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AL–03 COMPONENTS Brake Booster SGasket Master Cylinder 15 (155, 11) Clip SGasket w/ ABS (& TRAC) 2–way 3–way Clevis 25 (260, 19) 13 (130, 9) 13 (130, 9) N·m (kgf·cm, ft·lbf) : Specified torque S Non–reusable part Z19121 Author :...
Page 848 BR–19 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AM–03 REMOVAL REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE REMOVE MASTER CYLINDER (See page BR–11) REMOVE CHARCOL CANISTER DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER REMOVE PEDAL RETURN SPRING REMOVE CLIP AND CLEVIS PIN REMOVE BRAKE BOOSTER, GASKET AND CLEVIS Remove the 4 nuts and clevis.
Page 849 BR–20 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AN–03 INSTALLATION INSTALL BRAKE BOOSTER Install the booster and a new gasket. Install the clevis to the operating rod. Install and torque the booster installation nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install the clevis, and torque the lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin.
Page 850: Front Brake Pad
BR–21 BRAKE – FRONT BRAKE PAD FRONT BRAKE PAD BR0AO–03 COMPONENTS 5S–FE engine: 34 (350, 25) Anti–squeal Shim Inner Anti–squeal Shim Anti–squeal Spring Outer Pad Pad Support Plate Inner Pad 1MZ–FE engine: 34 (350, 25) Anti–squeal Shim Inner Anti–squeal Shim Pad Wear Indicator Plate Outer Pad Pad Support Plate...
Page 851 BR–22 BRAKE – FRONT BRAKE PAD BR0AP–03 REPLACEMENT REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification. Minimum thickness: 1.0 mm (0.039 in.) LIFT UP CALIPER F07213...
Page 852 BR–23 BRAKE – FRONT BRAKE PAD 1MZ–FE engine: Install a pad wear indicator plate on the inner pad. Apply disc brake grease to both sides of the inner anti– squeal shims (See page BR–21). Install the 2 anti–squeal shims on each pad. Install inner pad with the pad wear indicator plate facing upward.
Page 853: Front Brake Caliper
BR–24 BRAKE – FRONT BRAKE CALIPER FRONT BRAKE CALIPER BR0AQ–02 COMPONENTS 5S–FE engine: Caliper Torque Plate 29 (300, 21) 107 (1,090, 79) 34 (350, 25) Disc Bleeder Plug 8.3 (85, 74 in.·lbf) 29 (300, 21) SGasket Sliding Pin Piston SDust Boot Piston Seal Boot Set Ring...
Page 854 BR–25 BRAKE – FRONT BRAKE CALIPER 1MZ–FE engine: 29 (300, 21) 107 (1,090, 79) Caliper Torque Plate 34 (350, 25) Disc Bleeder Plug 8.3 (85, 74 in.·lbf) 29 (300, 21) SGasket Sliding pin SSliding Bushing Piston SDust Boot Set Ring Piston Seal Boot Sliding Pin...
Page 855 BR–26 BRAKE – FRONT BRAKE CALIPER BR0AR–03 REMOVAL REMOVE FRONT WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) HINT: At the time of installation, please refer to the following item.
Page 856 BR–27 BRAKE – FRONT BRAKE CALIPER BR0AS–03 DISASSEMBLY REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot from the caliper. R00121 REMOVE PISTON Place a piece of cloth or similar, between the piston and the caliper.
Page 857 BR–28 BRAKE – FRONT BRAKE CALIPER BR0AT–03 INSPECTION MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine: 12.0 mm (0.472 in.) 1MZ–FE engine: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the minimum thick- ness or less, or if the pad has severe and uneven wear.
Page 858 BR–29 BRAKE – FRONT BRAKE CALIPER BR0AU–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–27). NOTICE: Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR–24). Author : Date : 2052...
Page 859 BR–30 BRAKE – FRONT BRAKE CALIPER BR0AV–02 INSTALLATION Installation is in the reverse order of removal (See page BR–26). HINT: After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4). Check for leaks. Author : Date : 2053...
Page 860 BR–31 BRAKE – REAR DRUM BRAKE REAR DRUM BRAKE BR0AW–03 COMPONENTS Bleeder Plug Adjuster Plug 8.3 (85, 74 in.·lbf) 10 (100, 7) Wheel Cylinder Spring Boot Inspection Hole SC–washer Plug SCup Parking Brake Lever Piston Automatic Adjusting Lever E–ring Adjuster Rear Shoe Adjusting Lever Spring Anchor Spring...
Page 861 BR–32 BRAKE – REAR DRUM BRAKE BR0AX–03 REMOVAL INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than the minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) REMOVE REAR WHEEL BR1532 REMOVE BRAKE DRUM...
Page 862 BR–33 BRAKE – REAR DRUM BRAKE REMOVE REAR SHOE Using SST, remove the shoe hold–down spring, 2 cups and pin. 09718–00010 Using a screwdriver, disconnect the parking brake cable from the anchor plate. Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe together with adjuster.
Page 863 BR–34 BRAKE – REAR DRUM BRAKE INSPECTION INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the shoe lining thickness. Standard thickness: 5.0 mm (0.197 in.) Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, or shows signs of un- even wear, replace the brake shoes.
Page 864 BR–35 BRAKE – REAR DRUM BRAKE BR0AZ–02 INSTALLATION Installation is in the reverse order of removal (See page BR–32). NOTICE: Apply lithium soap base glycol grease and high tempera- ture grease to the parts indicated by the arrows (See page BR–31). AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR–4)
Page 865: Rear Brake Pad
BR–36 BRAKE – REAR BRAKE PAD REAR BRAKE PAD BR0B0–03 COMPONENTS Pad Support Plate Anti–squeal Shim Inner Anti–squeal Shim Inner Pad Outer Pad 29 (300, 21) 20 (200, 14) Pad Support Plate Anti–squeal Shim Inner Anti–squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F02610...
Page 866 BR–37 BRAKE – REAR BRAKE PAD BR0B1–03 REPLACEMENT REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) R00591 LIFT UP CALIPER...
Page 867 BR–38 BRAKE – REAR BRAKE PAD INSTALL REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE Author : Date : 2061...
Page 868: Rear Brake Caliper
BR–39 BRAKE – REAR BRAKE CALIPER REAR BRAKE CALIPER BR0B2–03 COMPONENTS 29 (300, 21) 20 (200, 14) SGasket 29 (300, 21) 47 (475, 34) Caliper Torque Plate Disc Plug Bleeder Plug 8.3 (85, 74 in.·lbf) Dust Boot Main Pin Boot Piston Seal Piston Main Pin...
Page 869 BR–40 BRAKE – REAR BRAKE CALIPER BR0B3–03 REMOVAL REMOVE REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) HINT: At the time of installation, please refer to the following item.
Page 870 BR–41 BRAKE – REAR BRAKE CALIPER BR0B4–02 DISASSEMBLY REMOVE SLIDING BUSHING REMOVE 2 DUST BOOTS REMOVE MAIN PIN BOOT NOTICE: Ensure that the boots are secured firmly to the bushing and caliper grooves. REMOVE CYLINDER BOOT SET RING AND BOOT (See step 1 on page BR–27) R00520 REMOVE PISTON (See step 2 on page BR–27)
Page 871 BR–42 BRAKE – REAR BRAKE CALIPER BR0B5–02 INSPECTION MEASURE PAD LINING THICKNESS (See step 1 on page BR–28) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) MEASURE DISC THICKNESS (See step 2 on page BR–28) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) MEASURE DISC RUNOUT (See step 3 on page BR–28)
Page 872 BR–43 BRAKE – REAR BRAKE CALIPER BR0B6–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–41). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR–24). Author : Date : 2066...
Page 873 BR–44 BRAKE – REAR BRAKE CALIPER BR0B7–02 INSTALLATION Installation is in the reverse order of removal (See page BR–40). HINT: After installation, fill the brake reservoir with brake fluid and bleed the brake system (See page BR–4). Check for leaks. Author : Date : 2067...
Page 874: Parking Brake
BR–45 BRAKE – PARKING BRAKE PARKING BRAKE BR0B8–03 COMPONENTS Guide Plate Shoe Strut Adjuster Shim Spring Rear Disc Brake Assembly Parking Brake Lever 47 (475, 34) Rear Shoe Shoe Return Spring SC–washer Front Shoe Disc Adjuster Tension Spring Shoe Hold–down Spring Plug Shoe Hold–down Spring Cup N·m (kgf·cm, ft·lbf) : Specified torque...
Page 875 BR–46 BRAKE – PARKING BRAKE BR0B9–03 DISASSEMBLY REMOVE REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) REMOVE REAR DISC BRAKE ASSEMBLY Remove the 2 mounting bolts and remove the disc brake assembly. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Suspend the disc brake securely.
Page 876 BR–47 BRAKE – PARKING BRAKE BR0BA–02 INSPECTION INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. MEASURE BRAKE SHOE LINING THICKNESS (See step 2 on page BR–34) Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) MEASURE DISC INSIDE DIAMETER (See step 3 on page BR–34) Standard inside diameter: 170 mm (6.69 in.)
Page 877 BR–48 BRAKE – PARKING BRAKE BR0BB–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–46). NOTICE: Apply high temperature grease to the parts indicated by the arrows (See page BR–45). ADJUST PARKING BRAKE SHOE CLEARANCE Temporarily install the hub nuts. Remove the hole plug.
Page 878 BR–49 BRAKE – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) BR0BC–03 INSPECTION W04698 INSTALL LSPV GAUGE (SST) 09709–29018 BLEED AIR FROM FLUID PRESSURE GAUGE RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER OR CALIPER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 5S–FE engine: 2,452 kPa (25 kgf/cm...
Page 879 BR–50 BRAKE – ABS ACTUATOR (DENSO Made) ABS ACTUATOR (DENSO Made) BR0BD–02 ON–VEHICLE INSPECTION HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the opera- tion of sub–wire harness G according to the instructions on pages DI–502 and DI–507.
Page 880 BR–51 BRAKE – ABS ACTUATOR (DENSO Made) Place the ”SHEET P” (SST) on the actuator checker. SST 09990–00430 INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to ”FRONT LH” position. Push and hold in the MOTOR switch for a few seconds.
Page 881 BR–52 BRAKE – ABS ACTUATOR (DENSO Made) Push and hold in the MOTOR switch for a few seconds. Stop the engine. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET P” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator. 09990–00150, 09990–00250, 09990–00300, 09990–00360, 09990–00430 CONNECT CONNECTORS...
Page 882 BR–53 BRAKE – ABS ACTUATOR (DENSO Made) BR0BE–02 COMPONENTS 15 (155, 11) 5.4 (55, 48 in.·lbf) ABS Actuator 19 (195, 14) A/C Tube Clamp Cushion Bracket Holder Cushion 19 (195, 14) Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque W03266 Author : Date : 2076...
Page 883 BR–54 BRAKE – ABS ACTUATOR (DENSO Made) BR0BF–02 REMOVAL REMOVE RIGHT FRONT FENDER LINER REMOVE A/C TUBE CLAMP BRACKET BOLT DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS actuator. 09751–36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) REMOVE ABS ACTUATOR ASSEMBLY Disconnect the 2 connectors.
Page 884 BR–55 BRAKE – ABS ACTUATOR (DENSO Made) BR0BG–02 INSTALLATION Installation is in the reverse order of removal (See page BR–54). HINT: After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4). Check for leaks. Author : Date : 2078...
Page 885 BR–56 BRAKE – ABS ACTUATOR (BOSCH Made) ABS ACTUATOR (BOSCH Made) BR0BH–03 COMPONENTS 15 (155, 11) 9.0 (92, 80 in.·lbf) Holder ABS Actuator (w/ ECU) 19 (195, 14) Cushion A/C Tube Clamp Bracket Cushion 19 (195, 14) Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque W03327 2.6 (27, 23 in.·lbf) Actuator...
Page 886 BR–57 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BI–03 REMOVAL REMOVE RIGHT FRONT FENDER LINER REMOVE A/C TUBE CLAMP BRACKET BOLT DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS actuator. 09751–36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) W03324 DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector.
Page 887 BR–58 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BJ–02 DISASSEMBLY DISCONNECT CONNECTOR Disconnect the connector, and remove the wire harness from the harness guide. REMOVE ECU Using a T20 torx wrench, loosen the 6 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf) NOTICE: When removing the ECU from the actuator, it must be removed it upward.
Page 888 BR–59 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BK–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–58). Author : Date : 2082...
Page 889 BR–60 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BL–02 INSTALLATION Installation is in the reverse order of removal (See page BR–57). HINT: After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4). Check for leaks. Author : Date : 2083...
Page 890 BR–61 BRAKE – ABS & TRAC ACTUATOR ABS & TRAC ACTUATOR BR07A–06 ON–VEHICLE INSPECTION HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the opera- tion of sub–wire harness G according to the instructions on pages DI–584 and DI–587.
Page 891 BR–62 BRAKE – ABS & TRAC ACTUATOR Place the ”SHEET A” (SST) on the actuator checker. 09990–00163 INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to ”FRONT RH” position. Push and hold in the MOTOR switch for a few seconds.
Page 892 BR–63 BRAKE – ABS & TRAC ACTUATOR Push and hold in the MOTOR switch for a few seconds. Stop the engine. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET A” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator. 09990–00150, 09990–00163, 09990–00250, 09990–00360, 09990–00450 CONNECT CONNECTORS...
Page 893 BR–64 BRAKE – ABS & TRAC ACTUATOR BR077–04 COMPONENTS 15 (155, 11) 5.4 (55, 48 in.·lbf) 20 (200, 14) ABS & TRAC Actuator 19 (195, 14) A/C Tube Clamp Bracket Cushion Holder Cushion 19 (195, 14) Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque W03272 Author :...
Page 894 BR–65 BRAKE – ABS & TRAC ACTUATOR BR078–03 REMOVAL REMOVE RIGHT FRONT FENDER LINER REMOVE A/C TUBE CLAMP BRACKET BOLT DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS & TRAC actuator. 09751–36011 Torque: 10 mm nut 15 N·m (155 kgf·cm, 11 ft·lbf) W03245 12 mm nut 20 N·m (200 kgf·cm, 14 ft·lbf) REMOVE ABS &...
Page 895 BR–66 BRAKE – ABS & TRAC ACTUATOR BR079–03 INSTALLATION Installation is in the reverse order of removal (See page BR–65). HINT: After installation, fill the brake reservoir with brake fluid and bleed the brake system. (See page BR–4) Check for leaks. Author : Date : 2089...
Page 896: Front Speed Sensor
BR–67 BRAKE – FRONT SPEED SENSOR FRONT SPEED SENSOR BR0BQ–03 COMPONENTS 5.4 (55, 48 in.·lbf) 29 (300, 21) Front Speed Sensor 7.8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque W03273 Author : Date : 2090...
Page 897 BR–68 BRAKE – FRONT SPEED SENSOR BR0BR–03 REMOVAL DISCONNECT SPEED SENSOR CONNECTOR Remove the fender liner. Disconnect the speed sensor connector. R00327 REMOVE SPEED SENSOR Remove the bolt, flexible hose and speed sensor harness clamp from the shock absorber. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) Remove the resin clip and clamp bolt holding the sensor harness to the body.
Page 898 BR–69 BRAKE – FRONT SPEED SENSOR BR0BS–02 INSTALLATION Installation is in the reverse order of removal (See pageBR–68). HINT: After installation, check the speed sensor signal (See page DI–493, DI–539). Author : Date : 2092...
Page 899: Rear Speed Sensor
BR–70 BRAKE – REAR SPEED SENSOR REAR SPEED SENSOR BR0BT–03 COMPONENTS 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) 7.8 (80, 69 in.·lbf) Rear Speed Sensor N·m (kgf·cm, ft·lbf) : Specified torque W03274 Author : Date : 2093...
Page 900 BR–71 BRAKE – REAR SPEED SENSOR BR0BU–03 REMOVAL DISCONNECT SPEED SENSOR CONNECTOR Remove the seat cushion and side seatback (See page BO–114 or BO–119). Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. R00330 REMOVE SPEED SENSOR Remove the 2 clamp bolts holding the sensor wire har- ness to the body and shock absorber.
Page 901 BR–72 BRAKE – REAR SPEED SENSOR BR0BV–02 INSTALLATION Installation is in the reverse order of removal (See page BR–71). HINT: After installation, check the speed sensor signal (See page DI–493, DI–539). Author : Date : 2095...
Page 902 CH–1 CHARGING (5S–FE) – CHARGING SYSTEM CHARGING SYSTEM CH02U–01 ON–VEHICLE INSPECTION CAUTION: Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is giv- en a quick charge. Do not perform tests with a high voltage insulation re- sistance tester.
Page 903 CH–2 CHARGING (5S–FE) – CHARGING SYSTEM HINT: Maintenance–Free Battery Check the indicator as shown in the illustration. Type A CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES CLEAR EYE or Check that the battery terminals are not loose or cor- GREEN EYE DARK EYE LIGHT YELLOW roded.
Page 904 CH–3 CHARGING (5S–FE) – CHARGING SYSTEM After installing a new belt, run the engine for about 5 min- utes and recheck the belt tension. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise from the generator while the engine is running.
Page 905 CH–4 CHARGING (5S–FE) – CHARGING SYSTEM If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows: With terminal F grounded, start the engine and check the voltmeter reading of terminal B. If the voltmeter reading is more than standard volt- age, replace the voltage regulator.
Page 906 CH–5 CHARGING (5S–FE) – GENERATOR GENERATOR CH02V–03 COMPONENTS Adjusting Lock Bolt Generator Wire Rubber Cap Pivot Bolt Generator Connector Wire Clamp Generator Drive Belt S05342 z Front Bearing Rotor Pulley Bearing Cover Bearing Cover Drive End Flame (Starter) Generator Washer Bearing Cover Rectifier Holder z Rear Bearing...
Page 907 CH–6 CHARGING (5S–FE) – GENERATOR CH02W–03 REMOVAL DISCONNECT CONNECTOR AND WIRE FROM GENERATOR Disconnect the wire clamp from the wire clip on the rectifi- er end frame. Disconnect the generator connector. Remove the rubber cap and nut, and disconnect the gen- erator wire.
Page 908 CH–7 CHARGING (5S–FE) – GENERATOR CH02X–01 DISASSEMBLY REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the bolt, 3 nuts, plate terminal and end cover. Z18635 REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator.
Page 909 CH–8 CHARGING (5S–FE) – GENERATOR To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: SST (C) To prevent damage to the rotor shaft, do not loosen the SST (A) pulley nut more than one–half of a turn. Remove the generator from SST (C).
Page 910 CH–9 CHARGING (5S–FE) – GENERATOR CH02Y–01 INSPECTION INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity be- Ohmmeter tween the slip rings. Standard resistance: 2.7 – 3.1 Ω at 20°C (68°F) If there is no continuity, replace the rotor. Continuity CH0784 Check the rotor for ground.
Page 911 CH–10 CHARGING (5S–FE) – GENERATOR INSPECT BRUSHES Using vernier calipers, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) Length If the exposed length is less than minimum, replace the brush holder assembly.
Page 912 CH–11 CHARGING (5S–FE) – GENERATOR CH02Z–01 REPLACEMENT REPLACE FRONT BEARING Remove the 4 screws, bearing retainer and bearing. CH0827 Using a socket wrench and press, press out the bearing. Socket Wrench P00100 Using SST and a press, press in a new bearing. 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws.
Page 913 CH–12 CHARGING (5S–FE) – GENERATOR Using SST and a press, press in a new bearing. 09820–00030 N00578 Using SST, push in the bearing cover (outside). 09285–76010 P00074 Author : Date : 1759...
Page 914 CH–13 CHARGING (5S–FE) – GENERATOR CH030–01 REASSEMBLY INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. Pulley Install the rotor to the rectifier end frame. P01364 INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. Z18637 Using a 29 mm socket wrench and press, slowly press in 29 mm...
Page 915 CH–14 CHARGING (5S–FE) – GENERATOR Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (C) P04210 To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf) SST (C) Remove the generator from SST (C).
Page 916 CH–15 CHARGING (5S–FE) – GENERATOR INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Place the seal plate on the rectifier end frame. Z18638 Place the voltage regulator and brush holder on the recti- fier end frame. NOTICE: Upward Be careful of the holder installation direction. Install the 5 screws.
Page 917 CH–16 CHARGING (5S–FE) – GENERATOR CH031–01 INSTALLATION Installation is in the reverse order of removal. (See page CH–6) Author : Date : 1763...
Page 918 CH–1 CHARGING (1MZ–FE) – CHARGING SYSTEM CHARGING SYSTEM CH01D–01 ON–VEHICLE INSPECTION CAUTION: Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester.
Page 919 CH–2 CHARGING (1MZ–FE) – CHARGING SYSTEM HINT: Maintenance–Free Battery Check the indicator as shown in the illustration. Type A CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES CLEAR EYE or Check that the battery terminals are not loose or cor- GREEN EYE DARK EYE LIGHT YELLOW roded.
Page 920 CH–3 CHARGING (1MZ–FE) – CHARGING SYSTEM After installing a new belt, run the engine for about 5 min- utes and recheck the belt tension. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES Check that the wiring is in good condition. Check that there is no abnormal noise from the generator while the engine is running.
Page 921 CH–4 CHARGING (1MZ–FE) – CHARGING SYSTEM If the voltmeter reading is less than standard voltage, check the Terminal F voltage regulator and generator as follows: With terminal F grounded, start the engine and check the voltmeter reading of terminal B. If the voltmeter reading is more than standard volt- age, replace the voltage regulator.
Page 922 CH–5 CHARGING (1MZ–FE) – GENERATOR GENERATOR CH01E–01 COMPONENTS Plate Washer Generator Wire Pivot Bolt Generator Connector Adjusting Bolt Generator Adjusting Lock Bolt Drive Belt S05218 Bearing Cover z Front Bearing Generator Washer Retainer Drive End Flame (Stator) Bearing Cover z Rear Bearing Pulley Plate Terminal Rotor...
Page 923 CH–6 CHARGING (1MZ–FE) – GENERATOR CH01F–01 REMOVAL Pivot Bolt REMOVE DRIVE BELT Loosen the pivot bolt, adjusting lock bolt, and adjusting bolt, and remove the drive belt. Torque: Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf) Lock bolt: 18 N·m (180 kgf·cm, 13 ft·lbf) Adjusting Bolt Adjusting Lock Bolt...
Page 924 CH–7 CHARGING (1MZ–FE) – GENERATOR CH01G–01 DISASSEMBLY REMOVE REAR END COVER Plate Terminal Remove the nut and terminal insulator. Remove the screw, 3 nuts, plate terminal and end cover. P14233 REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator.
Page 925 CH–8 CHARGING (1MZ–FE) – GENERATOR To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: SST (C) To prevent damage to the rotor shaft, do not SST (A) loosen the pulley nut more than one–half of a turn. Remove the generator from SST (C).
Page 926 CH–9 CHARGING (1MZ–FE) – GENERATOR CH01H–01 INSPECTION INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity be- Ohmmeter tween the slip rings. Standard resistance: 2.1 – 2.5 Ω at 20°C (68°F) If there is no continuity, replace the rotor. Continuity CH0784 Check the rotor for ground.
Page 927 CH–10 CHARGING (1MZ–FE) – GENERATOR INSPECT BRUSHES Using a vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) Length If the exposed length is less than minimum, replace the brushes and brush holder assembly.
Page 928 CH–11 CHARGING (1MZ–FE) – GENERATOR CH01I–01 REPLACEMENT REPLACE FRONT BEARING Remove the 4 screws, bearing retainer and bearing. P14225 Using a socket wrench and press, press out the bearing. Socket Wrench P00628 Using SST and a press, press in a new bearing. 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws.
Page 929 CH–12 CHARGING (1MZ–FE) – GENERATOR Using SST and a press, press in a new bearing. 09820–00030 N00578 Using SST, push in the bearing cover (outside). 09285–76010 P00074 Author : Date : 1775...
Page 930 CH–13 CHARGING (1MZ–FE) – GENERATOR CH01J–01 REASSEMBLY INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. Pulley Install the rotor to the rectifier end frame. P01364 INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. P00427 Using a 29 mm socket wrench and press, slowly press in 29 mm...
Page 931 CH–14 CHARGING (1MZ–FE) – GENERATOR Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (A) Insert SST (C) P10834 To torque the pulley nut, turn SST (A) in the direction shown in the illustration.
Page 932 CH–15 CHARGING (1MZ–FE) – GENERATOR Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) S05072 INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Upward Place the voltage regulator and brush holder on the recti- fier end frame. NOTICE: Be careful of the holder installation direction.
Page 933 CH–16 CHARGING (1MZ–FE) – GENERATOR CH01K–01 INSTALLATION Installation is in the reverse order of removal. (See page ST–5) Author : Date : 1779...
Page 934 CL–1 CLUTCH – TROUBLESHOOTING TROUBLESHOOTING CL034–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The 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...
Page 935: Clutch Pedal
CL–2 CLUTCH – CLUTCH PEDAL CLUTCH PEDAL CL035–01 INSPECTION CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: Pedal Height Adjust Point 1MZ–FE: 161.8 – 171.8 mm (6.370 – 6.764 in.) 5S–FE: 156.8 – 166.8 mm (6.173 – 6.567 in.) IF NECESSARY, ADJUST PEDAL HEIGHT Push Rod Play Loosen the lock nut and turn the stopper bolt until the height is...
Page 936 CL–3 CLUTCH – CLUTCH PEDAL CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch ped- al is released. Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch. Clutch Start Switch...
Page 937: Clutch Master Cylinder
CL–4 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER CL036–01 COMPONENTS Filler Cap Clip Float Clevis Pin Boot Slotted Spring Pin Washer Reservoir Master Cylinder Body Tank Clevis Piston zGrommet Lock Nut Clutch Line Snap Ring 15 (155, 11) Push Rod Spring 12 (120, 9) zNon–reusable part...
Page 938 CL–5 CLUTCH – CLUTCH MASTER CYLINDER CL037–01 REMOVAL DRAW OUT FLUID WITH SYRINGE DISCONNECT CLUTCH LINE Using SST, disconnect the clutch line. Use a container to catch the fluid. 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) REMOVE CLIP AND CLEVIS PIN REMOVE 2 MOUNTING NUTS AND PULL OUT MAS- Q10094 TER CYLINDER...
Page 939 CL–6 CLUTCH – CLUTCH MASTER CYLINDER CL038–01 DISASSEMBLY REMOVE RESERVOIR TANK Using a pin punch and hammer, drive out the slotted spring pin. Remove the reservoir tank and grommet. Q10083 REMOVE PUSH ROD Pull back the boot, and using snap ring pliers, remove the snap ring.
Page 940 CL–7 CLUTCH – CLUTCH MASTER CYLINDER CL039–01 REASSEMBLY COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSERT PISTON INTO CYLINDER INSTALL PUSH ROD ASSEMBLY WITH SNAP RING CL0528 INSTALL RESERVOIR TANK Install the reservoir tank and a new grommet. Using a pin punch and hammer, drive in the slotted spring pin.
Page 941 CL–8 CLUTCH – CLUTCH MASTER CYLINDER CL03A–01 INSTALLATION Installation is in the reverse order of removal (See page CL–5). HINT: After installation, bleed system and adjust clutch pedal (See page CL–2). Author : Date : 1787...
Page 942: Clutch Release Cylinder
CL–9 CLUTCH – CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CL03B–01 COMPONENTS Clutch Line 15 (155, 11) Release Cylinder Body 12 (120, 9) Piston Boot Bleeder Plug 8.4 (85, 74 in.·lbf) Spring Push Rod N·m (kgf·cm, ft·lbf) : Specified torque Q10016 Author : Date : 1788...
Page 943 CL–10 CLUTCH – CLUTCH RELEASE CYLINDER CL03C–01 REMOVAL DISCONNECT CLUTCH LINE Using SST, disconnect the line. Use a container to catch the fluid. 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) REMOVE 2 BOLTS AND PULL OUT RELEASE CYL- INDER Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Q10077 Author :...
Page 944 CL–11 CLUTCH – CLUTCH RELEASE CYLINDER CL03D–01 DISASSEMBLY REMOVE BLEEDER PLUG PULL OUT BOOT WITH PUSH ROD REMOVE PISTON Blow compressed air into the release cylinder and remove the piston with spring. Q05878 Author : Date : 1790...
Page 945 CL–12 CLUTCH – CLUTCH RELEASE CYLINDER CL03E–01 REASSEMBLY COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER INSTALL BLEEDER PLUG Torque: 8.4 N·m (85 kgf·cm, 74 in.·lbf) Q06048 Author : Date :...
Page 946 CL–13 CLUTCH – CLUTCH RELEASE CYLINDER CL03F–01 INSTALLATION Installation is in the reverse order of removal (See page CL–10). HINT: After installation, bleed clutch system. Author : Date : 1792...
Page 947 CL–14 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CLUTCH ACCUMULATOR (1MZ–FE) CL03G–01 COMPONENTS w/ Cruise Control System : Starter 39 (400, 29) Cruise Control Actuator 21 (210, 15) Battery 27 (270, 20) 13 (130, 9) 13 (130, 9) Clutch Accumulator Bracket 15 (155, 11) N·m (kgf·cm, ft·lbf) : Specified torque Q10092 Author :...
Page 948 CL–15 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CL03H–01 REMOVAL w/ Cruise Control System: REMOVE CRUISE CONTROL ACTUATOR Remove the battery. Remove the 3 bolts and cruise control actuator with bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Q10074 REMOVE STARTER Remove the nut and disconnect the connectors. Remove the 2 bolt and clamp.
Page 949 CL–16 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CL03I–01 INSTALLATION Installation is in the reverse order of removal (See page CL–15). Author : Date : 1795...
Page 950: Clutch Unit
CL–17 CLUTCH – CLUTCH UNIT CLUTCH UNIT CL03J–01 COMPONENTS 5S–FE : Release Fork Flywheel 39 (400, 29) 19 (195, 14) Release Bearing and Hub Release Fork 47 (480, 35) 5S–FE : Clutch Disc Clutch Cover Clutch Disc Boot N·m (kgf·cm, ft·lbf) : Specified torque Q10017 Author : Date :...
Page 951 CL–18 CLUTCH – CLUTCH UNIT CL03K–01 REMOVAL REMOVE TRANSAXLE FROM ENGINE (See page E153 MX–4, S51 MX–4) REMOVE CLUTCH COVER AND DISC Place matchmarks on the flywheel and clutch cover. Loosen each set bolt one turn at a time until spring tension is released.
Page 952 CL–19 CLUTCH – CLUTCH UNIT CL03L–01 INSPECTION 1MZ–FE: INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc. 5S–FE: Q10090 INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout.
Page 953 CL–20 CLUTCH – CLUTCH UNIT INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direc- tion. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the bearing. N00414 Author : Date : 1799...
Page 954 CL–21 CLUTCH – CLUTCH UNIT CL03M–02 INSTALLATION 1MZ–FE: INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL 1MZ–FE: Insert SST in the clutch disc, and then set them. 09301–00220 5S–FE: Insert SST in the clutch disc, and then set them. 09301–00210 Flywheel Side 5S–FE:...
Page 955 CL–22 CLUTCH – CLUTCH UNIT APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE 1MZ–FE Engine: GREASE (NLGI NO.2) Apply release hub grease to these parts: Release fork and hub contact point Release fork and push rod contact point Release fork pivot point Apply clutch spline grease: Clutch disc spline HINT: Recommended grease part number 08887–01706 (100 g).
Page 956 CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. CHECK ENGINE COOLANT QUALITY Remove the radiator cap.
Page 957 Use of improper coolants may damage engine cool- ing system. Radiator Drain Plug Use ”Toyota Long Life Coolant” or equivalent and mix it with plan water according to the manufactur- er’s directions. Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 %...
Page 958 CO–3 COOLING (5S–FE) – WATER PUMP WATER PUMP CO068–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt w/ Oil Cooler A/C Compressor Connector A/C Compressor Cylinder Block Insulator PS Pump Drive Belt...
Page 959 CO–4 COOLING (5S–FE) – WATER PUMP Generator Wire Generator Connector * Gasket Generator Wire Clamp No.2 Timing Belt Wire Clamp Cover Timing Belt No.1 Timing Belt Cover Timing Belt Guide High–Tension Cord Crankshaft Pulley Spark Plug * Gasket 18 (180,13) Wire Clamp 108 (1,100, 80) Wire Clamp...
Page 960 CO–5 COOLING (5S–FE) – WATER PUMP CO069–04 REMOVAL DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–17) DISCONNECT LOWER RADIATOR HOSE FROM WA- TER OUTLET REMOVE TIMING BELT TENSION SPRING Loosen the No.1 idler pulley bolt, and remove the tension spring.
Page 961 CO–6 COOLING (5S–FE) – WATER PUMP Disconnect the water pump cover from the water bypass Disconnect pipe, and remove the water pump and water pump cover assembly. Remove the gasket and 2 O–rings from the water pump and water bypass pipe. REMOVE WATER PUMP FROM WATER PUMP COVER Remove the 3 bolts, water pump and gasket.
Page 962 CO–7 COOLING (5S–FE) – WATER PUMP CO06A–03 INSPECTION Turn INSPECT WATER PUMP Visually check the air hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. Turn the pulley, and check that the water pump bearing Air Hole moves smoothly and quietly.
Page 963 CO–8 COOLING (5S–FE) – WATER PUMP CO06B–03 INSTALLATION INSTALL WATER PUMP TO WATER PUMP COVER Install a new gasket and the water pump with the 3 bolts. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) N00918 INSTALL WATER PUMP AND WATER PUMP COVER Connect ASSEMBLY Install new O–ring and gasket to water pump cover.
Page 964 CO–9 COOLING (5S–FE) – WATER PUMP INSTALL TIMING BELT TENSION SPRING (See page EM–23) CONNECT LOWER RADIATOR HOSE TO WATER IN- INSTALL TIMING BELT (See page EM–23) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author : Date : 1583...
Page 965 CO–10 COOLING (5S–FE) – THERMOSTAT THERMOSTAT CO06C–03 COMPONENTS w/ Oil Cooler Oil Filter Thermostat z Gasket Water Inlet z Non–reusable part S05299 Author : Date : 1584...
Page 966 CO–11 COOLING (5S–FE) – THERMOSTAT CO06D–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect, caus- ing a lowering of cooling efficiency. Do not remove the thermo- stat, even if the engine tends to overheat. DRAIN ENGINE COOLANT w/ Oil Cooler: REMOVE OIL FILTER (See page LU–2) REMOVE WATER INLET AND THERMOSTAT...
Page 967 CO–12 COOLING (5S–FE) – THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. CO06E–03 P13560 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified, replace the thermostat.
Page 968 CO–13 COOLING (5S–FE) – THERMOSTAT CO0SN–01 INSTALLATION Protrusion 5° 5° PLACE THERMOSTAT IN WATER INLET Install a new gasket to the thermostat. Align the jiggle valve of the thermostat with the protrusion of the water inlet, and insert the thermostat in the water inlet.
Page 969 CO–14 COOLING (5S–FE) – RADIATOR RADIATOR CO06G–03 ON–VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main- tain a distance between the cleaner nozzle and radiator core.) Author : Date :...
Page 970 CO–15 COOLING (5S–FE) – RADIATOR CO06H–04 ON–VEHICLE INSPECTION REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the ra- diator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. INSPECT RADIATOR CAP Radiator Cap Tester NOTICE:...
Page 971 CO–16 COOLING (5S–FE) – RADIATOR CO06I–03 COMPONENTS Upper Radiator Support No.2 Electric Radiator Reservoir Hose Cooling Fan Connector Upper Radiator Support Radiator Assembly No.1 Electric Cooling Fan Connector Lower Radiator ECT Switch Connector Support for Electric Cooling Fan Lower Radiator Hose Upper Radiator Hose Oil Cooler Hose for A/T S05951...
Page 972 CO–17 COOLING (5S–FE) – RADIATOR No.2 Electric Cooling Fan ECT Switch Connector for Lower Radiator Hose Electric Cooling No.1 Electric Cooling Wire Clamp Radiator Oil Cooler Hose for A/T S05948 Radiator Cap Upper Tank z O–Ring z O–Ring Plate Washer Core Pipe z O–Ring...
Page 973 CO–18 COOLING (5S–FE) – RADIATOR CO06J–04 REMOVAL DRAIN ENGINE COOLANT REMOVE RADIATOR ASSEMBLY Disconnect the No.1 electric cooling fan connector. Disconnect the No.2 electric cooling fan connector. Disconnect the ECT switch connector for the electric cool- ing fan. Disconnect the upper radiator hose from the radiator. Disconnect the lower radiator hose from the water inlet.
Page 974 CO–19 COOLING (5S–FE) – RADIATOR CO06K–03 DISASSEMBLY REMOVE ECT SWITCH Remove the ECT switch. Remove the O–ring. REMOVE DRAIN PLUG Remove the drain plug. Remove the O–ring. ASSEMBLE SST Part ”A” 09230–01010 Install the claw to the overhaul handle, inserting it in the hole in part ”A”...
Page 975 CO–20 COOLING (5S–FE) – RADIATOR CO06L–04 REASSEMBLY Pipe A/T: 18° INSTALL OIL COOLER TO LOWER TANK Downward Install 2 new O–rings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) Install the cooler pipe in the direction indicated in the il- lustration.
Page 976 CO–21 COOLING (5S–FE) – RADIATOR ASSEMBLE SST Part ”A” 09230–01010, 09231–14010 Install the punch assembly to the overhaul handle, insert- ing it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that Dimension ”B”...
Page 977 CO–22 COOLING (5S–FE) – RADIATOR Check the lock plate height (H) after completing the caulk- ing. Plate height: 7.40 – 7.80 mm (0.2913 – 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. INSTALL ECT SWITCH Install a new O–ring to the ECT switch.
Page 978 CO–23 COOLING (5S–FE) – RADIATOR CO06M–03 INSTALLATION INSTALL NO.1 ELECTRIC COOLING FAN TO RADIA- Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Connect the ECT switch connector for the cooling fan. Install the ECT switch wire clamp for the cooling fan to the bracket of the radiator.
Page 979 CO–24 COOLING (5S–FE) – ELECTRIC COOLING FAN ELECTRIC COOLING FAN CO06N–03 ON–VEHICLE INSPECTION CHECK COOLING FAN OPERATION WITH LOW TEM- PERATURE (Below 83°C (181°F)) Turn the ignition switch ON. Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling S05959 fan relay and ECT switch.
Page 980 CO–25 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06O–03 COMPONENTS No.1 Cooling Fan No.1 Electric Cooling Fan Connector Connector ECT Switch Holder Connector No.1 Electric Cooling Fan ECT Switch Upper Radiator Hose Wire S05950 No.1 Cooling Fan Fan Motor Connector Holder Fan Shroud S05238 Author :...
Page 981 CO–26 COOLING (5S–FE) – ELECTRIC COOLING FAN No.2 Cooling Fan No.2 Electric Cooling Fan Connector No.2 Electric Cooling Fan S05949 No.2 Cooling Fan Connector Holder Fan Motor Cover Fan Motor Fan Shroud S05239 Author : Date : 1600...
Page 982 CO–27 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06P–03 REMOVAL REMOVE NO.1 COOLING FAN Drain the engine coolant. Disconnect the upper radiator hose from the radiator. Remove the No.1 cooling fan. Disconnect the cooling fan connector. Disconnect the ECT switch connector. Remove the 2 bolts, and disconnect the cooling fan from the radiator.
Page 983 CO–28 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06Q–03 DISASSEMBLY REMOVE FAN Remove the nut and fan. No.2 Cooling Fan: REMOVE FAN MOTOR COVER Remove the 2 screws and motor cover. REMOVE FAN MOTOR Disconnect the wire and connector holder from the fan shroud.
Page 984 CO–29 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06R–04 REASSEMBLY No.1 Cooling Fan INSTALL FAN MOTOR Install the fan motor with the 3 screws. Install the wire and connector holder to the fan shroud. No.2 Cooling Fan: INSTALL FAN MOTOR COVER Install the motor cover with the 2 screws.
Page 985 CO–30 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06S–03 INSTALLATION INSTALL NO.1 COOLING FAN Install the No.1 cooling fan. Attach the lower side of the cooling fan to the brack- et of the radiator. Install the cooling fan with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) Install the wire and connector holder for the ECT Attach...
Page 986 CO–31 COOLING (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO06T–03 INSPECTION DRAIN ENGINE COOLANT REMOVE ECT SWITCH Disconnect the connector. ECT Switch Connector Remove the ECT switch. Remove the O–ring from the ECT switch. Switch O–Ring S05245 INSPECT ECT SWITCH...
Page 987 CO–32 COOLING (5S–FE) – ENGINE MAIN RELAY ENGINE MAIN RELAY CO06U–03 INSPECTION REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE Engine MAIN) Main Relay S05391 INSPECT ENGINE MAIN RELAY Ohmmeter Ohmmeter Inspect the relay continuity. Continuity Using an ohmmeter, check that there is continuity between terminals 3 and 5.
Page 988 CO–33 COOLING (5S–FE) – COOLING FAN RELAY COOLING FAN RELAY CO06V–03 INSPECTION INSPECT NO.1 COOLING FAN RELAY Remove the relay box cover. No.1 Cooling Remove the No.1 cooling fan relay. (Marking: FAN NO.1) Fan Relay S05390 Inspect the No.1 cooling fan relay continuity. Ohmmeter Ohmmeter Using an ohmmeter, check that there is continuity...
Page 989 CO–34 COOLING (5S–FE) – COOLING FAN RELAY Inspect the No.2 cooling fan relay operation. Apply battery positive voltage across terminals 1 Ohmmeter and 2. Using an ohmmeter, check that there is no continu- Battery ity between terminals 3 and 4 Ohmmeter If there is continuity, replace the relay.
Page 990 CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR 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. CHECK ENGINE COOLANT QUALITY Remove the radiator cap from the water outlet.
Page 991 Slowly fill the system with coolant. Use of improper coolants may damage engine cool- ing system. Use ”Toyota Long life Coolant” or equivalent and mix it with plan water according to the manufactur- er’s directions. Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 %...
Page 992 CO–3 COOLING (1MZ–FE) – WATER PUMP WATER PUMP CO03D–04 COMPONENTS RH Fender Apron Seal 64 (650, 47) 32 (320, 23) Engine Moving Generator Drive Belt Control Rod 64 (650, 47) RH Engine Mounting Stay No.2 RH Engine Mounting Bracket No.2 RH Engine PS Pump Drive Belt Ground Strap Mounting Stay (M/T)
Page 993 CO–4 COOLING (1MZ–FE) – WATER PUMP Timing Belt Gasket No.2 Timing Belt Cover RH Engine Mounting Bracket 28 (290, 21) Timing Belt Guide No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley Engine Wire Protector 215 (2,200, 159) No.2 Idler Pulley RH Camshaft Timing Pulley 43 (440, 32) 125 (1,300, 94)
Page 994 CO–5 COOLING (1MZ–FE) – WATER PUMP Gasket No.3 Timing Belt Cover Collar Bushing 8.5 (85, 74 in.·lbf) Engine Wire z Gasket Water Pump 8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part B04403 Author : Date : 1613...
Page 995 CO–6 COOLING (1MZ–FE) – WATER PUMP CO03E–03 REMOVAL DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–15) REMOVE CAMSHAFT TIMING PULLEYS (See page EM–15) REMOVE NO.2 IDLER PULLEY (See page EM–15) REMOVE NO.3 TIMING BELT COVER (See page EM–32) REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket.
Page 996 CO–7 COOLING (1MZ–FE) – WATER PUMP CO03F–03 INSPECTION INSPECT WATER PUMP Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.
Page 997 CO–8 COOLING (1MZ–FE) – WATER PUMP CO0SO–01 INSTALLATION INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) NOTICE: Do not get oil on the gasket. INSTALL NO.3 TIMING BELT COVER (See page EM–57) P12942...
Page 998 CO–9 COOLING (1MZ–FE) – THERMOSTAT THERMOSTAT CO03H–03 COMPONENTS MAF Meter Connector EGR Vacuum Hose EVAP Hose Air Cleaner Cap Assembly No.2 ECT Switch Air Filter Connector Engine Wire Protector Thermostat z Gasket Water Inlet z O–Ring Water Inlet Pipe 8 (80, 69 in.·lbf) 19.5 (200, 14) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part...
Page 999 CO–10 COOLING (1MZ–FE) – THERMOSTAT CO03I–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect, caus- ing a lowering of cooling efficiency. Do not remove the thermo- stat, even if the engine tends to overheat. DRAIN ENGINE COOLANT REMOVE AIR CLEANER CAP ASSEMBLY AND AIR FILTER DISCONNECT NO.2 ECT SWITCH CONNECTOR...
Page 1000 CO–11 COOLING (1MZ–FE) – THERMOSTAT CO03J–03 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening tempera- ture. P13255 Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified, replace the thermostat.

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