Page 1

TOYOTA

REPAIR MANUAL • MAINTENANCE • PREPARATION • SPECIFICATIONS •DIAGNOSTICS

Pub. No. RM744U1

VOLUME 1


FOREWORD This manual (Volume 1) contains maintenance, preparation, specifications and diagnostics procedures for the 2000 CELICA. Applicable models: ZZT230, 231 series i Fc* repair procedures for the engine, chassis and body, and electrical service procedures, refer to VOLUME 2 (Pub. No. RM744U2). The manual is divided into 6 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals for the components and systems in this vehicles. r

Manual Name

Pub. No.

• U240E Automatic Transaxte Repair Manual (Aug., 1999)

RM740U

•; U340E, U341 E Automatic Transaxle Repair Manual (Aug., 1 999)

RM735U

• 2000 CELICA Electrical Wiring Diagram

EWD399U

•,2000 CELICA New Car Features

NCF169U

All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

©1999 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Jul. 14,1999 01-990714-00


NOTE: The screen toned sections below are in VOLUME 2 (Pub. No. RM744U2).

INTRODUCTION MAINTENANCE PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS erjyrs

*»;K f.uife '-sJv SSKJ

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li,, Td A M<2! ?! V1 B I lll*ii^lis3'#iAi™L

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AIR ALPHABETICAL INDEX If


NOTE: The screen toned sections below are in VOLUME 1 (Pub. No. RM744U1).

Ill a

ENGINE MECHANICAL EMISSION CONTROL SFI COOLING LUBRICATION IGNITION STARTING CHARGING CLUTCH C56 MANUAL TRANSAXLE C60 MANUAL TRANSAXLE U240E AUTOMATIC TRANSAXLE U341E AUTOMATIC TRANSAXLE SUSPENSION AND AXLE BRAKE STEERING SUPPLEMENTAL RESTRAINT SYSTEM BODY ELECTRICAL BODY AIR CONDITIONING ALPHABETICAL INDEX


ENGINE MECHANICAL CO/HC COMPRESSION VALVE CLEARANCE IGNITION TIMING IDLE SPEED

EM-1 EM-3 EM-4 EM-13 EM-14

TIMING CHAIN CYLINDER HEAD ENGINE UNIT

EM-15 EM-36 EM-70

CYLINDER BLOCK EXHAUST SYSTEM

EM-85J EM-115


EM-1 ENGINE MECHANICAL

-

CO/HC

CO/HC INSPECTION

EMOSJ-OS

HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INSTALL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) Air pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected (f) SFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. CO/HC Meter

INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring with 3 minutes. HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations.


EM-2 ENGINE MECHANICAL

-

CO/HC

If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. • Check heated oxygen sensor operation (See page DI-49). • See the table below for possible causes, and then inspect and correct the applicable causes if necessary.

HC

CO Normal

High

Problems Rough idle

Causes 1. Faulty ignitions: • Incorrect timing • Fouled, shorted or improperly gapped plugs • Open or crossed high-tension cords 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinders

Low

High

Rough idle

1. Vacuum leaks:

(Fluctuating HC reading)

• PCV hoses • Intake manifold • Throttle body • IAC valve • Brake booster line 2. Lean mixture causing misfire

High

High

Rough idle (Black smoke from exhaust)

1. Restricted air filter 2. Plugged PCV valve 3. Faulty SFI systems: • Faulty pressure regulator • Defective ECT sensor • Defective IAT sensor • Faulty ECM • Faulty injectors • Faulty throttle position sensor


EM-3 ENGINE MECHANICAL

-

COMPRESSION

COMPRESSION INSPECTION

H037

EMOSK-05

HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE IGNITION COIL (See page IG-6) 3. REMOVE SPARK PLUGS 4. INSPECT CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression] pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1ZZ-FE 1,500 kPa (15.3 kgf/cm2, 218 psi) 2ZZ-GE 1,400 kPa (14.3 kgf/cm2,203 psi) or more Minimum pressure: 1ZZ-FE 1,000 kPa (10.2 kgf/cm2,145 psi) 2ZZ-GE 1,000 kPa (10.2 kgf/cm2,145 psi) Difference between each cylinder: 1ZZ-FE 100 kPa (1.0 kgf/cm2,15 psi) or less 2ZZ-GE 110 kPa (1.1 kgf/cm2,16 psi) or less (e) If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. â&#x20AC;¢ If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. REINSTALL SPARK PLUGS 6. INSTALL IGNITION COIL (See page IG-7)


EM-4 ENGINE MECHANICAL

-

VALVE CLEARANCE

VALVE CLEARANCE

BJlSQ-OI

ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (See page EM-18)

2. (a)

SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.

A01044

(b)

Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

1ZZ-FE:

2ZZ-GE:

3. (a)

INSPECT VALVE CLEARANCE Gheck only the valves indicated. • Using a feeler gauge, measure the clearance between the valve lifter and camshaft. • Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): 1ZZ-FE: Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.) 2ZZX3E: Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.35 - 0.45 mm (0.014 - 0.018 in.)


EM-5 ENGINE MECHANICAL

(b)

1Z2-FE:

(c)

-

VALVE CLEARANCE

Turn the crankshaft 1 revolution (360 °) and align the mark as above (See procedure in step 2). Check only the valves indicated as shown. Measure the valve clearance (See procedure in step (a)).

2Z2-GE:

A10366

4. (a) (b) (c)

1ZZ-FE: ADJUST VALVE CLEARANCE Set the No. 1 cylinder to the TDC/compression (See procedure in step 2). Place matchmarks on the timing chain and camshaft timing sprockets. Remove the 2 bolts and chain tensioner.

A10411

(d)

A10412

Remove the camshaft and timing sprocket assemblies (See page EM-42). (1) 19 camshaft bearing cap bolts (2) 9 camshaft bearing caps (No. 1 & No. 3) (3) Exhaust camshaft and timing sprocket assembly (4) Intake camshaft and timing sprocket assembly

HINT: When disconnect the timing chain from the camshaft timing sprocket, holding the timing chain. (e)

Tie the timing chain with a string as shown in the illustration. NOTICE: • Be careful not to drop anything inside the timing chain cover. • Do not allow the chain to come into contact with water or dust. (f) Remove the valve lifters.

Valve Lifter

YA01053


EM-6 ENGINE MECHANICAL

(g)

A01082

-

VALVE CLEARANCE

Determine the replacement valve lifter size according to these Formula or Charts: • Using a micrometer, measure the thickness of the removed lifter. • Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T. Thickness of used lifter A Measured valve clearance N Thickness of new lifter Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) • Select a new lifter with a thickness as close as possible to the calculated values.

HINT: Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.). 5. 2ZZ-GE: ADJUST VALVE CLEARANCE (a) Remove the adjusting shim. (1) Turn the crankshaft so that the cam lobe of camshaft on the adjusting valve points upward.

SST

(2) (3)

Using SST, press down the valve. Using SST, remove the adjusting shim.

(4)

Determine the replacement shim size according to these Formula or Charts: Using dial indicator, measure the thickness of the removed shim. Calculate the thickness of a new shim so the valve clearance comes within the specified value.


EM-7

ENGINE MECHANICAL -

VALVE CLEARANCE

T. Thickness of used shim A Measured valve clearance N Thickness of new shim Intake: N = T+ (A - 0.20 mm (0.008 in.)) Exhaust: N = T+ (A - 0.40 mm (0.016 in.)) Select a new shim with a thickness as close as possible to the calculated values. HINT: Shim are available in 41 size in increments of 0.020 mm (0.0008 in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).


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06 08 06 06 08 08 10 10 12 12 14

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06 08 06 08 08 10 10 12 12 14 14 16 16

06 06 06 08 10 12 12 14

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16 18 18 20 20 22 22 24 24 28 26 28 28 30 30 32 32 34 34 36 36 38 38 40 40 42 42 44 44 46 48 48 48

16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34 36 36 38 38 40 40 42 42

513 50 52 5 4 56 58 60 62 64

44 44 46 46 46 48 50 50 5 i 52 54 56 58 60 62 64 66

06 06 06 08 10 12 14 16 16 16 18 20 20 22 22 24 24 26 26 28 26 30 30 32 32 34 34 36 36 38 38 40 40 42 42 44 44 46 46 48 48 50 50 52 52 5 ) 54 56 5a 60 62 54 66 68

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12 14 16 16 20 22 24 26 26 28 30 30 32 32 34 34 38 38 38 38 40 40 42 42 44 44 46 46 48 48 50 50 52 52 54 54 56 56 58 58 60 60 62 62 64 64 6 S 66 86 70 72 74 74 74

0.271 - 0.2SO (0.0107 - 0.01 1 4)

14

0.291 - 0.310 (0.01 1 5 - 0.0122)

15 18 20 22 24 26 28 30 32 32 34 34 36 36 38 38 40 40 42 42 44 44 46 46 46 48 50 50 52 52 54 54 56 56 56 58 60 60 62 62 64 64 68 68 68 68 7 0 70 72 74 74 74

S

18 20 22 24 26 28 30 30 32 32 34 34 36 36 38 38 40 40 42 42 44 44 46 46 48 46 50 50 52 52 54 54 56 66 58 SB 60 60 62 62 84 64 66 66 6 8 68 70 72 74 74 74

0.311 -0.330 (0,0122 -0.0130)

18 20 22 24 28 28 30 32 34 34 36 36 38 38 40 40 42 42 44 44 48 46 48 48 50 50 62 52 54 54 66 66 68 58 60 60 62 62 64 64 6« 66 68 68 70 70 72 72 74 7 4 74

0.331 -0.350(0.0130-0.0138)

20 22 24 26 28 30 32 34 36 36 38 38 40 40 42 42 44 44 46 48 48 48 50 50 52 52 54 54 56 56 58 58 60 60 62 62 64 64 66 66 6 8 68 70 70 72 72 7 4 74 74 7 4

0.351 -0370(0.0138-0,0146)

22 24 26 28 30 32 34 36 38 38 40 40 42 42 44 44 46 46 48 48 50 60 52 52 64 54 56 56 58 68 60 60 62 62 84 64 66 66 88 88 70 70

0.371 - 0.390 (0.0146 - 0.0154)

24 26 28 30 32 34 36 38 40 40 42 42 44 44 46 46 48 48 50 60 52 52

0.391 - 0.410 (0.0154 - 0.0161)

26 28 3D 32 34 36 38 40 42 42 44 44 46 46 46 48 50 50 52 52 54 54 53 56 56 58 60

0.411-0.430(0.0162-0,0169)

28 30 32 34 38 38 40 42 44 44 46 46 48 48 SO 50 52 52 54 54 56 56 58 58 80 60 82 62 64 84 66 66 68 86 70 70 72 72 74

54 54 56 5G 58 58 60 60 62 62 84 64 66 66 68 88 70 70 72 72

eo

30 32 34 36 38 40 42 44 46 45 48 46 50 50 52 62

0.451 - 0 470 (0.0178 - 0.0185)

32 34 36 38 40 42 44 46 48 46 50 50 52 52 54 54 66 56 58 SB 60 60 82 62 84 64 66 66 6Q 68 70 70 72 72

0.491 - 0.510 (0.01 93 - 0.0201)

36 38 40 42 44 48 48 60 62 52 54 54 66 56 58 58 60 60 52 62 64 64 66 66 68 68 70 70 72 72 74 74 74 74 74 74

0.51 1 - 0.530 (0.0201 - 0.0209)

38 40 42 44 46 48 50 52 64 54 56 56 58 58 80 60 62 62 64 64 66 66 68 68 70 70 72 72

0.531 -0.550(0.0209-0.0217)

40 42 44 46 48 50 52 54 66 B6 58 68 60 60 62 62 64 64 66 66 68 68 70 70 72 72 74 74 74 74 74 74

0.351 - 0.570 (0.021 7 - 0.0224)

42 44 46 48 50 52 64 56 SB 58 50 60 62 52 64 64 66 66 68 68 70 70 72 72 74 74 74 74 74 74

0.571 - 0.590 (0.0225 - 0.0232]

44 46 48 50 62 54 66 58 60 60 62 62 64 64 6G 66 66 68 70 70 72 72

0.5B1 - 0.610 {0.0233 - 0.0240)

46 48 SO 52 54 58 58 60 62 62 64 64 66 66 68 68 70 70 72 72 74 74 74 74 74 74

0611 -0.630(0.0241 -0.0248)

48 50 52 54 55 58 50 62 64 64 66 E6 58 68 70 70 72 72 74 74 74 74 74 74

0.651 - 0.670 (0.0256 - 0.0264)

52 54 56 58 60 62 64 66 SB 88 70 70 72 72

0.691 -0,710(0.0272-0.0280)

06 68 60 62 64 86 68 70 72 72

0,7 1 1 - Q 730 {0.0280 - 0.0287)

58 BO 62 64 66 68 70 72 74 74 74 74 74 74

0 731 - 0.760 (0.0288 - 0.0295)

60 62 64 66 68 70 72 74 74 74 74 74

0.751 - 0,770 {0.0296 - 0.0303)

62 64 66 66 70 72 74 74 74 74

0.771 -0.790(0.0304-0.0311)

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0.791-0.610(0.0311-0.0319)

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0.811 -0.830(0.0319-0.0327)

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0,831 - 0.850 (0,0327 - 0.0335)

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0.851 - 0.870 (0.0335 - 0.0343)

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0.871 - 0.800 {0.0343 - 0.0350)

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54 54 56 56 68 58 60 60 82 62 64 64 66 66 68 68 70 70 72 72 74 74

74

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Intake va\ve clearance (Cold): 0.15 - 0.25 mm (0.006 - 0.010 in.) EXAMPLE: The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) lifter with a new No. 48 lifter.

74 74 7 4 74

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Lifter No.

Thickness

Lifter No.

Thickness

Lifter No.

Thickness

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5.060(0.1992)

30

5.300 (0.2087)

54

5.540(0.2181)

Tl > 33

08

5.080 (0.2000)

32

5.320 (0.2094)

56

5.560(0.2189)

10

5.100(0.2008)

34

5.340(0.2102)

58

5.580(0.2197)

12

5.120(0.2016)

36

5.360(0.2110)

60

5.600 (0.2205)

14

5.140(0.2024)

38

5.380(0.2118)

62

5.620(0.2213)

16

5.160(0.2031)

40

5.400(0.2126)

64

5.640 (0.2220)

18

5.180(0.2039)

42

5.420(0.2134)

66

5.660 (0.2228)

20

5.200 (0.2047)

44

5.440(0.2142)

68

5.680 (0.2236)

22

5.220(0.2055)

46

5.460(0.2150)

70

5.700 (0.2244)

24

5.240 (0.2063)

48

5.480(0.2157)

72

5.720(0.2252)

26

5.260(0.2071)

50

5,500(0.2165)

74

5.740 (0.2260)

26

5.280 (0.2079)

52

5.520(0.2173)


EM-9 -

VALVE CLEARANCE

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EM-12 ENGINE MECHANICAL

6. (a) (b) (c) (d) (e)

(f)

(g)

A10387

(h) (i) (j) 7.

VALVE CLEARANCE

1ZZ-FE: REINSTALL CAMSHAFT Reinstall the valve lifters (See page EM-61). Align the crankshaft pulley groove with the timing mark "0" of the timing chain cover. Hold the timing chain, and place the intake camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket. Reinstall the camshaft and timing sprocket assemblies (See page EM-65).

Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. Check that the matchmarks on the timing chain and camshaft timing sprockets. Install the chain tensioner (See page EM-25). Recheck the valve clearance (See procedure in step 3). Check the valve timing (See page EM-25). REINSTALL CYLINDER HEAD COVER (See page EM-25)


EM-13 ENGINE MECHANICAL

-

IGNITION TIMING

IGNITION TIMING INSPECTION

EM15FMM

1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature.

TOYOTA Hand-Held Tester

2.

CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

(a)

Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. (b) Please refer to the TOYOTA hand-held tester or OBDII scan tool operator's for further details. 3. CONNECT TIMING LIGHT TO ENGINE D07259

4. INSPECT IGNITION TIMING Using a timing light, check the ignition timing. Ignition timing: 1ZZ-FE: 10-18°BTDC@idle 22Z-GE: 8-12°BTDC@idle (Transmission in neutral position) HINT: After engine rpm is kept at 1,000 - 1,300 rpm for 5 seconds, check that it returns to idle speed. 5. DISCONNECT TIMING LIGHT FROM ENGINE 6. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL


EM-14 ENGINE MECHANICAL

-

IDLE SPEED

IDLE SPEED EM05N-0

INSPECTION 1. (a) (b) (c) (d) (e) (f) (g) (h) (i)

TOYOTA Hand-Held Tester

D072S9

2.

INSTALL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All vacuum lines properly connected SFI system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly Transmission in neutral position Air conditioning switched OFF

CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (a) Connect the TOYOTA hand-held tester or OBDII scan tool to the DLC3. (b) Please refer to the TOYOTA hand-held tester or OBDII scan tool operator's manual for further details. 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooling fan OFF): 1ZZ-FE M/T 700 ±50 rpm A/T 750 ± 50 rpm 2ZZ-GE M/T 800 ± 50 rpm A/T 750 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL


EM-15 ENGINE MECHANICAL

-

TIMING CHAIN

TIMING CHAIN COMPONENTS Upper Front Fender Apron Seal

PS Oil Pressure Switch Connector

Drive Belt

PS Pump

Upper Radiator Support Seal

Generator Connector 1ZZ-FE: I 52(530.38) RH Engine Mounting Insulator

2ZZ-GE: RH Engine Mounting Insulator

| 52(530,38)

RH Engine Under Cover

N-m (kgf-cm, ft-lbf)

: Specified torque A10352


EM-16 ENGINE MECHANICAL

-

TIMING CHAIN

1ZZ-FE: RH Engine Mounting Bracket

No. 2 Cylinder Head Cover

Wire Harness Protector

Belt Tensioner

Timing Chain Cover Timing Chain Tensioner

Front Crankshaft Oil Seal Crankshaft Position Sensor

Crankshaft Pulley x6 Water Pump

* Gasket Camshaft Timing Sprocket

Chain ^ Chain Tensioner Slipper

r I

-gym ^

45 (460,33)

Valve Timing Controller Assembly

Crankshaft Timing Sprocket Chain Vibration Dumper Crank Angle Sensor Plate N-m (kgf-cm, ft-lbf) [ : Specified torque + Non-reusable part A10380


EM-17 ENGINE MECHANICAL

-

TIMING CHAIN

2ZZ-GE:

RH Engine Mounting Bracket

Driver Belt Tensioner

Wire Harness Protector

*4 Ignition Coil (w/ Igniter).

No. 2 Cylinder Head Cover

9.0(90,80in.-lbf)

Timing Chain Cover

PCV Hose

Timing Chain Tensioner

Cylinder Head Cover

Front Crankshaft Oil Seal

Crankshaft Position Sensor Crankshaft Pulley_

'"

\ *• Gasket No. 1 Ventilation Pipe

Camshaft Timing Sprocket „---' I

Water Water Pump Pulley_. Timing Chain [-'"

Chain Tensioner Slipper

Valve Timing Controller Assembl

Oil Guide

Chain Vibration Dumper Crank Angle Sensor Plate

N-m (kgf-cm, ft-lbf) : Specified torque Non-reusable part

Crankshaft Timing Sprocket

* O-Ring

A10353


EM-18 ENGINE MECHANICAL

-

TIMING CHAIN

REMOVAL 1.

REMOVE UPPER FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL 2. DRAIN ENGINE COOLANT 3. REMOVE RH FRONT WHEEL 4. REMOVE RH ENGINE UNDER COVER 5. REMOVE DRIVE BELT AND GENERATOR (See page CH-7) 6. DISCONNECT PS PUMP FROM ENGINE (a) Disconnect the PS oil pressure switch connector. (b) Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine (See page SR-24). HINT: Put aside the pump and suspend it to the cowl with a string.

7. REMOVE RH ENGINE MOUNTING INSULATOR (a) Set the jack to the engine. HINT: Place a wooden block between the jack and engine.

A01045

(b) \

(c)

8. A10381

(a) (b) (c)

1ZZ-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insulator. 2ZZ-GE: Remove the 5 bolts, 2 nuts and RH engine mounting insulator. 1ZZ-FE: REMOVE CYLINDER HEAD COVER Remove the 4 bolts and No. 2 cylinder head cover. Remove the 4 ignition coils (See page IG-6). Disconnect the 2 PCV hoses from the cylinder head.


EM-19 ENGINE MECHANICAL

(d) 9. (a) (b) (c)

(d) (e)

(f) (g)

-

TIMING CHAIN

Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket. 2ZZ-GE: REMOVE CYLINDER HEAD COVER Remove the 4 bolts and No. 2 cylinder head cover. Remove the ignition coils (See page IG-6). Disconnect the 2 PCV hoses from the cylinder head cover.

Remove the 2 nuts, bolt and disconnect the No. 3 ventilation hose from the No. 1 ventilation pipe. Remove the No. 1 ventilation pipe and gasket.

Remove the 9 bolts, wire harness protector, cylinder head cover and gasket. Remove the O-ring from the cylinder head cover.

Itoase

10. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.

(b)

Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

M0387


EM-20 ENGINE MECHANICAL

-

TIMING CHAIN

11. REMOVE CRANKSHAFT PULLEY (a) Using SST and 2 nuts (width: 10 mm (0.25 in.)), remove the pulley bolt. SST 09213-70010,09330-00021 (b) Remove the crankshaft pulley.

SST

SST

HINT: If necessary, remove the pulley with SST. SST 09950-50012 (09951-05010, 09952-05010, 09953-05020,09954-05020)

SST

600298

12.

DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER Remove the 2 bolts and crankshaft position sensor. 13. REMOVE DRIVE BELT TENSIONER Remove the bolt, nut and drive belt tensioner. 14. REMOVE RH ENGINE MOUNTING BRACKET (a) 1ZZ-FE: Remove the 3 bolts and mounting bracket. (b) 2ZZ-GE: Remove the 4 bolts and mounting bracket. 15. REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner. 16. REMOVE WATER PUMP (See page CO-5)

A07317

17.

yA10389

1ZZ-FE: REMOVE TIMING CHAIN COVER (a) Remove the 11 bolts and nut. (b) Using a tone wrench socket (E8), remove the stud bolt. (c) Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.


EM-21 ENGINE MECHANICAL

-

TIMING CHAIN

18. 2ZZ-GE: REMOVE TIMING CHAIN COVER (a) Remove the 12 bolts. (b) Using a tone wrench socket (E8), remove the stud bolt. (c) Remove the timing chain cover and 2 gaskets. 19. REMOVE CRANK ANGLE SENSOR PLATE 20. REMOVE CHAIN TENSIONER SLIPPER Remove the bolt and slipper. A10390

21.

REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET If the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers. NOTICE: Position shop rags as shown to prevent damage. 22. REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper.

ft

B00302

N

A10371

23. REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt, valve timing controller assembly and timing sprocket. NOTICE: Be careful not to damage the cylinder head and valve lifter with the wrench. Do not disassemble the valve timing controller assembly.


EM-22 ENGINE MECHANICAL

-

TIMING CHAIN

INSPECTION 1. (a)

INSPECT TIMING CHAIN AND TIMING SPROCKETS Using a vernier calipers, measure the length of 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random.

122.6 mm

(b) (c)

EM2378

1ZZ-FE:

Wrap the chain around the timing sprocket. Using a vernier calipers, measure the timing sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum sprocket diameter (w/ Chain): Camshaft 97.3 mm (3.831 in.) Crankshaft 51.6 mm (2.031 in.) If the diameter is less than minimum, replace the chain and sprockets.

2.

INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 in.) If the wear is greater than maximum, replace the slipper and/or damper.


EM-23 ENGINE MECHANICAL

3. (a)

Raise Move

(b)

4. A07221

-

TIMING CHAIN

INSPECT CHAIN TENSIONER Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. INSPECT OIL JET (See page LU-11)


ENL-24 ENGINE MECHANICAL

-

TIMING CHAIN

REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL (a) If timing chain cover is removed from cylinder block. (1) Using a screwdriver and a hammer, tap out the oil seal. B00179

(2)

Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010 (3) Apply MP grease to the oil seal lip.

SST

B00178

(b)

Cut Position

If timing chain cover is installed to the cylinder block. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip.

A01149

(3)

Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010

B00177


EM-25 ENGINE MECHANICAL

-

TIMING CHAIN

INSTALLATION 1.

INSTALL VALVE TIMING CONTROLLER ASSEMBLY

(a)

Apply engine oil in the range from the tip of the intake camshaft to 16 mm from that tip. Align the timing mark on the value timing controller assembly with the knock pin, and install the value timing controller assembly to the cam shaft.

AND CAMSHAFT TIMING SPROCKET

(b)

A10438

NOTICE:

Do not push valve timing controller assembly to the camshaft forcibly when installing it. (c) Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft, and exhaust the sprocket to the cam shaft.

(d) (e)

Temporarily install the timing sprocket bolt. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt. Torque: 1ZZ-FE 45 N-m (460 kgf cm, 33 ftlhf) 2ZZ-GE 54 N-m (551 kgf cm, 40 ft-lbf)

2. (a)

SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.

(b)

Using a crankshaft pulley bolt, Turn the crankshaft and set the set key on the crankshaft upward.

A10371

o Set Key

B00280


EM-26 ENGINE MECHANICAL

-

TIMING CHAIN

3. INSTALL CHAIN VIBRATION DAMPER Install the damper with the 2 bolts. Torque: 1ZZ-FE 11 N-m (113 kgf-cm, 8 ft-lbf) 2ZZ-GE 20.5 N-m (209 kgf-cm, 15 ft-lbf)

1ZZ-FE:

2ZZ-GE:

N B00281

4. (a) Timing Mark

INSTALL TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshaft timing sprocket.

B00282

HINT: If necessary, install the sprocket with SST. SST 09223-22010

Mark

(b)

Mark

(c)

Timing Mark

A10395

1ZZ-FE: Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets. 2ZZ-GE: Install the timing chain on the camshaft timing sprockets with the orange color links aligned with the timing marks on the camshaft timing sprockets.


EM-27 ENGINE MECHANICAL

-

TIMING CHAIN

(d)

Check that the tension between the intake camshaft timing sprocket and crankshaft timing sprocket. 5. INSTALL CHAIN TENSIONER SLIPPER (a) Install the slipper with the bolt. Torque: 1ZZ-FE 18.5 N-rn (189 kgf-cm, 14 ft-lbf) 2ZZ-GE 20.5 N-m (209 kgf-cm, 15 ft-lbf) (b) Check that the slipper moves is caught on the cylinder head stopper. NOTICE: DO not turn the crankshaft.

Cylinder Head Stopper A10402

6. INSTALL CRANK ANGLE SENSOR PLATE Install the plate with the "F" mark facing forward.

A01047


EM-28 ENGINE MECHANICAL

-

TIMING CHAIN

7.

Chain Cover Groove Seal Width

Cylinder Head Groove

1.5 mm

7 mm

B 12mm 6mm

1ZZ-FE: INSTALL TIMING CHAIN COVER AND WATER PUMP (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and Cylinder block. • Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non-residue solvent, clean both sealing surfaces. (b) Apply seal packing to the timing chain cover as shown in the illustration. Seal packing: Part No. 08826 - 00100 or equivalent • Install a nozzle that has been cut to a 1.5 mm (0.16 - 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

.mm

A07223

(c)

A104Q3

Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 08826 - 00080 or equivalent Install a nozzle that has been cut to a 1.5 mm (0.16 - 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. • Immediately remove nozzle from the tube and reinstall cap.


EM-29 ENGINE MECHANICAL

(d)

B

A1137t

-

TIMING CHAIN

Install the timing chain cover, O-ring and water pump with the 17 bolts and nut. Uniformly tighten the bolts and nut in several passes. Torque: 10 mm head: 9 N-m (92 kgf-cm, 80 in.-lbf) for C 13 N-m (133 kgf-cm, 10 ft-lbf) for A 11 N-m (113 kgf-cm, 8 ft-lbf) for others 12 mm head: 18.5 N-m (189 kgf-cm, 14 ft-lbf) NOTICE: â&#x20AC;˘ Pay attention not to wrap the chain and slipper over the chain cover seal line. After installing the chain cover, must install the mounting bracket and water pump within 15 minutes. HINT: Each bolt length in indicated in the illustration. A 45mm (1.77 in.) B 35 mm (1.38 in.) C 30 mm (1.18 in.) D 25 mm (0.98 in.) (e) Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N-m (95 kgf-cm, 82 in.-lbf)


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2004 toyota celica service repair manual  
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