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Toyota 2002 Camry Service Manual

Toyota 2002 Camry Service Manual

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Owner's manual (506 pages)

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Service manual (168 pages)

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HOW TO USE THIS MANUAL

General Information

1.

GENERAL DESCRIPTION

(a)

This manual is made in accordance with SAE J2008.

(b)

Generally, repair operations can be separated in the following 3 main processes:

1. Diagnosis

2. Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting

3. Final Inspection

(c)

This manual explains the 1st process of "Diagnosis" (placed in the "Diagnostics" section), the 2nd pro-

cess of "Removing and Installing, Replacing, Disassembling, Installing and Checking, Adjusting", but

the 3rd process of "Final Inspection" is omitted.

(d)

The following essential operations are not written in this manual. However, these operations must be

done in the practical situation.

(1)

Operation with a jack or lift

(2)

Cleaning of a removed part when necessary

(3)

Visual check

2.

INDEX

(a)

An alphabetical INDEX is provided as a section on the end of the book to guide you to the item to be

repaired.

3.

PREPARATION

(a)

Use of special service tools (SST) and special service materials (SSM) may be required, depending

on the repairing condition. Be sure to use SST and SSM when they are required and follow the working

procedure properly. A list of SST and SSM is in the Preparation section of this manual.

4.

REPAIR PROCEDURES

(a)

Component drawing is placed under the title when necessary.

(b)

Illustrations are placed as "disassembled parts drawing" so that it enables you to understand the fitting

condition of the components.

(c)

Non–reusable parts, grease applied parts, precoated parts and tightening torque are specified in the

components drawing.

Example:

Slotted Spring Pin

15 (155, 11)

Cylinder

N·m (kgf·cm, ft·lbf)

: Specified torque

z Non–reusable part

2002 CAMRY REPAIR MANUAL (RM881U)

INTRODUCTION

–

Filler Cap

Float

Reservoir Tank

z Grommet

12 (120, 9)

Piston

HOW TO USE THIS MANUAL

z Gasket

Boot

Snap Ring

Washer

Push Rod

Author :

01–1

0108G–01

Clevis Pin

Clip

Clevis

Lock Nut

N17080

Date :

1

Table of Contents

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Summary of Contents for Toyota 2002 Camry

Page 1: How To Use This Manual
Grommet Slotted Spring Pin 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part N17080 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 2 Indicate the possibility of injury to you or other people. NOTICE Indicate the possibility of damage to the components being repaired. HINT Provide additional information to help you to perform the repair efficiently. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 3 The UNITS given in this manual are primarily expressed according to the SI UNIT (International Sys- tem of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N m (310 kgf cm, 22 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 4: Identification Information
The engine serial number is stamped on the cylinder block of the engine, and the transaxle serial number is stamped on the housing, as shown in the illustration. A: Engine Serial Number B: Transaxle Serial Number D26143 D26742 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 5 JACKING UP AND SUPPORTING VEHICLE Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page 01–18). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 6 DO NOT exceed the rating, or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE M–FUSE MEDIUM CURRENT FUSE HIGH CURRENT FUSE H–FUSE D27353 V35001 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 7 HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Clip Pliers Clip Remover Protective Tape Screwdriver Protective Tape Scraper D25786 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 8 When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air. D25064 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 9 Even in case of a minor collision where the SRS does not deploy, the horn button assembly, instrument panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat belt pretensioner should be inspected (See pages 60–17, 60–34, 60–44, 60–50 and 61–9). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 10 When using electric welding, first disconnect the airbag connector (2 yellow pins) under the steer- ing column near the combination switch connector before starting work. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 11 When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–34). Perform the operation in a safe place away from electrical noise. Example: WRONG CORRECT D26600 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 12 When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–50). Perform the operation in a safe place away from electrical noise. Example: WRONG CORRECT D26601 Example: B01546 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 13 When disposing of a vehicle or the curtain shield airbag assembly alone, the airbag should be deployed using an SST before disposal (See page 60–44). Perform the operation in a safe place away from electrical noise. Example: CORRECT WRONG Clear Plastic Bag D26602 Example: D26603 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 14 If the SRS wire harness becomes discon- nected or the connector becomes broken due to an accident, etc., repair or replace it. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 15 Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel is filled in those places. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 16 Check that the antenna and feeder are correctly adjusted. Do not install any powerful mobile communication sys- tem. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 17 Engine compression measurements must be performed as rapidly as possible. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 18 470 mm (18.50 in.) : JACK POSITION Front Side Notch : SUPPORT POSITION, PANTOGRAPH JACK POSITION : CENTER OF VEHICLE GRAVITY (unload condition) D26604 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 19 : CENTER OF VEHICLE Rubber Attachment GRAVITY (unload condition) Plate Type Lift Attachment Dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) Attachment 100 mm (3.94 in.) 200 mm (7.87 in.) D25021 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 20: General Information
If the communication is still impossible when the tester is connected to another vehicle, the prob- lem is probably in the tester itself, so perform the Self Test procedures outlined in the Tester Oper- ator’s Manual. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 21 Confirm the circuit for the system or the part which should be checked using the problem symptoms table or the results obtained in step 4. Repair Repair the affected system or part in accordance with the instructions in step 6. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 22 After completing repairs, confirm that the problem has been solved. (If the problem dose not reoccur, perform a confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 23 Frame No. Odometer Reading Date Vehicle Brought In miles Date Problem First Occurred Other Fine Cloudy Rainy Snowy Weather Approx. Temperature Starting Idling Vehicle Operation Driving Constant speed Acceleration Deceleration Other 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 24 DTC troubleshooting or to the troubleshoot- ing of problem symptoms table. DTC check Making a note and clearing of the DTCs displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Go to step 5 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 25 Troubleshooting of each problem symptom The problem is still occurring in a place other than the diagnostic circuit (The DTC displayed first is either for a past problem or it is a secondary problem). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 26 NOTICE: Do not heat to more than 60_C (140_F) (Temperature is limited so as not to damage the components). Do not apply heat directly to the parts in the ECU. D25084 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 27 OTHERS: When the malfunction seems to occur when electrical load is excessive. Turn on all the electrical loads including the heater blower, headlights, rear window defogger, etc., and check if the malfunction occurs. B02389 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 28 D Open in P squib circuit B0106/54 D Airbag sensor assembly D Wire harness D Front passenger airbag assembly (squib) D Short in P squib circuit (to Ground) D Airbag sensor assembly D Wire harness 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 29 1. DTC is not displayed. 2. SRS warning light is always lit up at the time of DTC check 1. Tc terminal circuit 05–187 procedure. 3. DTC is displayed without Tc and CG terminal connection. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 30: Circuit Inspection
O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. D25842 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 31 Connection of the connector with a lock should be securely done until it makes a click sound. WRONG In case of checking the connector with a Toyota electrical tester, perform it at the back side (harness side) of the connector using a mini test lead.
Page 32 Fig. 1 For the open circuit in the wire harness in Fig. 1, perform ”(b) Check the continuity” or ”(c) Check the voltage” to lo- OPEN Sensor cate the section. Z17004 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 33 0 v: between terminal 1 of connector ”c” and body ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and ter- minal 1 of ”C”. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 34 Between terminal 1 of connector ”B2” and body ground Continuity (short) Z17808 Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 35 IN0383 Disconnect the ECU connector, check the ground ECU Side terminals on the ECU side and wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 36 Compact Disc Cornering Force Center Of Gravity Channel Complete Knock Down COMB. Combination Coupe Combustion Pressure Sensor Central Processing Unit Child Restraint System Center Check Valve Control Valve Curb Weight Direct Current 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 37 Front–Engine Front–Wheel–Drive Fuel Gauge FIPG Formed In Place Gasket Fusible Link Fuel Pump Fuel Pressure Up Front Front–Engine Rear–Wheel–Drive Flywheel FW/D Flywheel Damper Front–Wheel–Drive Gasoline Ground Global Positioning System High Altitude Compensator 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 38 Malfunction Indicator Lamp MIN. Minimum Motor Generator No.1 Motor Generator No.2 Multipurpose Multipoint Electronic Injection Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) Mount Mounting Neutral Natural Aspiration Number Oxygen Sensor 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 39 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 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 40 Warm Up Three–way Catalytic Converter WU–OC Warm Up Oxidation Catalytic Converter First Second Two Wheel Drive Vehicle (4 x 2) Third Fourth Four Wheel Drive Vehicle (4 x 4) Four Wheel Steering System Fifth 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 41 – TERMS 01048–02 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 42 Service Reminder Indicator – System Readiness Test – Scan Tool – Throttle Body Throttle Body Single Point Injection Throttle Body Fuel Injection Central Fuel Injection (Ci) Turbocharger Turbocharger Torque Converter Clutch Torque Converter 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 43 Vehicle Speed Sensor Vehicle Speed Sensor Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter – WU–TWC Warm Up Three–Way Catalytic Converter – Third Gear – Fourth Gear – 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 44 POWER DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM ENGINE IMMOBILISER SYSTEM BODY MULTIPLEX COMMUNICATION SYSTEM CRUISE CONTROL SYSTEM COMBINATION METER ABS WITH EBD SYSTEM (DENSO MADE) SFI SYSTEM(1MZ–FE) SFI SYSTEM(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 45 POWER DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM ENGINE IMMOBILISER SYSTEM BODY MULTIPLEX COMMUNICATION SYSTEM CRUISE CONTROL SYSTEM COMBINATION METER ABS WITH EBD SYSTEM (DENSO MADE) SFI SYSTEM(1MZ–FE) SFI SYSTEM(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 46 02–3 PREPARATION – ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 020TK–01 PREPARATION Equipment Radiator cap tester Torque wrench Ohmmeter 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 47 (90467–13001) Clip FUEL SYSTEM(1MZ–FE) FUEL SYSTEM(2AZ–FE) Recomended Tools 09040–00011 Hexagon Wrench Set FUEL INJECTOR ASSY(1MZ–FE) Socket Hexagon Wrench 5 FUEL INJECTOR ASSY(1MZ–FE) (09043–20050) (09043–20080) Socket Hexagon Wrench 8 FUEL INJECTOR ASSY(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 48 FUEL SYSTEM(2AZ–FE) Equipment Service Wire Harness Stopwatch Measuring Flask Ohmmeter Radiator cap tester Torque wrench 08850–00065 Butyl Tape Set FUEL PUMP ASSY(1MZ–FE) FUEL TANK ASSY(1MZ–FE) FUEL PUMP ASSY(2AZ–FE) FUEL TANK ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 49: Emission Control
02–6 PREPARATION – EMISSION CONTROL EMISSION CONTROL 020TM–01 PREPARATION 09992–00242 Turbocharger Pressure Gauge EMISSION CONTROL SYSTEM(1MZ–FE) EMISSION CONTROL SYSTEM(2AZ–FE) Equipment Service Wire Harness Ohmmeter Torque wrench Vacuum gauge Hand–held vacuum pump 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 50 TOYOTA Electrical Tester INTAKE CONTROL SYSTEM(1MZ–FE) Test Lead Set INTAKE CONTROL (09083–00150) SYSTEM(1MZ–FE) Equipment Service Wire Harness Torque wrench Hand–held vacuum pump 08826–00080 Seal Packing Black or equivalent INTAKE CONTROL VALVE (FIPG) ASSY(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 51: Engine Mechanical
CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) TIMING BELT(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) CHAIN(2AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ–FE) ENGINE REAR OIL SEAL(2AZ–FE) CYLINDER HEAD GASKET(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 52 CAMSHAFT(RH BANK)(1MZ–FE) VALVE CLEARANCE(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) (09248–05410) Valve Lifter Press PARTIAL ENGINE ASSY(1MZ–FE) CAMSHAFT(RH BANK)(1MZ–FE) VALVE CLEARANCE(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) Valve Lifter Stopper PARTIAL ENGINE ASSY(1MZ–FE) (09248–05420) CAMSHAFT(RH BANK)(1MZ–FE) VALVE CLEARANCE(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 53 09628–62011 PARTIAL ENGINE ASSY(2AZ–FE) 09816–30010 Oil Pressure Switch Socket PARTIAL ENGINE ASSY(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) 09843–18020 Diagnosis Check Wire PARTIAL ENGINE ASSY(1MZ–FE) CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) ENGINE ASSEMBLY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 54 PARTIAL ENGINE ASSY(1MZ–FE) 09950–50013 CAMSHAFT(RH BANK)(1MZ–FE) OIL PUMP SEAL(1MZ–FE) CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) TIMING BELT(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) CHAIN(2AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 55 TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ–FE) (09954–05030) Claw No.3 PARTIAL ENGINE ASSY(1MZ–FE) CAMSHAFT(RH BANK)(1MZ–FE) OIL PUMP SEAL(1MZ–FE) CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) TIMING BELT(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 56 TIMING BELT(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) CHAIN(2AZ–FE) TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL(2AZ–FE) ENGINE REAR OIL SEAL(2AZ–FE) Pin 5 PARTIAL ENGINE ASSY(1MZ–FE) (09963–00500) CAMSHAFT(RH BANK)(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 57 CAMSHAFT(LH BANK)(1MZ–FE) (09043–20060) Socket Hexagon Wrench 6 PARTIAL ENGINE ASSY(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) Socket Hexagon Wrench 8 PARTIAL ENGINE ASSY(1MZ–FE) (09043–20080) CAMSHAFT(RH BANK)(1MZ–FE) CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) VALVE CLEARANCE(1MZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 58 OIL PUMP SEAL(1MZ–FE) CYLINDER HEAD GASKET(1MZ–FE) CYLINDER HEAD GASKET NO.2(1MZ–FE) DRIVE BELT(1MZ–FE) TIMING BELT(1MZ–FE) CAMSHAFT(LH BANK)(1MZ–FE) 09200–00010 Engine Adjust Kit . IGNITION SYSTEM(1MZ–FE) IGNITION SYSTEM(2AZ–FE) Thickness Gauge PARTIAL ENGINE ASSY(2AZ–FE) (09203–00010) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 59 Alignment tester Toe–in gauge Spring tension gauge OBD II scan tool Engine Sling Device Chain Block Spark plug cleaner Spring tester Plastigage Angle gauge Heater Universal engine lifter Plastic Hammer Chisel 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 60 PARTIAL ENGINE ASSY(2AZ–FE) ”Adhesive 1324,” PARTIAL ENGINE ASSY(1MZ–FE) 08833–00070 THREE BOND 1324 or equivalent CYLINDER HEAD ASSY(1MZ–FE) CYLINDER BLOCK(1MZ–FE) ENGINE REAR OIL SEAL(1MZ–FE) PARTIAL ENGINE ASSY(2AZ–FE) CYLINDER BLOCK(2AZ–FE) ENGINE REAR OIL SEAL(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 61 02–18 PREPARATION – EXHAUST EXHAUST 020TO–01 PREPARATION Equipment Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 62 WATER PUMP ASSY(1MZ–FE) Variable Pin Wrench Set WATER PUMP ASSY(1MZ–FE) 09960–10010 WATER PUMP ASSY(2AZ–FE) (09962–01000) Variable Pin Wrench Arm Assy WATER PUMP ASSY(1MZ–FE) WATER PUMP ASSY(2AZ–FE) (09963–00700) Pin 7 WATER PUMP ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 63 09216–00021 Belt Tension Gauge WATER PUMP ASSY(1MZ–FE) Equipment Ohmmeter Radiator cap tester Thermomete Torque wrench Vernier calipers Heater Seal Packing Black or equivalent WATER PUMP ASSY(1MZ–FE) 08826–00080 (FIPG) WATER PUMP ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 64 09309–37010 09330–00021 Companion Flange Holding Tool OIL PUMP ASSY(1MZ–FE) OIL PUMP ASSY(2AZ–FE) Puller B Set OIL PUMP ASSY(2AZ–FE) 09950–40011 (09951–04010) Hanger 150 OIL PUMP ASSY(2AZ–FE) (09952–04010) Slide Arm OIL PUMP ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 65 OIL PUMP ASSY(2AZ–FE) (09954–05010) Claw No.1 OIL PUMP ASSY(1MZ–FE) Claw No.2 OIL PUMP ASSY(2AZ–FE) (09954–05021) (09954–05030) Claw No.3 OIL PUMP ASSY(1MZ–FE) Variable Pin Wrench Set OIL PUMP ASSY(1MZ–FE) 09960–10010 OIL PUMP ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 66 Belt Tension Gauge OIL PUMP ASSY(1MZ–FE) 09216–00021 Equipment Feeler gauge Precision straight edge Radiator cap tester Torque wrench Seal Packing Black or equivalent OIL PUMP ASSY(1MZ–FE) 08826–00080 (FIPG) OIL PUMP ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 67 – IGNITION IGNITION 020TQ–01 PREPARATION Recomended Tools 09200–00010 Engine Adjust Kit . IGNITION SYSTEM(1MZ–FE) IGNITION SYSTEM(2AZ–FE) Spark Plug Gap Gauge IGNITION SYSTEM(1MZ–FE) (09857–00031) IGNITION SYSTEM(2AZ–FE) Equipment Spark plug cleaner Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 68 STARTING SYSTEM(2AZ–FE) Belt Tension Gauge GENERATOR ASSY(1MZ–FE) 09216–00021 Expander Set STARTER ASSY(1MZ–FE) 09904–00010 STARTER ASSY(2AZ–FE) Equipment Dial indicator Ammmeter(A) Ohmmeter Torque wrench V–block Vernier calipers Dial indicator with magnetic base Press 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 69: Front Suspension
COIL SPRING STABILIZER BAR FRONT Equipment Torque wrench Dial indicator with magnetic base Tire pressure gauge Alignment tester Toe–in gauge Angle gauge Plastic hammer Engine Sling Device Universal Engine Lifter Chain Block 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 70: Rear Suspension
STABILIZER BAR REAR Socket Hexagon Wrench 6 SHOCK ABSORBER ASSY REAR LH (09043–20060) Equipment Torque wrench Dial indicator with magnetic base Wheel balancer Tire pressure gauge Alignment tester Toe–in gauge Camber–caster–kingpin gauge Drill 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 71 02–28 PREPARATION – TIRE & WHEEL TIRE & WHEEL 020T4–01 PREPARATION Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 72 FRONT DRIVE SHAFT Rear Axle Shaft Bearing Remover FRONT AXLE HUB SUB–ASSY LH 09527–17011 09527–30010 Rear Axle Shaft Bearing Remover FRONT DRIVE SHAFT 09608–16042 Front Hub Bearing Adjusting Tool FRONT DRIVE SHAFT 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 73 Replacer 41 FRONT AXLE HUB SUB–ASSY LH Replacer 60 FRONT AXLE HUB SUB–ASSY LH (09951–00600) 09950–60020 Replacer Set No.2 FRONT AXLE HUB SUB–ASSY LH Replacer 79 FRONT AXLE HUB SUB–ASSY LH (09951–00790) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 74 105 – 125 g (3.7 – 4.4 oz.) 2AZ–FE (AT) Outboard joint grease 100 – 120 g (3.5 – 4.2 oz.) Inboard joint grease 185 – 195 g (6.5 – 6.9 oz.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 75 CYLINDER SUB–ASSY Brake Line Union Nut 10 x 12 mm REAR DRUM BRAKE 09751–36011 Wrench Front Mounting Cushion Remover SKID CONTROL SENSOR 09830–36010 & Replacer 09950–00020 Bearing Remover SKID CONTROL SENSOR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 76 Turbocharger Pressure Gauge BRAKE FLUID Brake Reservoir Pressure Adapter BRAKE FLUID 09992–00350 Recomended Tools Torx Socket T30 STEERING SENSOR 09042–00010 BRAKE PEDAL SUPPORT ASSY 09070–20010 Moulding Remover BRAKE PEDAL SUPPORT ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 77 Snap Ring Pliers BRAKE MASTER CYLINDER 09905–00013 SUB–ASSY Equipment Vernier calipers Dial indicator Torque wrench Brake drum gauge Lubricant Item Capacity Classification Brake fluid – SAE J1703 or FMVSS No. 116 DOT3 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 78: Parking Brake
02–35 PREPARATION – PARKING BRAKE PARKING BRAKE 020UQ–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover PARKING BRAKE CONTROL PEDAL ASSY PARKING BRAKE CABLE ASSY NO.1 Equipment Brake drum gauge Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 79 Handle 150 FRONT DIFFERENTIAL (09951–07150) SEAL(U140E) FRONT DIFFERENTIAL SEAL(U241E) Equipment Straight edge Torque converter Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Punch Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 80 Drain and refill 3.90 liters (4.1 US qts, 3.4 lmp.qts) SSM (Special Service Materials) ”Adhesive 1324,” 08833–00070 THREE BOND 1324 or equivalent 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 81 MANUAL TRANSAXLE ASSY(E351) Differential Drive Pinion Rear OUTPUT SHAFT ASSY(E351) 09506–30012 Bearing Cone Replacer 09520–01010 Drive Shaft Remover Attachment FRONT DIFFERENTIAL OIL SEAL 09520–24010 Differential Side Gear Shaft FRONT DIFFERENTIAL OIL SEAL Puller 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 82 OUTPUT SHAFT ASSY(E351) 09950–00030 Bearing Remover Attachment MANUAL TRANSAXLE ASSY(E351) 09950–30012 Puller A Set MANUAL TRANSAXLE ASSY(E351) Upper Plate MANUAL TRANSAXLE ASSY(E351) (09951–03010) (09953–03010) Center Bolt MANUAL TRANSAXLE ASSY(E351) MANUAL TRANSAXLE ASSY(E351) (09954–03010) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 83 Replacer 21 SHIFT & SELECT LEVER SHAFT ASSY(E351) Replacer 28 MANUAL TRANSAXLE ASSY(E351) (09951–00280) SHIFT & SELECT LEVER SHAFT ASSY(E351) (09951–00320) Replacer 32 OUTPUT SHAFT ASSY(E351) Replacer 42 MANUAL TRANSAXLE ASSY(E351) (09951–00420) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 84 09950–60020 (09951–00680) Replacer 68 MANUAL TRANSAXLE ASSY(E351) (09951–00730) Replacer 73 MANUAL TRANSAXLE ASSY(E351) Replacer 79 MANUAL TRANSAXLE ASSY(E351) (09951–00790) (09951–00890) Replacer 89 MANUAL TRANSAXLE ASSY(E351) Replacer 91 MANUAL TRANSAXLE ASSY(E351) (09951–00910) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 85 09042–00050 (09043–20060) Socket Hexagon Wrench 6 MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY(E351) Snap Ring No.1 Expander MANUAL TRANSAXLE ASSY(E351) 09905–00012 (09043–20060) Socket Hexagon Wrench 6 MANUAL TRANSAXLE ASSY MANUAL TRANSAXLE ASSY(E351) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 86 Cylinder gauge Feeler gauge Precision straight edge Lubricant Item Capacity Classification Manual transaxle oil API GL–4 or GL–5 2.5 liters (2.6 US qts, 2.2 lmp. qts) (w/ Differential oil) SAE 75W–90 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 87 Snap Ring Pliers CLUTCH MASTER CYLINDER ASSY Equipment Vernier calipers Dial indicator with magnetic base Torque wrench Lubricant Item Capacity Classification Brake fluid – SAE J1703 or FMVSS No. 116 DOT3 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 88: Steering Column
STEERING COLUMN ASSY(TMMK MADE) Recomended Tools 09904–00010 Expander Set STEERING COLUMN ASSY(TMC MADE) No. 4 Claw STEERING COLUMN ASSY(TMC (09904–00050) MADE) Snap Ring No.1 Expander STEERING COLUMN ASSY(TMC 09905–00012 MADE) Equipment Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 89: Power Steering
RACK & PINION POWER STEERING (09613–22011) Puller GEAR ASSY 09616–00011 Steering Worm Bearing Adjusting RACK & PINION POWER STEERING Socket GEAR ASSY 09628–62011 Boll Joint Puller RACK & PINION POWER STEERING GEAR ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 90 POWER STEERING SYSTEM (09641–01010) Gauge Assy POWER STEERING SYSTEM Attachment A POWER STEERING SYSTEM (09641–01020) (09641–01030) Attachment B POWER STEERING SYSTEM Variable Open Wrench RACK & PINION POWER STEERING 09922–10010 GEAR ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 91 RACK & PINION POWER STEERING GEAR ASSY Replacer 32 RACK & PINION POWER STEERING (09951–00320) GEAR ASSY (09951–00330) Replacer 33 VANE PUMP ASSY(1MZ–FE) Replacer 34 RACK & PINION POWER STEERING (09951–00340) GEAR ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 92 Torque Wrench (30 kgf–cm) RACK & PINION POWER STEERING GEAR ASSY Torx Socket T30 RACK & PINION POWER STEERING 09042–00010 GEAR ASSY (09043–20060) Socket Hexagon Wrench 6 RACK & PINION POWER STEERING GEAR ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 93 1.0 liters (1.1 US qts, 0.9 lmp.qts) ATF DEXRON® II or III 2AZ–FE 1MZ–FE Adhesive 1344 RACK & PINION POWER STEERING 08833–00080 THREE BOND 1344 GEAR ASSY LOCTITE 242 or equivalent 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 94 Quick Disconnect Adapter REFRIGERANT CONDITIONING RADIATOR ASSY COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(1MZ–FE) COOLER COMPRESSOR ASSY(2AZ–FE) (07117–78050) Refrigerant Charging Gauge REFRIGERANT CONDITIONING RADIATOR ASSY COOLER CONDENSER ASSY COOLER COMPRESSOR ASSY(1MZ–FE) COOLER COMPRESSOR ASSY(2AZ–FE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 95 Hanger 150 CONDITIONING RADIATOR ASSY BLOWER ASSY (09952–05010) Slide Arm CONDITIONING RADIATOR ASSY BLOWER ASSY Center Bolt 150 CONDITIONING RADIATOR (09953–05020) ASSY BLOWER ASSY Claw No.2 CONDITIONING RADIATOR (09954–05021) ASSY BLOWER ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 96 Hexagon wrench (4 mm) Torque socket wrench (E 8) Vise pliers Gas leak detector Belt tension gauge Dial indicator Torque wrench Lubricant Item Capacity Classification Compressor oil – ND–OIL 8 or equivalent 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 97: Supplemental Restraint System
Slide Arm SPIRAL CABLE SUB–ASSY INSTR PNL PASS L/DOOR AIR BAG ASSY Center Bolt 150 SPIRAL CABLE SUB–ASSY (09953–05020) INSTR PNL PASS L/DOOR AIR BAG ASSY Claw No.2 SPIRAL CABLE SUB–ASSY (09954–05021) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 98 Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Airbag disposal Inner diam.: 360 mm (14.17 in.) Vinyl bag Airbag disposal 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 99: Seat Belt
02–56 PREPARATION – SEAT BELT SEAT BELT 020V6–01 PREPARATION 09082–00700 SRS Airbag Deployment Tool FRONT SEAT BELT Airbag Deployment Wire FRONT SEAT BELT 09082–00770 Sub–harness No.5 Equipment Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 100 02–57 PREPARATION – LIGHTING LIGHTING 020UL–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester LIGHTING SYSTEM Test Lead Set LIGHTING SYSTEM (09083–00150) Equipment Torque wrench Voltmeter 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 101 WIPER & WASHER 020UM–01 PREPARATION 09843–18040 Diagnosis Check Wire No.2 WIPER AND WASHER SYSTEM Recomended Tools 09082–00040 TOYOTA Electrical Tester WIPER AND WASHER SYSTEM Test Lead Set WIPER AND WASHER SYSTEM (09083–00150) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 102 020TI–01 PREPARATION Recomended Tools 09070–20010 Moulding Remover REAR SPEAKER ASSY ANTENNA CORD SUB–ASSY NAVIGATION ANTENNA ASSY POWER POINT SOCKET ASSY POWER POINT SOCKET ASSY RR CIGARETTE LIGHTER ASSY Equipment Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 103 02–60 PREPARATION – COMMUNICATION SYSTEM COMMUNICATION SYSTEM 020UC–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester HORN SYSTEM 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 104 Wooden block or similar object For tying both piano wire ends 08833–00030 Three cement black or equivalent WINDSHIELD GLASS BACK WINDOW GLASS Windshield Glass Adhesive Set WINDSHIELD GLASS 08850–00801 or equivalent BACK WINDOW GLASS 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 105 Torx Driver T30 INSTRUMENT PANEL SAFETY PAD SUB–ASSY Torx Socket T30 INSTRUMENT PANEL SAFETY PAD 09042–00010 SUB–ASSY Moulding Remover INSTRUMENT PANEL SAFETY PAD 09070–20010 SUB–ASSY Equipment Voltmeter Ohmmeter Torque wrench Adhesive Tape 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 106 02–63 PREPARATION – SEAT SEAT 020V8–01 PREPARATION Equipment Hog ring pliers Hog ring Torque wrench Tape To avoid surface damage Ohmmeter 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 107 – SLIDING ROOF/CONVERTIBLE SLIDING ROOF/CONVERTIBLE 020UD–01 PREPARATION Recomended Tools 09041–00020 Torx Driver T25 SLIDING ROOF (TMMK Made) SLIDING ROOF (TMC Made) Moulding Remover SLIDING ROOF (TMC Made) 09070–20010 Equipment Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 108 Torx Socket T30 FRONT DOOR 09042–00010 REAR DOOR Torx Socket T40 REAR DOOR 09042–00020 09070–20010 Moulding Remover FRONT DOOR REAR DOOR Equipment Clip remover Tape To avoid surface damage Torque wrench 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 109 To avoid surface damage. Torque wrench Clip remover Cleaner Heat light Moulding Piano wire Moulding Tape To avoid surface damage. Wooden block or similar object For tying both piano wire ends 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 110 PREPARATION – VEHICLE CONTROL SYSTEM VEHICLE CONTROL SYSTEM 020UH–01 PREPARATION Recomended Tools 09082–00040 TOYOTA Electrical Tester IGNITION OR STARTER SWITCH ASSY TOYOTA Electrical Tester Set IGNITION OR STARTER SWITCH 09082–00050 ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 111: Cruise Control
CRUISE CONTROL MAIN SWITCH (09954–05021) ASSY Recomended Tools 09041–00030 Torx Driver T30 INSTRUMENT PANEL SAFETY PAD SUB–ASSY 09042–00010 Torx Socket T30 INSTRUMENT PANEL SAFETY PAD SUB–ASSY Equipment Torque wrench Adhesive Tape 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 112 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 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 113 10.5 1.25 1.25 1.25 1,050 1,500 1,700 2,300 – – – 1.25 1.25 1.25 1,100 1,250 1.25 1.25 1.25 1,300 1,450 1.25 1.25 1.25 1,450 1,600 1.25 1.25 1.25 1,600 1,800 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 114 Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas- sification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 115 M+ – M– 0.3 – 100 kΩ at 20 _C (68 _F) Throttle position sensor Resistance VC – E2 1.2 – 3.2 kΩ Coolant temperature sensor Resistance Approx. 20_C (68_F) 2.32 – 2.59 kΩ Approx. 80_C (176_F) 0.310 – 0.326 kΩ 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 116 Throttle body assy x Intake manifold 1MZ–FE Part Tightened kgf cm ft lbf Throttle position sensor x Throttle body 17 in. lbf Throttle body assy x Intake air surge tank 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 117 (3.7 – 4.5 cu in.) per 15 seconds Difference between each cylinder 13 cm (0.8 cu in.) or less Fuel leakage 1 drop or less per 12 minutes Fuel pump at 20_C (68_F) 0.2 – 3.0 Ω Resistance 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 118 Fuel tank protector lower center x Fuel tank 48 in. lbf Parking brake cable assy No.2 x Body 48 in. lbf Parking brake cable assy No.3 x Body 48 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 119 100 _C (212 _F) 11.89 – 14.37 Ω 2.79 – 3.59 Ω at 150 _C (302 _F) Vacuum switching valve No.1 at 20 _C (68 _F) 27 – 33 Ω Resistance 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 120 Part Tightened kgf cm ft lbf EGR gas temperature sensor x EGR valve EGR valve x Intake air surge tank EGR pipe No.2 x EGR valve EGR pipe No.2 x EGR cooler 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 121 030ER–01 SERVICE DATA 1MZ–FE Intake air control valve No.3 (VSV) at 20_C (68_F) 37 – 44 Ω Resistance Vacuum switching valve assy No.1 at 20_C (68_F) 33 – 39 Ω Resistance 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 122 03–11 SERVICE SPECIFICATIONS – INTAKE 030ES–01 TORQUE SPECIFICATION 1MZ–FE Part Tightened kgf cm ft lbf Intake air control valve assy x Intake air surge tank 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 123 161.3 – 162.7 mm (6.350 – 6.406 in.) Maximum 164.2 mm (6.465 in.) Chain sub–assy Elongation Maximum 115.4 mm (4.543 in.) Camshaft timing gear or sprocket Sprocket diameter (w/chain) Minimum 97.3 mm (3.831 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 124 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum 0.10 mm (0.0039 in.) 10.285 – 10.306 mm (0.4049 – 0.4057 in.) Diameter 9.6 – 10.0 mm (0.3779 – 0.3937 in.) Protrusion height 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 125 47.990 – 48.000 mm (1.8894 – 1.8898 in.) Crank pin diameter Crankshaft bearing cap set bolt Diameter Standard 7.5 – 7.6 mm (0.295 – 0.299 in.) Minimum 7.2 mm (0.283 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 126 45.50 mm (1.7913 in.) Valve spring deviation Maximum 2.0 mm (0.079 in.) Valve spring installed tension at 33.8 mm (1.331 in.) 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 127 7.2 – 7.3 mm (0.283 – 0.287 in.) Minimum 7.0 mm (0.276 in.) Crankshaft bearing cap set bolt diameter Standard 7.5 – 7.6 mm (0.295 – 0.299 in.) Minimum 7.2 mm (0.283 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 128 No. 2 and No. 3 journals 0.026 – 0.046 mm (0.0010 – 0.0018 in.) Maximum No. 1 and No. 4 journals 0.05 mm (0.0020 in.) 0.06 mm (0.0024 in.) No. 2 and No. 3 journals 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 129 Speed sensor front RH (w/ ABS) x Steering knuckle 71 in. lbf Front axle hub LH nut x Front drive shaft 3,000 Front stabilizer link assy x Front suspension Air cleaner assy x Body 44 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 130 44 in. lbf Stud bolt C 1MZ–FE Part Tightened kgf cm ft lbf Engine hanger No. 2 x Cylinder head Knock control sensor x Cylinder block Oil pressure switch assy x Cylinder block 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 131 71 in. lbf 12 mm head 12 mm head 14 mm head Crank position sensor x Oil pump assy 71 in. lbf Oil pan baffle plate x Oil pan sub–assy 71 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 132 EGR pipe No.2 x EGR cooler No.1 Exhaust manifold heat insulator No.2 x Exhaust manifold LH 55 in. lbf EGR cooler No.1 x Cylinder block 80 in. lbf EGR pipe No.1 x EGR cooler No.1 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 133 03–22 SERVICE SPECIFICATIONS – ENGINE MECHANICAL Part Tightened kgf cm ft lbf EGR pipe No.1 x Exhaust manifold LH Exhaust pipe support bracket No.1 x Automatic transaxle assy 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 134 Exhaust pipe No.1 support bracket x Body Floor panel brace rear x Body Exhaust pipe No.1 support bracket x Exhaust pipe support bracket No.1 Oxygen sensor x Exhaust pipe assy front 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 135 Minimum opening pressure 69 kPa (0.7 kgf/cm , 10.0 psi) Cooling fan Standard amperage at 20_C (68_F) 8.0 – 12.0 A Coolant Capacity 9.2 liters (9.7 US qts, 8.1 lmp. qts) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 136 Front wheel 1051 Water inlet x Cylinder block 71 in. lbf Water inlet pipe x Water inlet Fan assy, w/ motor x Radiator assy 44 in. lbf Radiator support upper x body 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 137 4.7 liters (5.0 US qts, 4.1 lmp. qts) Drain and refill w/o oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts) 5.5 liters (5.8 US qts, 4.8 lmp. qts) Dry fill 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 138 Generator bracket No.2 x Transverse engine engine mounting bracket Timing belt idler sub–assembly No.1 x Cylinder block Compressor and magnetic clutch x Compressor mounting bracket Front suspension brace sub–assembly upper center x Body Front wheel 1051 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 139 IFR6A11 Electrode gap Standard 1.0–1.1mm (0.039–0.043 in.) 1.2mm (0.047 in.) Maximum Camshaft position sensor Resistance at cold 835–1400Ω at hot 1060–1645Ω Crank position sensor Resistance at cold 1630–2740Ω at hot 2065–3225Ω 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 140 Ignition coil x Cylinder head cover 80 in. lbf 1MZ–FE Part Tightened kgf cm ft lbf Spark plug x Cylinder head cover Ignition coil x Cylinder head cover 71 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 141 Standard 14.2 – 14.4 mm (0.559 – 0.567 in.) Minimum 12.8 mm (0.504 in.) 9.5 – 11.5 mm (0.374 – 0.453 in.) Brush exposed length Standard 1.5 mm (0.059 in.) Minimum 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 142 Brush holder x Rectifire end frame 39 in. lbf Rear end cover x Rectifire holder 35 in. lbf Plate terminal x Rectifire holder 36 in. lbf Terminal insulator x Rectifire holder 1,125 Generator pulley x Rotor 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 143 : Ground clearance of front wheel center : Ground clearance of lower suspension arm No. 2 set bolt center : Ground clearance of strut rod set bolt center : Ground clearance of rear wheel center 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 144 Transverse engine engine mounting insulator set nut Transverse engine engine mounting insulator x Bracket (MT) Stabilizer bar bracket x Suspension member Front suspension member dynamic damper x Front frame assy Stabilizer bar link set nut 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 145 –1°09’ ± 45’ (–1.15° ± 0.75°) Mexico: Right–left error 45’ (0.75°) or less Rear suspension Stabilizer bar link ball joint turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 146 Stabilizer bar bracket Stabilizer bar x Stabilizer bar link Strut rod x Body 1,150 Strut rod x Rear axle carrier 1,152 Parking brake cable x Body 48 in. lbf Hub nut 1,050 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 147 03–36 SERVICE SPECIFICATIONS – TIRE & WHEEL TIRE & WHEEL 030E6–01 SERVICE DATA Tire runout 1.0 mm (0.039 in.) or less Imbalance after adjustment 8.0 g (0.018 lb) or less 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 148 Backlash Maximum: 0.05 mm (0.0020 in.) Front axle hub bearing Deviation Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing Backlash Maximum: 0.05 mm (0.0020 in.) Rear axle hub bearing Deviation Maximum: 0.07 mm (0.0027 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 149 Shock absorber x Rear axle carrier 2,600 Rear axle hub set bolt Rear axle carrier x Brake caliper (Rear disc brake) 61.8 Rear wheel brake cylinder x Brake tube (Rear drum brake) 15.2 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 150 Standard inside diameter: 228.0 mm (8.976 in.) Minimum inside diameter: 230.6 mm (9.079 in.) Rear drum brake shoe lining thickness Standard thickness: 5.0 mm (0.197 in.) Minimum thickness: 1.0 mm (0.039 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 151 Front speed sensor wire harness clamp x shock absorber Bolt A: 44 in. lbf Bolt B: 18.8 Rear axle hub set bolt Yawrate sensor x Body 12.5 Skid control ECU x Body 49 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 152 Parking brake shoe lining thickness Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) Parking brake shoe clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 153 48 in. lbf Parking brake cable No. 3 x Backing plate 69 in. lbf Parking brake cable heart insulator set nut 48 in. lbf Parking brake cable No. 4 x Body 12.5 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 154 Max. 0.30 mm (0.0118 in.) 0 " 0.5 mm (0 " 0.020 in.) Differential oil seal drive in depth LH side 0 " 0.5 mm (0 " 0.020 in.) RH side 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 155 50 – 58 km/h (31 – 36 mph) Lock–up point Throttle valve opening 5 % O/D gear Lock–up ON 55 – 63 km/h (34 – 39 mph) Lock–up OFF 49 – 56 km/h (30 – 35 mph) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 156 A bolt 58 in. lbf B bolt 10.8 Valve body x transaxle 10.8 Oil strainer x Valve body 10.8 Floor shift assy x Body 11.8 Control cable x Body 43 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 157 0.8 – 1.6 N m (8.16 – 16.32 kgf cm, 7.1 – 14.2 in. lbf) Used bearing 0.5 – 1.0 N m (5.10 – 10.20 kgf cm, 4.4 – 8.9 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 158 Transmission hub sleeve No.3 groove – thickness of the claw part on gear 0.15 – 0.35 mm (0.0059 – 0.0138 in.) shift fork No.1 Standard clearance Transmission clutch hub No.2 snap ring clearance Standard clearance 0.1 mm or less (0.0039 in. or less) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 159 Minimum thickness 0.9 mm (0.035 in.) Front differential pinion shaft No.1 thickness Minimum thickness 17.975 mm (0.70768 in.) Front differential side gear backlash Standard backlash 0.05 – 0.20 mm (0.0020 – 0.0079 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 160 Shift lever slotted pin clearance to the shift lever inner assy –0.5 – 0.5 mm (– 0.0197 – 0.0197 in.) Shift lever slotted pin clearance to the shift lever inner No.2 5.8 – 6.8 mm (0.228 – 0.268 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 161 Drain (MTM) plug sub–assy x Transmission case Manual transmission filler plug x Transmission case Back up lamp switch assy x Transmission case Manual transmission breather plug x Transmission case Lock ball assy No.1 x Transmission case 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 162 Selecting bell crank assy x Transmission case Selecting bellcrank support x Selecting bellcrank No.2 plate washer Release fork support x Manual transaxle case 47.1 Front differential ring gear x Front differential case 1,081 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 163 Flywheel runout Maximum 0.1 mm (0.004 in.) Diaphragm spring finger wear Maximum depth 0.5 mm (0.020 in.) Clutch release point from pedal full stroke end position 25 mm (0.98 in.) or more 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 164 Clutch release cylinder assy x Transaxle housing 11.8 Clutch release cylinder assy x flexible hose tube 15.2 Clutch cover assy x Flywheel 19.1 Release fork support x Transaxle assy 47.1 Clutch start switch assy set nut 15.68 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 165 SERVICE SPECIFICATIONS – STEERING COLUMN STEERING COLUMN 0304Y–02 SERVICE DATA Steering wheel freeplay Maximum 30 mm (1.18 in.) Standard length 474.5 " 1 mm (18.681 " 0.039 in.) Steering main shaft length 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 166 Steering column assembly set bolt and nut 20.6 Intermediate shaft sub–assy x Universal joint assembly 35.3 Intermediate shaft sub–assy x Control valve shaft 35.3 Steering wheel set nut Steering wheel pad set screw (Torx screw) 78 in.·lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 167 (Turning) 0.83 – 3.43 N·m (7.3 – 30.4 kgf·cm, 7.3 – 30.4 in.·lbf) Total preload (Control valve rotating torque) (Turning) 1.2 – 1.5 N·m (12.2 – 15.3 kgf·cm, 10.6 – 13.3 in.·lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 168 86 in. lbf Front stabilizer bracket Stabilizer link assy set nut Tie rod assy set nut Intermediate shaft sub–assy x Control valve 35.3 Hub nut 1,050 ( ): For use without SST 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 169 New belt: 88 " 22 lbf Used belt: Magnetic clutch clearance (1MZ–FE) 0.35 – 0.60 mm (0.014 – 0.024 in.) Magnetic clutch clearance (2AZ–FE) 0.35 – 0.60 mm (0.014 – 0.024 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 170 Cooler condenser assy x Body 85 in. lbf Cooler refrigerant liquid pipe A x Cooler condenser assy 47 in. lbf Cooler refrigerant discharge hose No. 1 x Cooler condenser assy 47 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 171 17.5 Side airbag sensor assy LH x Body Airbag sensor rear LH x Body Property class 8T: Property class 6T: 17.5 Seat position airbag sensor x Front seat 71 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 172 Wind shield wiper motor assy Wiper link assy 48 in. lbf Wiper link assy Body 62 in. lbf FR Wiper arm RH Wiper link 20.1 FR Wiper arm LH Wiper link 20.1 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 173 INSTRUMENT PANEL/METER 030FF–01 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Instrument panel reinforce Body Bolt <E> Front pillar garnish Body 7.5 – 20 76 – 204 66 – 117 in. lbf 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 174 Door hinge x Body Door hinge x Door panel Door lock striker x Body REAR DOOR – – – Door hinge x Body Door hinge x Door panel Door lock striker x Body 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 175 Check the engine speed when the OCV is operated by the hand–held tester. Standard: VVT system is OFF (OCV is OFF): Normal engine speed VVT system is ON (OCV is ON): Rough idle or engine stalled 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1431...
Page 176 Confirm the valve does not adhere. HINT: Bad returning of the valve by entrance of foreign objects causes subtle pressure leak to the advanced direction. Then, DTC can A50377 be detected. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1432...
Page 177 –20 20 40 60 80 100 (–4) (32) (80) (104) (140) (212) (176) TEMPERATURE_C(_F) A59896 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1433...
Page 178 Between terminal 3 and 5 No continuity E12471 Using an ohmmeter, check that continuity exists be- tween terminals 3 and 5 when the battery voltage is applied across terminals 1 and 2. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1434...
Page 179 Fuel Pipe Support Throttle Body Assy Water By–pass Hose Water By–pass Hose No.2 z Throttle Body Gasket : Specified torque N m (kgf cm, ft lbf) z Non–reusable part A60797 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1435...
Page 180 Connect 2 water by–pass hoses to the throttle body assy. Connect the throttle body assy connector. Connect the vacuum hose to the throttle body assy. A60798 ADD COOLANT (See page 16–6) INSPECT CHECK ENGINE COOLANT LEAK (See page 16–1) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1436...
Page 181 INSPECT ACCELERATOR PEDAL POSITION SENSOR When turning ignition switch ON, check that the voltage of the throttle position sensor of the CURRENT DATA shown the standard value. Standard voltage: 0.6 – 1.0 V 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1437...
Page 182 5.0 kΩ or less VPA1 5 (VPA1) 1 (EP2) 5.0 kΩ or less A60485 6 (VCP1) 3 (EP1) 2.25 – 4.75 kΩ 4 (VCP2) 1 (EP2) 2.25 – 4.75 kΩ 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1438...
Page 183 20 40 60 80 100 (–4) (32) (80) (104) (140) (212) (176) TEMPERATURE_C(_F) A50371 KNOCK CONTROL SENSOR Continuity inspection. Using an ohmmeter, check that no continuity exists between the terminal and body. P01630 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1439...
Page 184 Between terminal 3and 5 No continuity Using an ohmmeter, check that continuity exists be- tween terminals 3 and 5 when the battery voltage is applied across terminals 1 and 2. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1440...
Page 185 Body Gasket 20 (199, 14 in. lbf) Throttle Body Assy 20 (199, 14 in. lbf) Air Cleaner Cap w/Air Cleaner Hose N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A60483 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1441...
Page 186 Remove the 2 set screws and throttle position sensor. INSTALL E.F.I. THROTTLE POSITION SENSOR Check that the throttle valve is under the condition of the opener opening angle (about 7_). A59525 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1442...
Page 187 DLC3. Disconnect the throttle position sensor connector. INSTALL THROTTLE BODY ASSY Install a new gasket and the throttle body. Torque: 20 N m (199 kgf cm, 14 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1443...
Page 188 Torque: 80 N m (816 kgf cm, 59 ft lbf) ADD COOLANT (See page 16–20) CHECK ENGINE COOLANT LEAK (See page16–20) INSPECT FUNCTION OF THROTTLE BODY ASSY (See page 10–7) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1444...
Page 189 (See page 11–15) Drain the fuel remained inside the fuel pump tube. Prevent the disconnected fuel pump tube from damaging and mixing foreign objects by covering them with a vinyl bag. B00679 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1445...
Page 190 Observe these precautions when disconnecting the fuel delivery pipe. O–ring Retainer Pipe HINT: The structure of the metallic connector is shown as left. Nylon Tube Housing A50709 Remove the fuel pipe clamp No.2. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1446...
Page 191 Inspect if there is any dirt or the likes on the seal sur- face of the disconnected pipe and clean it away. B12944 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1447...
Page 192 A52581 CHECK FUEL LEAK Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See page 11–5) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1448...
Page 193 Perform disconnecting operations of the fuel tube connector (quick type) after observing the precau- tions. As there is retained pressure in the fuel pipe line, pre- vent it from splashing inside the engine compart- B12941 ment. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1449...
Page 194 Turn the ignition switch ON and hand–held tester main switch ON. NOTICE: Do not start the engine. Select the active test mode on the hand–held tester. Please refer to the hand–held tester operator’s manual for further details. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1450...
Page 195 Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. Check that there are no fuel leaks after doing mainte- nance anywhere on the fuel system. A62390 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1451...
Page 196 Put the injector into a graduated cylinder. (Clamp) HINT: Install a suitable vinyl tube onto the injector to prevent gasoline Vinyl Tube from splashing out. A51875 Operate the fuel pump.(See Page 11–5) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1452...
Page 197 These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep fuel pump as far away from the battery as pos- sible. Always do the switching at the battery side. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1453...
Page 198 Air Cleaner Hose Fuel Injector Assy z Insulator Engine Cover Sub–assy No. 1 Ventilation Hose No. 2 : Specified torque N m (kgf cm, ft lbf) z Non–reusable part A60820 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1454...
Page 199 Be careful not to twist the O–ring. Turn After installing injectors, check that they turns smoo- Connector thy. If an injector dose not, reinsiall it with a new O– ring. B09635 Position the injector connector downward. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1455...
Page 200 Position the injector connector outward. Tighten 2 bolts holding the delivery pipe to the cylinder head. A52073 Torque: 20 N m (204 kgf cm, 15 ft lbf) INSPECT FUEL LEAK(See page11–5 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1456...
Page 201 Fuel Tank Vent Tube Set Plate Fuel Suction Tube Assy w/ Pump & Gage z Fuel Suction Tube Set Gasket Fuel Pump Tube Sub–assy N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57122 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1457...
Page 202 Fuel Sender Gage Assy Fuel Filter Assy z O–ring Fuel Pump Fuel Pressure Regulator Assy Fuel Pump Filter z Clip Cushion Rubber Fuel Suction Support No.2 z Non–reusable part A57123 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1458...
Page 203 Pull out the fuel suction w/pump & gage from the fuel tank. NOTICE: Do not damage the fuel pump filter. Be careful that the arm of the sender gage should not bent. Remove the fuel suction tube gasket. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1459...
Page 204 Install a new gasket and fuel suction tube w/pump & gage. INSTALL FUEL TANK VENT TUBE SET PLATE Install the fuel tank vent tube set plate with the 8 bolts. 3.5 N·m (36 kgf·cm, 31 in.·lbf) A52586 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1460...
Page 205 After installing the clip of the tube joint, check that the connector is not pulled off. INSTALL REAR FLOOR SERVICE HOLE COVER Using a new butyl tape set, and install the rear floor service hole cover. INSPECT FUEL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1461...
Page 206 Fuel Tank Vent Tube Set Plate Fuel Suction Tube Assy w/ Pump & Gage z Fuel Suction Tube Set Gasket Fuel Pump Tube Sub–assy N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57122 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1462...
Page 207 5.4 (55, 48 in. lbf) z Exhaust Pipe Gasket Exhaust Center Pipe Assy Floor Panel Brace Rear 56 (571, 41) 19.5 (199 ,14) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A62249 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1463...
Page 208 Valve Gasket Fuel Tank Inlet Pipe Sub–assy 5.4 (55, 48 in. lbf) Fuel Main Tube Support Location of Fuel Tank Cushion N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57125 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1464...
Page 209 DISCONNECT PARKING BRAKE CABLE ASSY NO.3 Remove the bolt and nut, and disconnect the parking brake cable. A57128 REMOVE FUEL TANK PROTECTOR LOWER CENTER Remove the 4 bolts and the protector. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1465...
Page 210 Push Pinch portion A. Pull out the connector. Pinch Pinch B01253 Disconnect the fuel emission hose from the charcoal can- ister. Carefully, remove the fuel tank assembly from the vehicle. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1466...
Page 211 Remove the fuel tank protector No. 3 by sliding as shown in the illustration. A57336 REMOVE FUEL TANK PROTECTOR SUB–ASSY NO.1 Remove the fuel tank protector No. 1 by sliding as shown in the illustration. A57337 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1467...
Page 212 Be careful not to drop the gasket into the tank. Check that the fuel cut off valve is fully inserted. A60494 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1468...
Page 213 INSTALL FUEL TANK VENT TUBE SET PLATE (See page 11–15) INSTALL FUEL PUMP TUBE SUB–ASSY (See page 11–15) INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11–15) INSPECT FUEL LEAK CHECK EXHAUST LEAKAGE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1469...
Page 214 (See page 11–39) Drain the fuel remained inside the fuel pump tube. Prevent the disconnected fuel pump tube from damaging and mixing foreign objects by covering them with a vinyl bag. B00679 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1470...
Page 215 Fuel Pipe Clamp No.1 A60083 Disconnect the connector from the hose while pinching part A with fingers as shown in the illustra- tion. B12941 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1471...
Page 216 A52581 CHECK FUEL LEAK Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (See page 11–29) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1472...
Page 217 Perform disconnecting operations of the fuel tube connector (quick type) after observing the precau- tions. As there is retained pressure in the fuel pipe line, pre- vent it from splashing inside the engine compart- B12941 ment. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1473...
Page 218 Turn the ignition switch ON and hand–held tester main switch ON. NOTICE: Do not start the engine. Select the active test mode on the hand–held tester. Please refer to the hand–held tester operator’s manual for further details. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1474...
Page 219 Turn the ignition switch ON, and check that the fuel pump operates. NOTICE: Do not start the engine. Check that there are no fuel leaks after doing mainte- nance anywhere on the fuel system. A62390 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1475...
Page 220 Put the injector into a graduated cylinder. HINT: (Clamp) Install a suitable vinyl tube onto the injector to prevent gasoline Vinyl Tube from splashing out. A51873 Operate the fuel pump.(See Page 11–29) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1476...
Page 221 These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep fuel pump as far away from the battery as pos- sible. Always do the switching at the battery side. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1477...
Page 222 Union Bolt Fuel Delivery Pipe Sub–assy zGasket Spacer No.1 zO–Ring Fuel Delivery Pipe No.2 zGrommet Fuel Injector Assy zInjector Vibration Insulator N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A60464 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1478...
Page 223 Torque: 10 N m (102 kgf cm, 7 ft lbf) NOTICE: Be careful not to drop the injectors when installing the delivery pipe. Check that the injectors rotate smoothly after instal- ling the delivery pipe. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1479...
Page 224 INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10–12) INSTALL V–BANK COVER SUB–ASSY (See page 14–155) ADD COOLANT (See page 16–20) CHECK ENGINE COOLANT LEAK (See page 16–20) INSPECT FUEL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1480...
Page 225 Fuel Tank Vent Tube Set Plate Fuel Suction Tube Assy W/Pump & Gage zFuel Suction Tube Set Gasket Fuel Pump Tube Sub–assy N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57122 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1481...
Page 226 Fuel Pump Harness Fuel Sender Gage Assy Fuel Filter Assy zO–ring Fuel Pump Fuel Pressure Regulator Assy Fuel Pump Filter zClip Cushion Rubber Fuel Suction Support No.2 z Non–reusable part A57123 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1482...
Page 227 Remove the fuel suction tube gasket. REMOVE FUEL SUCTION SUPPORT NO.2 Using a screwdriver, disconnect the snap claws from the claw holes and remove the fuel suction sup- port No.2. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1483...
Page 228 INSTALL FUEL TANK VENT TUBE SET PLATE Install the fuel tank vent tube set plate with the 8 bolts. Torque: 3.5 N m (36 kgf cm, 31 in. lbf) A52586 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1484...
Page 229 After installing the clip of the tube joint, check that the connector is not pulled off. INSTALL REAR FLOOR SERVICE HOLE COVER Using a new butyl tape set, and install the rear floor service hole cover. INSPECT FUEL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1485...
Page 230 Fuel Tank Vent Tube Set Plate Fuel Suction Tube Assy W/Pump & Gage zFuel Suction Tube Set Gasket Fuel Pump Tube Sub–assy N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57122 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1486...
Page 231 5.4 (55, 48 in. lbf) zExhaust Pipe Gasket Exhaust Center Pipe Assy Floor Panel Brace Rear 56 (571, 41) 20 (199, 14 ) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57124 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1487...
Page 232 Valve Gasket Fuel Tank Inlet Pipe Sub–assy 5.4 (55, 48 in. lbf) Fuel Main Tube Support Location of Fuel Tank Cushion N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A57125 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1488...
Page 233 DISCONNECT PARKING BRAKE CABLE ASSY NO.3 Remove the bolt and nut, and disconnect the parking brake cable. A57128 REMOVE FUEL TANK PROTECTOR LOWER CENTER Remove the 4 bolts and remove the protector. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1489...
Page 234 Push Pinch portion A. Pull out the connector. Pinch Pinch B01253 Disconnect the fuel emission hose from the charcoal can- ister. Carefully, remove the fuel tank assembly from the vehicle. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1490...
Page 235 Remove the fuel tank protector No. 3 by sliding as shown in the illustration. A57336 REMOVE FUEL TANK PROTECTOR SUB–ASSY NO.1 Remove the fuel tank protector No. 1 by sliding as shown in the illustration. A57337 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1491...
Page 236 Be careful not to drop the gasket into the tank. Check that the fuel cut off valve is fully inserted. A60494 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1492...
Page 237 INSTALL FUEL TANK VENT TUBE SET PLATE (See page 11–39) INSTALL FUEL PUMP TUBE SUB–ASSY (See page 11–39) INSTALL REAR FLOOR SERVICE HOLE COVER (See page 11–39) INSPECT FUEL LEAK CHECK EXHAUST LEAKAGE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1493...
Page 238 Confirm vacuum occurs at the vsv port, when choosing ”ACTIVE TEST” and ”PURGE VSV” according to the dis- play on hand–held tester. Finish ”ACTIVE TEST”, then connect the vacuum hose again. A52599 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1494...
Page 239 VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. B06545 Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. Stop the engine. Disconnect the hand–held tester from the DLC3. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1495...
Page 240 Disconnect the pressure gauge from the EVAP service port on the purge line. A52634 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1496...
Page 241 Disconnect the air inlet line hose from the charcoal canis- Line Hose ter. Check that there is ventilation in the air inlet line. Reconnect the air inlet line hose to the charcoal canister. Disconnect B08625 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1497...
Page 242 12–5 EMISSION CONTROL – EMISSION CONTROL SYSTEM (2AZ–FE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. B11449 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1498...
Page 243 Purge Port decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released. Vacuum A59505 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1499...
Page 244 Check that air does not flow from ports E to F. B08663 Apply battery positive voltage across the terminals. Check that air flows from ports E to F. If operation is not as specified, replace the VSV. Battery B08664 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1500...
Page 245 Inspect the VSV for ground. Ohmmeter Using an ohmmeter, check that there is no continu- ity between each terminal and the body. If there is continuity, replace the VSV. No continuity A62242 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1501...
Page 246 Using an ohmmeter, check that there is no continu- Ohmmeter No Continuity ity between each terminal and the body. If there is continuity, replace the VSV. B09132 Check that air flows from ports A to B. B09133 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1502...
Page 247 Terminal No. Resistance 1.8 – 3.4 Ω at 20_C (68_F) 1 (HT) 2 (+B) 1 (HT) 4 (E1) No Continuity If the resistance is not as specified, replace the sensor. A61829 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1503...
Page 248 Confirm vacuum occurs at the vsv port, when choosing ”ACTIVE TEST” and ”PURGE VSV” according to the dis- play on hand–held tester. Finish ”ACTIVE TEST”, then connect the vacuum hose again. A52599 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1504...
Page 249 VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. A59500 Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. Stop the engine. Disconnect the hand–held tester from the DLC3. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1505...
Page 250 Disconnect the pressure gauge from the EVAP service port on the purge line. A52634 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1506...
Page 251 Disconnect the air inlet line hose from the charcoal canis- Line Hose ter. Check that there is ventilation in the air inlet line. Reconnect the air inlet line hose to the charcoal canister. Disconnect B08625 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1507...
Page 252 12–15 EMISSION CONTROL – EMISSION CONTROL SYSTEM (1MZ–FE) VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. P12931 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1508...
Page 253 Purge Port decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released. Vacuum A59505 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1509...
Page 254 Check that air does not flow from ports E to F. A59509 Apply battery positive voltage across the terminals. Check that air flows from ports E to F. If operation is not as specified, replace the VSV. A59510 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1510...
Page 255 Continuity A59514 Using an ohmmeter, check that there is no continu- Ohmmeter ity between each terminal and the body. If there is continuity, replace the VSV set. No Continuity A59515 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1511...
Page 256 Using an ohmmeter, check that there is no continu- Ohmmeter No Continuity ity between each terminal and the body. If there is continuity, replace the VSV. A60491 Check that air flows from ports A to B. A59520 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1512...
Page 257 Terminal No. Resistance 1.8 – 3.4 Ω at 20_C (68_F) 1 (HT) 2 (+B) 1 (HT) 4 (E1) No Continuity If the resistance is not as specified, replace the sensor. A52607 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1513...
Page 258 Release the vacuum from the EGR valve. Voltage: 0.4 – 1.6 V If the voltage is not as specified, replace the EGR valve position sensor. Reconnect the vacuum hose to the EGR valve. E2(–) EGLS(+) A59591 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1514...
Page 259 Resistance: 69.4 – 88.5 Ω At 50_C (122_F) 11.89 – 14.37 Ω At 100_C (212_F) 2.79 – 3.59 Ω At 150_C (302_F) A61681 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1515...
Page 260 Check that air flows from port E to port G. S04515 Apply battery positive voltage across the terminals. Check that air flows from port E to port F. If operation is not as specified, replace the VSV. Battery S04512 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1516...
Page 261 Connect the EGR valve position sensor connector. Connect the vacuum hose to the EGR valve. Connect the EVAP hose to the EGR valve hook. Connect the EGR gas temperature sensor connector and clamp. A59592 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1517...
Page 262 EGR VALVE ASSY (1MZ–FE) INSTALL EGR PIPE SUB–ASSY NO.2 Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N m (120 kgf cm, 9 ft lbf) A62373 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1518...
Page 263 Check the data monitor operation according to the il- lustration. HINT: The value in the illustration is only for reference; the throttle valve may operate diversely depend on the running condition. 35.7 3700 Engine Speed [r/min.] A59594 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1519...
Page 264 Cover port A and C with fingers, and apply 60 kPa (450 mm Hg, 18 in. Hg) of vacuum to port B, and check that there is no change of vacuum after one minute. A51995 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1520...
Page 265 Resistance: 33 – 39 Ω at 20_C (68_F) Check that air flows form port B to the filter. Apply battery voltage across the terminals. Check that air flows from port B to port A. A59586 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1521...
Page 266 Seal packing: Part No. 08226–00080 or equivalent. Install a new gasket and intake air control valve assembly. Torque: 15 N m (153 kgf cm, 11 ft lbf) A52930 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1522...
Page 267 When checking the ignition timing, the transmission is at A52004 neutral position. HINT: After engine rpm is kept at 1,000 – 1,300 r/min. for 5 seconds, check that it returns idle speed. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1523...
Page 268 Warm up and stop engine. Disconnect the injector connectors. Remove ignition coils. Remove spark plugs. Inspect cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle. A01037 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1524...
Page 269 If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check heated oxygen sensor operation. (See page 12–1) See the table below for possible causes, and then inspect and correct the applicable causes if necessary. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1525...
Page 270 S Faulty pressure regulator Rough idle S Defective water temperature sensor High High (Black smoke from exhaust) S DEFECTIVE Air–flow meter S Faulty ECU S Faulty injectors S Faulty throttle position sensor 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1526...
Page 271 Slowly turn the drive belt tensioner clockwise in more than 3 seconds, and install the drive bolt by using SST. 09249–63010 A62240 INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N m (531 kgf cm, 38 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1527...
Page 272 Install the engine mounting control rod with the 3 bolts w/ bracket. Torque: 64 N m (653 kgf cm, 47 ft lbf) A59888 INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1528...
Page 273 14–7 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) VALVE CLEARANCE (2AZ–FE) 1405V–02 ADJUSTMENT REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE ENGINE COVER SUB–ASSY NO.1 REMOVE IGNITION COIL ASSY DISCONNECT VENTILATION HOSE DISCONNECT VENTILATION HOSE NO.2 DISCONNECT ENGINE WIRE REMOVE CYLINDER HEAD COVER SUB–ASSY Remove the bolt and disconnect the engine wire harness clamp.
Page 274 14–8 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) INSPECT VALVE CLEARANCE HINT: Inspect and adjust the valve clearance when the engine is cold. Check only the valve indicated. No. 1 Cylinder TDC/Compression Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. Record the out–of specification valve clearance measurements.
Page 275 14–9 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) Loosen the camshaft bearing cap bolts on No.2 camshaft in the sequence shown in the illustration in several passes, and remove the caps. A32636 Raising the camshaft, remove the set bolt. Remove the timing chain sprocket from the camshaft with timing chain.
Page 276 14–10 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) Calculate the thickness of a new lifter so that the valve clearance comes within the specified value. Thickness of new lifter Thickness of used lifter Measured valve clearance Valve clearance: Intake A = B + (C – 0.24 mm (0.0094 in.)) Exhaust: A = B + (C –...
Page 277 Valve Lifter Selection Chart (Intake) Lifter Lifte Thickness 5.060 (0.1992) 5.080 (0.2000) 5.100 (0.2008) 5.120 (0.2016) 5.140 (0.2024) 5.160 (0.2031) 5.180 (0.2039) Intake valve clearance (Cold): 5.200 (0.2047) 0.19 to 0.29 mm (0.008 to 0.011 in.) 5.220 (0.2055) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured 5.240 (0.2063) clearance is 0.400 mm (0.0157 in.).
Page 278 Valve Lifter Selection Chart (Exhaust) Lifter Exhaust valve clearance (Cold): 0.30 to 0.40 mm (0.012 to 0.016 in.) EXAMPLE: The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm (0.2102 in.) lifter with a new No.
Page 279 14–13 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) Install the timing chain on the camshaft timing gear, with Paint Mark the painted links aligned with the timing marks on the camshaft timing sprockets. Timing Marks A52456 Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Page 280 14–13–1 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) Fix the camshaft with a spanner and so on, then tighten Tighten the camshaft timing gear set bolt. Torque: 54 N m (551 kgf cm, 40 ft lbf) NOTICE: Be careful not to damage the valve lifter. A52459 As shown in the illustration, check the matchmarks on the timing chain and camshaft timing sprockets and the align-...
Page 281 14–13–2 ENGINE MECHANICAL – VALVE CLEARANCE (2AZ–FE) Turn the crankshaft counterclockwise, and discon- nect the plunger knock pin from the hook. Disconnect Hook Turn A52463 Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. Plunger Push Turn A52464...
Page 282 Engine Under Cover RH Air Cleaner Air Cleaner Assy Inlet Assy Engine Under Air Cleaner Bracket Cover LH Battery Battery Tray N m (kgf cm, ft lbf) : Specified torque A60079 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1538...
Page 283 Exhaust Pipe No. 1 Exhaust Pipe No. 1 Support Bracket 33 (337, 24) Support Bracket 33 (337, 24) N m (kgf cm, ft lbf) : Specified torque z Non – reusable part A60078 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1539...
Page 284 85 (867, 63) 32 (326, 24) Member Brace Rear RH 32 (326, 24) Frame Suspension 85 (867, 63) Member Brace Rear LH N m (kgf cm, ft lbf) : Specified torque A60070 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1540...
Page 285 Member Brace Rear LH 85 (867, 63) 32 (326, 24) 32 (326, 24) Frame Suspension Member Brace Rear LH 85 (867, 63) N m (kgf cm, ft lbf) : Specified torque A59886 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1541...
Page 286 Drive Plate Automatic Transaxle Assy Spacer Rear 46 (470, 34) Starter Assy Front Drive Shaft Assy LH 39 (398, 29) N m (kgf cm, ft lbf) : Specified torque A60075 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1542...
Page 287 Clutch Cover Assy 64 (650, 47) 46 (470, 34) Manual Transaxle Assy Front Drive Shaft Assy LH Starter Assy 39 (398, 29) N m (kgf cm, ft lbf) : Specified torque A60074 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1543...
Page 288 Exhaust Manifold Converter Sub–assy Manifold Stay 44 (449, 32) 44 (449, 32) Manifold Stay No.2 N m (kgf cm, ft lbf) : Specified torque z Non – reusable part A60090 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1544...
Page 289 Water Housing Gasket No. 1 Oil Level Gage Guide z Oil Level Gage Guide O–ring N m (kgf cm, ft lbf) : Specified torque z Non – reusable part A62235 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1545...
Page 290 REMOVE ENGINE COVER SUB–ASSY NO.1 DISCONNECT ENGINE WIRE REMOVE GENERATOR ASSY REMOVE VANE PUMP ASSY (See page 51–8) NOTICE: Do not disconnect the hose. REMOVE IGNITION COIL ASSY DISCONNECT VENTILATION HOSE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1598...
Page 291 09213–54015 (91651–60855), 09330–00021 A52485 Using SST, remove the crankshaft pulley. 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) A36685 Remove the crankshaft pulley (TMMK made). Using SST, loosen the pulley bolt. 09960–10010 (09962–01000, 09963–01000) A62057 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1599...
Page 292 A00019 REMOVE CHAIN TENSIONER ASSY NO.1 Remove the 2 nuts, timing chain tensioner and gasket. NOTICE: Be sure not to revolve the crankshaft without the chain ten- sioner. A13325 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1600...
Page 293 A59880 Remove the bolt and disconnect the engine lateral control M/T: rod (M/T). A60825 Remove the bolt and disconnect the steering gear return hose cramp from the frame. A59901 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1601...
Page 294 REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1 REMOVE CHAIN TENSIONER SLIPPER REMOVE CHAIN VIBRATION DAMPER NO.1 REMOVE CHAIN SUB–ASSY REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1602...
Page 295 Remove the chain tensioner, oil pump drive shaft gear and No.2 chain. B11415 INSTALL NO.2 CHAIN SUB–ASSY Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top. B11424 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1603...
Page 296 Torque: 30 N m (301 kgf cm, 22 ft lbf) Groove A52512 Rotate the crankshaft counterclockwise 90_, and align the crankshaft key to the top. A36525 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1604...
Page 297 Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing gear. Timing Mark Mark Link A52523 Using a SST, install the sprocket. 09309–37010 A13337 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1605...
Page 298 Apply seal packing in the shape of bead (Diameter 2 mm (0.099 in.)) as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1606...
Page 299 Torque: 59.5 N m (607 kgf cm, 44 ft lbf) A52478 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N m (551 kgf cm, 40 ft lbf) A52481 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1607...
Page 300 Torque: 87 N m (888 kgf cm, 64 in. lbf) A59880 Install the engine lateral control rod with the bolt (M/T). M/T: Torque: 89 N m (910 kgf cm, 69 in. lbf) A60825 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1608...
Page 301 Align the pulley set key with the key groove of the pulley, and side on the pulley. 09213–54015 (91651–60855), 09330–00021 Using SST, install the pulley bolt. Torque: 170 N m (1,733 kgf cm, 125 ft lbf) A52486 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1609...
Page 302 INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque: 52 N m (531 kgf cm, 38 ft lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH Torque: 64 N m (653 kgf cm, 47 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1610...
Page 303 INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSTALL HOOD SUB–ASSY Torque: 13 N m (133 kgf cm, 10 ft lbf) ADD ENGINE OIL INSPECT OIL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1611...
Page 304 Place match marks on the timing chain and camshaft tim- ing sprocket. Timing Marks Paint Mark Paint Mark Timing Mark Timing Marks Groove A52453 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1612...
Page 305 A52473 REMOVE CAMSHAFT Loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustration in several passes, and remove the caps. Remove the intake camshaft. A36526 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1613...
Page 306 Be sure not to remove the other 4 bolts. In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear. A32639 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1614...
Page 307 INSTALL NO.2 CAMSHAFT Paint Mark Put the camshaft No.2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets. Timing Mark A53011 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1615...
Page 308 7 Links Paint Mark Paint Mark Timing Marks Timing Mark Groove A52460 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1616...
Page 309 Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook. Disconnect Hook Turn A52463 Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. Plunger Push Turn A52464 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1617...
Page 310 INSTALL IGNITION COIL ASSY Torque: 9.0 N m (92 kgf cm, 80 in. lbf) INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT OIL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1618...
Page 311 REMOVE INTAKE MANIFOLD INSULATOR NO.1 REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 REMOVE EXHAUST MANIFOLD CONVERTER SUB–ASSY Remove the 3 bolts, 2 nuts No.1 and No.2 exhaust man- ifold stay. A60067 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1619...
Page 312 Remove the No.1 and No.3 camshaft bearing cap in the sequence shown in the illustration. Remove the No.1 camshaft. A36531 REMOVE CAMSHAFT BEARING NO.2 A32664 REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1620...
Page 313 Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Install bolts and plate washers to the cylinder head. NOTICE: Do not drop the washers into the cylinder head. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1621...
Page 314 Bearing cap No.1 30 N m (301 kgf cm, 22 ft lbf) Bearing cap No.3 9.0 N m (92 kgf cm, 80 in. lbf) Bearing Cap No. 1 Bearing Cap No. 3 A52475 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1622...
Page 315 Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Torque: 30 N m (306 kgf cm, 22 ft lbf) A61987 CONNECT FUEL TUBE SUB–ASSY (See page 11–1) INSTALL CHAIN SUB–ASSY (See page 14–74) 09309–37010 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1623...
Page 316 INSPECT OIL LEAK CHECK ENGINE COOLANT LEAK (See page 16–1) INSPECT FUEL LEAK (See page 11–5) INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14–1) INSPECT CO/HC (See page 14–1) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1624...
Page 317 REMOVE CRANKSHAFT PULLEY Remove the crankshaft pulley (TMC made). Using SST, loosen the pulley bolt. 09213–54015 (91651–60855), 09330–00021 A52485 Using SST, remove the crankshaft pulley. 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05021) A36685 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1625...
Page 318 Using SST and a hammer, tap in the oil seal until its sur- face is flush with the rear oil seal retainer edge. 09223–22010 A32663 NOTICE: Wipe off extra grease on the crankshaft. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1626...
Page 319 Install the engine moving control rod w/bracket with 3 bolts. Torque: 64 N m (653 kgf cm, 47 ft lbf) A59888 INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT OIL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1627...
Page 320 (See page 42–14) REMOVE CLUTCH DISC ASSY(M/T TRANSAXLE) (See page 42–14) REMOVE FLYWHEEL SUB–ASSY(M/T TRANSAXLE) Fix the crankshaft with SST. 09213–54015 (91651–60855), 09330–00021 Remove the 8 bolts, rear spacer, flywheel sub–assy. A32665 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1628...
Page 321 Part No. 08833–00070, THREE BOND or equivalent A62061 Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown. Torque: 98 N m (1,000 kgf cm, 72 ft lbf) A61988 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1629...
Page 322 INSTALL CLUTCH DISC ASSY(M/T TRANSAXLE) (See page 42–14) INSTALL CLUTCH COVER ASSY(M/T TRANSAXLE) (See page 42–14) INSTALL AUTOMATIC TRANSAXLE ASSY(A/T TRANSAXLE) (SeePage 40–14) INSTALL MANUAL TRANSAXLE ASSY(M/T TRANSAXLE) (See page 41–11) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1630...
Page 323 Valve spring Exhaust valve Wooden Blocks A52472 REMOVE VALVE STEM OIL O SEAL OR RING Using needle–nose pliers, remove the oil seals. A13356 REMOVE VALVE SPRING SEAT REMOVE STUD BOLT 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1631...
Page 324 If not, resurface the seat. Check that the sat contact is in the middle of the valve face with the width between 1.0 – 1.4 mm (0.039 – 0.055 in.). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1632...
Page 325 INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft jour- nal. A36627 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1633...
Page 326 Mark ”2” 2.005 – 2.008 mm (0.07894 – 0.07905 in.) Mark ”3” 2.009 – 2.012 mm (0.07909 – 0.07921 in.) Camshaft journal diameter 35.971 – 35.985 mm (1.41648 – 1.41673 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1634...
Page 327 Using vernier calipers, measure the valve head margin thickness. Standard margin thickness: 1.05 – 1.45 mm (0.041 – 0.057 in.) Minimum margin thickness: 0.5 mm (0.020 in.) Margin Thickness EM0181 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1635...
Page 328 Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: A13367 0.025 – 0.060 mm (0.00098 – 0.00236 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1636...
Page 329 Diameter: 10.285 – 10.306 mm (0.4049 – 0.4057 in.) Install the STD bushing if the diameter is within specified diameter. HINT: 10.333 – 10.344 mm (0.4068 – 0.4072 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1637...
Page 330 Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.033 – 0.059 mm (0.0013 – 0.0023 in.) A13374 Maximum oil clearance: 0.07 mm (0.0028 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1638...
Page 331 CYLINDER HEAD ASSY (2AZ–FE) INSTALL RING W/HEAD PIN Upper Side Using a plastic–faced hammer, tap in a new ring pin to the specified protrusion height. Protrusion height: 3 mm (0.12 in.) (0.12) A62971 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1639...
Page 332 Bolt D 10 N m (97 kgf cm, 84 in. lbf) Front Upper Intake Side Exhaust Side 46.5 49.5 37.5 31.5 (M6) (M6) (M8) (M8) [mm] A52448 INSTALL VALVE SPRING SEAT 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1640...
Page 333 NOTICE: Be careful not to damage the valve stem tip. Valve Stem A13888 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1641...
Page 334 A13888 INSTALL VALVE LIFTER Assemble the valve lifter and the tip of the valve stem with a light coat of engine oil applied. NOTICE: Install the valve lifters originally placed. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1642...
Page 335 Using a 12 mm socket wrench, tighten the bolts in several passes by the specified torque. Torque: 25 N m (250 kgf cm, 18 ft lbf) A52515 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1643...
Page 336 HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. A13469 REMOVE CONNECTING ROD BEARING 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1644...
Page 337 Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: A36645 1.930 – 1.980 mm (0.0760 – 0.0780 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1645...
Page 338 INSPECT CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, mea- sure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) A36648 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1646...
Page 339 Using a feeler gauge, measure the clearance between the piston ring and the wall of the ring groove. Ring groove clearance: 0.030 – 0.070 mm (0.0012 – 0.0028 in.) A36650 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1647...
Page 340 Piston pin diameter Mark mm (in.) 21.997 – 22.000 (0.8660 – 0.8661) 22.000 – 22.003 (0.8661 – 0.8663) 22.003 – 22.006 (0.8663 – 0.8664) EM0227 22.006 – 22.009 (0.8664 – 0.8665) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1648...
Page 341 Check for out–of–alignment. Maximum out–of–alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out–of alignment is greater than maximum, replace the connecting rod assembly. Z00064 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1649...
Page 342 54.996 – 54.998 (2.16520 – 2.16528) 54.994 – 54.996 (2.16512 – 2.16520) 54.992 – 54.994 (2.16504 – 2.16512) 54.990 – 54.992 (2.16496 – 2.16504) 54.988 – 54.990 (2.16490 – 2.16496) A36653 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1650...
Page 343 Using a plastic–faced hammer, tap into the ring pin. Standard protrusion: Ring pin A 6 mm (0.236 in.) Ring pin B 5 mm (0.197 in.) Upper Side Bottom Side 6 (Ring Pin A) 5 (Ring Pin B) A53009 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1651...
Page 344 Torque: 20 N m (204 kgf cm, 15 ft lbf) Retighten the bolts in several passes, in the sequence shown, by the specified torque. Torque: 40 N m (408 kgf cm, 29 ft lbf) A36657 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1652...
Page 345 HINT: No. 1 EXAMPLE No. 2 No. 3 Cylinder block ”4” (A) + Crankshaft ”3” (B) = No. 5 No. 4 Total number 7 (Use bearing ”3”) Number Mark A13475 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1653...
Page 346 Using SST, into the tight plugs as shown in the illustration. 09950–60010 (09951–00200), 09950–70010 (09951–07100) Standard depth: Engine front 1.7 – 2.7 mm (0.067 – 0.106 in.) Engine rear 2.2 – 3.2 mm (0.087 – 0.126 in.) A62239 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1654...
Page 347 Using a plastic–faced hammer, tap into the straight pin. Standard protrusion Pin A 7.5 mm (0.295 in.) Pin B 12 mm (0.472 in.) Bottom Side Back Side Front Side 7.5 (Pin A) 12 (Pin B) A62248 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1655...
Page 348 Code Mark (2N) A52526 Position the piston rings so that the ring ends are as No. 1 and shown. Side Rail Lower Expander Front No. 2 Side Rail Upper Compression A52527 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1656...
Page 349 Examine the front marks and install the bearing caps on the cylinder block. Apply a light coat of engine oil on the threads and under the bearing cap bolts. A13502 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1657...
Page 350 NOTICE: Match the numbered connecting rod cap with the connect- ing rod. Front A52528 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1658...
Page 351 Mark the front of the connecting cap blots with paint. A52515 Retighten the cap bolts by 90_ as shown in the illustration. Paint Check that the crankshaft turns smoothly. Mark Engine Front A50671 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1659...
Page 352 Exhaust Pipe Assy Front 62 (633, 46) Exhaust Pipe No.1 Support Bracket 33 (337, 24) Exhaust Pipe No.1 Support Bracket 33 (337, 24) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A60080 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1814...
Page 353 Torque: 56 N m (571 kgf cm, 41 ft lbf) Install a new gasket and the front pipe to exhaust manifold converter. Torque: 62 N m (633 kgf cm, 46 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 354 INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET Torque: 33 N m (337 kgf cm, 24 ft lbf) INSTALL OXYGEN SENSOR Torque: 44 N m (450 kgf cm, 33 ft lbf) CHECK EXHAUST GAS LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1816...
Page 355 Exhaust Pipe Assy Front 62 (633, 46) Exhaust Pipe No.1 Support Bracket Exhaust Pipe No.1 Support Bracket 33 (337, 24) 33 (337, 24) N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part A59529 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1817...
Page 356 INSTALL TAIL PIPE ASSY INSTALL EXHAUST PIPE ASSY CENTER Install a new gasket and the center pipe to the tail pipe. Torque: 56 N m (571 kgf cm, 41 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1818...
Page 357 INSTALL OXYGEN SENSOR Torque: 44 N m (449 kgf cm, 32 ft lbf) INSTALL OXYGEN NO.2 SENSOR Torque: 44 N m (449 kgf cm, 32 ft lbf) CHECK EXHAUST GAS LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1819...
Page 358 CHECK ENGINE COOLANT LEVEL AT 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.
Page 359 NOTICE: If the reservoir cap has contaminations, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1821...
Page 360 78 kPa (0.8 kgf/cm , 11.2 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the reser- voir cap. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1822...
Page 361 Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 4.9 – 8.5 A at 20_C (68_F) Reconnect the cooling fan connector. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1823...
Page 362 If there is continuity, replace the relay. Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1824...
Page 363 If the coolant level gets lower, pour coolant. Use of improper coolants may damage engine cooling system. Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur- er’s directions. Using of coolant with includes more than 50 % (freezing protection down to –35_C (–31_F) or 60 % (freezing protection down to –50_C (–58_F)) of ethylene–glycol is recommended but not more than...
Page 364 Install the radiator cap and check the radiator reservoir tank coolant level. INSPECT CHECK ENGINE COOLANT LEAK Fill the radiator with coolant and attach a radiator cap tester. Pump it to 118 kPa (1.2 kgf/cm ), and check leakage. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1826...
Page 365 5 minutes after apply- 0.5 – 1.0 mm ing. (0.020 – 0.039 in.) Do not put into engine oil within 2 hours after instal- B11278 ling. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1827...
Page 366 B11275 INSTALL GENERATOR ASSY (See page 19–13) INSTALL FAN AND GENERATOR V BELT (See page 14–5) 09249–63010 ADD COOLANT (See page 16–6) INSPECT CHECK ENGINE COOLANT LEAK (See page 16–1) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1828...
Page 367 WATER PUMP ASSY (2AZ–FE) 1602W–02 INSPECTION INSPECT WATER PUMP ASSY Visually check the drain hole coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. A36661 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1829...
Page 368 Install the water inlet with 2 nuts. Torque: 9 N m (92 kgf cm, 80 in. lbf) ADD COOLANT (See page 16–6) INSPECT CHECK ENGINE COOLANT LEAK (See page 16–1) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1830...
Page 369 Disconnect the 2 horn connector. Remove the hood lock release lever cover. Clip A60497 Remove the bolt shown in the illustration. Remove the 4 bolts and radiator support upper. A60480 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1831...
Page 370 Install the radiator support upper with the 4 bolts. Torque: 14 N m (142 kgf cm, 10 ft lbf) ADJUST HOOD SUB–ASSY (See page 16–6) ADD COOLANT (See page 16–6) CHECK ENGINE COOLANT LEAK (See page 16–6) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1832...
Page 371 CHECK ENGINE COOLANT LEVEL AT 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.
Page 372 Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps (a) and (b) below, keep the tester at an angle of over 30_ above the horizontal. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1834...
Page 373 69 kPa (0.7 kgf/cm , 10.0 psi) HINT: Use the tester’s maximum reading as the opening pres- sure. If the opening pressure is less than minimum, replace the reservoir cap. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1835...
Page 374 Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.0 – 12.0 A at 20_C (68_F) Reconnect the cooling fan connector. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1836...
Page 375 If there is no continuity, replace the switch. Check that there is no continuity, between terminals when the coolant temperature is below 88_C (190_F). If there is continuity, replace the switch. P01924 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1837...
Page 376 If there is no continuity, replace the switch. Check that there is no continuity, between terminals when the coolant temperature is below 83_C (181_F). If there is continuity, replace the switch. P06722 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1838...
Page 377 HINT: Use of improper coolants may damage engine cooling system. Use ”Toyota Long Life Coolant” or equivalent and mix it with plain water according to the manufactur- er’s directions. Using of coolant with includes more than 50 % (freezing protection down to –35_C (–31_F) or 60 % (freezing protection down to –50_C (–58_F)) of ethylene–glycol is recommended but not more than...
Page 378 REMOVE TIMING BELT IDLER SUB–ASSY NO.2 Remove the bolt and timing belt idler sub assembly No. A05055 REMOVE CAMSHAFT TIMING PULLEY (See page 14–212) 09960–10010 (09962–01000, 09963–01000), 09249–63010 REMOVE TIMING BELT NO.3 COVER 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1840...
Page 379 Torque: 28 N m (286 kgf cm, 21 ft lbf) INSTALL ENGINE MOUNTING STAY NO.2 RH (See page 14–155) INSTALL ENGINE MOVING CONTROL ROD (See page 14–155) INSTALL VANE PUMP V BELT (See page 14–140) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1841...
Page 380 INSPECT DRIVE BELT DEFLECTION AND TENSION(REFERENCE) (See page 14–136) ADD COOLANT (See page 16–20) CHECK ENGINE COOLANT LEAK (See page 16–20) INSTALL FRONT WHEEL RH Torque: 103 N m (1051 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1842...
Page 381 WATER PUMP ASSY (1MZ–FE) 1602H–02 INSPECTION INSPECT WATER PUMP ASSY Visually check the drain hole for coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. P12487 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1843...
Page 382 Torque: 20 N m (204 kgf cm, 15 ft lbf) INSTALL AIR CLEANER ASSEMBLY WITH HOSE (See page 10–12) CONNECT VACUUM HOSE ADD COOLANT (See page 16–20) CHECK ENGINE COOLANT LEAK (See page 16–20) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1844...
Page 383 Disconnect the 2 horn connector. Remove the hood lock release lever cover. Clip A60497 Remove the bolt shown in the illustration. Remove the 4 bolts and radiator support upper. A60480 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1845...
Page 384 Install the radiator support upper with the 4 bolts. Torque: 14 N·m (142 kgf·cm,10 ft·lbf) ADJUST HOOD SUB–ASSY (See page 75–1) ADD COOLANT (See page 16–20) CHECK ENGINE COOLANT LEAK (See page 16–20) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1846...
Page 385 Disconnect the oil pressure switch connector. Remove the oil pressure switch. Oil Pressure Switch B11410 INSTALL OIL PRESSURE GAUGE Oil Pressure Gauge Install the oil pressure gauge. B11411 WARM UP ENGINE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1847...
Page 386 LOCTITE 242 or equivalent Install the oil pressure switch. Torque: 15 N m (152 kgf cm, 11 ft lbf) Connect the oil pressure switch connector. A50082 START ENGINE AND CHECK FOR LEAKS 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1848...
Page 387 INSTALL OIL PUMP ASSY Place a new gasket on the cylinder block. Install the oil pump assembly with 3 bolts. Torque: 19 N m (194 kgf cm, 14 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1849...
Page 388 Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. B11419 Remove the oil pump cover. Remove 5 bolts and oil pump body cover. B11431 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1850...
Page 389 Install the oil pump rotor set. Coat the drive rotor and driven rotors with engine oil. Place the drive and driven rotors into pump body with the marks facing the pump body cover side. B11423 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1851...
Page 390 Install oil pump strainer. Place a new gasket on the oil pump. Install the oil pump strainer with 2 nuts. Torque: 8.8 N m (90 kgf cm, 78 in. lbf) B11430 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1852...
Page 391 Drain and refill w/o Oil filter change 3.6 liters (3.8 US qts, 3.2 lmp. qts) Dry fill 4.5 liters (4.8 US qts, 4.0 lmp. qts) Install the oil filler cap. INSPECT OIL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1853...
Page 392 Disconnect the oil pressure switch connector. Remove the oil pressure switch. Oil Pressure Switch A52637 INSTALL OIL PRESSURE GAUGE Oil Pressure Install the oil pressure gauge. Gauge B04132 WARM UP ENGINE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1854...
Page 393 LOCTITE 242 or equivalent Install the oil pressure switch. Torque: 15 N m (152 kgf cm, 11 ft lbf) Connect the oil pressure switch connector. A50082 START ENGINE AND CHECK FOR LEAKS 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1855...
Page 394 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET REMOVE TIMING BELT GUIDE NO.2 REMOVE TIMING BELT (See page 14–243) REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REMOVE EXHAUST PIPE ASSY FRONT REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1856...
Page 395 Using a 10mm socket hexagon wrench, remove the timing belt idler sub–assembly No. 1 and the plate washer. REMOVE CRANKSHAFT TIMING PULLEY (See page 14–243) 09950–50013 (09951–05010, 09952–05010, 09953–05020, 09954–05010) REMOVE TIMING BELT NO.3 COVER 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1857...
Page 396 Handle a jack up to remove the engine mounting insulator A52016 NOTICE: Be careful not to damage the contact surfaces of the oil pan. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1858...
Page 397 Be careful not to damage the oil pan No. 2 flange. A00019 REMOVE OIL STRAINER SUB–ASSY Remove the bolt, 2 nuts and oil strainer sub–assembly. REMOVE OIL PAN SUB–ASSY Remove the 17 bolts and 2 nuts. A36754 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1859...
Page 398 Apply a small amount of MP grease to the oil seal lip. NOTICE: A62376 Keep the lip off foreign materials. Apply engine oil to the O–ring. Install a new O–ring on the cylinder block. A36784 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1860...
Page 399 12 mm head 20 N m (199 kgf cm, 14 ft lbf) 14 mm head 43 N m (439 kgf cm, 32 ft lbf) A36785 INSTALL CRANK POSITION SENSOR Torque: 8 N m (82 kgf cm, 71 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1861...
Page 400 Torque: 8 N m (82 kgf cm, 71 in. lbf) NOTICE: Remove any oil from the contact surface. Do not put into engine oil within 2 hours after instal- ling. Seal Width 4 – 5 mm A52360 P12568 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1862...
Page 401 Torque: 8 N m (82 kgf cm, 71 in. lbf) INSTALL COMPRESSOR MOUNTING BRACKET NO.1 Torque: 25 N m (250 kgf cm, 18 ft lbf) INSTALL TIMING BELT NO.3 COVER (See page 14–212) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1863...
Page 402 (See page 14–155) INSTALL VANE PUMP V BELT (See page 14–140) INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 14–140) INSPECT DRIVE BELT DEFLECTION AND TENSION(REFERENCE) (See page 14–136) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1864...
Page 403 Torque: 80 N m (816 kgf cm, 59 ft lbf) ADD ENGINE OIL INSPECT OIL LEAK INSTALL FRONT WHEEL RH Torque: 103 N m (1,051 kgf cm, 76 ft lbf) CHECK EXHAUST GAS LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1865...
Page 404 Using a feeler gauge, measure the clearance be- tween the driven rotor and body. Standard body clearance: 0.125 – 0.162 mm (0.0050 – 0.0064 in.) Maximum body clearance: 0.30 mm (0.0118 in.) A33004 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1866...
Page 405 Apply a light coat of engine oil to the relief valve, and insert the relief valve and spring into the pump body hole. Install the oil pump relief valve plug. Torque: 24 N m (245 kgf cm, 18 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1867...
Page 406 Drain and refill w/o oil filter change 4.5 liters (4.8 US qts, 4.0 lmp. qts) Dry fill 5.5 liters (5.8 US qts, 4.8 lmp. qts) Install the oil filler cap. INSPECT OIL LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1868...
Page 407 Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 19 N m (194 kgf cm, 14 ft lbf) Install the ignition coil with igniter. Torque: 9.0 N m (92 kgf cm, 80 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1869...
Page 408 NOTICE: ”Cold” and ”Hot” on the table express the temperature of the coils themselves.”Cold” is from –10_C (14_F) to 50_C (122_F) and ”Hot” is from 50_C (122_F) to 100_C (212_F). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1870...
Page 409 Using a 16 mm (0.63 in.) plug wrench, install the spark plugs. Torque: 18 N m (184 kgf cm, 13 ft lbf) Install the ignition coils. Torque: 8.0 N m (82 kgf cm, 71 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1871...
Page 410 NOTICE: ”Cold” and ”Hot” on the table express the temperature of the coils themselves.”Cold” is from –10_C (14_F) to 50_C (122_F) and ”Hot” is from 50_C (122_F) to 100_C (212_F). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1872...
Page 411 Check that the clutch pinion gear returns inward. A60461 Connect the lead wire to the terminal C with the nut. Torque: 5.9 N m (60 kgf cm, 52 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1873...
Page 412 Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1874...
Page 413 Bolt 39 N m (398 kgf cm, 29 ft lbf) Terminal 30 13 N m (130 kgf cm, 9 ft lbf) INSTALL AIR CLEANER INLET ASSY INSTALL AIR CLEANER BRACKET INSTALL AIR CLEANER ASSY INSTALL BATTERY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1875...
Page 414 Repair Servise Starter Kit 6.5 (66, 58 in. lbf) 6.0 (61, 53 in. lbf) Starter Armature Assy Starter Yoke Assy Starter Commutator End Frame Assy N·m (kgf·cm, ft·lbf) : Specified torque A59593 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1876...
Page 415 Using snap ring pliers, remove the snap ring and plate washer. A58582 Remove the 2 through bolts, and pull out the starter yoke assy together with the commutator end frame assy. A57561 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1877...
Page 416 Using vernier calipers, measure the commutator length. Standard length: 3.3 mm (0.130 in.) Maximum length: 4.0 mm (0.158 in.) If the length is greater than maximum, replace the armature. Length A58584 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1878...
Page 417 Check whether the hold–in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the repair service kit. Terminal 50 Continuity A58376 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1879...
Page 418 Align the starer yoke assy with the cutout of motor termi- nal starter kit. A58806 Install the starter yoke assy with the 2 through bolts. Torque: 6.0 N m (61 kgf cm, 53 in. lbf) A57561 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1880...
Page 419 Apply grease to the nut of the lead wire. Connect the lead wire to the terminal with the nut. Torque: 6.5 N m (66 kgf cm, 58 in. lbf) A57559 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1881...
Page 420 Check that the charging cable is tightened on terminal B of the alternator and the fuse box. Do not check whether the alternator generators or not with connecting terminal F to the other terminal. 2002 CAMRY REPAIR MANUAL (RM881U) Author :...
Page 421 Replace the drive belt if the cracks reached to the wire more than one place. Replace the drive belt if the belt has chunks missing from B00543 the ribs. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1883...
Page 422 Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the alternator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1884...
Page 423 Alternator wire 9.8 N m (100 kgf cm, 7 ft lbf) NOTICE: Be careful not to put the wire harness in when install the al- ternator. INSTALL FAN AND GENERATOR V BELT (See page 14–1) 09249–63010 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1885...
Page 424 Drive End Frame Pulley Alternator Washer Rear End Cover 111 (1,125, 81) Brush Holder Cover Brush Holder Rectifier End Frame Voltage Regulator Rectifier Holder N·m (kgf·cm, ft·lbf) : Specified torque A59147 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1886...
Page 425 Remove the alternator form SST 2. A38104 Turn SST 1 – B, and remove SST 1 – A, B. Remove the pulley nut and pulley. A38105 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1887...
Page 426 F and B are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the voltage regula- A59143 tor. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1888...
Page 427 E terminal and the other to each rectifier terminal. Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity. A36999 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1889...
Page 428 Be careful of the rubber insulators installation direction. A51921 INSTALL GENERATOR HOLDER W/RECTIFIER Install the rectifier holder while pushing it with the 4 screws. Torque: 2.9 N m (30 kgf cm, 26 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1890...
Page 429 Hold SST 1 – A with a torque wrench, and tighten SST 1 – B clockwise to the specified to torque. Torque: 39 N m (400 kgf cm, 29 ft lbf) NOTICE: Check that SST is secured to the pulley shaft. A38024 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1891...
Page 430 Remove the alternator form SST 2. SST 1 – A A38126 Turn SST 1 – B, and remove SST 1 – A, B. Turn the pulley, and check that the pulley moves smooth- A38105 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1892...
Page 431 Check that the clutch pinion gear returns inward. A60461 Connect the lead wire to the terminal C with the nut. Torque: 5.9 N m (60 kgf cm, 52 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1893...
Page 432 Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1894...
Page 433 INSTALL STARTER ASSY Torque: Bolt 42 N m (429 kgf cm, 31 ft lbf) Nut 9.8 N m (100 kgf cm, 7 ft lbf) INSTALL AIR CLEANER ASSEMBLY WITH HOSE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1895...
Page 434 Repair Servise Starter Kit 6.5 (66, 58 in. lbf) 6.0 (61, 53 in. lbf) Starter Armature Assy Starter Yoke Assy Starter Commutator End Frame Assy N·m (kgf·cm, ft·lbf) : Specified torque A59593 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1896...
Page 435 Using snap ring pliers, remove the snap ring and plate washer. A58582 Remove the 2 through bolts, and pull out the starter yoke assy together with the commutator end frame assy. A57561 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1897...
Page 436 Using vernier calipers, measure the commutator length. Standard length: 3.3 mm (0.130 in.) Maximum length: 4.0 mm (0.158 in.) If the length is greater than maximum, replace the armature. Length A58584 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1898...
Page 437 Check whether the hold–in coil has an open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the repair service kit. Terminal 50 Continuity A58376 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1899...
Page 438 A58806 Install the starter yoke assy with the 2 through bolts. Torque: 6.0 N m (61 kgf cm, 53 in. lbf) Install the starter commutator end frame cover. A57561 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1900...
Page 439 Apply grease to the nut of the lead wire. Connect the lead wire to the terminal with the nut. Torque: 6.5 N m (66 kgf cm, 58 in. lbf) A57559 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1901...
Page 440 Check that the charging cable is tightened on terminal B of the alternator and the fuse box. Do not check whether the alternator generates or not with conncting terminal F to the other terminal. 2002 CAMRY REPAIR MANUAL (RM881U) Author :...
Page 441 If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be re- placed. B00543 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1903...
Page 442 Standard amperage: 30 A or more If the ammeter reading is less than standard amperage, repair the alternator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1904...
Page 443 Bolt B 18 N m (184 kgf cm, 13 ft lbf) Install the lead wire from terminal B. Torque: 9.8 N m (100 kgf cm, 7 ft lbf) INSPECT DRIVE BELT DEFLECTION AND TENSION(REFERENCE) (Seee page 14–136) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1905...
Page 444 Drive End Frame Pulley Alternator Washer Rear End Cover Brush Holder Cover 111 (1,125, 81) Brush Holder Rectifier End Frame Voltage Regulator Rectifier Holder N·m (kgf·cm, ft·lbf) : Specified torque A59147 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1906...
Page 445 Remove the alternator form SST 2. A38104 Turn SST 1 – B, and remove SST 1 – A, B. Remove the pulley nut and pulley. A38105 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1907...
Page 446 F and B are exchanged, there is continuity in one way but no continuity in another way. If the continuity is not as specified, replace the voltage regula- A59143 tor. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1908...
Page 447 E terminal and the other to each rectifier terminal. Reverse the polarity of the tester probes and repeat step (a). Check that one shows continuity and the other shows no continuity. A36999 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1909...
Page 448 Torque: 2.9 N m (30 kgf cm, 26 in. lbf) INSTALL GENERATOR REGULATOR ASSY Install the 3 screws and voltage regulator. Torque: 2.0 N m (20 kgf cm, 18 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1910...
Page 449 Check that SST is secured to the pulley shaft. A38024 Mount SST 2 in a vise. Insert SST 1 – A, B into SST 2, and attach the pulley nut to SST 2. A38025 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1911...
Page 450 Remove the alternator form SST 2. SST 1 – A A38126 Turn SST 1 – B, and remove SST 1 – A, B. Turn the pulley, and check that the pulley moves smooth- A38105 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1912...
Page 451 7. Steering linkage (Loose or worn) 1. Tire (Worn or improperly inflated) 28–1 2. Wheel alignment (Incorrect) 26–5 Abnormal tire wear 27–3 26–9 3. Shock absorber (Worn) – 4. Suspension parts (Worn) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1913...
Page 452 100 meters at a constant speed of 35mph without holding the steering wheel. (1) The vehicle can keep straight but the steering wheel has some angle. STEERING OFF CENTER (See page 50–4) (2) The vehicle cannot keep straight. STEERING PULL 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1914...
Page 453 Insulator Lower LH w/ABS: Speed Sensor Front Flexible Hose Front LH No. 1 Shock Absorber Assy Front LH Front Axle Assy LH : Specified torque N·m (kgf·cm, ft·lbf) z Non–reusable part C90258 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1915...
Page 454 294 (2,998, 217) Arm Sub–assy Caliper Assy Lower No. 1 LH 49 (500, 36) z Cotter Pin 127 (1,295, 94) : Specified torque N·m (kgf·cm, ft·lbf) z Non–reusable part C91581 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1916...
Page 455: Front Wheel Alignment
If the toe–in is not within the specified value, adjust it at the rack ends. ADJUST TOE–IN Remove the rack boot set clips. Loosen the tie rod end lock nuts. SA3213 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1917...
Page 456 45’ (0.75°) or less 45’ (0.75°) or less 11°27’ ± 45’ 11°05’’ ± 45’ Steering axis inclination (11.45° ± 0.75°) (11.08° ± 0.75°) Right–left error 45’ (0.75°) or less 45’ (0.75°) or less 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1918...
Page 457 When removing nut, stop the bolt from rotating and loosen the nut. Clean the installation surfaces of the shock absorber and the steering knuckle. Temporarily install the 2 nuts. C93871 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1919...
Page 458 1_00’ 1_15’ 1_30’ Do the steps mentioned above again. At step (b), replace 1 or 2 selected bolts. HINT: When replacing the 2 bolts, replace 1 bolt for each time. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1920...
Page 459 Remove the 2 nuts and 2 bolts on the lower side of front shock absorber with coil spring. NOTICE: When removing bolt, stop the bolt from rotating and loosen the nut. C93871 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1921...
Page 460 INSTALL SHOCK ABSORBER ASSY FRONT LH Install the front coil spring insulator lower LH onto the shock absorber assy front LH. Install the front spring bumper LH to the piston rod. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1922...
Page 461 Install the front coil spring seat upper LH to the shock ab- Outside sorber assy front LH with the mark facing to the outside of the vehicle. F40161 Install a new front suspension support bearing LH. F40162 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1923...
Page 462 Torque: 18.8 N m (192 kgf cm, 14 ft lbf) w/o ABS: Install the front flexible hose No. 1 with the bolt. Torque: 18.8 N m (192 kgf cm, 14 ft lbf) C65925 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1924...
Page 463 If the ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud. F40136 INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1925...
Page 464 Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: N00204 When drilling, chips may fly out, work carefully. The gas is colorless, odorless and non–poisonous. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1926...
Page 465 No. 1 LH. Remove the front suspension arm sub–assy lower No. 1 Remove the front lower arm bush stopper from the front suspension arm sub–assy lower No. 1 LH. F02227 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1927...
Page 466 Install the transverse engine engine mounting insulator with the 3 nuts. Torque: 87 N m (887 kgf cm, 64 ft lbf) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(2AZ–FE ENGINE TYPE)(Seepage 14–22) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(1MZ–FE ENGINE TYPE)(Seepage 14–155) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1928...
Page 467 INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH(See page 30–21) INSTALL SPEED SENSOR FRONT LH(W/ ABS) (See page 30–8) INSTALL FRONT AXLE HUB LH NUT (See page 30–8) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1929...
Page 468 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) CHECK ABS SPEED SENSOR SIGNAL(W/ ABS) w/ VSC (See page 05–452) w/o VSC (BOSCH MADE) (See page 05–363) w/o VSC (DENSO MADE) (See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1930...
Page 469 Remove the 2 bolts and 2 front stabilizer brackets No. 1 C91607 REMOVE FRONT STABILIZER BRACKET NO.1 RH HINT: Remove the RH side by the same procedures with the LH side. DISCONNECT TIE ROD ASSY LH (See page 30–8) 09628–62011 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1931...
Page 470 INSTALL STABILIZER BAR FRONT INSTALL RACK & PINION POWER STEERING GEAR ASSY (See page 51–29) INSTALL STEERING INTERMEDIATE SHAFT SUB–ASSY (See page 51–29) INSTALL PRESSURE FEED TUBE ASSY (See page 51–29) 09023–00100 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1932...
Page 471 INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) BLEED POWER STEERING FLUID(See page 51–3) CHECK POWERSTEERING FLUID LEAKAGE INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1933...
Page 472 5. Hub bearing (Worn) 1. Tire (Worn or improperly inflated) 28–1 2. Wheel alignment (Incorrect) 26–5 Abnormal tire wear 27–3 27–4 3. Shock absorber (Worn) – 4. Suspension parts (Worn) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1934...
Page 473 19 (195, 14) Stabilizer Bar Rear Parking Brake Cable Rear Stabilizer Link Assy LH N m (kgf cm, ft lbf) : Specified torque 255 (2,600, 188) z Non–reusable part B53746 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1935...
Page 474: Rear Wheel Alignment
45’ (0.75°) or less HINT: Camber is not adjustable. If the measurement is not within the specification, inspect the suspension parts for damaged and/or worn–out parts and replace them if necessary. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1936...
Page 475 Remove the nut and disconnect the stabilizer bar link from the shock absorber. HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. C66631 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1937...
Page 476 REMOVE SHOCK ABSORBER ASSY REAR LH Install 2 nuts and a bolt to the bracket at the lower part of 28mm the shock absorber, and secure it in a vise. (1.1 in) F40121 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1938...
Page 477 Fit the lower end of the coil spring into the gap of the lower seat. F41029 Check that the 2 flat faces of the piston rod are positioned in parallel with the 2 flat faces of the rear suspension sup- port. C93791 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1939...
Page 478 2 bolts. Torque: A: Flexible hose: 19 N m (194 kgf cm, 14 ft lbf) B: ABS speed sensor wire harness: 5.5 N m (56 kgf cm, 49 in lbf) F41030 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1940...
Page 479 Install the LH side by the same procedures with the RH side. INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT REAR WHEEL ALIGNMENT(See page 27–3) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1941...
Page 480 Using a drill, make a hole in the cylinder as shown in the illustration to discharge the gas inside. CAUTION: When drilling, chips may fly out, work carefully. The gas is colorless, odorless and non–poisonous. C83384 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1942...
Page 481 Keep the nut fixed while loosening and removing the bolt. B53736 SEPARATE REAR SUSPENSION ARM ASSY NO.1 RH HINT: Separate the RH side by the procedures with the LH side. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1943...
Page 482 38 mm (1.5 in.) B53747 HINT: Front Install the lower suspension No. 1 so that the bracket leans to- ward the front of the vehicle, as shown in the illustration. B53748 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1944...
Page 483 TEMPORARY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 RH HINT: Temporarily tighten the RH side by the procedures with the LH side. TEMPORARY TIGHTEN STRUT ROD ASSY REAR (See page 27–19) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1945...
Page 484 INSTALL EXHAUST PIPE ASSY CENTER 1MZ–FE engine: See page 15–5 2AZ–FE engine: See page 15–2 INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT REAR WHEEL ALIGNMENT(See page 27–3) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1946...
Page 485 C82992 Remove the bolt, nut and the rear suspension arm No. 2 (outer side) from rear axle carrier. HINT: Keep the nut fixed while loosening and removing the bolt. C82993 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1947...
Page 486 FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.1 RH HINT: Fully tighten the RH side by the procedures with the LH side. FULLY TIGHTEN REAR SUSPENSION ARM ASSY NO.2 LH (See page 27–14) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1948...
Page 487 INSTALL EXHAUST PIPE ASSY CENTER 1MZ–FE engine: See page 15–5 2AZ–FE engine: See page 15–2 INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT REAR WHEEL ALIGNMENT(See page 27–3) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1949...
Page 488 Turning torque: 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) C66721 REMOVE STABILIZER BAR REAR Remove the 8 bolts, 2 No. 1 brackets and 2 bushings. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1950...
Page 489 INSTALL REAR STABILIZER LINK ASSY RH HINT: Install the RH side by the same procedures with the LH side. INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1951...
Page 490 Install the strut rod (rear side), bolt nut and temporarily tighten the bolt. HINT: Insert the bolt from the inner side of the vehicle and tem- porarily install the bolt. Keep the nut fixed while tightening the bolt. B53741 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1952...
Page 491 Torque: 5.4 N m (55 kgf cm, 48 in. lbf) B53739 INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT REAR WHEEL ALIGNMENT(See page 27–3) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1953...
Page 492: Wheel And Tire System
Imbalance after adjustment: 8.0 g (0.018 lb) or less C80976 INSPECT BEARING BACKLASH(See page 30–2) INSPECT BEARING BACKLASH(See page 30–2) INSPECT AXLE HUB DEVIATION(See page 30–2) INSPECT AXLE HUB DEVIATION(See page 30–2) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1954...
Page 493 28–1 2. Shock absorber 26–9 Front wheel shimmy 27–4 3. Ball joint (Worn) 26–17 4. Hub bearing (Worn) 30–2 1. Inbord joint (Worn) 30–8 Noise 2. Outbord joint (Worn) 30–8 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1955...
Page 494 Set a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub as- sembly. C83015 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1956...
Page 495 INSTALL REAR DISC BRAKE CALIPER ASSY LH(DISC REAR BRAKE TYPE) (See page 30–28) INSTALL REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1957...
Page 496 Front Axle Assy LH 294 (2,998, 217) Front Suspension 49 (500, 36) Arm Sub–assy Lower No.1 LH z Cotter Pin : Specified torque N·m (kgf·cm, ft·lbf) z Non–reusable part 127 (1,295 94) C91583 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1958...
Page 497 Snap Ring RH Front Drive Shaft Dust Cover LH Front Drive Shaft Front Drive Inboard Dust Cover Joint Assy LH Front Drive Shaft Dust Cover RH z Non–reusable part C91590 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1959...
Page 498 8.3 (85, 73 in. lbf) Lower Ball Joint Assy LH 8.3 (85, 73 in. lbf) Front Axle Hub Sub–assy LH N m (kgf cm, ft lbf) : Specified torque z Non–reusable part C91584 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1960...
Page 499 5.4 (55, 48 in. lbf) REAR DRUM BRAKE: 80 (816, 59) Rear Axle LH Hub Bolt Rear Brake Drum Sub–assy N m (kgf cm, ft lbf) : Specified torque C91593 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1961...
Page 500: Front Drive Shaft
DISCONNECT SPEED SENSOR FRONT LH(W/ ABS) Remove the sensor wire clamp. Remove the bolt, disconnect the sensor wire and front flexible hose No.1 from the shock absorber assy front LH. C83022 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1962...
Page 501 Be careful not to damage the boot and speed sensor rotor. REMOVE FRONT DRIVE SHAFT ASSY LH Using SST, remove the front drive shaft assy LH. 09520–01010, 09520–24010 (09520–32040) NOTICE: Be careful not to damage the oil seal. C83850 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1963...
Page 502 LH No.2 clamp and remove it. Using a side cutter, cut the front axle inboard joint boot LH clamp and remove it. F07391 DISCONNECT FR AXLE INBOARD JOINT BOOT 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1964...
Page 503 Mount the front drive outboard joint shaft assy LH in a soft jaw vise. Using a screwdriver and a hammer, remove the front wheel bearing dust deflector LH No.2. C91603 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1965...
Page 504 Using SST and a press, remove the front drive shaft dust cover. 09950–00020 F40648 REMOVE FRONT DRIVE SHAFT BEARING Using a snap ring pliers, remove the front drive shaft hole snap ring RH. C53236 F40209 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1966...
Page 505 RH reaches the specification, as shown in the illustration. 09527–10011 Distance: 1MZ–FE: 110.5 " 0.5 mm (4.3 " 0.02 in.) C92422 2AZ–FE: 91.5 " 0.5 mm (3.6 " 0.02 in.) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1967...
Page 506 Secure the 2 outboard joint boot clamps onto the boot. Place SST onto the outboard joint large boot clamp. 09521–24010 Tighten the SST so that the large clamp is pinched. NOTICE: Do not overtighten the SST. R10425 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1968...
Page 507 Distance: 207 " 2.0 mm (8.15 " 0.079 in.) Make sure that the front drive shaft damper RH is on the shaft groove. 207 " 2.0 mm (8.15 " 0.079 in.) F40646 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1969...
Page 508 Install the front axle inboard joint boot to the front drive outboard joint shaft assy LH. INSTALL FRONT AXLE INBOARD JOINT BOOT CLAMP Using pliers, pinch the claws to compress the front axle inboard joint boot LH No.2 clamp and engage the other claws. F07391 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1970...
Page 509 Drive shaft standard length: mm (in.) 1MZ–FE: 576.9 " 2.0 (22.713 " 0.079) 895.4 " 2.0 (35.252 " 0.079) 2AZ–FE: 591.2 " 2.0 (23.276 " 0.079) R00764 890 " 2.0 (35.039 " 0.079) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1971...
Page 510 F40142 INSTALL TIE ROD ASSY LH Install the tie rod assy LH to the steering knuckle LH with the nut. Torque: 49 N m (500 kgf cm, 36 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1972...
Page 511 Using chisel and hammer, stake the front axle hub LH nut. F40152 INSTALL FRONT WHEEL ADD AUTOMATIC TRANSAXLE FLUID(A/T TRANSAXLE)(See page 40–1) INSPECT AUTOMATIC TRANSAXLE FLUID(A/T TRANSAXLE) ADD MANUAL TRANSAXLE OIL(M/T TRANSAXLE) INSPECT MANUAL TRANSAXLE OIL(M/T TRANSAXLE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1973...
Page 512 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) CHECK ABS SPEED SENSOR SIGNAL(W/ ABS) w/ VSC (See page 05–452) w/o VSC (BOSCH MADE) (See page 05–363) w/o VSC (DENSO MADE) (See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1974...
Page 513 Remove the 2 bolts, nuts and steering knuckle LH with the front axle hub sub–assy LH. REMOVE LOWER BALL JOINT ASSY FRONT LH Remove the cotter pin and nut. C83023 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1975...
Page 514 LH. 09950–00020, 09950–60010 (09951–00410), 09950–70010 (09951–07100) F02261 REMOVE DISC BRAKE DUST COVER FRONT LH Using a torx wrench (T30), remove the 4 bolts and disc brake dust cover front LH. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1976...
Page 515 Place the disc brake dust cover front LH and using a torx wrench (T30), torque the 4 bolts. INSTALL FRONT AXLE HUB SUB–ASSY LH Using SST and a press, install the front axle hub sub– assy LH. 09608–32010, 09950–60020 (09951–00790), 09950–70010 (09951–07100) F40157 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1977...
Page 516 Be careful not to damage the speed sensor rotor. INSTALL FRONT SUSPENSION ARM SUB–ASSY LOWER NO.1 LH (See page 30–8) INSTALL TIE ROD ASSY LH (See page 30–8) INSTALL FRONT DISC 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1978...
Page 517 Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub. F40164 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1979...
Page 518 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) CHECK ABS SPEED SENSOR SIGNAL(W/ ABS) w/ VSC (See page 05–452) w/o VSC (BOSCH MADE) (See page 05–363) w/o VSC (DENSO MADE) (See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1980...
Page 519 Using a screwdriver to hold, install the hub bolt by torqu- ing the nut. F40171 INSTALL FRONT DISC INSTALL FRONT DISC BRAKE CALIPER ASSY LH(See page 30–21) INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1981...
Page 520 REMOVE REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE) DISCONNECT SKID CONTROL SENSOR WIRE(W/ ABS) REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and rear axle hub LH & bearing assy C83035 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1982...
Page 521 Maximum: 0.07 mm (0.0028 in.) If the backlash exceeds the maximum, replace the axle hub as- sembly. C83016 INSTALL REAR DISC(DISC REAR BRAKE TYPE) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1983...
Page 522 INSPECT AND ADJUST REAR WHEEL ALIGNMENT(See page 27–3) CHECK ABS SPEED SENSOR SIGNAL(W/ ABS) w/ VSC (See page 05–452) w/o VSC (BOSCH MADE) (See page 05–363) w/o VSC (DENSO MADE) (See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1984...
Page 523 DISCONNECT REAR SUSPENSION ARM ASSY NO.1 Remove the bolt, nut and rear suspension arm assy No.1 LH from the rear axle carrier sub–assy LH. HINT: While fixing the nut, turn and remove the bolt. C83018 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1985...
Page 524 Insert the bolt from the rear side of the vehicle and while fixing the nut, turn and install the bolt. C83017 INSTALL REAR AXLE HUB & BEARING ASSY LH (See page 30–28) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1986...
Page 525 INSPECT AND ADJUST REAR WHEEL ALIGNMENT(See page 27–3) CHECK ABS SPEED SENSOR SIGNAL(W/ ABS) w/ VSC (See page 05–452) w/o VSC (BOSCH MADE) (See page 05–363) w/o VSC (DENSO MADE) (See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1987...
Page 526 INSTALL REAR DISC BRAKE CALIPER ASSY LH(DISC REAR BRAKE TYPE)(See page 30–28) INSTALL REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE) INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1988...
Page 527: Brake System
It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION section. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 528 2. Pad or lining (Oily) 32–25 32–33 32–39 3. Piston (Frozen) 32–25 Brake pull 32–33 4. Disc (Scored) 32–25 32–33 5. Pad or lining (Cracked or distorted) 32–25 32–33 32–39 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1990...
Page 529 32–39 7. Pad or lining (Glanzed) 32–25 32–33 32–39 8. Anchor, tension or return spring (Faulty) 32–39 33–21 9. Anti–squeal shim (Damaged) 32–25 32–33 10.Shoe hold–down spring (Damaged) 32–39 33–21 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1991...
Page 530: Brake Fluid
Torque: 8.3 N m (85 kgf cm, 74 in. lbf) Repeat (b) and (c) until all the air in the fluid has been bled out. C80826 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1992...
Page 531 Torque: 8.3 N m (85 kgf cm, 74 in. lbf) F41006 CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3 F41007 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1993...
Page 532 (0.20 – 0.39 in.), check that stop lamp lights up. (11) TMMK made: Install the . (12) Install the instrument panel insert sub–assy lower LH and instrument panel finish panel sub–assy low- Push Rod Pedal Height F41699 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1994...
Page 533 Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 63 mm (2.48 in.) If incorrect, troubleshoot the brake system. Pedal Reserve Distance R00934 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1995...
Page 534 Brake Master Cylinder Push Rod Pin Brake Pedal Pad M/T models: Brake Pedal Pad N m (kgf cm, ft lbf) : Specified torque z Non–reusable part Lithium soap base glycol grease F41014 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1996...
Page 535 Return Spring Clip Brake Pedal Support 13 (130, 9) Sub–Assy M/T models: Brake Pedal Pad N m (kgf cm, ft lbf) : Specified torque Lithium soap base glycol grease C86251 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1997...
Page 536 Install the brake pedal support assy with the bolt and 4 nuts. Torque: Bolt: 20 N m (204 kgf cm, 15 ft lbf) Nut: 13 N m (130 kgf cm, 9 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1998...
Page 537 INSTALL BRAKE PEDAL RETURN SPRING INSTALL INSTRUMENT PANEL REINFORCEMENT (See page 71–12) CHECK AND ADJUST BRAKE PEDAL HEIGHT(See page 32–6) CHECK PEDAL FREE PLAY(See page 32–6) CHECK PEDAL RESERVE DISTANCE(See page 32–6) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 1999...
Page 538 REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER Pull out the master cylinder reservoir strainer. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB–ASSY Remove the screw and pull out the master cylinder reservoir sub–assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2000...
Page 539 Push in the piston and remove the snap ring with snap ring pliers. NOTICE: If pulled out at an angle, there is a possibility that the cylin- der bore could be damaged. F41707 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2001...
Page 540 Push in the piston and install the snap ring with snap ring pliers. Apply the lithium soap base grycol grease on a new O– ring and install the O–ring to the master cylinder. F40004 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2002...
Page 541 INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER Install the brake master cylinder reservoir strainer. INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY Install the brake master cylinder reservoir filler cap assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2003...
Page 542 Torque: 13 N m (130 kgf cm, 9 ft lbf) w/ ABS: Install the master cylinder sub–assy and 2–way with the 2 nuts. F40992 Torque: 13 N m (130 kgf cm, 9 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2004...
Page 543 F40991 FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) INSTALL AIR CLEANER ASSY CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2005...
Page 544 Check that there is ventilation from the booster to Ventilation engine, and no ventilation from the engine to the booster. If any fault is found, replace the vacuum check valve. No Ventilation C16481 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2006...
Page 545 2–way 15 (155, 11) 43 (440, 32) 13 (130, 9) 15 (155, 11) Front Brake Tube No.5 N m (kgf cm, ft lbf) : Specified torque z Non–reusable part F40997 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2007...
Page 546 (See page 71–12) REMOVE PUSH ROD PIN Remove the clip and push rod pin. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS Loosen the lock nut and remove the push rod clevis. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2008...
Page 547 Torque: 13 N m (130 kgf cm, 9 ft lbf) BR3753 INSTALL FRONT BRAKE TUBE NO.5 Using SST and install the front brake tube No.5. Torque: 15 N m (155 kgf cm, 11 ft lbf) 09023–00100 F40996 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2009...
Page 548 INSTALL BRAKE MASTER CYLINDER SUB–ASSY (See page 32–12) 09023–00100 INSTALL AIR CLEANER ASSY FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2010...
Page 549 32–23 BRAKE – BRAKE BOOSTER ASSY CHECK BRAKE FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL HEIGHT(See page 32–6) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2011...
Page 550: Front Brake
Anti–Squeal Shim No.1 Anti–Squeal Shim No.2 Front Disc Brake Pad N m (kgf cm, ft lbf) : Specified torque Non–reusable part Lithium soap base glycol grease Disc brake grease F41701 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2012...
Page 551 REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE Remove the upper side front disc brake pad support plate. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE Remove the bottom side front disc brake pad support plate. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2013...
Page 552 REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH Remove the 2 bolts and disc brake cylinder mounting LH. REMOVE CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot. R09298 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2014...
Page 553 INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt cleaned off. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2015...
Page 554 INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP INSTALL PISTON SEAL Apply the lithium soap base glycol grease on a new piston seal. Install the piston seal to the disc brake cylinder. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2016...
Page 555 INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE Install the upper side front disc brake pad support plate. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE Install the bottom side front disc brake pad support plate. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2017...
Page 556 BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2018...
Page 557: Rear Disc Brake
Anti Squeal Shim No.2 Adjusting Hole Plug Anti Squeal Shim No.1 N m (kgf cm, ft lbf) : Specified torque Non–reusable part Lithium soap base glycol grease Disc brake grease F41546 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2019...
Page 558 Anti–Squeal Shim No.2 Rear Disc Brake Pad Support Plate No.2 N m (kgf cm, ft lbf) : Specified torque Non–reusable part Lithium soap base glycol grease Disc brake grease F41706 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2020...
Page 559 Remove the rear disc brake pad support plate No.2. REMOVE REAR DISC BRAKE BUSH DUST BOOT TMC made: Remove the rear disc brake bush dust boot. TMMK made: Remove the 2 rear disc brake bush dust boots. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2021...
Page 560 INSPECT REAR DISC BRAKE PAD SUPPORT PLATE Make sure that they have sufficient rebound, no deformation cracks or wear, and have had all rust and dirt and cleaned off. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2022...
Page 561 Install the piston seal to the disc brake cylinder. INSTALL REAR DISC BRAKE DISC BRAKE PISTON Apply the lithium soap base glycol grease on the piston. Install the piston to the disc brake cylinder. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2023...
Page 562 F41562 Apply the lithium soap base glycol grease to seal surface of a 2 new bush dust boots. Install the 2 bush dust boots to the each cylinder slide pin. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2024...
Page 563 BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE INSTALL REAR WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2025...
Page 564 Spring Rear Brake Shoe Tension Spring Front Brake Shoe N·m (kgf·cm, ft·lbf) : Specified torque zNon–reusable part Rear Brake Drum Sub–assy Lithium soap base glycol grease High temperature grease F41708 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2026...
Page 565 SEPARATE PARKING BRAKE SHOE STRUT SET LH Using SST, disconnect the shoe return spring and sepa- rate the parking brake shoe strut set LH. 09703–30010 NOTICE: Do not damage the wheel cylinder boot. BR1534 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2027...
Page 566 Remove the adjusting lever spring. Remove the E–ring. Remove the automatic adjusting lever. F41684 REMOVE PARKING BRAKE SHOE LEVER LH Using screwdriver, remove the C–washer and parking brake shoe lever. F41685 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2028...
Page 567 Check the cylinder bore and piston for rust or scoring. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP REMOVE REAR DISC BRAKE BLEEDER PLUG TEMPORARY TIGHTEN REAR DISC BRAKE BLEEDER PLUG INSTALL REAR DISC BRAKE BLEEDER PLUG CAP 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2029...
Page 568 Install the parking brake shoe lever with a new C–washer. C86259 INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER Install the automatic adjust lever and automatic adjust le- ver spring to the rear brake shoe with the E–ring. C86258 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2030...
Page 569 CONNECT PARKING BRAKE SHOE STRUT SET LH Using SST, connect the tension spring to the front and rear brake shoe. 09703–30010 BR1534 INSTALL TENSION SPRING Connect the tension spring to the front brake shoe. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2031...
Page 570 Using a screwdriver, reduce the brake shoe adjustment by turning the adjuster. R00285 FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2032...
Page 571 CHECK PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE)(See page 33–2) ADJUST PARKING BRAKE LEVER TRAVEL (LEVER TYPE PARKING BRAKE) (See page 33–2) ADJUST PARKING BRAKE PEDAL TRAVEL (PEDAL TYPE PARKING BRAKE) (See page 33–2) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2033...
Page 572 INSPECT OTHER WHEEL OPERATION As in the same procedure, check the solenoids of other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2034...
Page 573 Wash off the brake fluied immediately if it comes into contact with a painted surface. REMOVE BRAKE ACTUATOR WITH BRACKET DENSO made: Using SST, disconnect the 6 brake lines from the actuator. BOSCH made: F40998 F41952 C86256 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2035...
Page 574 Install the 3 cushions and 2 holders to the brake actuator. Install the brake actuator to the bracket with the 2 nuts. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 575 To FL W/C From M/C 1st To RR W/C From M/C 1st BOSCH made: From M/C 2nd To FL W/C To FR W/C To RL W/C To RR W/C C84798 C86257 F41953 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2037...
Page 576 FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE CHECK OPERATION OF BRAKE ACTUATOR(See page 32–46) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2038...
Page 577 INSPECT OTHER WHEEL OPERATION As in the same procedure, check the solenoids of other wheels. HINT: Left front wheel: SFLH, SFLR Right rear wheel: SRRH, SRRR Left rear wheel: SRLH, SRLR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2039...
Page 578 Install the 3 cushions and 2 holders to the ABS & TRACTION actuator. Install the actuator to the bracket with the 2 nuts. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 579 FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER(See page 32–4) 09023–00100 BLEED BRAKE LINE(See page 32–4) CHECK FLUID LEVEL IN RESERVOIR CHECK BRAKE FLUID LEAKAGE CHECK OPERATION OF BRAKE ACTUATOR(See page 32–51) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2041...
Page 580 REMOVE LSPV GAUGE (SST) Remove the LSPV gauge (SST). 09709–29018 Install the bleeder plugs. Torque: 8.3 N m (85 kgf cm, 74 in. lbf) BLEED BRAKE SYSTEM (See page 32–4) CHECK FOR LEAKS 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2042...
Page 581 Torque: 15.2 N m (155 kgf cm, 11 ft lbf) F42704 FILL RESERVOIR WITH BRAKE FLUID BLEED MASTER CYLINDER (See page 32–4) 09023–00100 BLEED BRAKE LINE (See page 32–4) CHECK FLUID LEVEL IN RESERVOIR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2043...
Page 582 F41017 F41018 Remove the bolt and speed sensor FR LH. NOTICE: Do not stick and foreign matter on the sensor tip. C84803 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2044...
Page 583 Connect the speed sensor connector and clamp. F41016 INSTALL FRONT FENDER LINER LH INSTALL FRONT WHEEL Torque: 103 N m (1,050 kgf cm, 76 ft lbf) CHECK ABS SPEED SENSOR SIGNAL(See page 05–363 05–404 or 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2045...
Page 584 REMOVE REAR DISC BRAKE CALIPER ASSY, LH(See page 32–33) REMOVE REAR DISC REMOVE REAR AXLE HUB & BEARING ASSY LH Remove the 4 bolts and rear axle hub & bearing assy. C83035 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2046...
Page 585 Do not tap the skid control sensor with a hammer di- rectly. Check that the skid control sensor detection part is clean. Press in the skid control sensor straight and slowly. 09830–36010, 09950–60010 (09951–00650), F40304 09950–70010 (09951–07100) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2047...
Page 586 MEASURE VEHICLE HEIGHT(See page 27–3) INSPECT SIDE SLIP(See page 27–3) INSPECT CAMBER(See page 27–3) INSPECT TOE–IN(See page 27–3) ADJUST CAMBER AND TOE–IN(See page 27–3) CHECK ABS SPEED SENSOR SIGNAL(See page 05–363, 05–404 or 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2048...
Page 587 INSTALL RR CONSOLE BOX(See page 71–12) INSTALL CONSOLE PANEL UPPER REAR (See page 71–12) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION(See page 05–452) PERFORM DECELERATION SENSOR ZERO POINT CALIBRATION(See page 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2049...
Page 588 CENTER SPIRAL CABLE(See page 60–25) INSTALL STEERING WHEEL ASSY (See page 60–25) INSTALL HORN BUTTON ASSY (See page 60–25) INSPECT HORN BUTTON ASSY (See page 60–25) INSPECT SRS WARNING LIGHT(See page 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2050...
Page 589 INSTALL INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.1 (See page 71–25) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION(W/ VSC)(See page 05–452) PERFORM DECELERATION SENSOR ZERO POINT CALIBRATION(W/ VSC)(See page 05–452) CHECK VSC SENSOR SIGNAL(W/ VSC)(See page 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2051...
Page 590: Parking Brake System
33–12 33–16 Brake drag 33–19 3. Parking brake shoe clearance (Out of adjustment) 33–21 33–21 4. Parking brake shoe lining (Cracked or distorted) 33–21 5. Tension or return spring (Damaged) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2052...
Page 591 Lock Nut Tighten the lock nut. Torque: 5.0 N m (51 kgf cm, 44 in. lbf) Install the air duct rear No.1. Install the console panel upper. Adjusting Nut F40014 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2053...
Page 592 33–3 PARKING BRAKE – PARKING BRAKE PARKING BRAKE 3304Z–01 COMPONENTS Parking Brake Lever Sub–assy: Lock Nut 5.0 (51, 44 in. lbf) Parking Brake Lever Sub–assy 23 (235, 17) Adjusting Nut 23 (235, 17) Parking Brake Switch Assy 23 (235, 17) Parking Brake Cable Assy No.1 Air Duct Rear No.1 N m (kgf cm, ft lbf) : Specified torque...
Page 593 33–4 PARKING BRAKE – PARKING BRAKE Parking Brake Control Pedal Assy: 39 (398, 29) Parking Brake Control Pedal Assy Parking Brake Switch Assy Return Spring Damper Adjusting Nut Tension Spring Parking Brake Cable Assy No.1 Lock Nut 5.4 (55, 48 in. lbf) Clip 39 (398, 29) 39 (398, 29)
Page 594 33–5 PARKING BRAKE – PARKING BRAKE Parking Brake Cable: Parking Brake Control Pedal Models: Parking Brake Cable Assy No.4 Consol Box Mounting Bracket No.2 12.5 (128, 9) 8.0 (85, 73 in. lbf) 8.0 (85, 73 in. lbf) 12.5 (128, 9) Parking Brake Cable Assy No.3 Parking Brake Equalizer 5.4 (55, 48 in.
Page 595 33–6 PARKING BRAKE – PARKING BRAKE Parking Brake Assy: Rear Disc Brake Caliper Assy LH 47 (480, 35) Shoe Hold–down Spring Pin C–Washer Shim Parking Brake Shoe Return Parking Brake Shoe Tension Spring Parking Brake Shoe Strut Compression Spring Parking Brake Shoe Lever Parking Brake Shoe Strut LH Shoe Hold–down Spring...
Page 596 33–7 PARKING BRAKE – PARKING BRAKE LEVER SUB–ASSY PARKING BRAKE LEVER SUB–ASSY 3304U–01 REPLACEMENT HINT: COMPONENTS: See page 71–7 33–3 REMOVE CONSOLE PANEL UPPER (See page 71–12) REMOVE AIR DUCT REAR NO.1 (See page 71–12) REMOVE PARKING BRAKE LEVER SUB–ASSY Disconnect the parking brake switch connector.
Page 597 33–8 PARKING BRAKE – PARKING BRAKE LEVER SUB–ASSY ADJUST PARKING BRAKE LEVER TRAVEL(See page 33–2) Author : Date : 2059...
Page 598 Remove the 2 bolts, nut and parking brake control pedal assy. F41009 REMOVE PARKING BRAKE CABLE ASSY NO.1 Remove the lock nut, adjusting nut, clip and parking brake assy No. 1. F41010 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2060...
Page 599 INSTALL PARKING BRAKE CONTROL PEDAL ASSY Install the parking brake control pedal assy with the 2 bolts and nut. Torque: 39 N m (398 kgf cm, 29ft lbf) Connect the parking brake switch connector. F41009 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2061...
Page 600 INSTALL FRONT DOOR SCUFF PLATE LH (See page 71–12) INSTALL COMBINATION METER ASSY (See page 71–12) INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page 71–12) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33–2) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2062...
Page 601 33–12 PARKING BRAKE – PARKING BRAKE CABLE ASSY NO.1 PARKING BRAKE CABLE ASSY NO.1 3304W–01 REPLACEMENT HINT: COMPONENTS: See page 71–7 33–3 REMOVE FRONT DOOR SCUFF PLATE LH(PEDAL TYPE PARKING BRAKE) (See page 71–12) REMOVE COWL SIDE TRIM SUB–ASSY LH(PEDAL TYPE PARKING BRAKE) (See page 71–12) REMOVE INSTRUMENT PANEL SUB–ASSY UPPER(PEDAL TYPE PARKING BRAKE) (See page 71–12)
Page 602 33–13 PARKING BRAKE – PARKING BRAKE CABLE ASSY NO.1 Remove the lock nut, adjusting nut, clip and disconnect the parking brake cable assy No.1 from the parking brake control pedal assy. F41010 Remove the 2 nuts, 2 bolts, clip and parking brake cable assy No.1.
Page 603 33–14 PARKING BRAKE – PARKING BRAKE CABLE ASSY NO.1 INSTALL PARKING BRAKE CABLE ASSY NO.1(PEDAL TYPE PARKING BRAKE) Install the parking brake cable assy No.1 with the 2 nuts, 2 bolts and clip. F41687 Install the parking brake cable assy No.1 with the clip, ad- justing nut and lock nut to the parking brake control pedal assy.
Page 604 33–15 PARKING BRAKE – PARKING BRAKE CABLE ASSY NO.1 Install the parking brake cable assy No.1 with the adjust- ing nut and lock nut to the parking brake lever assy. Torque: 5.0 N m (51 kgf cm, 44 in. lbf) F41000 INSTALL YAWRATE SENSOR(W/ VSC) (See page 32–61)
Page 605 Remove the 2 bolts and disconnect the parking brake cable assy No.3 from the backing plate. Remove the 2 nuts, bolt and parking brake cable assy No.3. C90471 C90462 F41690 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2067...
Page 606 Torque: 5.4 N m (55 kgf cm, 48 in. lbf) APPLICATION HIGH TEMPERATURE GREASE(See page 33–21) INSTALL PARKING BRAKE SHOE(See page 33–21) CHECK PARKING BRAKE INSTALLATION(See page 33–21) INSTALL REAR BRAKE DRUM SUB–ASSY(DRUM REAR BRAKE TYPE) (See page 32–39) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2068...
Page 607 Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(PEDAL TYPE PARKING BRAKE)(See page 33–2) INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL(LEVER TYPE PARKING BRAKE) (See page 33–2) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2069...
Page 608 Install the parking brake cable No.4 with the 2 bolts. Torque: 12.5 N m (128 kgf cm, 9 ft lbf) Connect the parking brake cable assy No.4 to the parking brake equolizer. C90464 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2070...
Page 609 INSTALL CONSOLE BOX CARPET (See page 71–12) INSTALL CONSOLE PANEL UPPER REAR (See page 71–12) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(See page 33–2) PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION(W/ VSC)(See page 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2071...
Page 610 Using a needle-nose pliers, remove the 2 return tension springs. F40318 REMOVE PARKING BRAKE SHOE STRUT COMPRESSION SPRING Slide out the front shoe and remove the compression spring. REMOVE PARKING BRAKE SHOE STRUT LH 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2072...
Page 611 BR0828 APPLICATION HIGH TEMPERATURE GREASE Apply the high temperature grease to the shoe attached surface of backing plate. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2073...
Page 612 INSTALL PARKING BRAKE SHOE STRUT LH INSTALL PARKING BRAKE SHOE STRUT COMPRESSION SPRING INSTALL PARKING BRAKE SHOE RETURN TENSION SPRING Using a needle nose pliers, install the 2 return tension springs. F40318 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2074...
Page 613 Torque: 103 N m (1,050 kgf cm, 76 ft lbf) INSPECT AND ADJUST PARKING BRAKE PEDAL TRAVEL(PEDAL TYPE PARKING BRAKE)(See page 33-2 INSPECT AND ADJUST PARKING BRAKE LEVER TRAVEL(LEVER TYPE PARKING BRAKE) (See page 33-2 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2075...
Page 614: Automatic Transaxle Fluid
Take it out and check that the fluid level is in the HOT posi- tion. D25120 If there are leaks, it is necessary to repair or replace O–rings, FIPGs, oil seals, plugs or other parts. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2076...
Page 615 Thoroughly clean all components to remove all the material being come off. Clean both sealing surfaces with a non–residue solvent. Parts must be reassembled within 10 minutes of application. Otherwise, the packing (FIPG) ma- terial must be removed and reapplied. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2077...
Page 616 Remove the clip and disconnect the control cable from the control cable bracket. D25415 REMOVE PARK/NEUTRAL POSITION SWITCH ASSY Disconnect the park/neutral position switch connector. Remove the nut, washer and control shaft lever. D09644 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2078...
Page 617 Torque: 6.9 N m (70 kgf cm, 61 in. lbf) Temporarily install the control shaft lever. D09639 Turn the lever counterclockwise until it stops, then turn it clockwise 2 notches. Remove the control shaft lever. D09641 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2079...
Page 618 Temporarily install the control cable to the control shaft le- ver with the nut. D25414 Install the control cable and a new clip to the bracket. Connect the park/neutral position switch connector. D25415 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2080...
Page 619 INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 40–7) INSTALL ENGINE UNDER COVER LH INSTALL INTAKE AIR RESONATOR SUB–ASSY INSTALL AIR CLEANER HOSE NO.1 INSTALL AIR CLEANER ASSY INSTALL ENGINE COVER SUB–ASSY NO.1 INSTALL BATTERY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2081...
Page 620 Hold the switch in position and tighten the 2 bolts. Torque: 5.4 N m (55 kgf cm, 48 in. lbf) After adjustment, perform the inspection described in Groove step 1. D25514 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2082...
Page 621 Remove the 2 bolts and 2 clamps. C90565 DISCONNECT WIRE HARNESS Remove the bolt and wire harness. C83204 REMOVE STARTER ASSY Disconnect the connector. Remove the 2 bolts and starter assy. C90567 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2083...
Page 622 REMOVE OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler outlet tube No.1. 09023–12700 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket FR. D25420 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2084...
Page 623 Install the torque converter clutch to the automatic trans- axle. Using vernier calipers, measure the dimension ”A” be- tween the transaxle fitting part and the converter fitting part of the drive plate. C83119 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2085...
Page 624 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 3 bolts to the automatic transaxle. Torque: 64 N m (653 kgf cm, 47 ft lbf) D25420 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2086...
Page 625 C92540 INSTALL OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, tighten the oil cooler outlet tube No.1 . 09023–12700 Torque: 34.3 N m (350 kgf cm, 25 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2087...
Page 626 Torque: 11.8 N m (122 kgf cm, 9 ft lbf) C90566 INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–8) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–8) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(See page 14–155) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2088...
Page 627 Remove the 2 bolts and 2 clamps. C90565 DISCONNECT WIRE HARNESS Remove the bolt and wire harness. C83204 REMOVE STARTER ASSY Disconnect the connector. Remove the 2 bolts and starter assy. C90567 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2089...
Page 628 REMOVE OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, disconnect the oil cooler outlet tube No.1. 09023–12700 REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket FR. D25420 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2090...
Page 629 Install the torque converter clutch to the automatic trans- axle. Using vernier calipers, measure the dimension ”A” be- tween the transaxle fitting part and the converter fitting part of the drive plate. C83051 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2091...
Page 630 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket FR and 3 bolts to the automatic transaxle. Torque: 64 N m (653 kgf cm, 47 ft lbf) D25420 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2092...
Page 631 Torque: 34.3 N m (350 kgf cm, 25 ft lbf) C92540 INSTALL OIL COOLER OUTLET TUBE NO.1 Using SST and spanner, tighten the oil cooler outlet tube No.1. 09023–12700 Torque: 34.3 N m (350 kgf cm, 25 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2093...
Page 632 Torque: 11.8 N m (122 kgf cm, 9 ft lbf) C90566 INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–8) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–8) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(See page 14–22) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2094...
Page 633 If the ATF is discolored and/or has a foul odor, com- pletely stir the ATF in the torque converter clutch D25367 and drain the ATF with the torque converter facing to up. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2095...
Page 634 Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or ring gear is dam- aged, replace the drive plate. C81014 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2096...
Page 635 Install the transmission revolution sensor with the bolt. Torque: 11.3 N m (115 kgf cm, 8 ft lbf) HINT: Make sure of the manufacturer’s name. Connect the transmission revolution sensor connector. C90570 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2097...
Page 636 Connect the transmission revolution sensor connector. C90569 INSTALL AIR CLEANER HOSE NO.1 INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf) INSTALL ENGINE COVER SUB–ASSY NO.1 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2098...
Page 637: Speed Sensor
Install the speed sensor with the bolt. Torque: 11.3 N m (115 kgf cm, 8 ft lbf) HINT: Make sure of the manufacturer’s name. Connect the speed sensor connector. C90570 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2099...
Page 638 Connect the speed sensor connector. C90569 INSTALL AIR CLEANER HOSE NO.1 INSTALL AIR CLEANER ASSY Torque: 5.0 N m (51 kgf cm, 44 in. lbf) INSTALL ENGINE COVER SUB–ASSY NO.1 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2100...
Page 639 Disconnect the 5 shift solenoid valve connectors. Remove the bolt and lock plate, and disconnect the ATF temperature sensor. D25591 REMOVE TRANSMISSION WIRE Disconnect the transmission wire connector. Remove the bolt and transmission wire. C50009 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2101...
Page 640 Torque: 7.8 N m (80 kgf cm, 69 in. lbf) NOTICE: Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after applica- tion. C83111 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2102...
Page 641 40–28 AUTOMATIC TRANSMISSION / TRANS – TRANSMISSION WIRE ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID(See page 40–1) INSTALL ENGINE UNDER COVER LH 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2103...
Page 642 D25591 REMOVE VALVE BODY OIL STRAINER ASSY Remove the 3 bolts and oil strainer. NOTICE: Be careful as some fluid will come out with the oil strainer. D09179 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2104...
Page 643 Bolt A: 6.6 N·m (67 kgf·cm, 58 in. lbf) Bolt B: 10.8 N·m (110 kgf·cm, 8 ft ·lbf) Bolt length: Bolt A: 12 mm (0.47 in.) Bolt B: 45 mm (1.77 in.) D02938 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2105...
Page 644 Coat a new O–ring with ATF. Install the O–ring to the oil strainer. C69150 Install the oil strainer with the 3 bolts. Torque: 10.8 N m (110 kgf cm, 8 ft lbf) D09179 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2106...
Page 645 Because the bolts should be seal bolts, apply seal packing to bolts and tighten them within 10 minutes after applica- tion. C83111 ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID(See page 40–1) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2107...
Page 646 Using SST and a hammer, drive in a new oil seal. 09316–60011 (09316–00011) Oil seal drive in depth: 0 " 0.5 mm (0 " 0.020 in.) Coat the lip of the oil seal with MP grease. D25829 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2108...
Page 647 Torque: 103 N m (1,050 kgf cm, 76 ft lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID(See page 40–1) CHECK ABS SPEED SENSOR SIGNAL(See page 05–363, 05–404 or 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2109...
Page 648 Using SST and a hammer, drive in a new oil seal. 09316–60011 (09316–00011) Oil seal drive in depth: 0 " 0.5 mm (0 " 0.020 in.) Coat the lip of the oil seal with MP grease. D25833 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2110...
Page 649 Torque: 103 N m (1,050 kgf cm, 76 ft lbf) ADD AUTOMATIC TRANSAXLE FLUID INSPECT AUTOMATIC TRANSAXLE FLUID(See page 40–1) CHECK ABS SPEED SENSOR SIGNAL(See page 05–363, 05–404 or 05–452) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2111...
Page 650: Shift Lock System
10 – 14 5 (IG) – 1 (E) Ignition switch OFF 3 (STP) – 1 (E) Depress brake pedal 10 – 14 3 (STP) – 1 (E) Release brake pedal 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2112...
Page 651 – SHIFT LOCK SYSTEM Using an ohmmeter, measure the resistance at terminal E (1) and body ground. C63995 Terminal Measuring Condition Specified Value 1 (E) – Body ground Always Continuity 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2113...
Page 652 CONTROL SHIFT Disconnect the floor shift cable from the transmission floor shift assy. REMOVE FLOOR SHIFT ASSY Disconnect the shift lock control computer connector. Disconnect the transmission control switch connector. C92346 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2114...
Page 653 Lower the position indicator slide cover. Remove the 2 screws and shift lever knob from the shift lever. C90592 REMOVE POSITION INDICATOR SLIDE COVER Remove the position indicator slide cover from the shift lever. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2115...
Page 654 REMOVE POSITION INDICATOR HOUSING UPPER Using a screwdriver, release the 4 claws and remove the position indicator housing upper. C90596 REMOVE POSITION INDICATOR HOUSING COVER REMOVE POSITION INDICATOR SLIDE COVER 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2116...
Page 655 Install the 4 shift lever No.1 inserts to the shift lever control plate. INSTALL SHIFT LOCK CONTROL UNIT ASSY Install the shift lock control unit assy and toggle lever sup- port pin. C90599 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2117...
Page 656 Install the control position indicator housing upper. HINT: Fit the claws securely. C90596 INSTALL SHIFT LOCK RELEASE BUTTON COVER Install the shift lock release button cover to the position in- dicator housing upper. C90595 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2118...
Page 657 Install the indicator lamp wire to the position indicator housing lower. Install the indicator lamp wire harness and connector as C90590 shown in the illustration. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2119...
Page 658 Only in the case of reusing the shift lock control unit assy. Accessory tool C92314 C92571 C92745 Using a screwdriver, unlock the claw of the lock key of au- tomatic adjustment part. C90586 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2120...
Page 659 INSTALL CONSOLE PANEL UPPER INSTALL INSTRUMENT PANEL CUP HOLDER TRAY(W/O ASHTRAY) INSTALL INSTRUMENT PANEL ASH RECEPTACLE ASSY(W/ ASHTRAY) INSTALL RR CONSOLE BOX INSTALL CONSOLE BOX CARPET INSTALL CONSOLE PANEL UPPER REAR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2121...
Page 660 Start the engine and make sure that the vehicle moves forward when shifting the lever from N to D position and moves rearward when shifting it to R position. D25119 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2122...
Page 661 REMOVE INSTRUMENT PANEL ASH RECEPTACLE ASSY(W/ ASHTRAY) (See page 71–12) REMOVE CONSOLE PANEL UPPER (See page 71–12) REMOVE CONSOLE BOX FRONT (See page 71–12) REMOVE AIR DUCT REAR NO.2 (See page 55–29) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2123...
Page 662 C90583 Disconnect the cable clamp. Turn the ignition switch to ACC or ON. C90584 Using a screwdriver, remove the cable from the upper bracket. C90585 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2124...
Page 663 Set the accessory tool to the shift lock control unit assy. Accessory tool parts No.: TMC Made: 33693–33010 Accessory tool TMMK Made: 33693–06010 TMMK Made: Accessory tool C92314 C92571 C92745 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2125...
Page 664 INSTALL CONSOLE BOX FRONT INSTALL CONSOLE PANEL UPPER INSTRUMENT PANEL CUP HOLDER TRAY(W/O ASHTRAY) INSTRUMENT PANEL ASH RECEPTACLE ASSY(W/ ASHTRAY) INSTALL RR CONSOLE BOX INSTALL CONSOLE BOX CARPET INSTALL CONSOLE PANEL UPPER REAR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2126...
Page 665 INSTALL CONNECTOR COVER(W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50–6) INSTALL STEERING WHEEL COVER LOWER NO.3(3 SPOKE STEERING WHEEL ASSY) (See page 50–6) CONNECT BATTERY NEGATIVE TERMINAL INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2127...
Page 666 Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. D25414 Remove the clip and disconnect the control cable from the control cable bracket. D25415 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2128...
Page 667 Install it with the uneven surface facing to up. C90580 Fit the claws securely. Connect the control cable to the control cable clamp. C90579 Install the control cable and a new clip to the bracket. D25415 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2129...
Page 668 INSTALL AIR CONDITIONING RADIATOR ASSY ADJUST SHIFT LEVER POSITION(See page 40–47) INSPECT SHIFT LEVER POSITION(See page 40–47) INSTALL INTAKE AIR RESONATOR SUB–ASSY INSTALL AIR CLEANER HOSE NO.1 INSTALL AIR CLEANER ASSY INSTALL BATTERY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2130...
Page 669 3. Shift key spring (Damaged) 41–15 1. Locking ball spring (Damaged) 41–15 2. Shift fork (Worn) 41–15 Jumps out of gear 3. Gear (Worn or damaged) 41–15 4. Bearing (Worn or damaged) 41–15 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2131...
Page 670: Manual Transaxle Oil
Check for oil leakage when the oil level is low. Install the transmission filler plug and new gasket. Torque: 49 N m (500 kgf cm, 36 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2132...
Page 671 Using SST and a hammer, install the oil seal. 09608–10010, 09950–70010 (09951–07200) Drive in depth: 0 " 0.5 mm (0 " 0.020 in.) NOTICE: Be careful not to damage the oil seal lip. D25722 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2133...
Page 672 0 – 5 mm (0 – 0.20 in.) D25304 INSPECT AND ADJUST MANUAL TRANSAXLE OIL(See page 41–2) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) CHECK ABS SPEED SENSOR SIGNAL(See page 05–404) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2134...
Page 673 The projecting part of the cable outer should face up- ward when the select cable is installed. Make sure that after installation the cable outer lock is projecting from A shown in the illustration. D26290 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2135...
Page 674 INSTALL AIR DUCT REAR NO.2 (See page 55–29) INSTALL AIR DUCT REAR NO.1 (See page 55–29) REMOVE CONSOLE BOX FRONT (See page 71–12) REMOVE RR CONSOLE BOX REMOVE FLOOR SHIFT SHIFT LEVER KNOB SUB–ASSY 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2136...
Page 675 Fit 3 projections of the grommet into 3 holes of the retainer. Retainer Install the 2 retainer set bolts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf) Grommet Shift Cable D26291 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2137...
Page 676 INSTALL AIR BAG SENSOR ASSY CENTER (See page 60–56) INSTALL AIR CONDITIONING RADIATOR ASSY (See page 55–29) INSTALL INSTRUMENT PANEL SAFETY PAD SUB–ASSY (See page 71–12) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2138...
Page 677 Fit 3 projections of the grommet into 3 holes of the retainer. Retainer Install the 2 retainer set bolts. Torque: 5.0 N m (51 kgf cm, 44 in. lbf) Grommet Shift Cable D26291 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2139...
Page 678 INSTALL AIR BAG SENSOR ASSY CENTER (See page 60–56) INSTALL AIR CONDITIONING RADIATOR ASSY (See page 55–29) INSTALL INSTRUMENT PANEL SAFETY PAD SUB–ASSY (See page 71–12) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2140...
Page 679 Remove the bolt and engine wire No.3. C92366 REMOVE WIRE HARNESS CLAMP Remove the 2 bolts and 2 wire harness clamps. C90604 REMOVE STARTER ASSY Remove the 2 bolts and starter assy. C90605 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2141...
Page 680 Remove the 10 bolts. Separate and remove the transaxle from the engine. INSTALL MANUAL TRANSAXLE ASSY Align the input shaft with the clutch disc and install the transaxle to the engine. D25747 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2142...
Page 681 Torque: 18 N m (184 kgf cm, 13 ft lbf) C90607 INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET Install the engine mounting bracket with the 3 bolts. Torque: 64 N m (653 kgf cm, 47 ft lbf) C90606 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2143...
Page 682 Connect the back–up lamp switch connector and starter connector. C92365 INSTALL FRONT DRIVE SHAFT ASSY LH (See page 30–8) INSTALL FRONT DRIVE SHAFT ASSY RH (See page 30–8) INSTALL ENGINE ASSEMBLY WITH TRANSAXLE(See page 14–22) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2144...
Page 683 REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB–ASSY Remove the bolt and speedometer driven hole cover. REMOVE SELECTING BELL CRANK ASSY Remove the 2 bolts and selecting bell crank assy from manual transmission case. C90198 C92831 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2145...
Page 684 FIX MANUAL TRANSAXLE ASSY Using wooden blocks, fix the manual transaxle assy. C87963 REMOVE LOCK BALL ASSY NO.1 Remove the lock ball assy No.1 from the manual trans- mission case. C87964 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2146...
Page 685 Remove the manual transmission filler plug and gasket from the manual transmission case. C70824 REMOVE DRAIN (MTM) PLUG SUB–ASSY Remove the drain (MTM) plug sub–assy and gasket from the manual transmission case. C87967 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2147...
Page 686 Disengage the double meshing of the gear. C87969 INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator, inspect the 5th gear thrust clear- ance. Standard clearance: 0.10 – 0.65 mm (0.0039 – 0.0256 in.) C69517 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2148...
Page 687 Using SST, remove the transmission clutch hub No.3 and gear shift fork No.3 from the input shaft. 09950–30012 (09951–03010, 09953–03010, 09954–03010), 09950–50013 (09957–04010), 09950–60010 (09951–00280) C69777 REMOVE 5TH GEAR Remove the 5th gear from the input shaft. C69454 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2149...
Page 688 C69458 REMOVE INPUT SHAFT REAR BEARING SHAFT SNAP RING Using a snap ring expander, remove the input shaft rear bearing shaft snap ring from the input shaft. C87970 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2150...
Page 689 REMOVE CLUTCH TUBE BRACKET NO.1 Remove the 3 bolts and remove the clutch tube bracket. REMOVE MANUAL TRANSMISSION CASE Remove the 3 bolts of the manual transaxle case side. C83226 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2151...
Page 690 Using a hexagon wrench (6 mm), remove the reverse re- strict pin plug from the manual transmission case. C70521 Using a pin punch (φ 5 mm), remove the slotted pin and reverse restrict pin assy. C69467 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2152...
Page 691 Remove the 2 bolts and reverse shift arm bracket from the manual transaxle case. C83230 REMOVE GEAR SHIFT FORK SHAFT NO.1 Remove the shift fork bolt from the gear shift fork No.1. C83231 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2153...
Page 692 No.1. C83234 Remove the gear shift fork shaft No.2 and gear shift head Shift Fork Shaft No.1 from the manual transaxle case. No.2 Shift Head No.1 C87976 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2154...
Page 693 Remove the gear shift fork No.2 from the input shaft assy. Shift Fork No.2 C87979 REMOVE INPUT SHAFT ASSY Incline the output shaft then remove the input shaft from the manual transaxle case. C83240 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2155...
Page 694 09612–65014 (09612–01040, 09612–01050) C87980 REMOVE FRONT TRANSAXLE CASE OIL SEAL Using SST, remove the manual transaxle case oil seal from the manual transaxle case. 09612–65014 (09612–01040, 09612–01050) C87981 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2156...
Page 695 09308–00010 C87984 REMOVE FRONT TRANSAXLE CASE COVER OIL SEAL Using a screwdriver, remove the front transaxle case cov- er oil seal. HINT: Tape the screwdriver tip before use. C87985 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2157...
Page 696 (inner race) from front differential case. 09950–00020, 09950–00030, 09950–40011 (09957–04010), 09950–60010 (09951–00490) C90344 REMOVE CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST, remove the shift & select lever shaft bimetal formed bush. 09319–60020 C90202 C92835 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2158...
Page 697 Using a screwdriver, remove the synchronizer pull ring snap ring. Remove the synchronizer pull ring, synchronizer outer ring No.5, synchronizer inner ring No.5 and synchronizer middle ring No.5 from the synchronizer ring No.5. C69508 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2159...
Page 698 INSTALL SYNCHRONIZER PULL RING Install the synchronizer middle ring No.5, synchronizer ring outer No.5 and synchronizer pull ring to the synchro- nizer ring inner No.5. using a screwdriver, fix with snap ring. C69514 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2160...
Page 699 INSTALL CONTROL SHAFT COVER BIMETAL FORMED BUSH Using SST, install the shift & select lever shaft bimetal formed bush. 09950–60010 (09951–00180), 09950–70010 (09951–07100) Clearance: 0.081 – 0.149 mm (0.0032 – 0.0059 in.) C90203 C92836 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2161...
Page 700 Using SST and a hammer, install FR differential case front tapered roller bearing (outer race). 09950–60020 (09951–00890), 09950–70010 (09951–07100) NOTICE: C87992 Install the case shim as thick as the removed one. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2162...
Page 701 Align the projection of the output shaft with the transmis- sion grooves and install them. C69709 INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a hammer, install the output shaft front bearing (outer race). 09950–60020 (09951–00730), 09950–70010 (09951–07100) C87995 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2163...
Page 702 RR with 7 screws to the manual transmission case. Torque: 42 N m (428 kgf cm, 31 ft lbf) Install the new output rear set nut to the output shaft. C83256 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2164...
Page 703 Remove the output shaft rear set nut from the output shaft. Using a torx socket wrench (T45), remove the 7 screws and bearing retainer RR from the manual transmission case. C83258 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2165...
Page 704 C83227 Remove the output shaft assy from the front manual transaxle case. C83254 ADJUST TAPERED POLLER BEARING PRELOAD Install differential case assy to the manual transaxle case. C83242 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2166...
Page 705 90564–56061 2.30 (0.0906) 90564–56062 2.35 (0.0925) 90564–56063 2.40 (0.0945) 90564–56064 2.45 (0.0965) 90564–56065 2.50 (0.0984) 90564–56066 2.55 (0.1004) 90564–56067 2.60 (0.1024) 90564–56068 2.65 (0.1043) 90564–56069 2.70 (0.1063) 90564–56070 2.75 (0.1083) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2167...
Page 706 No.1 to the manual transaxle case. 09950–60010 (09951–00420), 09950–70010 (09951–07150) Coat the lip of front transaxle case oil seal No.1 with MP grease. Clearance: 1 – 2 mm (0.0394 – 0.0787 in.) C87997 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2168...
Page 707 INSTALL INPUT SHAFT ASSY Apply gear oil to each sliding part of the input shaft assy. With the output shaft assy leaned, install the input shaft assy to the manual transaxle case. C83240 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2169...
Page 708 Install the gear shift head No.1 to the gear shift fork shaft Shift Head No.2. No.1 Apply gear oil to each sliding part of the gear shift fork shaft No.2, install it to the manual transaxle case. C88002 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2170...
Page 709 Install the gear shift fork shaft No.1 to the manual trans- Shift Fork axle case. Shaft No.1 C88003 Install the shift fork bolt to the gear shift fork No.1. Torque: 24 N m (245 kgf cm, 18 ft lbf) C83231 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2171...
Page 710 INSTALL REVERSE RESTRICT PIN ASSY Using a pin punch (φ 5mm), install the reverse restrict pin and reverse restrict pin assy. Clearance: 12.5 – 13.5 mm (0.492 – 0.531 in.) C69759 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2172...
Page 711 Install within 10 minutes after applying FIPG. C69755 Install the manual transmission case and 14 bolts to the manual transaxle case. Torque: 29 N m (296 kgf cm, 21 ft lbf) C83227 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2173...
Page 712 No.1. C69758 Using a brass bar and hammer, install the shift fork shaft snap ring to the gear shift fork shaft No.2. C69757 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2174...
Page 713 09950–30012 (09951–03010, 09953–03010, 09954–03010, 09956–03030, 09955–03011) C88005 103. INSTALL 5TH GEAR NEEDLE ROLLER BEARING Coat the 5th gear needle roller bearing with gear oil, install it to the input shaft. C69455 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2175...
Page 714 Clearance: 0.1 mm or less Snap ring: mm (in.) Part No. Thickness Mark 1.75 – 1.80 90520–27061 (0.0689 – 0.0709) 1.80 – 1.85 90520–27062 (0.0709 – 0.0728) C69763 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2176...
Page 715 Using a dial indicator, inspect the 5th gear thrust clear- ance. Standard clearance: 0.10 – 0.65 mm (0.0039 – 0.0260 in.) C69517 108. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT Engage the gear double meshing. C69266 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2177...
Page 716 110. INSTALL DRAIN (MTM) PLUG SUB–ASSY Install the drain plug sub–assy with new gasket to the manual transmission case. Torque: 49 N m (500 kgf cm, 36 ft lbf) C87967 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2178...
Page 717 Torque: 49 N m (500 kgf cm, 36 ft lbf) C87965 115. INSTALL LOCK BALL ASSY NO.1 Install the lock ball assy No.1 to the manual transmission case. Torque: 29 N m (296 kgf cm, 21 ft lbf) C87964 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2179...
Page 718 121. INSTALL RELEASE FORK SUPPORT Using a deep socket wrench, install the release fork sup- port to the manual transaxle case. Torque: 47.1 N m (480 kgf cm, 35 ft lbf) C83809 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2180...
Page 719 Part No. 08887–01806, RELEASE HUB GREASE or equivalent Apply clutch spline grease to the input shaft spline. 123. INSTALL CLUTCH RELEASE FORK SUB–ASSY Install the clutch release fork sub – assy to the input shaft. C69774 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2181...
Page 720 0.009 – 0.053 KOYO made (0.0004 – 0.0021) 0.009 – 0.051 NSK made (0.0004 – 0.0020) C69548 If the clearance exceeds the maximum, replace the 4th gear needle roller bearing. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2182...
Page 721 4th gear. 09950–00020 NOTICE: Do not tighten SST excessively. C92867 REMOVE 4TH GEAR NEEDLE ROLLER BEARING Remove the 4th gear needle roller bearing from the input shaft. C69551 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2183...
Page 722 No.2 and 3rd gear from the input shaft. 09950–00020 NOTICE: Do not tighten SST excessively. C92868 REMOVE 3RD GEAR NEEDLE ROLLER BEARING Remove the 3rd gear needle roller bearing from the input shaft. C69617 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2184...
Page 723 INSPECT INPUT SHAFT Using V–block and dial indicator, measure the shaft run out. Maximum run out: 0.03 mm (0.0012 in.) If the run out exceeds the maximum, replace the input shaft. C69620 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2185...
Page 724 Coat the 4th gear cone with gear oil. Turn the synchroniz- er ring No.3 in one direction while pushing it to the 4th gear cone. Check that the ring locks. C69623 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2186...
Page 725 INSPECT TRANSMISSION HUB SLEEVE NO.2 Inspect the sliding condition between transmission hub sleeve No.2 and transmission clutch hub No.2. Inspect tip of spline gear on the transmission hub sleeve No.2 for wear. C67843 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2187...
Page 726 Using a screwdriver, install the synchromesh shifting key C69660 to the input shaft. INSTALL 3RD GEAR NEEDLE ROLLER BEARING Coat the 3rd gear bearing with gear oil, install it to the in- put shaft. C69617 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2188...
Page 727 (0.0945 – 0.0965) 2.45 – 2.50 90520–34006 (0.0965 – 0.0984) 2.50 – 2.55 90520–34007 (0.0984 – 0.1004) 2.55 – 2.60 90520–34008 (0.1004 – 0.1024) 2.60 – 2.65 90520–34009 (0.1024 –0.1043) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2189...
Page 728 Using SST and a press, install the input shaft rear radial ball bearing to the input shaft. NOTICE: Make the groove on the bearing face to the rear and install. Make sure that the 3rd gear rotates. C92857 09608–06041 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2190...
Page 729 0.009 – 0.053 KOYO made (0.0004 – 0.0021) 0.009 – 0.051 NSK made (0.0004 – 0.0020) C69549 If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2191...
Page 730 0.10 – 0.35 mm (0.0039 – 0.0138 in.) C69547 INSPECT 4TH GEAR THRUST CLEARANCE Using a feeler gauge, measure the 4th gear thrust clear- ance. Standard clearance: 0.10 – 0.57 mm (0.0039 – 0.0224 in.) C69546 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2192...
Page 731 0.009 – 0.053 KOYO made (0.0004 – 0.0021) 0.009 – 0.051 NSK made (0.0004 – 0.0020) C69638 If the clearance is out of the specification, replace the 1st gear needle roller bearing. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2193...
Page 732 Remove the output gear spacer from the output shaft. C69641 REMOVE 2ND GEAR Using SST and a press, remove the 3rd driven gear and 2nd gear from the out put shaft. 09950–00020 C92859 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2194...
Page 733 Remove the 2nd gear bush from the output shaft. C69646 REMOVE 2ND GEAR BUSH BALL Using a magnetic finger, remove the 2nd gear bush ball from the output shaft. C83814 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2195...
Page 734 Do not tighten SST excessively. C92861 REMOVE REVERSE GEAR Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from the trans- mission clutch hub No.1. C69652 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2196...
Page 735 Coat the cone of the 2nd gear with gear oil, check that it does not turn in the both circumference directions while pushing it to the synchronizer ring No.2. C69657 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2197...
Page 736 0.15 – 0.35 mm (0.0059 – 0.0138 in.) {A – B} If the clearance is out of the specification, replace the reverse gear and gear shift fork No.1 with the new one. C70507 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2198...
Page 737 Align the synchronizer ring set No.1 with the hole of 1st gear and install. C69649 INSTALL 1ST GEAR NEEDLE ROLLER BEARING Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft. C69650 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2199...
Page 738 Coat the 2nd gear bush with gear oil, install it to the output shaft. C69646 INSTALL 2ND GEAR BEARING SPACER Coat the 2nd gear bearing spacer with gear oil, install it to the output shaft. C69645 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2200...
Page 739 Using SST and a press, install the 3rd driven gear to the output shaft. 09608–00071, 09950–60010 (09951–00320), 09950–70010 (09951–07100) C92863 INSTALL OUTPUT GEAR SPACER Install the output gear spacer to the output shaft. C69641 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2201...
Page 740 0.009 – 0.053 KOYO made (0.0004 – 0.0021) 0.009 – 0.051 NSK made (0.0004 – 0.0020) C69638 If the clearance is out of the specification, replace the 1st gear needle roller bearing. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2202...
Page 741 0.10 – 0.35 mm (0.0039 – 0.0138 in.) C69637 INSPECT 1ST GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st gear thrust clear- ance. Standard clearance: 0.25 – 0.40 mm (0.0098 in. – 0.0157 in.) C69636 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2203...
Page 742 SUB–ASSY Remove the nut, washer and selecting bellcrank No.2 plate washer from the selecting bellcrank No.2. C69532 Remove the selecting bellcrank support sub–assy from the selecting bell crank No.2. C69799 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2204...
Page 743 Using 2 screwdrivers and a hammer, remove the select seat snap ring from the shift & select lever shaft. NOTICE: Do not damage the shift & select lever shaft. C69535 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2205...
Page 744 REMOVE SELECT SPRING NO.1 SEAT SHAFT SNAP RING Using 2 screwdrivers and a hammer, remove the select spring No.1 seat shaft snap ring. NOTICE: Do not damage the shaft. C69539 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2206...
Page 745 28.5 " 0.50 mm (1.122 " 0.020 in.) C92886 INSTALL SELECT SPRING NO.1 SEAT SHAFT SNAP RING Using a brass bar and a hammer, install the select spring No.1 seat shaft snap ring. C69540 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2207...
Page 746 No.2 to the shift & select lever shaft. Using a brass bar and a hammer, install the select seat snap ring to the shift & select lever shaft. C69536 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2208...
Page 747 Install the selecting bellcrank support sub–assy to the se- lecting bellcrank No.2. C69799 Install the selecting bellcrank No.2 plate washer, washer and nut. Torque: 12 N m (122 kgf cm, 9 ft lbf) C69532 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2209...
Page 748 Install the selecting bellcrank dust cover No.1 to the se- lecting bellcrank No.2. C69530 INSTALL CONTROL SHIFT LEVER BUSH Install the control shift lever bush to the selecting bell crank No.2. C69529 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2210...
Page 749 Fixing the front differential pinion to the front differential case side. Using a dial indicator, measure the front differ- ential side gear backlash. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) C83562 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2211...
Page 750 Using a micrometer, measure the thickness of the front differential pinion thrust washer. Minimum thickness: 0.9 mm (0.035 in.) If the thickness smaller than the minimum, replace the front dif- ferential pinion thrust washer. C68517 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2212...
Page 751 C83565 INSTALL FRONT DIFFERENTIAL PINION SHAFT STRAIGHT PIN Using a pin punch and a hammer, install the front differen- tial pinion shaft straight pin to the front differential case. C83567 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2213...
Page 752 Clean the contact surface differential case. C92888 Aligning the matchmarks, quickly install the front differen- tial ring gear to the front differential case. Matchmarks Torque: 106 N m (1,081 kgf cm, 78 ft lbf) C70796 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2214...
Page 753 41–85 MANUAL TRANSMISSION/TRANSAXLE – DIFFERENTIAL CASE ASSY (E351) INSTALL SPEEDOMETER DRIVE (MTM) GEAR Install the speedometer drive (MTM) gear to the front dif- ferential case. C70795 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2215...
Page 754: Clutch System
6. Clutch disc (Runout of excessive) 42–14 7. Clutch disc (Lining broken) 42–14 8. Clutch disc (Dirty or burned) 42–14 9. Clutch disc (Oily) 42–14 10.Clutch disc (Lack of spline grease) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2216...
Page 755 Using a small screwdriver, remove the E–ring. Remove the compression spring. D26274 REMOVE CLUTCH PEDAL SUB–ASSY Remove the clutch pedal spring. Mount the clutch pedal assy in a soft jaw vise. D26275 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2217...
Page 756 D26277 REMOVE CLUTCH PEDAL TURNOVER BUSH Over Center Spring Cap REMOVE OVER CENTER SPRING CAP Clutch Pedal Turnover Bush D26278 REMOVE CLUTCH PEDAL PAD REMOVE CLUTCH PEDAL NO.1 CUSHION D26280 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2218...
Page 757 Clutch Pedal Turnover Bush MP Grease D26278 INSTALL CLUTCH PEDAL BUSH Apply MP grease to both side of 2 new bushes. Install the 2 bushes to the clutch pedal sub–assy. MP Grease D26277 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2219...
Page 758 Connect the clevis to the clutch pedal assy with the hole pin. HINT: Install the hole pin from the left side of the vehicle. MP Grease D26271 Install the clip to the hole pin. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2220...
Page 759 INSTALL COMBINATION METER ASSEMBLY(See page 71–25) INSTALL INSTRUMENT CLUSTER FINISH PANEL (See page 71–12) INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY (See page 42–7) INSPECT CLUTCH START SWITCH ASSY (See page 42–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2221...
Page 760 Start the engine and idle the engine. Without depressing the clutch pedal, slowly shift the Release Point shift lever into reverse position until the gears con- tact. Full Stroke End Position CL0512 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2222...
Page 761 If the distance is not as specified, perform the following opera- tions. Check pedal height. Check push rod play and pedal free play. Bleed the clutch line. Check the clutch cover assy and disc assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2223...
Page 762 Remove the inlet union and grommet. Loosen the lock nut, and remove the push rod clevis. Remove the lock nut from the push rod. Remove the boot from the cylinder body. D05850 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2224...
Page 763 (0.059 – 0.138 in.) D05852 INSTALL CLUTCH MASTER CYLINDER ASSY Install the clutch master cylinder assy with the 2 nuts. Torque: 11.8 N m (120 kgf cm, 9 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2225...
Page 764 CHECK AND ADJUST BRAKE PEDAL HEIGHT(See page 32–6) INSPECT AND ADJUST CLUTCH PEDAL SUB–ASSY (See page 42–7) CHECK BRAKE FLUID LEAKAGE CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2226...
Page 765 Install the piston to the cylinder body. NOTICE: Be careful not to damage the inside of the cylinder body. Install the push rod to the cylinder body. Install the boot to the cylinder body. CL0672 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2227...
Page 766 Fill the brake reservoir tank with clutch fluid and bleed clutch system. Torque: 8.3 N m (85 kgf cm, 73 in. lbf) CHECK CLUTCH FLUID LEAKAGE CHECK FLUID LEVEL IN RESERVOIR 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2228...
Page 767: Clutch Unit
INSPECT CLUTCH DISC ASSY Using vernier calipers, measure the rivet head depth. Maximum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc assy. Q06032 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2229...
Page 768 Turn the release bearing assy by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing assy. N00414 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2230...
Page 769 Install the release fork support to the manual transaxle assy. Torque: 47.1 N m (480 kgf cm, 35 ft lbf) INSTALL RELEASE BEARING HUB CLIP Install the release bearing hub clip to the release bearing assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2231...
Page 770 NOTICE: After the installation, move the folk forward and backward to check that the release bearing slides smoothly. INSTALL CLUTCH RELEASE FORK BOOT INSTALL MANUAL TRANSAXLE ASSY (See page 41–11) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2232...
Page 771 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 assy. Clutch Start Switch Assy D26283 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2233...
Page 772 5.0 " 0.5 mm (0.197 " 0.020 in.) Check the continuity between terminals when the switch is ON and OFF. Switch position Condition ON (pushed) Continuity OFF (free) No continuity CL0477 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2234...
Page 773 Install the clutch start switch assy with the nut. Torque: 15.68 N m (160 kgf cm, 12 ft lbf) D26284 Connect the clutch start switch assy connector. INSPECT CLUTCH START SWITCH ASSY (See page 42–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2235...
Page 774: Steering System
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 notice for the supplemental restraint system (See page 60–1). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 775 5. Power steering gear 51–29 1. Power steering fluid level (Low) 51–3 2. Steering system joints (Worn) – Abnormal noise 3. Power steering vane pump 51–8 51–17 4. Power steering gear 51–29 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2237...
Page 776 Stop the vehicle and face the tires straight ahead. Freeplay Rock the steering wheel gently up and down by your hand, check the steering wheel freeplay. Maximum freeplay: 30 mm (1.18 in.) 30 mm (1.18 in.) F08857 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2238...
Page 777 Draw a new line on the masking tape or the steering Steering Wheel wheel as shown in the illustration. Measure the distance between the 2 lines on the masking tape of the steering wheel. F16017 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2239...
Page 778 Make sure that the difference in length between RH and LH tie rod ends and rack end screws are within 1.5 mm (0.059 in.). Install the RH and LH boot clips. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2240...
Page 779 Door Scuff Plate Clamp 35.3 (360, 26) Cowl Side Trim Sub–assy Heater to Foot Duct No.3 Instrument PNL Insert Sub–assy LWR LH N m (kgf cm, ft lbf) : Specified torque C92312 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2241...
Page 780 Switch Bracket Assy Ignition or Starter Steering Column Tube Switch Assy z Snap Ring z Steering Main Shaft Radial Ball Bearing Steering Main Shaft Assy z Non–reusable part C92313 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2242...
Page 781 Ignition Switch Lock Cylinder Assy Un–lock Warning Switch Assy Steering Column Clamp Upper Steering Column Upper w/ Switch Bracket Assy Ignition or Starter Switch Assy Steering Column Assy C92652 C92313 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2243...
Page 782 Disconnect the horn connector. (4 Spoke steering wheel) NOTICE: When removing the horn button assy, take care not to pull the airbag wire harness. 4 Spoke 3 Spoke Steering Wheel Steering Wheel C92270 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2244...
Page 783 Using a screwdriver, disconnect the floor shift parking lock cable from the upper bracket. C90585 REMOVE SPIRAL CABLE SUB–ASSY (See page 60–25) REMOVE HEADLAMP DIMMER SWITCH ASSY Disconnect the connector and remove the headlamp dimmer switch assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2245...
Page 784 Loosen the bolt B. C92274 Place matchmarks on the steering intermediate shaft sub–assy and steering gear assy. Matchmarks Remove the bolt and disconnect the steering intermedi- ate shaft sub–assy. F40352 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2246...
Page 785 REMOVE STEERING SLIDING YOKE SUB–ASSY Place matchmarks on the steering sliding yoke sub–assy and steering main shaft assy. Remove the bolt and steering sliding yoke sub–assy from the steering main shaft assy. Matchmarks C92362 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2247...
Page 786 C92363 REMOVE STEERING COLUMN CLAMP UPPER REMOVE STEERING MAIN SHAFT ASSY Using a snap ring expander, remove the steering main shaft snap ring (outer side). C92358 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2248...
Page 787 Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition or starter switch assy to the steering column bracket assy with the 2 screws. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 788 Install the steering main shaft assy to the steering column tube. C92359 Using a snap ring expander, install a new steering main shaft snap ring (outer side) to the steering main shaft assy. C92358 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2250...
Page 789 Align the matchmark with the one on the steering sliding yoke sub–assy and steering main shaft assy. Install the steering sliding yoke sub–assy with the bolt. Torque: 35.3 N m (360 kgf cm, 26 ft lbf) Matchmarks C92362 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2251...
Page 790 Align the matchmarks on the intermediate shaft sub–assy and steering gear assy. Install the steering intermediate shaft sub–assy with the bolt. Torque: 35.3 N m (360 kgf cm, 26 ft lbf) F40352 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2252...
Page 791 CHECK KEY INTERLOCK OPERATION(See page 40–37) INSTALL STEERING COLUMN COVER Install the steering column cover with the 2 screws. C92273 INSTALL INSTRUMENT CLUSTER FINISH PANEL INSTALL HEATER TO FOOT DUCT NO.3 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2253...
Page 792 Align the matchmark with the one on the steering wheel assy and steering main shaft assy. Install the steering wheel assy with the set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Connect the connector. INSPECT HORN BUTTON ASSY (See page 60–15) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2254...
Page 793 Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) C92272 INSTALL STEERING WHEEL COVER LOWER NO.2 (See page 50–6) INSTALL STEERING WHEEL COVER LOWER NO.3(W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50–6) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2255...
Page 794 INSTALL CONNECTOR COVER(W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50–6) INSTALL STEERING WHEEL COVER LOWER NO.3(3 SPOKE STEERING WHEEL ASSY) (See page 50–6) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2256...
Page 795 Disconnect the horn connector. (4 Spoke steering wheel) NOTICE: When removing the horn button assy, take care not to pull the airbag wire harness. 4 Spoke 3 Spoke Steering Wheel Steering Wheel C92270 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2257...
Page 796 Remove the 2 screws and steering column cover upper. C92273 REMOVE STEERING COLUMN COVER UPR DISCONNECT FLOOR SHIFT PARKING LOCK CABLE ASSY Using a screwdriver, disconnect the floor shift parking lock cable from the upper bracket. C90585 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2258...
Page 797 Loosen the bolt B. C92274 Place matchmarks on the steering intermediate shaft sub–assy and steering gear assy. Matchmarks Remove the bolt and disconnect the steering intermedi- ate shaft sub–assy. F40352 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2259...
Page 798 Pull the transponder key amplifier toward the rear of the vehicle with the claw open. NOTICE: Take care not to apply excessive force to prevent the case C92306 from being damaged. REMOVE KEY CYLINDER LAMP ASSY(W/ ILLUMINATED ENTRY SYSTEM) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2260...
Page 799 Remove the 2 screws and ignition or starter switch assy from the steering column bracket assy. INSTALL IGNITION OR STARTER SWITCH ASSY Install the ignition or starter switch assy to the steering column bracket assy with the 2 screws. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 800 Push the trasponder key amplifier up and connect it to the upper bracket. NOTICE: Take care not to push the amplifier up with excessive force C92306 to prevent it from being damaged. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2262...
Page 801 Align the matchmarks on the intermediate shaft sub–assy and steering gear assy. Install the steering intermediate shaft sub–assy with the bolt. Torque: 35.3 N m (360 kgf cm, 26 ft lbf) F40352 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2263...
Page 802 INSTALL STEERING COLUMN COVER UPR INSTALL STEERING COLUMN COVER LWR Install the steering column cover with the 2 screws. C92273 INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSY INSTALL HEATER TO FOOT DUCT NO.3 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2264...
Page 803 Align the matchmark with the one on the steering wheel assy and steering main shaft assy. Install the steering wheel assy with the set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Connect the connector. INSPECT HORN BUTTON ASSY (See page 60–15) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2265...
Page 804 Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) C92272 INSTALL STEERING WHEEL COVER LOWER NO.2 (See page 50–6) INSTALL STEERING WHEEL COVER LOWER NO.3(W/O STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50–6) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2266...
Page 805 INSTALL CONNECTOR COVER(W/ STEERING PAD SWITCH 4 SPOKE STEERING WHEEL) (See page 50–6) INSTALL STEERING WHEEL COVER LOWER NO.3(3 SPOKE STEERING WHEEL ASSY) (See page 50–6) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2267...
Page 806: Power Steering System
Before servicing (in- cluding removal or installation of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint system (See page 60–1). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 807 5. Power steering gear 51–29 1. Power steering fluid level (Low) 51–3 2. Steering system joints (Worn) – Abnormal noise 3. Power steering vane pump 51–8 51–17 4. Power steering gear 51–29 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2269...
Page 808 Check that the fluid level is within the HOT LEVEL range on the reservoir cap. If the fluid is cold, check that it is within the COLD F40898 LEVEL range. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2270...
Page 809 Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to raise fluid temperature. Fluid temperature: 75 – 80 °C (167 – 176 °F) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2271...
Page 810 Lock Position NOTICE: PS Gear Open Do not maintain lock position for more than 10 se- conds. PS Vane Pump Do not let the fluid temperature become too high. Z15500 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2272...
Page 811 Take the tire type, pressure and contact surface into consider- ation before making your diagnosis. Install the steering wheel assy set nut. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) Install the horn button assy (See page 50–9, 50–22). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2273...
Page 812 Vane Pump Rotor 22 (224, 16) Vane Pump Plate Vane Pump Cam Ring N m (kgf cm, ft lbf) : Specified torque z Non–reusable part Power steering fluid F41489 F41621 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2274...
Page 813 FIX VANE PUMP ASSY Using SST, hold the vane pump assy on the vise through the aluminum plate. 09630–00014 (09631–00132) HINT: As follow the necessity, remove and install SST for holding. F41481 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2275...
Page 814 Remove the vane pump side plate front from the vane pump housing front. Remove the O–ring from the vane pump side plate front. C65368 Remove the O–ring from the vane pump housing front. C65369 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2276...
Page 815 INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. F41493 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2277...
Page 816 Oil Seal F08480 INSTALL VANE PUMP SIDE PLATE FRONT Coat a new O–ring with power steering fluid and install it to the vane pump housing front. C65369 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2278...
Page 817 Install the vane pump rotor with the inscribed mark facing outward. Round End Coat 10 vane pump plates with power steering fluid. Install the vane pump plates with the round end facing outward. F08484 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2279...
Page 818 Coat a new O–ring with power steering fluid and install it to the power steering suction port union. Install the power steering suction port union with the bolt. Torque: 12 N m (122 kgf cm, 9 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 819 INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT FENDER LINER RH INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) BLEED POWER STEERING FLUID INSPECT FLUID LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2281...
Page 820 Vane Pump Housing Oil Seal z Vane Pump Shaft Snap Ring Vane Pump Pulley N m (kgf cm, ft lbf) : Specified torque z Non–reusable part Power steering fluid F41917 F41597 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2282...
Page 821 Vane Pump Cam Ring Vane Pump Plate W/Pulley Shaft Sub–assy zVane Pump Shaft Snap Ring N m (kgf cm, ft lbf) : Specified torque z Non–reusable part Power steering fluid F41488 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2283...
Page 822 F41598 REMOVE VANE PUMP V BELT Loosen the 2 bolts and remove the vane pump V belt. REMOVE VANE PUMP ASSY Remove the 2 bolts and vane pump assy. F41599 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2284...
Page 823 Using a screwdriver, remove the vane pump shaft snap ring from the vane pump shaft. Remove the vane pump rotor. C65312 REMOVE VANE PUMP SHAFT(TYPE A VANE PUMP) REMOVE W/PULLEY SHAFT SUB–ASSY(TYPE B VANE PUMP) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2285...
Page 824 If it is more than the maximum, replace the vane pump assy. Micrometer TYPE A VANE PUMP Vane Pump Shaft Bushing Vane pump Housing Front TYPE B VANE PUMP Bushing Vane pump W/Pulley Shaft Housing Front Sub–assy F41618 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2286...
Page 825 Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole by its own weight. Except Sport Grade: R11288 F41490 F41529 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2287...
Page 826 Using SST and a press, install the new vane pump hous- ing oil seal. 09950–60010 (09951–00330), 09950–70010 (09951–07100) NOTICE: Oil Seal W03541 Make sure that the vane pump housing oil seal is installed F41624 facing the correct direction. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2288...
Page 827 INSTALL VANE PUMP CAM RING Align the holes of the vane pump cam ring with 2 straight Inscribed pins, and install the vane pump cam ring with inscribed Mark mark facing outward. F40341 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2289...
Page 828 Temporarily install the pulley set nut. Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.27 N m (2.8 kgf cm, 2.4 in. lbf) or less F41573 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2290...
Page 829 Install the vane pump pulley to the vane pump shaft. Using SST, stop the vane pump pulley rotation and install the nut. 09960–10010 (09962–01000, 09963–01000) Torque: 44 N m (449 kgf cm, 32 ft lbf) F41600 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2291...
Page 830 INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT FENDER LINER RH INSTALL FRONT WHEEL RH Torque: 103 N m (1,050 kgf cm, 76 ft lbf) BLEED POWER STEERING FLUID INSPECT FLUID LEAK 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2292...
Page 831 Front Stabilizer Bar Bush No.1 Front Stabilizer Bar 74 (755, 55) 74 (755, 55) N m (kgf cm, ft lbf) : Specified torque z Non–reusable part * For use with SST F41605 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2293...
Page 832 N m (kgf cm, ft lbf) : Specified torque 58.5 (597, 43) z Non–reusable part L Precoated part Molybdenum disulfide lithium base grease Power steering fluid MP grease * For use with SST F41889 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2294...
Page 833 N m (kgf cm, ft lbf) : Specified torque z Non–reusable part z Steering Rack Boot No.2 Clamp Molybdenum disulfide lithium base grease Power steering fluid * For use with SST F41890 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2295...
Page 834 Loosen the bolt. C92274 Place matchmarks on the steering intermediate shaft sub–assy and rack & pinion power steering gear assy. Matchmarks Remove the bolt and separate the steering intermediate shaft sub–assy. F41595 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2296...
Page 835 Using SST, disconnect the return tube assy from the rack & pinion power steering gear assy. 09023–12700 F41578 Using SST, disconnect the pressure feed tube assy from the rack & pinion power steering gear assy. 09023–12700 F42897 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2297...
Page 836 Remove the 2 O–rings from the left turn pressure tube. REMOVE STEERING RIGHT TURN PRESSURE TUBE Using SST, renove the right turn pressure tube. 09023–38200 Remove the 2 O–rings from the right turn pressure tube. F41497 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2298...
Page 837 Remove the 2 steering rack boot clips. REMOVE STEERING RACK BOOT NO.2 CLAMP Using pliers, remove the steering rack boot No.2 clamp. NOTICE: Be careful not to damage the steering rack boot No.2. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2299...
Page 838 Using 2 SSTs, remove the 2 steering rack ends sub–assy and 2 claw washers. 09922–10010 NOTICE: Use SST 09922–10010 in the direction shown in the il- lustration. Securely hold the power steering rack end with a SST. F41526 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2300...
Page 839 Using SST, hold the control valve and remove the nut. 09616–00011 F41503 Wind vinyl tape around the serrated part of the control Vinyl Tape valve. Remove the dust cover from the control valve housing. F41504 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2301...
Page 840 UPPER OIL SEAL Using SST and a press, remove the control valve upper bearing and power steering control valve upper oil seal from the control valve housing. 09950–70010 (09951–07150), 09950–60010 (09951–00250) F40911 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2302...
Page 841 Using a dial indicator, check the power steering rack for runout and for teeth wear and damage. Maximum runout: 0.3 mm (0.012 in.) Check the back surface for wear and damage. ZX9355 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2303...
Page 842 Coat a new rack steering piston ring with power steering fluid. C03629 Install the rack steering piston ring to the power steering rack, and settle it down with your fingers. N00401 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2304...
Page 843 Make sure that the rack bush oil seal is installed facing in the correct direction. Coat a new O–ring with power steering fluid and install it F40543 to the power steering rack bush. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2305...
Page 844 Using SST and a press, install the power steering control valve upper oil seal. 09950–70010 (09951–07150), 09950–60010 (09951–00180, 09952–06010, 09951–00320) F40912 Using SST and a press, install the control valve upper bearing. 09950–70010 (09951–07150), 09950–60010 (09951–00180, 09952–06010, 09951–00340) F40913 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2306...
Page 845 Wind vinyl tape around the serration part of the control valve. Install the control valve housing to the rack housing with the 2 bolts. Torque: 21 N m (214 kgf cm, 15 ft lbf) F41512 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2307...
Page 846 RH and LH steering rack ends sub–assy. Using SST, torque the rack guide spring cap. 09631–10021 Torque: 25 N m (254 kgf cm, 18 ft lbf) F41514 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2308...
Page 847 Precheck the total preload. Preload (turning): 1.2 – 1.5 N m (12.2 – 15.3 kgf cm, 10.6 – 13.3 in. lbf) Remove the RH and LH steering rack ends sub–assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2309...
Page 848 Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). Fulcrum Length F41576 Using a brass bar and a hammer, stake the claw washer. NOTICE: Avoid any impact to the power steering rack. C35928 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2310...
Page 849 Screw the lock nut and tie rod assy LH onto the steering rack end sub–assy until the matchmarks are aligned. HINT: After adjusting toe–in, torque the lock nut. INSTALL TIE ROD ASSY RH HINT: Install the RH side by the same procedures with LH side. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2311...
Page 850 INSTALL RACK & PINION POWER STEERING GEAR ASSY Install the rack & pinion power steering gear assy with the 2 bolts and nuts. Torque: 70 N m (714 kgf cm, 52 ft lbf) F41496 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2312...
Page 851 This torque value is effective in the case that SST is paral- lel to a torque wrench. F41586 Install the return tube clamp with the nut. Torque: 9.8 N m (100 kgf cm, 86 in. lbf) F41602 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2313...
Page 852 Torque: 35.3 N m (360 kgf cm, 26 ft lbf) Install the steering column hole cover No.2 to the steering hole cover No.1. Connect the clamp to the steering column hole cover No.1 and tighten the bolt. C92274 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2314...
Page 853 (See page 50–9, 50–22) INSTALL HORN BUTTON ASSY (See page 50–9, 50–22) INSPECT AND ADJUST FRONT WHEEL ALIGNMENT(See page 26–5) INSPECT STEERING WHEEL CENTER POINT INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2315...
Page 854: Air Conditioning System
BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insuffi- cient cooling, poor fuel economy, engine overheating etc. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2316...
Page 855 1. Illumination light system – Brightness does not changes when rheostat volume or light con- 2. A/C cotrol assy 55–3 trol switch it turned. 3. Wire harness or connector – 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2317...
Page 856 If operation is not as specified, replace the pressure switch. 1,226 kpa (12.5 kgf/cm 178 psi) (Continuity) 1,520 kpa (No continuity) (15.5 kgf/cm 220 psi) I30291 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2318...
Page 857 Below 1.0 V Blower switch: OFF Ignition switch: ON Open Below 1.0 V R/F switch: FRESH RECIRCULATION (A10 A32) Ignition switch: ON Open Below 1.0 V R/F switch: RECIRCULATION FRESH (A11 A32) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2319...
Page 858 Evaporator temp.: 0 _C (32 _F) 15 _C (59 _F) 2.0 – 2.4 1.4 – 1.8 V (B32 E28) A/CI Body ground Ignition switch: ON Below 1.0 V Magnetic clutch: OFF (B33 Body ground) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2320...
Page 859 1.34 Mpa (32 kgf cm22, 2,455 psi) *1: 2AZ–FE If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2321...
Page 860 Specified condition Constant 1 – 2 Continuity Apply B + between 3 – 5 Continuity terminals 1 and 2. If continuity is not as specified, replace the magnet–clutch relay. E50315 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2322...
Page 861 Connected terminal Position FOOT/DEF FOOT FACE If operation is not as specified, replace the servomotor. I31408 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2323...
Page 862 5 and negative (–) lead to terminal 2, then check that the arm turns to ”FRS” side smoothly. If operations are not as specified, replace the mode damper servomotor. I31407 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2324...
Page 863 Connect the positive (+) lead from the battery to terminal 2 and negative (–) to terminal 1, then check that the motor operation smoothly. If operation is not as specified, replace the blower motor. I31402 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2325...
Page 864 Continuity 3 – 4 Apply B + between termi- 3 – 5 Continuity nals 1 and 2. If continuity is not as specified, replace the heater blower motor relay. E32993 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2326...
Page 865 Immediately after air conditioning is turned off, refrigerant foams and then becomes Correct – clear *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2327...
Page 866 (3) Supply proper amount of new state is restored. refrigerant 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2328...
Page 867: Insufficient Cooling
Corrective Action S Pressure low on both low and high pressure sides Refrigerant flow obstructed by dirt Receiver clogged Replace condenser S Frost on pipe from condenser to in receiver unit 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2329...
Page 868 S Insufficient cooling of condenser insufficient condenser fins rpm is lowered and supply proper amount of re- clogged at cooling fan frigerant 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2330...
Page 869 Trouble in expansion valve Check expansion valve S Frost or large amount of dew on S Expansion valve opened too piping on low pressure side wide 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2331...
Page 870 0.22 (2.25) Blower LO Zone 0.2 (2.0) 0.2 (2.1) 1.25 (12.8) 0.14 (1.5) 1.32 (13.5) Pressure on HI 0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) pressure side MPa (kgf/cm I30081 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2332...
Page 871 " 50 g ("1. 76 oz.) Over charged Hight Pressure Point where bubbles disappear Refrigerant Amount Sub–cool system I30082 WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2333...
Page 872: Refrigerant Line
Cooler Refrigerant Suction Hose No. 1 9.8 (100, 87 in. lbf) 5.4 (55, 49 in. lbf) Cooler Refrigerant Discharge Hose No. 1 N m (kgf cm, ft lbf) : Specified torque I31330 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2334...
Page 873 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) 5.4 (55, 49 in. lbf) Cooler Refrigerant Discharge Hose No. 1 N m (kgf cm, ft lbf) : Specified torque I31331 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2335...
Page 874 ”Used belt” refers to a belt which has been used on a run- DENSO Boroughs ning engine for 5 minutes or more. After installing the drive belt, check that it fits properly in the ribbed grooves. N01881 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2336...
Page 875 Tighten the bolt A. Torque: 17.5 N m (178 kgf cm, 12 ft lbf) Bolt A Tighten the bolt C. Torque: 58 N m (591 kgf cm, 43 ft lbf) I30370 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2337...
Page 876 55–23 HEATER & AIR CONDITIONER – AIR CONDITIONER CONTROL ASSEMBLY AIR CONDITIONER CONTROL ASSEMBLY 550BV–01 COMPONENTS Heater Control Housing Sub–assy Air Conditioning Control Bulb Heater Control Base Sub–assy I31555 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2338...
Page 877 INSTALL AIR CONDITIONING CONTROL BULB Install the air conditioning control bulb to the heater con- trol base sub–assy. Bulb position: Position Part No. 90010 – 03054 90010 – 03055 90010 – 03056 I31535 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2339...
Page 878 55–25 HEATER & AIR CONDITIONER – AIR CONDITIONING PANEL SUB–ASSY AIR CONDITIONING PANEL SUB–ASSY 550BY–01 COMPONENTS Heater Control Housing I31579 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2340...
Page 879 55–25 REMOVE AIR CONDITIONING PANEL SUB–ASSY (See page 71–12) REMOVE HEATER CONTROL HOUSING Remove the 2 screws. Release the 10 fitting claws, remove the heater control housing. 10 Claws I31580 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2341...
Page 880 No. 1 N m (kgf cm, ft lbf) : Specified torque 1.5 (15, 12 in. lbf) Compressor Oil ND–OIL 8 or equivalent z Non–reusable part Air Conditioning Radiator Assy I31556 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2342...
Page 881 Auto A/C Model: Piping Clamp Air Duct Sub–assy Heater Radiator Unit Sub–assy : Specified torque N m (kgf cm, ft lbf) Compressor Oil ND–OIL 8 or equivalent z Non–reusable part I31557 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2343...
Page 882 I06919 DISCONNECT COOLER REFRIGERANT LIQUID PIPE A 09870–00025 HINT: Disconnect cooler refrigerant liquid pipe A in the same way as the cooler refrigerant suction hose No. 1. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2344...
Page 883 Remove the screw, air duct rear No. 2 and console box mounting bracket No. 1. I31496 REMOVE CONSOLE BOX DUCT NO.1(AUTO AIR CONDITIONER) Remove the clip and console box duct No. 1. I31497 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2345...
Page 884 Remove the bolt and screw. Remove the nut and instrument panel brace sub–assy No. 1. I31501 REMOVE INSTRUMENT FINISH PANEL RETAINER LOWER Remove the 2 bolts and instrument finish retainer lower. I31502 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2346...
Page 885 Remove the 2 nuts, bolt and instrument panel brace sub– assy No. 2. I31504 REMOVE HEATER TO FOOT DUCT NO.3 Remove the clip and heater to foot duct No. 3. I31499 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2347...
Page 886 Remove the 3 nuts and driver side junction block. I31505 Remove the 2 nuts and steering side connector block. I31577 Release the 2 clamps. Remove the 3 bolts, disconnect the steering column assy. 2 Clamps I31506 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2348...
Page 887 – AIR CONDITIONING RADIATOR ASSY REMOVE INSTRUMENT PANEL REINFORCEMENT Disconnect the 7 clamps and the wire harness. 7 Clamps I31507 Remove the 3 nuts, disconnect the 3 earth wires. I31649 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2349...
Page 888 Remove the screw, clamp and blower connector holder. Clamp I31563 Disconnect the 6 clamps and the wire harness. 6 Clamps I31772 Remove the 2 screws, 2 nuts and blower assy. I31509 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2350...
Page 889 Prepare a support plate and waste to catch the leaked cool- ant. 2 Claws I31513 REMOVE AIRMIX DAMPER SERVO SUB–ASSY Remove the 3 screws and air mix damper servo sub– assy. I31514 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2351...
Page 890 No. 1. I31517 REMOVE COOLER THERMISTOR NO.1 REMOVE COOLER EVAPORATOR SUB–ASSY NO.1 Auto A/C model: Release the fitting claw, remove the 3 screws and air duct sub–assy. Claw I31518 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2352...
Page 891 Install the cooler evaporator sub–assy No. 1 to the heater case RH. Install the heater case LH with the 12 screws. I31519 Auto A/C model: Install the air duct sub–assy with the 3 screws. Claw I31518 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2353...
Page 892 Torque: 1.5 N m (15 kgf cm, 12 in. lbf) Connect the connector. I31511 INSTALL DEFROSTER NOZZLE ASSY LOWER Install the defroster nozzle assy lower. NOTICE: After locating the pin (1) in the illustration, install (2), then (3). I31552 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2354...
Page 893 Install the blower connector holder with the screw and clamp. Connect the connectors. Clamp I31563 INSTALL INSTRUMENT PANEL REINFORCEMENT Install the instrument panel reinforcement with the 7 bolts and 3 caps. I31508 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2355...
Page 894 Install the 7 clamps, connect the wire harness. 7 Clamps I31507 INSTALL STEERING COLUMN ASSY Install the steering column assy with the 3 bolts. Install the 2 clamps. 2 Clamps I31506 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2356...
Page 895 Install the instrument panel brace sub–assy No. 2 with the 2 nuts and bolt. I31504 Install the nut and clamp. Clamp I31648 Install the earth wire with the bolt. I31576 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2357...
Page 896 Install the bolt and screw. Torque: 9.8 N m (100 kgf cm, 87 in. lbf) (Screw) I31501 Install the 2 clamps. 2 Clamps I31581 Install the 2 earth wires with the 2 bolts. I31575 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2358...
Page 897 Specified amount: 550 " 50 g (19.37 " 1.76 oz.) WARM UP ENGINE CHECK ENGINE COOLANT LEAK 1MZ–FE: (See page 16–14) 2AZ–FE: (See page 16–1) INSPECT LEAKAGE OF REFRIGERANT (See page 55–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2359...
Page 898 Blower w/ fan Motor Sub–assy Auto A/C Model: Blower Motor Control Instrument Panel Wire No. 3 Instrument Panel Wire No. 3 : Specified torque N m (kgf cm, ft lbf) I31558 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2360...
Page 899 REMOVE AIR REFINER ELEMENT REMOVE COWL WIRE NO.2 Remove the clamp and cowl wire No. 2. Clamp I31523 REMOVE RECIRCULATION DAMPER SERVO SUB–ASSY Remove the 3 screws and recirculation damper servo sub–assy. I31524 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2361...
Page 900 REMOVE BLOWER MOTOR CONTROL (AUTO AIR CONDITIONER) Remove the 2 screws and blower motor control. I31525 REMOVE BLOWER W/FAN MOTOR SUB–ASSY Remove the 3 screws and blower w/fan motor sub–assy. I31527 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2362...
Page 901 55–48 HEATER & AIR CONDITIONER – BLOWER ASSY INSTALL BLOWER ASSY (See page 55–29) INSTALL INSTRUMENT PANEL SAFETY PAD SUB–ASSY (See page 71–12) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2363...
Page 902 Magnet Clutch Assy Cooler Compressor Assy z Snap Ring Snap Ring Magnet Clutch Washer 18 (184, 13) : Specified torque N m (kgf cm, ft lbf) z Non–reusable part I31774 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2364...
Page 903 Seal the opening of the disconnected parts using vinyl tape I31542 to prevent moisture and foreign matter from entering. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector and clamp. Remove the 2 bolts, nut and cooler compressor bracket. I31544 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2365...
Page 904 Using a vise pliers, hold the magnet clutch hub. Remove the bolt, magnet clutch hub and magnet clutch washer. I31547 Using a snap ring expander, remove the snap ring and magnet clutch rotor. Disconnect the connector. E37091 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2366...
Page 905 Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch wash- ers used before disassembly. I31582 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2367...
Page 906 Remove the compressor and magnetic clutch from the vise. Install the bolt and bracket. I30363 INSTALL COOLER COMPRESSOR BRACKET Install the earth wire and cooler compressor bracket with the screw. E58517 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2368...
Page 907 25 N m (250 kgf cm, 18 ft lbf) (Bolt (C)) 25 N m (250 kgf cm, 18 ft lbf) (Nut (D)) 18 N m (184 kgf cm, 13 ft lbf) (Bolt (E)) I31544 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2369...
Page 908 INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See page 55–21) CHARGE REFRIGERANT (See page 55–18) 07110–58060 (07117–58060, 07117–58070, 07117–58080, 07117–58090, 07117–78050, 07117–88060, 07117–88070, 07117–88080) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2370...
Page 909 Magnet Clutch Assy Cooler Compressor Assy z Snap Ring z Snap Ring Magnet Clutch Washer 18 (184, 13) N m (kgf cm, ft lbf) : Specified torque z Non–reusable part I31629 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2371...
Page 910 Seal the opening of the disconnected parts using vinyl tape I31550 to prevent moisture and foreign matter from entering. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the nut. E57139 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2372...
Page 911 Using a vise pliers, hold the magnet clutch hub. Remove the bolt, magnet clutch hub and magnet clutch washer. E57141 Using a snap ring expander, remove the snap ring and magnet clutch rotor. Disconnect the connector. E37091 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2373...
Page 912 Install the magnet clutch washer and magnet clutch hub. NOTICE: Do not change the combination of the magnet clutch wash- ers used before disassembly. I31582 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2374...
Page 913 NOTICE: Adjustment shall be performed with 3 or less magnet clutch washers. Remove the compressor and magnetic clutch from the vise. Install the bolt and bracket. I30371 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2375...
Page 914 Sufficiently apply compressor oil to the new O–ring and fit surface of the compressor and magnetic clutch. Compressor oil: ND–OIL 8 or equivalent Install a O–ring to the cooler refrigerant suction hose No. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2376...
Page 915 CHARGE REFRIGERANT (See page 55–18) 07110–58060 (07117–58060, 07117–58070, 07117–58080, 07117–58090, 07117–78050, 07117–88060, 07117–88070, 07117–88080) Specified amount: 550 " 50 g (19.37 " 1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2377...
Page 916 INSPECT CONDENSER FOR LEAKAGE OF REFRIGERANT Using a halogen leak detector, check pipe joints for gas leakage. If gas leakage is detected in a joint, check the torque of the joint. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 917 5.4 (55, 47 in. lbf) O–ring Cooler Condenser Assy Cooler Dryer Filter O–ring 12 (125, 9) N m (kgf cm, ft lbf) : Specified torque Compressor oil ND–OIL 8 or equivalent Non–reusable parts I31559 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2379...
Page 918 1MZ–FE: (See page 16–26) 2AZ–FE: (See page 16–12) REMOVE RADIATOR SUPPORT UPPER 1MZ–FE: (See page 16–26) 2AZ–FE: (See page 16–12) REMOVE COOLER CONDENSER ASSY Remove the 2 nuts and cooler condenser assy. I31540 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2380...
Page 919 Using hexagon wrench 10 mm (0.39 in.), install the cap to the cooler condenser assy. Torque: 12 N m (125 kgf cm, 9 ft lbf) 10 mm (0.39 in.) Hexagon Wrench Modulator I30086 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2381...
Page 920 Install a O–ring to the cooler refrigerant discharge hose No. 1. Connect the cooler refrigerant discharge hose No. 1 to the cooler condenser assy with the bolt. Torque: 5.4 N m (55 kgf cm, 47 in. lbf) I31538 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2382...
Page 921 CHARGE REFRIGERANT (See page 55–18) 07110–58060 (07117–58060, 07117–58070, 07117–58080, 07117–58090, 07117–78050, 07117–88060, 07117–88070, 07117–88080) Specified amount: 550 " 50 g (19.37 " 1.76 oz.) WARM UP ENGINE INSPECT LEAKAGE OF REFRIGERANT (See page 55–18) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2383...
Page 922 60–1 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM 6008V–02 PRECAUTION CAUTION: The CAMRY is equipped with SRS, which comprises a driver airbag, front passenger airbag, side airbag and curtain shield airbag. Failure to carry out service operations in the correct se- quence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident.
Page 923 60–2 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM SRS CONNECTORS Curtain Shield Airbag Sensor Airbag Assy (RH) Rear (RH) (Squib) Seat Belt Side Airbag Pretensioner (RH) Sensor Assy (RH) Front Seat Airbag Assy (RH) Airbag Front RH (Squib) Sensor Instr Pnl Pass L/Door Airbag Assy (Squib) Airbag Sensor...
Page 924 60–3 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM Item Application Terminal Twin–Lock Mechanism Connectors 2, 4, 6, 8, 10, 12, 13, 14, 15, 16, 17, 23, 24 Airbag Activation Prevention Mechanism Connectors 2, 4, 18, 20, 22, 24, 26, 28 Electrical Connection Check Mechanism Connectors 1, 2, 3, 4 Half Connection Prevention Mechanism...
Page 925 60–4 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM HINT: The type of connector is shown in the diagram on the previous page. Electrical connection check mechanism: This mechanism electrically checks that connectors are connected correctly and completely. The electri- cal connection check mechanism is designed so Disconnection that the disconnection detection pin connects with Detection...
Page 926 60–5 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM Connector lock mechanism: Locking the connector lock button securely con- nects the connector. H40181 When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the pre- determined level, the SRS is activated automatically.
Page 927 60–6 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF CONNECTOR FRONT SEAT AIRBAG ASSY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01584 CONNECTION OF CONNECTOR FOR FRONT SEAT AIRBAG ASSY Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing.
Page 928 60–7 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR CON- Outer NECTOR While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. Lock of the connectors is released, then disconnect the connectors.
Page 929 60–8 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM CONNECTION OF CONNECTORS FOR AIRBAG FRONT SENSOR, SIDE AIRBAG SENSOR AND AIRBAG SENSOR REAR Align the male connector (on the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing.
Page 930 CAUTION: For removal and installation of the horn button assy, see page 60–15, and be sure to follow the correct procedure. H41397 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2392...
Page 931 Always replace it with a new one. CAUTION: For removal and installation of the instrument panel pas- senger airbag assy, see page 60–30, and be sure to follow the correct procedure. H41399 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2393...
Page 932 Check cuts, minute cracks or marked discoloration on the curtain shield airbag assy. Check cuts and cracks in wire harness, and for chip- H41402 ping in connectors. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2394...
Page 933 Do a diagnostic system check (See page 05–690). AIRBAG SENSOR REAR(VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED) Replace the curtain shield airbag assy and airbag sensor rear (See page 60–41, 60–65). 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 934 Check to see if the SRS wire harness connectors are cracked or chipped. HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2396...
Page 935 Steering Wheel Cover Lower No. 2 8.8 (90, 78 in. lbf) 3 Spoke Steering Wheel Assy: Steering Wheel Cover Lower No. 3 H41405 N m (kgf cm, ft lbf) : Specified torque H41427 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2397...
Page 936 Disconnect the airbag connectors and horn connector and remove the horn button assy. 3 spoke steering wheel assy: Disconnect the airbag connectors and remove the horn button assy. 3 Spoke Steering Wheel Assy: H41407 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2398...
Page 937 Using a torx socket wrench (T 30), install the 2 screws. Torque: 8.8 N m (90 kgf cm, 78 in. lbf) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2399...
Page 938 When scrapping vehicle equipped with an SRS or disposing of a horn button assy, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deploy- ment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Never dispose of a horn button assy which has an un- deployed airbag.
Page 939 Connect the red clip of the SST to the battery posi- tive (+) terminal and the black clip to the negative (–) 10 m (33 ft) or more terminal. H40007 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2401...
Page 940 This is highly Stripped Wire Harness Section dangerous. Always use a wire harness for vehicle use H40008 which is at least 1.25 mm (0.0019 in 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2402...
Page 941 3 Spoke Steering Wheel Assy: Do not tighten the bolts too much. H41410 Connect the connectors of the SST to the horn but- ton assy connectors. 09082–00801 (09082–10801, 09082–30801) C93770 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2403...
Page 942 H41694 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2404...
Page 943 X should be the following size. X = 460 mm (18.11 in.) + width of tire 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 944 Remove the horn button assy from the disc wheel. Place the horn button assy in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2406...
Page 945 60–24 SUPPLEMENTAL RESTRAINT SYSTEM – SPIRAL CABLE SUB–ASSY SPIRAL CABLE SUB–ASSY 6007H–01 COMPONENTS (See page 60–14) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2407...
Page 946 Scratches or cracks on the connector Cracks, dents or chipping of the spiral cable sub–assy PLACE FRONT WHEELS FACING STRAIGHT AHEAD Check that the front wheels are facing straight ahead. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2408...
Page 947 INSTALL HORN BUTTON ASSY (See page 60–15) Torque: 8.8 N m (90 kgf cm, 78 in. lbf) INSPECT HORN BUTTON ASSY (See page 60–9) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2409...
Page 948 Instrument Panel Console Panel Upper Rear Upper Rear Console Box Carpet Console Box Front RR Console Box RR Console Box N m (kgf cm, ft lbf) : Specified torque B56812 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2410...
Page 949 Instrument Panel Console Panel Upper Rear Upper Rear Console Box Carpet Console Box Front RR Console Box RR Console Box N m (kgf cm, ft lbf) : Specified torque B56811 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2411...
Page 950 Airbag Assy 20 (200, 14) Instrument Panel Safety Pad Sub–Assy Instrument Panel Register Assy No.2 Instrument Panel Register Assy No.1 N m (kgf cm, ft lbf) : Specified torque H42155 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2412...
Page 951 (See page 71–12) REMOVE AIR CONDITIONER CONTROL ASSEMBLY(See page 71–12) REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB–ASSY CENTER (See page 71–12) REMOVE INSTRUMENT PANEL UNDER COVER SUB–ASSY NO.1 (See page 71–12) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2413...
Page 952 (See page 71–12) REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 (See page 71–12) REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (See page 71–12) REMOVE SIDE DEFROSTER NOZZLE DUCT NO.2 (See page 71–12) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2414...
Page 953 INSTALL FRONT PILLAR GARNISH RH(W/ CURTAIN SHIELD AIR BAG) (See page 71–12) PLACE FRONT WHEELS FACING STRAIGHT AHEAD INSTALL SPIRAL CABLE SUB–ASSY (See page 60–25) CENTER SPIRAL CABLE(See page 60–25) INSTALL STEERING WHEEL ASSY (See page 50–9) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2415...
Page 954 SUPPLEMENTAL RESTRAINT SYSTEM – INSTR PNL PASS L/DOOR AIR BAG ASSY INSTALL HORN BUTTON ASSY (See page 60–15) INSPECT HORN BUTTON ASSY (See page 60–9) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2416...
Page 955 When scrapping vehicle equipped with an SRS or disposing of a instr pnl pass l/door airbag assy, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Never dispose of a instr pnl pass l/door airbag assy which has an undeployed airbag.
Page 956 Press the SST activation switch and deploy the air- bag. HINT: The airbag deploys simultaneously as the LED of the SST ac- tivation switch lights up. Dispose of the instr pnl pass l/door airbag assy. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2418...
Page 957 This Stripped Wire Harness Section is highly dangerous. Always use a wire harness which is H40008 at least 1.25 mm (0.0019 in. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2419...
Page 958 Always tie down the instr pnl pass l/door airbag assy with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. Inner Diam. Tire Width H41433 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2420...
Page 959 Also, se- 10 m (33 ft) or more cure some slack for the SST wire harness inside the tire. H41696 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2421...
Page 960 Place the instr pnl pass l/door airbag assy in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2422...
Page 961 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) 9.8 (100, 87 in. lbf) N m (kgf cm, ft lbf) : Specified torque H41535 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2423...
Page 962 (See page 76–20) REMOVE CENTER PILLAR GARNISH UPPER RH (See page 76–20) REMOVE CENTER PILLAR GARNISH UPPER LH (See page 76–20) REMOVE ROOF SIDE GARNISH INNER RH (See page 76–20) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2424...
Page 963 (See page 76–20) REMOVE ROOF CONSOLE BOX ASSY (See page 76–20) REMOVE ROOM LAMP ASSY NO.1 (See page 76–20) REMOVE VISOR HOLDER (See page 76–20) REMOVE ROOF HEADLINING ASSY (See page 76–20) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2425...
Page 964 INSTALL REAR SEAT BACK ASSY(See page 72–34) INSTALL REAR SEAT CUSHION ASSY(See page 72–34) INSTALL FRONT SEAT ASSEMBLY LH(See page 72–7) INSTALL FRONT SEAT ASSEMBLY RH(See page 72–7) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2426...
Page 965 When scrapping vehicle equipped with an SRS or disposing of a curtain shield airbag assy, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the air- bag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Never dispose of a curtain shield airbag assy which has an undeployed airbag.
Page 966 Always wash your hands with water after completing the operation. HINT: When scrapping a vehicle, deploy the airbag and scrap the ve- hicle with the curtain shield airbag assy still installed. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2428...
Page 967 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. H41402 Cut off the deployment section in airbag from inflator. H41417 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2429...
Page 968 Always tie down the curtain shield airbag assy LH with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. H41549 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2430...
Page 969 To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside 10 m (33 ft) or more H41421 the tire. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2431...
Page 970 Remove the curtain shield airbag assy from the tire. Place the curtain shield airbag assy in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2432...
Page 971 If any abnormality occurs with the airbag de- ployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat airbag assy with an airbag deployed in a collision, follow the same procedure given in step 1–(e) in ”DISPOSAL”.
Page 972 Do not apply water, etc. to a front seat airbag assy with the deployed airbag. Always wash your hands with water after completing the operation. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2434...
Page 973 This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm (0.0019 in Install the 2 nuts in the front seat airbag assy. H41437 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2435...
Page 974 Place at least 2 tires over the tire to which the front Tires seat airbag assy is tied. The top tire should have the (5 or More) wheel installed. H01336 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2436...
Page 975 Remove the front seat airbag assy from the tire. Place the front seat airbag assy in a vinyl bag, tie the end tightly and dispose of it in the same way as oth- er general parts disposal. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2437...
Page 976 Air Duct Rear No. 1 Auto A/C Model: 17.5 (178, 13) Console Box Duct No. 1 Airbag Sensor Assy Center N m (kgf cm, ft lbf) : Specified torque H41536 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2438...
Page 977 Connect the connector to the air bag sensor assy center. Check that no play is identified. Check that the water–proof sheet is properly set. INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2439...
Page 978 Airbag Front RH Sensor 17.5 (178, 13) Engine Under Cover RH Airbag Sensor Front LH 17.5 (178, 13) Engine Under Cover LH N m (kgf cm, ft lbf) : Specified torque H41544 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2440...
Page 979 Torque: 17.5 N m (178 kgf cm, 13 ft lbf) Connect the connector to the front airbag sensor RH. Check that no play is identified. INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2441...
Page 980 60–59 SUPPLEMENTAL RESTRAINT SYSTEM – AIR BAG SENSOR FRONT LH AIR BAG SENSOR FRONT LH 6007U–01 COMPONENTS (See page 60–57) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2442...
Page 981 Torque: 17.5 N m (178 kgf cm, 13 ft lbf) Connect the connector to the front airbag sensor LH. Check that no play is identified. INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2443...
Page 982 Front Door Opening Trim Weatherstrip RH Rear Door Opening Trim Weatherstrip RH Rear Door Scuff Plate RH Front Door Scuff Plate RH N m (kgf cm, ft lbf) : Specified torque H41545 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2444...
Page 983 When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. After installation, shake the sensor assembly to check that there is no looseness. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date :...
Page 984 INSTALL FRONT SEAT OUTER BELT ASSY RH Torque: Upper bolt: 8.5 N m (87 kgf cm, 75 in. lbf) Lower bolt: 42 N m (420 kgf cm, 31 ft lbf) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2446...
Page 985 Airbag Sensor Rear LH Property Class 6T 17.5 (178, 13) Rear Side Seat Back Assy LH 18 (184, 13) Rear Seat Cushion Assy N m (kgf cm, ft lbf) : Specified torque H41546 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2447...
Page 986 After installation, shake the sensor assembly to check that there is no looseness. INSPECT AIR BAG SENSOR REAR LH (See page 60–9) INSTALL REAR SIDE SEAT BACK ASSY LH (See page 72–34) INSPECT SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2448...
Page 987 Front Seat Track Cover RH Rear Inner Manual Seat: Seat Track Upper Rail Cover RH Seat Position Airbag Sensor 8.0 (82, 71 in. lbf) N m (kgf cm, ft lbf) : Specified torque H41547 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2449...
Page 988 After installation, shake the sensor assembly to check that there is no looseness. INSTALL FRONT SEAT ASSY LH Torque: 36.8 N m (375 kgf cm, 27 ft lbf) SRS WARNING LIGHT(See page 05–690) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2450...
Page 989: Seat Belt Warning System
Combination Meter (Driver’s Seat Belt Warning Lamp) Clock Assy (Passenger’s Seat Belt Warning Lamp) Seat Belt Warning Sensor Front Seat Inner Belt Assy LH Front Seat Inner Belt Assy RH B56637 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2451...
Page 990 5. Wire harness 1. GAUGE 10 A Fuse 2. Clock assembly 71–26 Passenger’ seat belt warning lamp does not light up 3. Front seat inner belt assembly RH 61–3 4. Wire harness 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2452...
Page 991 If the result is not as specified, replace the front seat inner belt assembly. B31196 Standard (TMMK made): TMMK Made Terminal No. Specified condition 1330Ω If the result is not as specified, replace the front seat inner belt assembly. B31270 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2453...
Page 992 If the result is not as specified, replace the front seat inner belt assembly. B31196 Standard (TMMK made): TMMK Made Terminal No. Specified condition Continuity Continuity If the result is not as specified, replace the front seat inner belt assembly. B31235 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2454...
Page 993 If the result is not as specified, replace the front seat inner belt assembly. B31196 Standard (TMMK made): TMMK Made Terminal No. Specified condition No continuity Continuity If the result is not as specified, replace the front seat inner belt assembly. B31235 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2455...
Page 994: Front Seat Belt
Front Seat Inner Belt Assy RH 42 (420, 31) TMMK Made: Front Seat Inner Belt Assy RH 42 (420, 31) N m (kgf cm ft. lbf) : Specified torque B56625 B57644 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2456...
Page 995 REMOVE FRONT SEAT INNER BELT ASSY RH Disconnect the connector and clamp. TMC made: Remove the bolt and the front seat inner belt assembly. TMMK made: Remove the nut and the front seat inner belt assembly. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2457...
Page 996 Install the shoulder anchor with the nut. Torque: 42 N m (420 kgf cm, 31 ft lbf) Install the floor anchor with the bolt. Torque: 42 N m (420 kgf cm, 31 ft lbf) 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2458...
Page 997 If any abnormality occurs in the seat belt pretensioner operation, contact the SERVICE DEPT. of the TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front seat outer belt (with seat belt preten- sioner) activated in a collision, follow the same procedure given in step 1–(d) in ”DISPOSAL”.
Page 998 Remove the center pillar garnish upper RH (See page 76–20). Disconnect the pretensioner connector as shown in the illustration. Install the SST. Install the floor anchor of the seat belt. B50195 B57295 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2460...
Page 999 Be sure to follow the procedure given on the next page when activating the seat belt pretension- Remove the front seat outer belt (See page 61–7). HINT: Cut the belt near the seat belt retractor. 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2461...
Page 1000 Remove the disc wheel and SST. Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as oth- er general parts. B51516 2002 CAMRY REPAIR MANUAL (RM881U) Author : Date : 2462...

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