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Table Of Contents - Toyota Celica 2000 Repair Manual

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Operating manual (255 pages)

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Owner's manual (255 pages)

Table Of Contents

Table of Contents

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Table of Contents

Engine Mechanical5

Compression Inspection8

Valve Clearance Adjustment9

Inspect Valve Clearance9

Adjust Valve Clearance10

2Zz-Ge: Valve Shim Selection Chart (Intake)15

2Zz-Ge: Valve Shim Selection Chart (Exhaust)16

Reinstall Camshaft17

Ignition Timing Inspection18

Warm Up Engine18

Inspect Ignition Timing18

Idle Speed Inspection19

Install Conditions19

Timing Chain Components20

Remove Crankshaft Pulley25

Remove Timing Chain Cover25

Remove Timing Chain And Crankshaft Timing Sprocket26

Inspect Timing Chain And Timing Sprockets27

Inspect Chain Tensioner Slipper And Vibration Damper27

Inspect Chain Tensioner28

Replace Crankshaft Front Oil Seal29

Install Valve Timing Controller Assembly And Camshaft Timing Sprocket30

Install Chain Vibration Damper31

Install Timing Chain And Crankshaft Timing Sprocket31

Install Timing Chain Cover And Water Pump33

Install Rh Engine Mounting Bracket36

Install Crankshaft Position Sensor37

Install Crankshaft Pulley37

Install Chain Tensioner37

Set Chain Tension38

Check Valve Timing38

Install Cylinder Head Cover38

Install Rh Engine Mounting Insulator40

Cylinder Head Components41

Remove Exhaust Manifold48

Disconnect Engine Wire From Cylinder Head48

Remove Intake Manifold48

Remove Cylinder Head50

Remove Gasket Material53

Clean Combustion Chambers53

Clean Cylinder Head53

Clean Valve Guide Bushings54

Inspect For Flatness54

Inspect For Cracks54

Inspect Valve Stems And Guide Bushings55

Inspect Valves55

Inspect And Clean Valve Seats56

Inspect Valve Springs57

Inspect Camshaft For Runout58

Inspect Cam Lobes59

Inspect Camshaft Journals59

Inspect Camshaft Journal Clearance60

Inspect Camshaft Thrust Clearance61

Inspect Valve Timing Controller Assembly61

Inspect Valve Lifters And Lifter Bores62

Inspect Intake Manifold63

Inspect Exhaust Manifold63

Inspect Cylinder Head Bolts63

Replace Valve Guide Bushings64

Install Water Hose Unions66

Install Valves67

Install Valve Lifters68

Install Oil Control Valve Housing68

Place Cylinder Head On Cylinder Block70

Install Cylinder Head Bolts70

Install Camshafts71

Install Intake Manifold72

Connect Engine Wire To Cylinder Head73

Install Exhaust Manifold73

Engine Unit Components75

Remove Air Cleaner Cap79

Remove Air Cleaner Case79

Remove Ecm Box79

Disconnect Engine Wire From Engine80

Compartment Relay Box80

Disconnect Cruise Control Actuator80

Disconnect Ajc Compressor80

Disconnect Clutch Release Cylinder81

Disconnect Ps Pump82

Disconnect Ps Gear82

Remove Suspension Member82

Remove Rear Engine Mounting83

Remove Engine And Transaxle Assembly83

Assembly Engine And Transaxle85

Install Engine And Transaxle Assembly In Vehicle85

Install Rear Engine Mounting85

Install Suspension Member86

Install Stabilizer Bar Bracket86

Install Exhaust Pipe87

Connect Clutch Release Cylinder87

Install Ajc Compressor87

Install Cruise Control Actuator88

Connect Engine Wire To Engine Compartment Relay Box88

Install Ecm Box88

Install Air Cleaner Case89

Install Air Cleaner Cap89

Cylinder Block Components90

Remove Oil Dipstick And Guide94

Remove Ventilation Case94

Remove Oil Pan95

Remove Oil Strainer95

Remove Oil Strainer And Oil Pan Baffle95

Check Connecting Rod Thrust Clearance96

Remove Connecting Rod Caps And Check Oil Clearance96

Remove Piston And Connecting Rod98

Check Crankshaft Thrust Clearance101

Check Fit Between Piston And Piston Pin102

Remove Piston Rings102

Disconnect Connecting Rod From Piston102

Clean Cylinder Block103

Inspect Top Surface Of Cylinder Block For Flatness103

Inspect Cylinder Bore Diameter103

Remove Cylinder Ridge104

Clean Piston104

Inspect Piston Oil Clearance105

Inspect Piston Ring End Gap106

Inspect Piston Pin Fit106

Inspect Connecting Rod Alignment106

Inspect Piston Pin Oil Clearance107

Inspect Connecting Rod Bolts108

Inspect Crankshaft For Circle Runout108

Inspect Main Journals And Crank Pins108

Replace Connecting Rod Bushings109

Replace Crankshaft Rear Oil Seal109

Assemble Piston And Connecting Rod111

Install Piston Rings112

Install Connecting Rod Bearings112

Install Main Bearings112

Install Thrust Washers113

Install Oil Strainer116

Install Oil Pan Baffle And Oil Strainer116

Install Oil Pan116

Install Engine Coolant Drain Union117

Install Knock Sensor117

Install Ventilation Case118

Install Water Bypass Pipe118

Install Oil Dipstick And Guide118

Install Flywheel118

Install Drive Plate119

Exhaust System Components120

Emission Control122

Emission Control System Purpose124

Parts Layout And Schematic Drawing Location125

Positive Crankcase127

Ventilation (Pcv) System Inspection127

Remove Pcv Valve127

Inspect Pcv Valve Operation127

Evaporative Emission (Evap) Control System Components128

Inspect Fuel Tank Filler Pipe129

Inspect Fuel Tank Cap129

Inspect Evap System Line129

Check Airtightness In Fuel Tank And Filler Pipe131

Inspect Fuel Cutoff Valve And Fill Check Valve131

Check Air Inlet Line132

Remove Charcoal Canister Assembly132

Inspect Charcoal Canister132

Three-Way Catalytic Converter (Twc} System Inspection134

Sfi136

Sfi System Precaution138

Maintenance Precautions138

Air Induction System138

Electronic Control System138

Fuel Pump On-Vehicle Inspection143

Check Fuel Pump Operation143

Check Fuel Pressure143

Inspect Fuel Pump Resistance146

Inspect Fuel Pump Operation146

Fuel Pump Components147

Remove Fuel Pump Assembly From Fuel Tank148

Remove No. 1 Fuel Suction Support149

Remove Vapor Pressure Sensor149

Remove Fuel Pressure Regulator149

Remove Fuel Pump149

Install Fuel Pressure Regulator150

Install Fuel Pump Assembly151

Connect Fuel Tube151

Install Floor Service Hole Cover151

Fuel Pressure Regulator Components152

Fuel Pressure Regulator Removal153

Injector On-Vehicle Inspection155

Check Operation Sound From Each Injector155

Inspect Injector Resistance155

Install Wire Harness Protector Cover155

Disconnect Fuel Tube158

Remove Delivery Pipe And Injectors158

Inspect Injector Inspection159

Inspect Leakage160

Install Injectors And Delivery Pipes161

Fuel Tank And Line Precaution163

Fuel Tank And Line Components164

Inspect Fuel Tank And Line165

Mass Air Flow (Maf) Meter Components166

Remove Air Flow Meter167

Inspect Maf Meter Resistance168

Inspect Maf Meter Operation168

Install Air Flow Meter169

Throttle Body On-Vehicle Inspection170

Inspect Throttle Body170

Inspect Throttle Position Sensor170

Throttle Body Components171

Remove Throttle Body173

Inspect Throttle Valve175

Install Throttle Body176

Idle Air Control Valve On-Vehicle Inspection177

Inspect Lac Valve Operation177

Inspect Iac Valve Operation181

Camshaft Timing Oil Control Valve183

Inspect Oil Control Valve Resistance183

Remove Camshaft Timing Oil Control Valve186

Remove 2 Camshaft Timing Oil Control Valves186

Inspect Camshaft Oil Control Valve Operation187

Efi Main Relay Inspection189

Inspect Efi Main Relay Continuity189

Inspect Efi Main Relay Operation189

Circuit Opening Relay Inspection190

Inspect Circuit Opening Relay Continuity190

Inspect Circuit Opening Relay Operation190

Vsv For Intake Air Control Valve Components191

Vsv For Evaporative Emission (Evap) Components193

Inspect Vsv For Open Circuit194

Inspect Vsv For Ground194

Inspect Vsv Operation194

Vsv For Canister Closed Valve {Ccv) Components195

Vsv For Pressure Switching Valve Components197

Engine Coolant Temperature (Ect) Sensor Components199

Inspect Ect Sensor Resistance200

Vapor Pressure Sensor Components201

Inspect Power Source Voltage Of Vapor Pressure Sensor202

Inspect Power Output Of Vapor Pressure Sensor202

Knock Sensor Components203

Remove Knock Sensor205

Inspect Knock Sensor205

Heated Oxygen Sensor Components206

Inspect Heater Resistance Of Heated Oxygen Sensor207

Engine Control Module (Ecm) Components208

Fuel Cut Rpm Inspection210

Inspect Fuel Cut Off Rpm210

Coolant Inspection214

Coolant Replacement215

Drain Engine Coolant215

Fill Engine Coolant215

Water Pump Components217

Remove Water Pump218

Inspect Water Pump219

Install Water Pump220

Thermostat Components221

Thermostat Removal222

Inspect Thermostat223

Place Thermostat In Cylinder Block224

Radiator On-Vehicle Cleaning225

Remove Reservoir Cap226

Inspect Reservoir Cap226

Inspect Cooling System For Leaks227

Remove Engine Coolant Reservoir230

Remove Radiator Assembly230

Remove Drain Plug231

Assemble Sst231

Uncaulk Lock Plates231

Remove Tanks And 0-Rings231

Inspect Lock Plate For Damage232

Radiator Reassembly233

Install Oil Cooler To Lower Tank233

Install New O-Rings And Tanks233

Caulk Lock Plate234

Install Drain Plug234

Inspect For Water Leaks235

Install Radiator Assembly236

Install Engine Coolant Reservoir236

Electric Cooling Fan On-Vehicle Inspection237

Check Cooling Fan Operation With Low Temperature237

Check Cooling Fan Operation With High Temperature237

Inspect Cooling Fans237

Electric Cooling Fan Components238

Electric Cooling Fan Removal240

Install Fan Motor(S)242

Install Fan(S)242

Install Cooling Fan243

Install Radiator Upper Support243

Cooling Fan Relay Inspection244

Inspect No. 1 Cooling Fan Relay244

Inspect No. 2 Cooling Fan Relay244

Inspect No. 3 Cooling Fan Relay245

Oil And Filter Inspection248

Check Engine Oil Quality248

Check Oil Pressure248

Remove Center Engine Under Cover250

Replace Oil Filter250

Refill With Engine Oil250

Oil Pump Components252

Oil Pump Removal256

Oil Pump Disassembly257

Inspect Oil Jet258

Inspect Relief Valve258

Inspect Rotor Side Clearance258

Inspect Rotor Tip Clearance258

Install Drive And Driven Rotors259

Install Relief Valve259

Install Oil Pump260

Oil Nozzle (2Zz-Ge) Components261

Inspect Relief Valve (Oil Nozzle)263

Install Oil Nozzle (With Relief Valve)264

Ignition System On-Vehicle Inspection268

Recommended Spark Plug270

Inspect Camshaft Position Sensor271

Ignition Coil Components272

Remove Ignition Coils (With Igniter) From Spark Plugs273

Camshaft Position Sensor Components275

Camshaft Position Sensor Removal276

Remove Camshaft Position Sensor276

Camshaft Position Sensor Installation277

Crankshaft Position Sensor Components278

Remove Crankshaft Position Sensor280

Starting System On-Vehicle Inspection286

Starter Components287

Starter Removal289

Starter Disassembly290

Remove Steel Ball291

Starter Inspection292

Inspect Armature Coil Commutator For Open Circuit292

Inspect Commutator Circle Runout292

Inspect Commutator Diameter292

Inspect Field Frame (Field Coil) For Open Circuit293

Inspect Field Frame (Field Coil) Ground293

Inspect Brush Length293

Inspect Brush Spring Load293

Inspect Brush Holder Insulation294

Inspect Gear Teeth294

Inspect Clutch294

Starter Replacement295

Inspect Bearing295

Replace Bearings295

Remove Magnetic Switch End Cover295

Install Armature To Magnetic Switch Assembly298

Insert Steel Ball Into Clutch Shaft Hole298

Install Starter Housing, Clutch Assembly And Gears298

Install Field Frame299

Install Brush Holder299

Install End Cover299

Install New Dust Protector299

Do Pull-In Test300

Do Hold-In Test300

Inspect Clutch Pinion Gear Return300

Do No-Load Performance Test300

Install Starter301

Starter Relay Inspection302

Inspect Starter Relay Continuity302

Charging System306

Check Battery Electrolyte Level307

Check Battery Specific Gravity307

Check Battery Voltage307

Check Battery Terminals, Fusible Link And Fuses307

Inspect Drive Belt308

Visually Check Generator Wiring And Listen For Abnormal Noises308

Inspect Discharge Warning Light Circuit308

Inspect Charging Circuit Without Load309

Inspect Charging Circuit With Load309

Generator Components310

Generator Removal312

Remove Drive Belt312

Remove Generator312

Generator Disassembly313

Remove Rear End Cover313

Remove Brush Holder And Voltage Regulator313

Remove Rectifier Holder313

Remove Rectifier End Frame314

Generator Inspection315

Inspect Exposed Brush Length316

Inspect Positive Rectifier Holder316

Inspect Negative Rectifier Holder316

Inspect Front Bearing316

Inspect Rear Bearing317

Install Rotor To Drive End Frame319

Install Rectifier End Frame319

Install Pulley319

Install Rectifier Holder320

Install Voltage Regulator And Brush Holder321

Install Rear End Cover321

Install Generator322

Clutch Troubleshooting326

Problem Symptoms Table326

Clutch Pedal Inspection327

Check Pedal Height327

Check Pedal Free Play And Push Rod Play327

Check Clutch Release Point327

Check Clutch Start System328

Inspect Clutch Start Switch Continuity328

Clutch Master Cylinder Components329

Disconnect Reservoir Hose330

Disconnect Clutch Line330

Clutch Master Cylinder330

Remove Inlet Union331

Remove Boot From Cylinder331

Remove Push Rod331

Install Push Rod332

Install Inlet Union332

Connect Clutch Line333

Connect Reservoir Hose333

Clutch Release Cylinder Components334

Remove Release Cylinder335

Remove Boot Ano Push Rod336

Remove Piston And Spring336

Install Bleeder Plug337

Release Cylinder Installation338

Clutch Unit Components339

Clutch Unit Removal340

Remove Clutch Cover And Disc340

Clutch Unit Inspection341

Inspect Clutch Disc For Wear Or Damage341

Inspect Clutch Disc Runout341

Inspect Flywheel Runout341

Clutch Unit Installation342

Install Clutch Disc And Clutch Cover On Flywheel342

Manual Transaxle (C56)344

Table Of Contents344

Manual Transaxle (C56) Troubleshooting346

Manual Transaxle Unit Components347

Manual Transaxle Unit Removal349

Disconnect Control Cable349

Disconnect Ground Cable349

Remove Starter350

Remove Control Cable Bracket350

Attach Engine Sling Device To Engine Hanger350

Remove Engine Left Mounting Bracket351

Drain Transaxle Oil351

Remove Front Sub-Frame And Lower Suspension Arm352

Remove Engine Rear Mounting Insulator And Bracket352

Remove 4 Transaxle Lower Side Mounting Bolts352

Manual Transaxle Unit Installation353

Manual Transaxle Assembly Components354

Manual Transaxle Assembly Disassembly357

Remove Vehicle Speed Sensor357

Remove Control Shaft Assembly357

Remove Selecting Bellcrank Assembly357

Remove Control Shift Lever And Dust Boot358

Remove Transmission Case Cover358

Remove Lock Ball Assembly And Control Shaft Cover359

Remove Lock Nut359

Inspect 5Th Gear Thrust Clearance360

Inspect 5Th Gear Radial Clearance360

Remove No. 3 Clutch Hub And 5Th Gear361

Remove 5Th Driven Gear361

Remove Rear Bearing Retainer362

Remove Bearing Snap Ring362

Remove Lock Ball Assembly362

Remove Transmission Case363

Remove Oil Receiver Pipe363

Remove Reverse Shift Arm Bracket363

Manual Transaxle Assembly Inspection366

Inspect 5Th Gear Synchronizer Ring366

Inspect Gear Shift Fork And Hub Sleeve Clearance366

Install Transaxle Case Receiver368

Manual Transaxle Assembly Reassembly370

Input Shaft Components371

Input Shaft Disassembly372

Inspect 3Rd And 4Th Gears Thrust Clearance372

Input Shaft Inspection374

Inspect Synchronizer Ring374

Input Shaft Reassembly376

Install Snap Ring377

Inspect 3Rd Gear Thrust Clearance377

Output Shaft Components379

Output Shaft Disassembly380

Remove Snap Ring381

Remove Front Bearing Inner Race382

Disassemble Reverse Gear Assembly382

Output Shaft Inspection383

Inspect 1St Gear Synchronizer Ring383

Inspect 2Nd Gear Synchronizer Ring383

Inspect Gear Shift Fork And Reverse Gear Clearance384

Inspect Output Shaft384

Output Shaft Reassembly385

Install Front Bearing Inner Race385

Assemble Reverse Gear Assembly385

Inspect 1St Gear Thrust Clearance387

Install Output Gear Spacer, 4Th Driven Gear And Rear Radial Ball Bearing388

Shift And Select Lever Shaft Components389

Differential Case Components390

Differential Case Disassembly391

Remove Ring Gear391

Inspect Side Gear Backlash391

Disassemble Differential Case391

Differential Case Reassembly394

Assemble Differential Case394

Install Tapered Roller Bearing394

Install Ring Gear On Differential Case395

Inspect Differential Tapered Roller Bearing Preload395

Shift Lever And Control Cable Components397

Manual Transaxle (C60)400

Manual Transaxle (C60) Troubleshooting402

Manual Transaxle (C60) Components403

Manual Transaxle (C60) Removal405

Manual Transaxle (C60) Assembly Components410

Manual Transaxle (C60) Disassembly413

Manual Transaxle (C60) Assembly Inspection425

Manual Transaxle (C60) Assembly Reassembly429

Manual Transaxle (C60) Input Shaft430

Manual Transaxle (C60) Assembly Output Shaft438

Manual Transaxle (C60) Shift And Select Lever Shaft448

Manual Transaxle (C60) Differential Case449

Manual Transaxle (C60) Reverse Shift Warning Buzzer System456

Shift Lever And Control Cable458

Automatic Transaxle (U240E)462

Automatic Transaxle (U240E) System Precaution464

Automatic Transaxle (U240E) Operation465

Automatic Transaxle (U240E) Vehicle Speed Sensor466

Speed Sensor467

Atf Temperature Sensor On-Vehicle Repair469

Park/Neutral Position (Pnp) Switch On-Vehicle Repair471

Valve Body Assembly On-Vehicle Repair473

Shift Lock System Components478

Inspect Shift Lock Control Unit Assembly479

Floor Shift Assembly Components480

Shift Assembly Disassembly486

Automatic Transaxle Unit Components493

Automatic Transaxle Unit Removal494

Automatic Transaxle Unit Installation498

Transaxle Installation498

Torque Converter Clutch And Drive Plate Inspection499

Inspect One-Way Clutch499

Measure Drive Plate Runout And Inspect Ring Gear499

Measure Torque Converter Clutch Sleeve Runout499

Automatic Transaxle (U341 E)502

Automatic Transaxle (U341 E) System Precaution504

Automatic Transaxle (U341 E) Operation505

Automatic Transaxle (U341 E) Vehicle Speed Sensor506

Input Turbin Speed Sensor On-Vehicle Repair507

Remove Valve Body513

Install Check Valve And Spring514

Install Valve Body514

Install Atf Temperature Sensor514

Differential Oil Seal On-Vehicle Repair516

Floor Shift Assembly519

Remove Key Interlock Cable523

Remove 0/D Main Switch Terminal525

Remove Shift Lever Knob Sub-Assembly525

Remove Upper Position Indicator Housing525

Remove Lower Position Indicator Housing525

Install Floor Shift Assembly530

Install Key Interlock Cable530

Suspension And Axle542

Suspension And Axle Troubleshooting544

Tire And Wheel Inspection545

Inspect Tire545

Rotating Tires545

Inspect Wheel Balance546

Check Wheel Bearing Looseness546

Front Wheel Alignment Inspection547

Measure Vehicle Height547

Inspect Camber, Caster And Steering Axis Inclination547

Adjust Camber548

Inspect Toe-In549

Adjust Toe-In549

Inspect Wheel Angle550

Rear Wheel Alignment Inspection551

Adjust Camber And Toe-In551

How To Read Adjustment Chart (Example)552

Front Axle Hub Components554

Remove Lower Ball Joint557

Remove Axle Hub557

Remove Dust Cover557

Remove Bearing From Steering Knuckle557

Front Wheel Hub Bolt Replacement560

Install Hub Bolt560

Front Drive Shaft Components561

Remove Drive Shaft Lock Nut563

Disconnect Tie Rod End From Steering Knuckle563

Disconnect Lower Ball Joint From Lower Suspension Arm564

Disconnect Drive Shaft From Axle Hub564

Remove Drive Shaft564

Disassemble Drive Shaft566

Disassemble Inboard Joint Shaft567

Reassemble Inboard Joint Shaft569

Reassemble Drive Shaft570

Front Shock Absorber Components576

Front Shock Absorber Removal577

Disconnect Stabilizer Bar Link577

Front Shock Absorber Disassembly578

Remove Coil Spring578

Front Shock Absorber Inspection579

Inspect Shock Absorber579

Front Shock Absorber Disposal580

Drill Hole To Discharge Gas From Cylinder580

Front Shock Absorber Reassembly581

Install Coil Spring581

Front Lower Suspension Arm Components584

Front Lower Suspension Arm Removal585

Front Lower Ball Joint Components589

Front Lower Ball Joint Removal590

Front Lower Ball Joint Inspection591

Inspect Lower Ball Joint For Rotation Condition591

Front Lower Ball Joint Installation592

Install Lower Ball Joint592

Front Stabilizer Bar Components593

Front Stabilizer Bar Removal594

Remove Stabilizer Bar Links594

Remove Stabilizer Bar594

Front Stabilizer Bar Inspection595

Inspect Stabilizer Bar Link Ball Joint For Rotation Condition595

Front Stabilizer Bar Installation596

Rear Axle Carrier Components597

Rear Axle Carrier Removal598

Check Bearing Backlash And Axle Hub Deviation598

Remove Rear Axle Hub598

Disconnect Upper Support Suspension Arm599

Remove Rear Axle Carrier599

Rear Axle Carrier Disassembly600

Remove Abs Speed Sensor600

Rear Axle Carrier Reassembly601

Install New Abs Speed Sensor601

Rear Axle Carrier Installation602

Rear Wheel Hub Bolt Replacement603

Rear Shock Absorber Components604

Rear Shock Absorber Removal605

Rear Shock Absorber Disassembly606

Rear Shock Absorber Inspection607

Rear Shock Absorber Disposal608

Rear Shock Absorber Reassembly609

Rear Shock Absorber Installation610

Rear Upper Suspension Arm Components611

Rear Upper Suspension Arm Removal612

Rear Upper Suspension Arm Installation613

Rear Lower Suspension Arm Components614

Rear Lower Suspension Arm Removal615

Rear Stabilizer Bar Components618

Rear Stabilizer Bar Removal619

Rear Stabilizer Bar Inspection620

Rear Stabilizer Bar Installation621

Brake System Precaution624

Brake System Troubleshooting625

Brake Fluid Bleeding627

Bleed Master Cylinder627

Bleed Brake Line627

Brake Pedal On-Vehicle Inspection629

Check Pedal Freeplay629

Brake Pedal Components630

Parking Brake Lever On-Vehicle Inspection631

Check Parking Brake Lever Travel631

Brake Master Cylinder Components632

Brake Master Cylinder Removal633

Disconnect Brake Line633

Remove Master Cylinder633

Remove Reservoir634

Brake Master Cylinder Installation635

Brake Booster Assembly On-Vehicle Inspection636

Air Tightness Check636

Brake Booster Assembly Components637

Brake Booster Assembly Removal638

Brake Booster Assembly Installation639

Install Brake Booster639

Front Brake Pad Components640

Front Brake Pad Replacement641

Inspect Pad Lining Thickness641

Lift Up Caliper641

Install New Pads641

Install Caliper642

Front Brake Caliper Components643

Front Brake Caliper Removal645

Remove Front Wheel645

Disconnect Flexible Hose645

Remove Caliper645

Front Brake Caliper Disassembly646

Remove Set Ring And Cylinder Boot646

Remove Piston646

Remove Sliding Pins And Dust Boots646

Front Brake Caliper Inspection647

Measure Pad Lining Thickness647

Measure Disc Thickness647

Measure Disc Runout647

Front Brake Caliper Reassembly649

Front Brake Caliper Installation650

Rear Drum Brake Components651

Rear Drum Brake Removal652

Inspect Shoe Lining Thickness652

Remove Brake Drum652

Remove Front Shoe652

Remove Parking Brake Lever653

Remove Wheel Cylinder653

Disassemble Wheel Cylinder653

Rear Drum Brake Inspection654

Inspect Disassembled Parts654

Measure Brake Shoe Lining Thickness654

Measure Brake Drum Inside Diameter654

Rear Drum Brake Installation655

Check Operation Of Automatic Adjusting Mechanism655

Check Clearance Between Brake Shoes And Drum655

Rear Brake Pad Components656

Rear Brake Pad Replacement657

Rear Brake Caliper Components659

Rear Brake Caliper Removal660

Remove Piston Seal From Cylinder661

Parking Brake Components665

Remove Rear Wheel666

Remove Front Shoe And Adjuster666

Remove Rear Shoe667

Remove Parking Brake Shoe Lever667

Measure Disc Inside Diameter668

Adjust Parking Brake Shoe Clearance669

Settling Parking Brake Shoes And Disc669

Proportioning Valve (P Valve) On-Vehicle Inspection670

Abs Actuator On-Vehicle Inspection671

Push Motor Switch674

Front Speed Sensor Components678

Disconnect Speed Sensor Connector679

Remove Speed Sensor679

Rear Speed Sensor Components681

Rear Speed Sensor Removal682

Rear Speed Sensor Installation684

Steering System Precaution688

Steering System Troubleshooting689

Drive Belt Inspection690

Power Steering Fluid Bleeding691

Power Steering Fluid Inspection692

Check Fluid Level692

Check Steering Fluid Pressure693

Steering Wheel Inspection695

Check Steering Wheel Freeplay695

Check Steering Effort695

Tilt Steering Column Components696

Tilt Steering Column Removal698

Remove Steering Wheel Pad698

Remove Steering Wheel698

Remove Transmission Shift Switch Assembly From Steering Wheel700

Remove Column Upper Bracket And Column Upper Clamp701

Remove Bracket Spacer And 2 No. 1 Support Collars701

Remove Main Shaft Bushing702

Remove Main Shaft Assembly702

Inspect Steering Lock Operation703

Steering Reassembly704

Install Main Shaft Assembly704

Install Main Shaft Bushing704

Install Break Away Bracket And Tilt Lever704

Install 2 No. 1 Support Collars And Bracket Spacer705

Install Column Upper Bracket And Column Upper Clamp705

Install Transmission Shift Switch Assembly To Steering Wheel706

Install Transmission Shift Switch Assembly And Speed Control Main Switch Assembly To Steering Wheel706

Connect No. 2 Intermediate Shaft Assembly707

Center Spiral Cable708

Install Steering Wheel708

Install Steering Wheel Pad708

Power Steering Vane Pump Components709

Power Steering Vane Pump Removal711

Power Steering Vane Pump Disassembly712

Power Steering Vane Pump Inspection713

Inspect Flow Control Valve714

Inspect Spring715

Power Steering Vane Pump Replacement716

Power Steering Vane Pump Reassembly717

Install Side Plate717

Install Cam Ring717

Install Vane Pump Rotor717

Power Steering Vane Pump Installation719

Install Ps Vane Pump Assembly719

Connect Pressure Feed Tube719

Install Drive Belt719

Power Steering Gear Components720

Power Steering Gear Removal723

Power Steering Gear Disassembly726

Power Steering Gear Replacement729

Power Steering Gear Reassembly733

Install Oil Seal733

Install Steering Rack733

Install Cylinder End Stopper734

Air Tightness Test734

Install Control Valve Assembly734

Install Rack Housing Cap734

Adjust Total Preload735

Install Rh And Lh Rack Boots, Wires And Clips736

Power Steering Gear Installation738

Install Ps Gear Assembly738

Connect Tube Clamp739

Connect Pressure Feed And Return Tubes739

Supplemental Restraint System742

Srs Airbag Precaution744

Srs Airbag Operation745

Steering Wheel Pad745

Spiral Cable745

Front Passenger Airbag Assembly745

Srs Warning Light746

Airbag Sensor Assembly746

Front Airbag Sensor746

Side Airbag Sensor Assembly746

Srs Connectors747

Terminal Twin-Lock Mechanism748

Electrical Connection Check Mechanism749

Disconnection Of Connectors For Front Airbag Sensor, Side Airbag Sensor And Door Side Airbag Sensor750

Disconnection Of Side Airbag Connector752

Connection Of Side Air Bag Connector752

Steering Wheel Pad And Spiral Cable Components755

Steering Wheel Pad And Spiral Cable Removal756

Steering Wheel Pad And Spiral Cable Inspection757

Inspect Supplemental Restraint System757

Steering Wheel Pad And Spiral Cable Disposal759

Deployment When Disposing Of Steering Wheel Pad With Airbag Deployed In Collision768

Steering Wheel Pad And Spiral Cable Replacement769

Steering Wheel Pad And Spiral Cable Installation770

Front Passenger Airbag Assembly Components771

Front Passenger Airbag Assembly Removal772

Disconnect Air Bag Connector772

Remove Front Passenger Airbag Assembly772

Front Passenger Airbag Assembly Inspection773

Front Passenger Airbag Assembly Disposal775

Front Passenger Airbag Assembly Replacement782

Front Passenger Airbag Assembly Installation783

Side Airbag Assembly Components784

Side Airbag Assembly Removal785

Remove Seat Back Assembly786

Side Airbag Assembly Inspection787

Side Airbag Assembly Disposal788

Side Airbag Assembly Installation795

Install Inner Front Seat Cushion Shield796

Install Front Seat796

Airbag Sensor Assembly Components797

Airbag Sensor Assembly Removal798

Airbag Sensor Assembly Inspection799

Airbag Sensor Assembly Replacement800

Airbag Sensor Assembly Installation801

Install Airbag Sensor Assembly801

Front Airbag Sensor Components802

Front Airbag Sensor Removal803

Front Airbag Sensor Inspection804

Front Airbag Sensor Replacement805

Front Airbag Sensor Installation806

Side Airbag Sensor Assembly Components807

Side Airbag Sensor Assembly Removal808

Side Airbag Sensor Assembly Inspection809

Side Airbag Sensor Assembly Replacement810

Side Airbag Sensor Assembly Installation811

Door Side Airbag Sensor Components812

Door Side Airbag Sensor Removal813

Door Side Airbag Sensor Inspection814

Door Side Airbag Sensor Replacement815

Door Side Airbag Sensor Installation816

Wire Harness And Connector Location817

Wire Harness And Connector Inspection818

Wire Harness And Connector Replacement819

Body Electrical820

Body Electrical System822

Headlight System822

Audio System822

Body Electrical System Troubleshooting823

Warning Lights827

Power Source Location831

Engine Room Junction Block832

Center Junction Block833

Ignition Switch And Key Unlock Warning Switch Location834

Ignition Switch And Key Unlock Warning Switch Inspection835

Inspect Ignition Switch Continuity835

Inspect Key Unlock Warning Buzzer835

Headlight And Taillight System Location836

Headlight And Taillight System Components837

Headlight And Taillight System Inspection838

Inspect Automatic Light Control839

Inspect Light-Off Condition839

Inspect Sensor Circuit839

Headlight And Taillight System Adjustment841

Adjust Headlight Aim Only841

Fog Light System Location843

Fog Light System Inspection844

Inspect Front Fog Light Switch Continuity844

Inspect Front Fog Light Relay Continuity844

Fog Light System Adjustment845

Turn Signal And Hazard Warning System Location846

Turn Signal And Hazard Warning System Inspection847

Interior Light System Location848

Interior Light System Inspection849

Inspect Rear Room Light Continuity849

Inspect Door Courtesy Switch Continuity849

Inspect Licence Plate Light Continuity850

Back-Up Light System Location851

Back-Up Light System Inspection852

Inspect Back-Up Light Switch Continuity852

Stop Light System Location853

Stop Light System Inspection854

Inspect Stop Light Switch Continuity854

Wiper And Washer System Location855

Wiper And Washer System Inspection856

Inspect Front Washer Linked Operation857

Inspect Rear Wiper And Washer Switch Continuity857

Inspect Front Wiper Motor Operation857

Combination Meter Location860

Combination Meter Circuit863

Combination Meter Components865

Combination Meter Disassembly866

Combination Meter Cover866

Combination Meter Inspection867

Inspect Tachometer Resistance868

Inspect Fuel Receiver Gauge Operation868

Inspect Fuel Sender Gauge Resistance869

Inspect Engine Coolant Temperature Receiver Gauge Operation869

Inspect Low Oil Pressure Warning Light870

Inspect Low Oil Pressure Switch Continuity870

Inspect Brake Warning System Light870

Inspect Brake Fluid Level Warning Switch Continuity871

Inspect Parking Brake Warning Light871

Inspect Parking Brake Switch Continuity871

Inspect Open Door Warning Light871

Inspect Light Control Thermostat Operation872

Electric Tension Reducer System Location873

Electric Tension Reducer System Inspection874

Inspect Buckle Switch Continuity874

Defogger System Location875

Defogger System Inspection876

Inspect Defogger Timer Operation876

Inspect Defogger Switch Circuit876

Power Window Control System Location879

Power Window Control System Inspection880

Inspect Power Main Relay Continuity880

Inspect Power Window Motor Operation880

Inspect Ptc Operation881

Power Door Lock Control System Location883

Power Door Lock Control System Inspection884

Wireless Door Lock Control System Location888

Wireless Door Lock Control System Pre-Check889

Wireless Door Lock Control System Inspection894

Inspect Wireless Door Lock Transmitter Operation894

Check Battery Capacity895

Inspect Wireless Door Lock Control Receiver Circuit896

Replace Transmitter (Lithium) Battery898

Replace Door Control Receiver And Transmitter899

Sliding Roof System Location904

Sliding Roof System Inspection905

Power Mirror Control System Location906

Power Mirror Control System Inspection907

Audio System Description909

Radio Wave Band909

Service Area909

Reception Problems909

Noise Problems910

Diagnosis Code List917

Radio Troubleshooting918

Radio Not Operating When Power Switch Turned To "On"919

Audio System Location937

Inspect Radio Receiver Assembly Circuit938

Antenna Location940

Clock Troubleshooting943

Clock Loses Or Gains Time944

Horn System Location946

Inspect Horn Switch947

Inspect Horn Operation947

Inspect Horn Relay Continuity948

Clip Replacement952

Front Bumper Components955

Rear Bumper Components956

Headlight Components957

Remove Headlight958

Hood Adjustment960

Front Door Components961

Front Door Disassembly962

Remove Regulator Handle962

Remove Lower Frame Bracket Garnish962

Remove No, 2 Door Inside Handle Bezel962

Remove Door Trim963

Remove Door Side Airbag Sensor963

Remove Front Door Weatherstrip964

Remove Front Door Belt Moulding964

Remove Upper Window Stops965

Remove Door Glass965

Remove Window Regulator965

Remove Window Regulator From Motor966

Remove Speaker966

Remove Door Glass Female Stabilizer967

Remove Front Lower Frame967

Remove Front Door No. 2 Weatherstrip967

Remove Door Lock967

Remove Outside Handle968

Inspect Front Door Glass969

Front Door Adjustment970

Adjust Front Door Glass970

Back Door Components973

Back Door Disassembly974

Remove Back Door Trim Board974

Remove Rear Wiper Arm974

Remove Rear Wiper Motor974

Remove Control Cable975

Remove Back Door Lock975

Remove Key Cylinder975

Remove Outside Back Door Garnish975

Adjust Door In Left/Right And Vertical Directions976

Adjust Door In Forward/Rearward And Yertical Directions976

Adjust Door Lock Striker976

Adjust Lower Stopper976

Back Door Reassembly977

Back Door Stay Replacement978

Remove Back Door Stay978

Front Wiper And Washer Components979

Front Wiper And Washer Removal980

Remove Wiper Arms980

Remove Cowl Top Ventilator Louver980

Remove Wiper Motor And Link Assembly980

Front Wiper And Washer Inspection981

Inspect Washer Nozzle981

Front Wiper And Washer Adjustment982

Adjust Front Washer Nozzle982

Front Wiper And Washer Installation983

Install Wiper Motor983

Install Wiper Motor And Link Assembly983

Install Cowl Top Ventilator Louver983

Rear Wiper And Washer Components984

Rear Wiper And Washer Removal985

Remove Rear Washer Nozzle985

Rear Wiper And Washer Inspection986

Rear Wiper And Washer Installation987

Roof Drip Side Moulding Components989

Roof Drip Side Moulding Removal990

Roof Drip Side Moulding Installation991

Clean Body Mounting Surface991

Clean Moulding991

Install Roof Drip Side Moulding991

Install Roof Side Rail Weatherstrip992

Roof Side Moulding Components993

Roof Side Moulding Removal994

Roof Side Moulding Installation995

Clean Contract Surface Of Body995

Apply Adhesive996

Install Moulding996

Side Mudguard Components997

Windshield Components998

Windshield Removal999

Remove Front Pillar Garnish999

Remove Map Light Assembly999

Remove Inner Rear View Mirror999

Remove Winoshield Outside Moulding1000

Remove Windshield Glass1000

Windshield Installation1001

Clean And Shape Contact Surface Of Body1001

Clean Removed Glass1001

Install New Dams1002

Position Glass1002

Clean Contact Surface Of Glass1002

Coat Contact Surface Of Body With Primer1002

Coat Contact Surface Of Glass With Primer1003

Install Windshield Glass And Moulding1003

Inspect For Leak And Repair1004

Install Wiper Arms1004

Quarter Window Glass Components1006

Quarter Window Glass Removal1007

Remove Door Scuff Plate1007

Remove Luggage Compartment Tray1007

Remove Rear Deck Trim Cover1007

Remove Quarter Trim Panel1008

Remove Roof Side Inner Garnish1008

Remove Roof Side Rail Weatherstrip1008

Remove Quarter Window Glass1009

Quarter Window Glass Installation1011

Clean And Shape Contact Surface Of Body Panel1011

Clean Contact Surface Of New Glass1011

Install New Spacers1011

Quarter Window Glass1012

Back Door Glass Components1015

Back Door Glass Removal1016

Remove Center Stop Light1016

Remove Back Door Glass1016

Back Door Glass Installation1017

Install New Dams And Outside Lower Moulding1017

Install Rear Wiper Arm1019

Sliding Roof On-Vehicle Inspection1020

Inspect Sliding Roof Glass Alignment1020

Sliding Roof Components1021

Sliding Roof Removal1022

Sliding Roof Disassembly1023

Remove Sunshade Stoppers1023

Remove Front Housing Frame1023

Remove Drive Cable1023

Sliding Roof Adjustment1024

Sliding Roof Reassembly1025

Sliding Roof Installation1026

Instrument Panel Components1027

Instrument Panel Removal1030

Instrument Panel Disassembly1034

Instrument Panel Reassembly1035

Roof Headlining Components1037

Roof Headlining Removal1039

Remove Deck Trim Side Panel1039

Front Seat Components1043

Front Seat B0-921043

Front Seat Removal1044

Remove Seat Track Covers1044

Remove Front Seat1044

Front Seat Disassembly1045

Front Seat Reassembly1048

Install Reclining Connecting Pipe1048

Install Seat Cushion Assembly1048

Install Front Seat Inner Belt1048

Install Seatback Cover1049

Install Seatback Assembly1049

Front Seat Installation1051

Rear Seat Components1052

Rear Seat Removal1053

Rear Seat Disassembly1054

Rear Seat Reassembly1055

Install Seat Cushion Coyer1055

Install Seatback Frame1055

Rear Seat Installation1056

Seat Belt Components1057

Seat Belt Inspection1058

Seat Belt Pretensioner Removal1060

Seat Belt Pretensioner Inspection1062

Seat Belt Pretensioner Disposal1063

Seat Belt Pretensioner Activation When Scrapping Vehicle1064

Seat Belt Pretensioner Replacement1068

Seat Belt Pretensioner Installation1069

Air Conditioning1070

Air Conditioning System Precaution1072

Supplemental Restraint System (Srs)1073

Air Conditioning System On-Vehicle Inspection1074

Inspect Refrigerant Volume1074

Inspect Refrigerant Pressure With Manifold Gauge Set1075

Inspect Idle-Up Speed1079

Inspect For Leakage Of Refrigerant1080

Air Conditioning System Evacuating1081

Evacuate Air From Refrigeration System1081

Air Conditioning System Charging1082

Install Charging Cylinder1082

Inspect Refrigeration System For Leaks1082

Charge Refrigerant Into Refrigerant System1083

Air Conditioning System Location1084

Air Conditioning System Troubleshooting1085

Drive Belt On-Vehicle Inspection1087

Drive Belt Removal1088

Drive Belt Installation1089

Manifold Gauge Set1090

Refrigerant Line On-Vehicle Inspection1092

Refrigerant Line Location1093

Refrigerant Line Replacement1094

Air Conditioning Unit On-Vehicle Inspection1095

Air Conditioning Unit Components1096

Air Conditioning Unit Removal1097

Air Conditioning Unit Inspection1099

Inspect Evaporator1099

Inspect Heater Radiator1099

Air Conditioning Unit Installation1100

Blower Unit Components1101

Blower Unit Removal1102

Remove Blower Unit1102

Blower Unit Disassembly1103

Remove Air Refiner Filter1103

Remove Blower Motor1103

Blower Unit Reassembly1104

Blower Unit Installation1105

Compressor And Magnetic Clutch On-Vehicle Inspection1106

Inspect Compressor For Metallic Sound1106

Inspect Compressor Lock Sensor Resistance1106

Inspect Magnetic Clutch Operation1106

Compressor And Magnetic Clutch Components1107

Compressor And Magnetic Clutch Removal1108

Compressor And Magnetic Clutch Disassembly1109

Remove Pressure Plate1109

Remove Rotor1109

Remove Stator1110

Compressor And Magnetic Clutch Reassembly1111

Install Pressure Plate1112

Inspect Magnetic Clutch Clearance1112

Compressor And Magnetic Clutch Installation1113

Condenser On-Vehicle Inspection1114

Inspect Condenser Fins For Blockage Or Damage1114

Inspect Condenser And Fittings For Leakage1114

Condenser Components1115

Condenser Removal1116

Remove Liquid Tube And Discharge Hose1116

Remove Radiator Upper Mountings1116

Condenser Replacement1117

Replace Dryer From Modulator1117

Condenser Installation1118

Blower Motor Inspection1119

Inspect Blower Motor Operation1119

Install Blower Motor1119

Blower Resistor Inspection1120

Thermistor Inspection1121

Remove Thermistor1121

Install Thermistor1121

Pressure Switch On-Vehicle Inspection1122

Inspect Pressure Switch Operation1122

Pressure Switch Removal1123

Pressure Switch Installation1124

Heater Main Relay Inspection1125

Magnetic Clutch Relay Inspection1126

Condenser Fan On-Vehicle Inspection1128

Condenser Fan Components1129

Air Conditioning Amplifier On-Vehicle Inspection1131

Inspect Aic Amplifier Circuit1131

Heater Control Assembly On-Vehicle Inspection1136

Inspect Heater Control Dials Operation1136

Heater Control Assembly Components1137

Heater Control Assembly Removal1138

Heater Control Assembly Inspection1139

Inspect Bulb1139

Inspect Aic Indicator Operation1139

Inspect Dimming Operation1139

Inspect Aic Switch Continuity1140

Inspect Defroster Mode Switch Operation1140

Heater Control Assembly Installation1141

Connect A/C Control Cables1142

Engine Coolant Temperature (Ect) Switch Inspection1143

Air Refiner Filter Replacement1144

Install Air Refiner Filter1144

Alphabetical Index1146

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Troubleshooting