Toyota 2002 Camry

How to Use this Manual1

Service Specifications2

Terms Definition2

SI Unit3

Identification Information4

Vehicle Identification Number4

Factory of Production4

Engine Serial Number and Transaxle Serial Number4

Jacking up and Supporting Vehicle5

Bolts, Nuts and Screws6

Fuses6

Clips7

Removal and Installation of Vacuum Hoses8

For Vehicles Equipped with SRS Airbag and Seat Belt Pretensioner9

Torque When Using Torque Wrench with Extension Tool9

Spiral Cable10

Horn Button Assembly10

Instrument Panel Passenger Airbag Assembly11

Front Seat Airbag Assembly12

Curtain Shield Airbag Assembly13

Seat Belt Pretensioner14

Airbag Sensor Assembly14

Wire Harness and Connector14

Electronic Control15

Removal and Installation of Fuel Control Parts15

Removal and Installation of Battery Terminal15

Handling of Electronic Parts15

Removal and Installation of Engine Intake Parts16

Handling of Hose Clamps16

For Vehicles Equipped with Mobile Communication System16

Removing and Installing of Fuel System Parts16

Notices When Using 2-Wheel Drum Tester17

For Vehicles Equipped with Traction Control (Trac) System17

For Vehicles Equipped with Catalytic Converter17

For Vehicles Equipped with Vehicle Skid Control (Vsc) System17

Vehicle Lift and Support Locations18

Notice about Vehicle Condition When Jacking up18

Notice for Using 4 Post Lift18

Notice for Using Jack and Safety Stand18

Notice for Using Swing Arm Type Lift19

Notice for Using Plate Type Lift19

How to Troubleshoot ECU Controlled Systems20

For Using OBDII Scan Tool or Hand-Held Tester20

General Information20

How to Proceed with Troubleshooting21

Customer Problem Analysis23

Symptom Confirmation and Diagnostic Trouble Code24

Symptom Simulation26

Vibration Method26

Heat Method26

Water Sprinkling Method27

Diagnostic Trouble Code Chart28

Problem Symptoms Table29

Circuit Inspection30

Electronic Circuit Inspection Procedure31

Basic Inspection31

Resistance Measuring Condition of Electronic Parts31

Handling of Connector31

Handling of Wire Harness32

Check Open Circuit32

Repair Method of Connector Terminal32

Check Short Circuit34

Check and Replace ECU35

Terms36

Abbreviations Used in this Manual36

Glossary of SAE and Toyota Terms41

Diagnostics Preparation44

Diagnostics Recommended Tools44

Engine Control System Preparation46

Fuel Preparation47

Emission Control Preparation49

Intake Preparation50

Engine Mechanical Preparation51

Exhaust Preparation61

Cooling Preparation62

Cooling Recommended Tools63

Lubrication Preparation64

Lubrication Recommended Tools66

Ignition Preparation67

Starting & Charging Preparation68

Starting & Charging Recommended Tools68

Front Suspension Preparation69

Front Suspension Recommended Tools69

Rear Suspension Preparation70

Tire & Wheel Preparation71

Drive Shaft / Propeller Shaft Preparation72

Brake Preparation75

Parking Brake Preparation78

Automatic Transmission/Trans Preparation79

Manual Transmission/Transaxle Preparation81

Clutch Preparation87

Clutch Recommended Tools87

Steering Column Preparation88

Steering Column Recommended Tools88

Power Steering Preparation89

Heater & Air Conditioner Preparation94

Heater & Air Conditioner Recommended Tools96

Supplemental Restraint System Preparation97

Supplemental Restraint System Recommended Tools98

Seat Belt Preparation99

Lighting Preparation100

Wiper & Washer Preparation101

Audio & Visual System Preparation102

Communication System Preparation103

Windshield/Windowglass/Mirror Preparation104

Instrument Panel/Meter Preparation105

Seat Preparation106

Sliding Roof/Convertible Preparation107

Engine Hood/Door Preparation108

Exterior/Interior Trim Preparation109

Vehicle Control System Preparation110

Cruise Control Preparation111

Standard Bolt112

How to Determine Bolt Strength112

Specified Torque for Standard Bolts113

How to Determine Nut Strength114

Engine Control System115

Service Data115

Torque Specification116

Fuel Service Data117

Fuel Torque Specification118

Emission Control Service Data119

Emission Control Torque Specification120

Intake Service Data121

Intake Torque Specification122

Engine Mechanical Service Data123

Engine Mechanical Torque Specification129

Exhaust Torque Specification134

Cooling Service Data135

Cooling Torque Specification136

Lubrication Service Data137

Lubrication Torque Specification138

Ignition Service Data139

Ignition Torque Specification140

Starting & Charging Service Data141

Starting & Charging Torque Specification142

Front Suspension Service Data143

Front Suspension Torque Specification144

Rear Suspension Service Data145

Rear Suspension Torque Specification146

Tire & Wheel Service Data147

Drive Shaft/Propeller Shaft/Axle Service Data148

Drive Shaft/Propeller Shaft/Axle Torque Specification149

Brake Service Data150

Brake Torque Specification151

Parking Brake Service Data152

Parking Brake Torque Specification153

Automatic Transmission/Transaxle Service Data154

Automatic Transmission/Transaxle Torque Specification156

Manual Transmission/Transaxle Service Data157

Clutch Service Data163

Clutch Torque Specification164

Steering Column Service Data165

Steering Column Torque Specification166

Power Steering Service Data167

Power Steering Torque Specification168

Heater & Air Conditioner Service Data169

Heater & Air Conditioner Torque Specification170

Supplemental Restraint System Torque Specification171

Wiper & Washer Torque Specification172

Instrument Panel/Meter Torque Specification173

Engine Hood/Door Torque Specification174

Inspect Accelerator Pedal Position Sensor175

Inspection Throttle Body175

On-Vehicle Inspection175

SFI System (2AZ-FE)175

Intake Air Flow Meter Sub-Assy176

Camshaft Timing Oil Control Valve Assy176

Accelerator Pedal Assy177

Throttle Body Assy177

E.F.I. Engine Coolant Temperature Sensor177

Knock Control Sensor178

E.F.I. Circuit Opening Relay Assy178

E.F.I. ECU Relay178

Throttle Body Assy (2AZ-FE) Components179

Remote Throttle Body Assy180

Install Throttle Body Assy180

SFI System (1MZ-FE) On-Vehicle Inspection181

Throttle Body Assy (1MZ-FE) Components185

Fuel System Precaution189

Work for Prevent Gasoline from Spilling out189

Check Fuel Pressure193

Fuel Injector Assy196

Fuel Injector Assy Components198

Fuel Injector Assy Replacement199

Remove Fuel Delivery Pipe Winjector199

Install Fuel Injector Assy199

Install Fuel Delivery Pipe Winjector200

Fuel Pump Assy (2AZ-FE) Components201

Remove Fuel Suction Tube Assy W/Pump & Gage203

Remove Fuel Tank Vent Tube Set Plate203

Separate Fuel Pump Tube Sub-Assy203

Install Fuel Pump Tube Sub-Assy205

Fuel Tank Assy (2AZ-FE) Components206

Disconnect Fuel Pump Tube Sub-Assy210

Remove Fuel Tank Assy210

Remove Fuel Tank over Fill Check Valve Assy211

Install Fuel Tank over Fill Check Valve Assy213

Install Fuel Tank Assy213

Fuel Injector Assy (1MZ-FE) Components222

Fuel Injector Assy (1MZ-FE) Replacement223

Fuel Pump Assy (1MZ-FE) Components225

Fuel Tank Assy (1MZ-FE) Components230

Emission Control System (2AZ-FE) On-Vehicle Inspection238

Inspect Air-Fuel Ratio Compensation System238

Inspect Evap System Line239

Check Airtightness in Fuel Tank and Filler Pipe241

Inspect Fuel Cut off Valve and Fill Check Valve241

Check Air Inlet Line241

Charcoal Canister Assy243

Emission Control System (1MZ-FE) On-Vehicle Inspection248

Ventilation Valve Sub-Assy255

Fuel Tank Cap Assy255

Emission Control Valve Set255

Air Cleaner Cap Sub-Assy256

Oxygen Sensor257

Air Fuel Ratio Sensor257

Inspect EGR Valve Position Sensor258

EGR System (1MZ-FE) On-Vehicle Inspection258

EGR Valve Assy259

Vacuum Control Valve259

E.G.R. Gas Temperature Sensor259

Vacuum Switching Valve No.1260

EGR Valve Assy (1MZ-FE) Replacement261

Intake Air Control System (1MZ-FE) On-Vehicle Inspection263

Intake Air Control Valve Assy264

Intake Air Control Valve Assy No.3264

Vacuum Switching Valve Assy No.1265

Intake Air Control Valve Assy (1MZ-FE) Replacement266

Engine Assembly (2AZ-FE) Inspection267

Fan and Generator V Belt (2AZ-FE) Replacement271

Valve Clearance (2AZ-FE) Adjustment273

Valve Lifter Selection Chart (Intake)277

Valve Lifter Selection Chart (Exhaust)278

Partial Engine Assy (2AZ-FE) Components282

Chain (2AZ-FE) Replacement290

Camshaft (2AZ-FE) Replacement304

Cylinder Head Gasket (2AZ-FE) Replacement311

Remove Intake Manifold311

Remove No.2 Camshaft312

Remove Camshaft312

Install Cylinder Head Gasket313

Install Cylinder Head Sub-Assy313

Inspect Cylinder Head Set Bolt313

Remove Cylinder Head Sub-Assy313

Install Camshaft314

Install No.2 Camshaft315

Install Exhaust Manifold Converter Sub-Assy315

Install Intake Manifold315

Timing Gear Case or Timing Chain Case Oil Seal (2AZ-FE) Replacement317

Remove Crankshaft Pulley317

Remove Timing Gear Case or Timing Chain Case Oil Seal318

Install Timing Gear Case or Timing Chain Case Oil Seal318

Install Crankshaft Pulley319

Engine Rear Oil Seal (2AZ-FE) Replacement320

Remove Drive Plate & Ring Gear Sub-Assy(A/T Transaxle)320

Install Drive Plate & Ring Gear Sub-Assy321

Remove Engine Rear Oil Seal321

Install Engine Rear Oil Seal321

Install Flywheel Sub-Assy322

Cylinder Head Assy (2AZ-FE) Overhaul323

Remove Intake Valve323

Remove Exhaust Valve323

Inspect Cylinder Head for Flatness324

Inspect Valve Seats324

Repair Valve Seats325

Inspect Camshaft Thrust Clearance325

Inspect Camshaft Oil Clearance325

Inspect Inner Compression Spring327

Inspect Intake Valve327

Inspect Exhaust Valve328

Inspect Intake Valve Guide Bush328

Inspect Exhaust Valve Guide Bush329

Remove Intake Valve Guide Bush329

Remove Exhaust Valve Guide Bush329

Install Intake Valve Guide Bush329

Install Exhaust Valve Guide Bush330

Install Ring W/Head Pin331

Install Stud Bolt332

Install Valve Stem Oil O Seal or Ring333

Install Intake Valve333

Install Exhaust Valve334

Inspect Connecting Rod Oil Clearance335

Inspect Connecting Rod Thrust Clearance335

Cylinder Block (2AZ-FE) Overhaul335

Remove Piston Sub-Assy W/Connecting Rod336

Remove Piston Ring Set337

Remove Piston Pin Hole Snap Ring337

Remove Piston337

Inspect Crankshaft Thrust Clearance337

Remove Crankshaft338

Inspect Cylinder Block for Flatness338

Inspect Cylinder Bore339

Inspect Piston Diameter339

Inspect Piston Clearance339

Inspect Ring Groove Clearance339

Inspect Piston Ring End Cap340

Inspect Piston Pin Oil Clearance340

Inspect Connecting Rod Sub-Assy341

Inspect Connecting Rod Bolt342

Inspect Crankshaft342

Inspect Crankshaft Bearing Cap Set Bolt343

Install Ring Pin343

Inspect Crankshaft Oil Clearance344

Install Tight Plug346

Install Straight Pin347

Install Piston348

Install Piston Ring Set348

Install Crankshaft Thrust Washer Upper349

Install Crankshaft Bearing No.2349

Install Crankshaft Bearing349

Install Connecting Rod Bearing350

Exhaust Pipe (2AZ-FE) Components352

Exhaust Pipe (1MZ-FE) Components355

Cooling System (2AZ-FE) On-Vehicle Inspection358

Inspect Cooling System for Leaks358

Check Engine Coolant Level at Reservoir358

Check Engine Coolant Quality358

Thermostat359

Radiator Cap Sub-Assy359

Cooling Fan System (2AZ-FE) On-Vehicle Inspection361

Cooling Fan Relay362

Add Coolant363

Drain Coolant363

Coolant (2AZ-FE) Replacement363

Water Pump Assy (2AZ-FE) Replacement365

Remove Water Pump Pulley365

Remove Water Pump Assy365

Install Water Pump Assy365

Thermostat (2AZ-FE) Replacement368

Radiator Assy (2AZ-FE) Removal & Installation and Disassembly & Reassembly369

Cooling System (1MZ-FE) On-Vehicle Inspection371

Cooling Fan System (1MZ-FE) On-Vehicle Inspection374

Coolant (1MZ-FE) Replacement377

Water Pump Assy (1MZ-FE) Replacement378

Thermostat (1MZ-FE) Replacement382

Radiator Assy (1MZ-FE) Removal & Installation and Disassembly & Reassembly383

Lubrication System (2AZ-FE) On-Vehicle Inspection385

Check Engine Oil Level385

Check Engine Oil Quality385

Remove Oil Pressure Switch Assy385

Check Oil Pressure386

Install Oil Pressure Switch386

Start Engine and Check for Leaks386

Oil Pump Assy (2AZ-FE) Replacement387

Oil Filter Sub-Assy (2AZ-FE) Replacement391

Lubrication System (1MZ-FE) On-Vehicle Inspection392

Oil Pump Assy (1MZ-FE) Replacement394

Oil Filter Sub-Assy (1MZ-FE) Replacement406

Ignition System (2AZ-FE) On-Vehicle Inspection407

Ignition System (1MZ-FE) On-Vehicle Inspection409

Starting System (2AZ-FE) Inspection411

Starter Assy (2AZ-FE) Replacement413

Starter Assy (2AZ-FE) Components414

Remove Repair Service Starter Kit415

Remove Starter Commutator End Frame Assy415

Remove Starter Armature Assy416

Inspect Starter Armature Assy416

Inspect Starter Commutator End Frame Assy417

Inspect Repair Service Starter Kit417

Install Starter Armature Assy418

Install Starter Commutator End Frame Assy418

Install Repair Service Starter Kit419

Charging System (2AZ-FE) Precaution420

Charging System (2AZ-FE) On-Vehicle Inspection421

Check Battery Electrolyte Level421

Check Battery Voltage421

Check Battery Terminals, Fusible Link and Fuses421

Inspect Charging Circuit Without Load422

Generator Assy (2AZ-FE) Replacement423

Generator Assy (2AZ-FE) Components424

Remove Generator Pulley425

Remove Generator Brush Holder Assy426

Remove Alternator Rectifier End Frame426

Remove Generator Rotor Assy426

Inspect Generator Regulator Assy426

Inspect Generator Rotor Assy427

Inspect Generator Holder W/Rectifier427

Inspect Brush428

Install Generator Rotor Assy428

Starting System (1MZ-FE) Inspection431

Starter Assy (1MZ-FE) Replacement433

Starter Assy (1MZ-FE) Components434

Charging System (1MZ-FE) Precaution440

Charging System (1MZ-FE) On-Vehicle Inspection441

Generator Assy (1MZ-FE) Replacement443

Generator Assy (1MZ-FE) Components444

Front Suspension System451

Front Suspension System Repair452

Front Suspension Components453

Front Wheel Alignment Adjustment455

Front Shock Absorber with Coil Spring Overhaul459

Front Suspension Arm Sub-Assy Lower No.1 LH Replacement465

Lower Ball Joint Assy Front LH Replacement467

Stabilizer Bar Front Replacement469

Rear Suspension System Problem Symptoms Table472

Rear Suspension System Components473

Rear Wheel Alignment Adjustment474

Shock Absorber Assy Rear LH Replacement475

Shock Absorber Assy Rear LH Disposal480

Rear Suspension Arm Assy No.1 LH Replacement481

Rear Suspension Arm Assy No.2 LH Replacement485

Stabilizer Bar Rear Replacement488

Strut Rod Assy Rear Replacement490

Wheel and Tire System Inspection492

Drive Shaft, Propeller Shaft, Axle Problem Symptoms Table493

Drive Shaft, Propeller Shaft, Axle On-Vehicle Inspection494

Drive Shaft, Propeller Shaft, Axle Components496

Front Drive Shaft Overhaul500

Front Axle Hub Sub-Assy LH Replacement513

Inspect and Adjust Front Wheel Alignment518

Check Abs Speed Sensor Signal(W/ Abs)522

Toyota 2002 Camry - Page 549

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