Toyota Celica 2000 - Repair Manual

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System2
Caution3
Engine Mechanical5
Inspection6
Compression Inspection8
Valve Clearance Adjustment9
Inspect Valve Clearance9
Adjust Valve Clearance10
2ZZ-GE: Valve Shim Selection Chart (Intake)15
2ZZ-GE: Valve Shim Selection Chart (Exhaust)16
Reinstall Camshaft17
Ignition Timing Inspection18
Warm up Engine18
Inspect Ignition Timing18
Idle Speed Inspection19
Install Conditions19
Timing Chain Components20
Remove Crankshaft Pulley25
Remove Timing Chain Cover25
Remove Timing Chain and Crankshaft Timing Sprocket26
Inspect Timing Chain and Timing Sprockets27
Inspect Chain Tensioner Slipper and Vibration Damper27
Inspect Chain Tensioner28
Replace Crankshaft Front Oil Seal29
Install Valve Timing Controller Assembly and Camshaft Timing Sprocket30
Install Chain Vibration Damper31
Install Timing Chain and Crankshaft Timing Sprocket31
Install Timing Chain Cover and Water Pump33
Install Rh Engine Mounting Bracket36
Install Crankshaft Position Sensor37
Install Crankshaft Pulley37
Install Chain Tensioner37
Set Chain Tension38
Check Valve Timing38
Install Cylinder Head Cover38
Install Rh Engine Mounting Insulator40
Cylinder Head Components41
Remove Exhaust Manifold48
Disconnect Engine Wire from Cylinder Head48
Remove Intake Manifold48
Remove Cylinder Head50
Remove Gasket Material53
Clean Combustion Chambers53
Clean Cylinder Head53
Clean Valve Guide Bushings54
Inspect for Flatness54
Inspect for Cracks54
Clean Valves54
Inspect Valve Stems and Guide Bushings55
Inspect Valves55
Inspect and Clean Valve Seats56
Inspect Valve Springs57
Inspect Camshaft for Runout58
Inspect Cam Lobes59
Inspect Camshaft Journals59
Inspect Camshaft Journal Clearance60
Inspect Camshaft Thrust Clearance61
Inspect Valve Timing Controller Assembly61
Inspect Valve Lifters and Lifter Bores62
Inspect Intake Manifold63
Inspect Exhaust Manifold63
Inspect Cylinder Head Bolts63
Replace Valve Guide Bushings64
Install Water Hose Unions66
Install Valves67
Install Valve Lifters68
Install Oil Control Valve Housing68
Place Cylinder Head on Cylinder Block70
Install Cylinder Head Bolts70
Install Camshafts71
Install Intake Manifold72
Connect Engine Wire to Cylinder Head73
Install Exhaust Manifold73
Engine Unit Components75
Remove Air Cleaner Cap79
Remove Air Cleaner Case79
Remove Ecm Box79
Disconnect Engine Wire from Engine80
Compartment Relay Box80
Disconnect Cruise Control Actuator80
Disconnect Ajc Compressor80
Disconnect Clutch Release Cylinder81
Disconnect Ps Pump82
Disconnect Ps Gear82
Remove Suspension Member82
Remove Rear Engine Mounting83
Remove Engine and Transaxle Assembly83
Installation85
Assembly Engine and Transaxle85
Install Engine and Transaxle Assembly in Vehicle85
Install Rear Engine Mounting85
Install Suspension Member86
Install Stabilizer Bar Bracket86
Install Exhaust Pipe87
Connect Clutch Release Cylinder87
Install Ajc Compressor87
Install Cruise Control Actuator88
Connect Engine Wire to Engine Compartment Relay Box88
Install Ecm Box88
Install Air Cleaner Case89
Install Air Cleaner Cap89
Cylinder Block Components90
Remove Oil Dipstick and Guide94
Remove Ventilation Case94
Remove Oil Pan95
Remove Oil Strainer95
Remove Oil Strainer and Oil Pan Baffle95
Check Connecting Rod Thrust Clearance96
Remove Connecting Rod Caps and Check Oil Clearance96
Remove Piston and Connecting Rod98
Check Crankshaft Thrust Clearance101
Check Fit between Piston and Piston Pin102
Remove Piston Rings102
Disconnect Connecting Rod from Piston102
Clean Cylinder Block103
Inspect Top Surface of Cylinder Block for Flatness103
Inspect Cylinder Bore Diameter103
Remove Cylinder Ridge104
Clean Piston104
Inspect Piston Oil Clearance105
Inspect Piston Ring End Gap106
Inspect Piston Pin Fit106
Inspect Connecting Rod Alignment106
Inspect Piston Pin Oil Clearance107
Inspect Connecting Rod Bolts108
Inspect Crankshaft for Circle Runout108
Inspect Main Journals and Crank Pins108
Replace Connecting Rod Bushings109
Replace Crankshaft Rear Oil Seal109
Assemble Piston and Connecting Rod111
Install Piston Rings112
Install Connecting Rod Bearings112
Install Main Bearings112
Install Thrust Washers113
Install Oil Strainer116
Install Oil Pan Baffle and Oil Strainer116
Install Oil Pan116
Install Engine Coolant Drain Union117
Install Knock Sensor117
Install Ventilation Case118
Install Water Bypass Pipe118
Install Oil Dipstick and Guide118
Install Flywheel118
Install Drive Plate119
Exhaust System Components120
Emission Control122
Emission Control System Purpose124
Parts Layout and Schematic Drawing Location125
Drawing126
Positive Crankcase127
Ventilation (Pcv) System Inspection127
Remove Pcv Valve127
Inspect Pcv Valve Operation127
Evaporative Emission (Evap) Control System Components128
Inspect Fuel Tank Filler Pipe129
Inspect Fuel Tank Cap129
Inspect Evap System Line129
Check Airtightness in Fuel Tank and Filler Pipe131
Inspect Fuel Cutoff Valve and Fill Check Valve131
Check Air Inlet Line132
Remove Charcoal Canister Assembly132
Inspect Charcoal Canister132
Three-Way Catalytic Converter (Twc} System Inspection134
Sfi136
SFI System Precaution138
Maintenance Precautions138
Air Induction System138
Electronic Control System138
Fuel System139
Fuel Pump On-Vehicle Inspection143
Check Fuel Pump Operation143
Check Fuel Pressure143
Inspect Fuel Pump Resistance146
Inspect Fuel Pump Operation146
Fuel Pump Components147
Remove Fuel Pump Assembly from Fuel Tank148
Remove No. 1 Fuel Suction Support149
Remove Vapor Pressure Sensor149
Remove Fuel Pressure Regulator149
Remove Fuel Pump149
Install Fuel Pressure Regulator150
Install Fuel Pump Assembly151
Connect Fuel Tube151
Install Floor Service Hole Cover151
Fuel Pressure Regulator Components152
Fuel Pressure Regulator Removal153
Injector On-Vehicle Inspection155
Check Operation Sound from each Injector155
Inspect Injector Resistance155
Install Wire Harness Protector Cover155
Disconnect Fuel Tube158
Remove Delivery Pipe and Injectors158
Inspect Injector Inspection159
Inspect Leakage160
Install Injectors and Delivery Pipes161
Fuel Tank and Line Precaution163
Fuel Tank and Line Components164
Inspect Fuel Tank and Line165
Mass Air Flow (Maf) Meter Components166
Remove Air Flow Meter167
Inspect Maf Meter Resistance168
Inspect Maf Meter Operation168
Install Air Flow Meter169
Throttle Body On-Vehicle Inspection170
Inspect Throttle Body170
Inspect Throttle Position Sensor170
Throttle Body Components171
Remove Throttle Body173
Inspect Throttle Valve175
Install Throttle Body176
Idle Air Control Valve On-Vehicle Inspection177
INSPECT Lac VALVE OPERATION177
Inspect Iac Valve Operation181
Camshaft Timing Oil Control Valve183
Inspect Oil Control Valve Resistance183
Remove Camshaft Timing Oil Control Valve186
Remove 2 Camshaft Timing Oil Control Valves186
Inspect Camshaft Oil Control Valve Operation187
EFI Main Relay Inspection189
Inspect Efi Main Relay Continuity189
Inspect Efi Main Relay Operation189
Circuit Opening Relay Inspection190
Inspect Circuit Opening Relay Continuity190
Inspect Circuit Opening Relay Operation190
VSV for Intake Air Control Valve Components191
VSV for Evaporative Emission (Evap) Components193
Inspect Vsv for Open Circuit194
Inspect Vsv for Ground194
Inspect Vsv Operation194
Vsv for Canister Closed Valve {CCV) Components195
Vsv for Pressure Switching Valve Components197
Engine Coolant Temperature (Ect) Sensor Components199
Inspect Ect Sensor Resistance200
Vapor Pressure Sensor Components201
Inspect Power Source Voltage of Vapor Pressure Sensor202
Inspect Power Output of Vapor Pressure Sensor202
Knock Sensor Components203
Remove Knock Sensor205
Inspect Knock Sensor205
Heated Oxygen Sensor Components206
Inspect Heater Resistance of Heated Oxygen Sensor207
Engine Control Module (Ecm) Components208
Fuel Cut Rpm Inspection210
Inspect Fuel Cut off Rpm210
Cooling212
Coolant Inspection214
Coolant Replacement215
Drain Engine Coolant215
Fill Engine Coolant215
Water Pump Components217
Remove Water Pump218
Inspect Water Pump219
Install Water Pump220
Thermostat Components221
Thermostat Removal222
Inspect Thermostat223
Place Thermostat in Cylinder Block224
Radiator On-Vehicle Cleaning225
Remove Reservoir Cap226
Inspect Reservoir Cap226
Inspect Cooling System for Leaks227
Remove Engine Coolant Reservoir230
Remove Radiator Assembly230
Remove Drain Plug231
Assemble Sst231
Uncaulk Lock Plates231
Remove Tanks and 0-Rings231
Inspect Lock Plate for Damage232
Radiator Reassembly233
Install Oil Cooler to Lower Tank233
Install New O-Rings and Tanks233
Caulk Lock Plate234
Install Drain Plug234
Inspect for Water Leaks235
Install Radiator Assembly236
Install Engine Coolant Reservoir236
Electric Cooling Fan On-Vehicle Inspection237
Check Cooling Fan Operation with Low Temperature237
Check Cooling Fan Operation with High Temperature237
Inspect Cooling Fans237
Electric Cooling Fan Components238
Electric Cooling Fan Removal240
Install Fan Motor(S)242
Install Fan(S)242
Install Cooling Fan243
Install Radiator Upper Support243
Cooling Fan Relay Inspection244
Inspect No. 1 Cooling Fan Relay244
Inspect No. 2 Cooling Fan Relay244
Inspect No. 3 Cooling Fan Relay245
Lubrication246
Oil and Filter Inspection248
Check Engine Oil Quality248
Check Oil Pressure248
Remove Center Engine under Cover250
Replace Oil Filter250
Refill with Engine Oil250
Oil Pump Components252
Oil Pump Removal256
Oil Pump Disassembly257
Inspect Oil Jet258
Inspect Relief Valve258
Inspect Rotor Side Clearance258
Inspect Rotor Tip Clearance258
Install Drive and Driven Rotors259
Install Relief Valve259
Install Oil Pump260
Oil Nozzle (2ZZ-GE) Components261
Inspect Relief Valve (Oil Nozzle)263
Install Oil Nozzle (with Relief Valve)264
Ignition266
Ignition System On-Vehicle Inspection268
Recommended Spark Plug270
Inspect Camshaft Position Sensor271
Ignition Coil Components272
Remove Ignition Coils (with Igniter) from Spark Plugs273
Camshaft Position Sensor Components275
Camshaft Position Sensor Removal276
Remove Camshaft Position Sensor276
Camshaft Position Sensor Installation277
Crankshaft Position Sensor Components278
Remove Crankshaft Position Sensor280
Starting284
Starting System On-Vehicle Inspection286
Starter Components287
Starter Removal289
Starter Disassembly290
Remove Steel Ball291
Starter Inspection292
Inspect Armature Coil Commutator for Open Circuit292
Inspect Commutator Circle Runout292
Inspect Commutator Diameter292
Inspect Field Frame (Field Coil) for Open Circuit293
Inspect Field Frame (Field Coil) Ground293
Inspect Brush Length293
Inspect Brush Spring Load293
Inspect Brush Holder Insulation294
Inspect Gear Teeth294
Inspect Clutch294
Starter Replacement295
Inspect Bearing295
Replace Bearings295
Remove Magnetic Switch End Cover295
Install Armature to Magnetic Switch Assembly298
Insert Steel Ball into Clutch Shaft Hole298
Install Starter Housing, Clutch Assembly and Gears298
Install Field Frame299
Install Brush Holder299
Install End Cover299
Install New Dust Protector299
Do Pull-In Test300
Do Hold-In Test300
Inspect Clutch Pinion Gear Return300
Do No-Load Performance Test300
Install Starter301
Starter Relay Inspection302
Inspect Starter Relay Continuity302
Charging304
Charging System306
Check Battery Electrolyte Level307
Check Battery Specific Gravity307
Check Battery Voltage307
Check Battery Terminals, Fusible Link and Fuses307
Inspect Drive Belt308
Visually Check Generator Wiring and Listen for Abnormal Noises308
Inspect Discharge Warning Light Circuit308
Inspect Charging Circuit Without Load309
Inspect Charging Circuit with Load309
Generator Components310
Generator Removal312
Remove Drive Belt312
Remove Generator312
Generator Disassembly313
Remove Rear End Cover313
Remove Brush Holder and Voltage Regulator313
Remove Rectifier Holder313
Remove Rectifier End Frame314
Generator Inspection315
Inspect Exposed Brush Length316
Inspect Positive Rectifier Holder316
Inspect Negative Rectifier Holder316
Inspect Front Bearing316
Inspect Rear Bearing317
Install Rotor to Drive End Frame319
Install Rectifier End Frame319
Install Pulley319
Install Rectifier Holder320
Install Voltage Regulator and Brush Holder321
Install Rear End Cover321
Install Generator322
Clutch324
Clutch Troubleshooting326
Problem Symptoms Table326
Clutch Pedal Inspection327
Check Pedal Height327
Check Pedal Free Play and Push Rod Play327
Check Clutch Release Point327
Check Clutch Start System328
Inspect Clutch Start Switch Continuity328
Clutch Master Cylinder Components329
Disconnect Reservoir Hose330
Disconnect Clutch Line330
Clutch Master Cylinder330
Remove Inlet Union331
Remove Boot from Cylinder331
Remove Push Rod331
Install Push Rod332
Install Inlet Union332
Connect Clutch Line333
Connect Reservoir Hose333
Clutch Release Cylinder Components334
Remove Release Cylinder335
Remove Boot Ano Push Rod336
Remove Piston and Spring336
Install Bleeder Plug337
Release Cylinder Installation338
Clutch Unit Components339
Clutch Unit Removal340
Remove Clutch Cover and Disc340
Clutch Unit Inspection341
Inspect Clutch Disc for Wear or Damage341
Inspect Clutch Disc Runout341
Inspect Flywheel Runout341
Clutch Unit Installation342
Install Clutch Disc and Clutch Cover on Flywheel342
Manual Transaxle (C56)344
Table of Contents344
Manual Transaxle (C56) Troubleshooting346
Manual Transaxle Unit Components347
Manual Transaxle Unit Removal349
Remove Hood349
Disconnect Control Cable349
Disconnect Ground Cable349
Remove Starter350
Remove Control Cable Bracket350
Attach Engine Sling Device to Engine Hanger350
Remove Engine Left Mounting Bracket351
Drain Transaxle Oil351
Remove Front Sub-Frame and Lower Suspension Arm352
Remove Engine Rear Mounting Insulator and Bracket352
Remove 4 Transaxle Lower Side Mounting Bolts352
Manual Transaxle Unit Installation353
Manual Transaxle Assembly Components354
Manual Transaxle Assembly Disassembly357
Remove Vehicle Speed Sensor357
Remove Control Shaft Assembly357
Remove Selecting Bellcrank Assembly357
Remove Control Shift Lever and Dust Boot358
Remove Transmission Case Cover358
Remove Lock Ball Assembly and Control Shaft Cover359
Remove Lock Nut359
Inspect 5Th Gear Thrust Clearance360
Inspect 5Th Gear Radial Clearance360
Remove No. 3 Clutch Hub and 5Th Gear361
Remove 5Th Driven Gear361
Remove Rear Bearing Retainer362
Remove Bearing Snap Ring362
Remove Lock Ball Assembly362
Remove Transmission Case363
Remove Oil Receiver Pipe363
Remove Reverse Shift Arm Bracket363
Manual Transaxle Assembly Inspection366
Inspect 5Th Gear Synchronizer Ring366
Inspect Gear Shift Fork and Hub Sleeve Clearance366
Install Transaxle Case Receiver368
Manual Transaxle Assembly Reassembly370
Input Shaft Components371
Input Shaft Disassembly372
Inspect 3Rd and 4Th Gears Thrust Clearance372
Input Shaft Inspection374
Inspect Synchronizer Ring374
Input Shaft Reassembly376
Install Snap Ring377
Inspect 3Rd Gear Thrust Clearance377
Output Shaft Components379
Output Shaft Disassembly380
Remove Snap Ring381
Remove Front Bearing Inner Race382
Disassemble Reverse Gear Assembly382
Output Shaft Inspection383
Inspect 1St Gear Synchronizer Ring383
Inspect 2Nd Gear Synchronizer Ring383
Inspect Gear Shift Fork and Reverse Gear Clearance384
Inspect Output Shaft384
Output Shaft Reassembly385
Install Front Bearing Inner Race385
Assemble Reverse Gear Assembly385
Inspect 1St Gear Thrust Clearance387
Install Output Gear Spacer, 4Th Driven Gear and Rear Radial Ball Bearing388
Shift and Select Lever Shaft Components389
Differential Case Components390
Differential Case Disassembly391
Remove Ring Gear391
Inspect Side Gear Backlash391
Disassemble Differential Case391
Differential Case Reassembly394
Assemble Differential Case394
Install Tapered Roller Bearing394
Install Ring Gear on Differential Case395
Inspect Differential Tapered Roller Bearing Preload395
Shift Lever and Control Cable Components397
Manual Transaxle (C60)400
Manual Transaxle (C60) Troubleshooting402
Manual Transaxle (C60) Components403
Manual Transaxle (C60) Removal405
Manual Transaxle (C60) Assembly Components410
Manual Transaxle (C60) Disassembly413
Manual Transaxle (C60) Assembly Inspection425
Manual Transaxle (C60) Assembly Reassembly429
Manual Transaxle (C60) Input Shaft430
Manual Transaxle (C60) Assembly Output Shaft438
Manual Transaxle (C60) Shift and Select Lever Shaft448
Manual Transaxle (C60) Differential Case449
Manual Transaxle (C60) Reverse Shift Warning Buzzer System456
Shift Lever and Control Cable458
Automatic Transaxle (U240E)462
Automatic Transaxle (U240E) System Precaution464
Automatic Transaxle (U240E) Operation465
Automatic Transaxle (U240E) Vehicle Speed Sensor466
Speed Sensor467
Atf Temperature Sensor On-Vehicle Repair469
Park/Neutral Position (Pnp) Switch On-Vehicle Repair471
Valve Body Assembly On-Vehicle Repair473
Shift Lock System Components478
Inspect Shift Lock Control Unit Assembly479
Floor Shift Assembly Components480
Shift Assembly Disassembly486
Automatic Transaxle Unit Components493
Automatic Transaxle Unit Removal494
Automatic Transaxle Unit Installation498
Transaxle Installation498
Torque Converter Clutch and Drive Plate Inspection499
Inspect One-Way Clutch499
Measure Drive Plate Runout and Inspect Ring Gear499
Measure Torque Converter Clutch Sleeve Runout499
Automatic Transaxle (U341 E)502
Automatic Transaxle (U341 E) System Precaution504
Automatic Transaxle (U341 E) Operation505
Automatic Transaxle (U341 E) Vehicle Speed Sensor506
Input Turbin Speed Sensor On-Vehicle Repair507
Remove Valve Body513
Install Check Valve and Spring514
Install Valve Body514
Install Atf Temperature Sensor514
Differential Oil Seal On-Vehicle Repair516
Floor Shift Assembly519
Remove Key Interlock Cable523
Remove 0/D Main Switch Terminal525
Remove Shift Lever Knob Sub-Assembly525
Remove Upper Position Indicator Housing525
Remove Lower Position Indicator Housing525
Install Floor Shift Assembly530
Install Key Interlock Cable530
Suspension and Axle542
Suspension and Axle Troubleshooting544
Tire and Wheel Inspection545
Inspect Tire545
Rotating Tires545
Inspect Wheel Balance546
Check Wheel Bearing Looseness546
Front Wheel Alignment Inspection547
Measure Vehicle Height547
Inspect Camber, Caster and Steering Axis Inclination547
Adjust Camber548
Inspect Toe-In549
Adjust Toe-In549
Inspect Wheel Angle550
Rear Wheel Alignment Inspection551
Adjust Camber and Toe-In551
How to Read Adjustment Chart (Example)552
Front Axle Hub Components554
Remove Lower Ball Joint557
Remove Axle Hub557
Remove Dust Cover557
Remove Bearing from Steering Knuckle557
Front Wheel Hub Bolt Replacement560
Install Hub Bolt560
Front Drive Shaft Components561
Remove Drive Shaft Lock Nut563
Disconnect Tie Rod End from Steering Knuckle563
Disconnect Lower Ball Joint from Lower Suspension Arm564
Disconnect Drive Shaft from Axle Hub564
Remove Drive Shaft564
Disassemble Drive Shaft566
Disassemble Inboard Joint Shaft567
Reassemble Inboard Joint Shaft569
Reassemble Drive Shaft570
Front Shock Absorber Components576
Front Shock Absorber Removal577
Disconnect Stabilizer Bar Link577
Front Shock Absorber Disassembly578
Remove Coil Spring578
Front Shock Absorber Inspection579
Inspect Shock Absorber579
Front Shock Absorber Disposal580
Drill Hole to Discharge Gas from Cylinder580
Front Shock Absorber Reassembly581
Install Coil Spring581
Front Lower Suspension Arm Components584
Front Lower Suspension Arm Removal585
Front Lower Ball Joint Components589
Front Lower Ball Joint Removal590
Front Lower Ball Joint Inspection591
Inspect Lower Ball Joint for Rotation Condition591
Front Lower Ball Joint Installation592
Install Lower Ball Joint592
Front Stabilizer Bar Components593
Front Stabilizer Bar Removal594
Remove Stabilizer Bar Links594
Remove Stabilizer Bar594
Front Stabilizer Bar Inspection595
Inspect Stabilizer Bar Link Ball Joint for Rotation Condition595
Front Stabilizer Bar Installation596
Rear Axle Carrier Components597
Rear Axle Carrier Removal598
Check Bearing Backlash and Axle Hub Deviation598
Remove Rear Axle Hub598
Disconnect Upper Support Suspension Arm599
Remove Rear Axle Carrier599
Rear Axle Carrier Disassembly600
Remove Abs Speed Sensor600
Rear Axle Carrier Reassembly601
Install New Abs Speed Sensor601
Rear Axle Carrier Installation602
Rear Wheel Hub Bolt Replacement603
Rear Shock Absorber Components604
Rear Shock Absorber Removal605
Rear Shock Absorber Disassembly606
Rear Shock Absorber Inspection607
Rear Shock Absorber Disposal608
Rear Shock Absorber Reassembly609
Rear Shock Absorber Installation610
Rear Upper Suspension Arm Components611
Rear Upper Suspension Arm Removal612
Rear Upper Suspension Arm Installation613
Rear Lower Suspension Arm Components614
Rear Lower Suspension Arm Removal615
Rear Stabilizer Bar Components618
Rear Stabilizer Bar Removal619
Rear Stabilizer Bar Inspection620
Rear Stabilizer Bar Installation621
Brake622
Brake System Precaution624
Brake System Troubleshooting625
Brake Fluid Bleeding627
Bleed Master Cylinder627
Bleed Brake Line627
Brake Pedal On-Vehicle Inspection629
Check Pedal Freeplay629
Brake Pedal Components630
Parking Brake Lever On-Vehicle Inspection631
Check Parking Brake Lever Travel631
Brake Master Cylinder Components632
Brake Master Cylinder Removal633
Disconnect Brake Line633
Remove Master Cylinder633
Remove Reservoir634
Brake Master Cylinder Installation635
Brake Booster Assembly On-Vehicle Inspection636
Air Tightness Check636
Brake Booster Assembly Components637
Brake Booster Assembly Removal638
Brake Booster Assembly Installation639
Install Brake Booster639
Front Brake Pad Components640
Front Brake Pad Replacement641
Inspect Pad Lining Thickness641
Lift up Caliper641
Install New Pads641
Install Caliper642
Front Brake Caliper Components643
Front Brake Caliper Removal645
Remove Front Wheel645
Disconnect Flexible Hose645
Remove Caliper645
Front Brake Caliper Disassembly646
Remove Set Ring and Cylinder Boot646
Remove Piston646
Remove Sliding Pins and Dust Boots646
Front Brake Caliper Inspection647
Measure Pad Lining Thickness647
Measure Disc Thickness647
Measure Disc Runout647
Front Brake Caliper Reassembly649
Front Brake Caliper Installation650
Rear Drum Brake Components651
Rear Drum Brake Removal652
Inspect Shoe Lining Thickness652
Remove Brake Drum652
Remove Front Shoe652
Remove Parking Brake Lever653
Remove Wheel Cylinder653
Disassemble Wheel Cylinder653
Rear Drum Brake Inspection654
Inspect Disassembled Parts654
Measure Brake Shoe Lining Thickness654
Measure Brake Drum Inside Diameter654
Rear Drum Brake Installation655
Check Operation of Automatic Adjusting Mechanism655
Check Clearance between Brake Shoes and Drum655
Rear Brake Pad Components656
Rear Brake Pad Replacement657
Rear Brake Caliper Components659
Rear Brake Caliper Removal660
Remove Piston Seal from Cylinder661
Parking Brake Components665
Remove Rear Wheel666
Remove Disc666
Remove Front Shoe and Adjuster666
Remove Rear Shoe667
Remove Parking Brake Shoe Lever667
Measure Disc Inside Diameter668
Adjust Parking Brake Shoe Clearance669
Settling Parking Brake Shoes and Disc669
Proportioning Valve (P Valve) On-Vehicle Inspection670
ABS Actuator On-Vehicle Inspection671
Push Motor Switch674
Components675
Front Speed Sensor Components678
Disconnect Speed Sensor Connector679
Remove Speed Sensor679
Rear Speed Sensor Components681
Rear Speed Sensor Removal682
Rear Speed Sensor Installation684
Steering686
Steering System Precaution688
Steering System Troubleshooting689
Drive Belt Inspection690
Power Steering Fluid Bleeding691
Power Steering Fluid Inspection692
Check Fluid Level692
Check Steering Fluid Pressure693
Steering Wheel Inspection695
Check Steering Wheel Freeplay695
Check Steering Effort695
Tilt Steering Column Components696
Tilt Steering Column Removal698
Remove Steering Wheel Pad698
Remove Steering Wheel698
Remove Transmission Shift Switch Assembly from Steering Wheel700
Remove Column Upper Bracket and Column Upper Clamp701
Remove Bracket Spacer and 2 No. 1 Support Collars701
Remove Main Shaft Bushing702
Remove Main Shaft Assembly702
Inspect Steering Lock Operation703
Steering Reassembly704
Install Main Shaft Assembly704
Install Main Shaft Bushing704
Install Break Away Bracket and Tilt Lever704
Install 2 No. 1 Support Collars and Bracket Spacer705
Install Column Upper Bracket and Column Upper Clamp705
Install Transmission Shift Switch Assembly to Steering Wheel706
Install Transmission Shift Switch Assembly and Speed Control Main Switch Assembly to Steering Wheel706
Connect No. 2 Intermediate Shaft Assembly707
Center Spiral Cable708
Install Steering Wheel708
Install Steering Wheel Pad708
Power Steering Vane Pump Components709
Power Steering Vane Pump Removal711
Power Steering Vane Pump Disassembly712
Power Steering Vane Pump Inspection713
Inspect Flow Control Valve714
Inspect Spring715
Power Steering Vane Pump Replacement716
Power Steering Vane Pump Reassembly717
Install Side Plate717
Install Cam Ring717
Install Vane Pump Rotor717
Power Steering Vane Pump Installation719
Install Ps Vane Pump Assembly719
Connect Pressure Feed Tube719
Install Drive Belt719
Power Steering Gear Components720
Power Steering Gear Removal723
Power Steering Gear Disassembly726
Power Steering Gear Replacement729
Power Steering Gear Reassembly733
Install Oil Seal733
Install Steering Rack733
Install Cylinder End Stopper734
Air Tightness Test734
Install Control Valve Assembly734
Install Rack Housing Cap734
Adjust Total Preload735
INSTALL RH and LH RACK BOOTS, WIRES and Clips736
Power Steering Gear Installation738
Install Ps Gear Assembly738
Connect Tube Clamp739
Connect Pressure Feed and Return Tubes739
Supplemental Restraint System742
Srs Airbag Precaution744
Srs Airbag Operation745
Steering Wheel Pad745
Spiral Cable745
Front Passenger Airbag Assembly745
SRS Warning Light746
Airbag Sensor Assembly746
Front Airbag Sensor746
Side Airbag Sensor Assembly746
SRS Connectors747
Terminal Twin-Lock Mechanism748
Electrical Connection Check Mechanism749
Disconnection of Connectors for Front Airbag Sensor, Side Airbag Sensor and Door Side Airbag Sensor750
Disconnection of Side Airbag Connector752
Connection of Side Air Bag Connector752
Steering Wheel Pad and Spiral Cable Components755
Steering Wheel Pad and Spiral Cable Removal756
Steering Wheel Pad and Spiral Cable Inspection757
Inspect Supplemental Restraint System757
Steering Wheel Pad and Spiral Cable Disposal759
Deployment When Disposing of Steering Wheel Pad with Airbag Deployed in Collision768
Steering Wheel Pad and Spiral Cable Replacement769
Steering Wheel Pad and Spiral Cable Installation770
Front Passenger Airbag Assembly Components771
Front Passenger Airbag Assembly Removal772
Disconnect Air Bag Connector772
Remove Front Passenger Airbag Assembly772
Front Passenger Airbag Assembly Inspection773
Front Passenger Airbag Assembly Disposal775
Front Passenger Airbag Assembly Replacement782
Front Passenger Airbag Assembly Installation783
Side Airbag Assembly Components784
Side Airbag Assembly Removal785
Remove Seat Back Assembly786
Side Airbag Assembly Inspection787
Side Airbag Assembly Disposal788
Side Airbag Assembly Installation795
Install Inner Front Seat Cushion Shield796
Install Front Seat796
Airbag Sensor Assembly Components797
Airbag Sensor Assembly Removal798
Airbag Sensor Assembly Inspection799
Airbag Sensor Assembly Replacement800
Airbag Sensor Assembly Installation801
Install Airbag Sensor Assembly801
Front Airbag Sensor Components802
Front Airbag Sensor Removal803
Front Airbag Sensor Inspection804
Front Airbag Sensor Replacement805
Front Airbag Sensor Installation806
Side Airbag Sensor Assembly Components807
Side Airbag Sensor Assembly Removal808
Side Airbag Sensor Assembly Inspection809
Side Airbag Sensor Assembly Replacement810
Side Airbag Sensor Assembly Installation811
Door Side Airbag Sensor Components812
Door Side Airbag Sensor Removal813
Door Side Airbag Sensor Inspection814
Door Side Airbag Sensor Replacement815
Door Side Airbag Sensor Installation816
Wire Harness and Connector Location817
Wire Harness and Connector Inspection818
Wire Harness and Connector Replacement819
Body Electrical820
Body Electrical System822
Headlight System822
Audio System822
Body Electrical System Troubleshooting823
Warning Lights827
Power Source Location831
Engine Room Junction Block832
Center Junction Block833
Ignition Switch and Key Unlock Warning Switch Location834
Ignition Switch and Key Unlock Warning Switch Inspection835
Inspect Ignition Switch Continuity835
Inspect Key Unlock Warning Buzzer835
Headlight and Taillight System Location836
Headlight and Taillight System Components837
Headlight and Taillight System Inspection838
Inspect Automatic Light Control839
Inspect Light-Off Condition839
Inspect Sensor Circuit839
Headlight and Taillight System Adjustment841
Adjust Headlight Aim Only841
Fog Light System Location843
Fog Light System Inspection844
Inspect Front Fog Light Switch Continuity844
Inspect Front Fog Light Relay Continuity844
Fog Light System Adjustment845
Turn Signal and Hazard Warning System Location846
Turn Signal and Hazard Warning System Inspection847
Interior Light System Location848
Interior Light System Inspection849
Inspect Rear Room Light Continuity849
Inspect Door Courtesy Switch Continuity849
Inspect Licence Plate Light Continuity850
Back-Up Light System Location851
Back-Up Light System Inspection852
Inspect Back-Up Light Switch Continuity852
Stop Light System Location853
Stop Light System Inspection854
Inspect Stop Light Switch Continuity854
Wiper and Washer System Location855
Wiper and Washer System Inspection856
Inspect Front Washer Linked Operation857
Inspect Rear Wiper and Washer Switch Continuity857
Inspect Front Wiper Motor Operation857
Combination Meter Location860
Combination Meter Circuit863
Combination Meter Components865
Combination Meter Disassembly866
Combination Meter Cover866
Combination Meter Inspection867
Inspect Tachometer Resistance868
Inspect Fuel Receiver Gauge Operation868
Inspect Fuel Sender Gauge Resistance869
Inspect Engine Coolant Temperature Receiver Gauge Operation869
Inspect Low Oil Pressure Warning Light870
Inspect Low Oil Pressure Switch Continuity870
Inspect Brake Warning System Light870
Inspect Brake Fluid Level Warning Switch Continuity871
Inspect Parking Brake Warning Light871
Inspect Parking Brake Switch Continuity871
Inspect Open Door Warning Light871
Inspect Light Control Thermostat Operation872
Electric Tension Reducer System Location873
Electric Tension Reducer System Inspection874
Inspect Buckle Switch Continuity874
Defogger System Location875
Defogger System Inspection876
Inspect Defogger Timer Operation876
Inspect Defogger Switch Circuit876
Power Window Control System Location879
Power Window Control System Inspection880
Inspect Power Main Relay Continuity880
Inspect Power Window Motor Operation880
Inspect Ptc Operation881
Power Door Lock Control System Location883
Power Door Lock Control System Inspection884
Wireless Door Lock Control System Location888
Wireless Door Lock Control System Pre-Check889
Wireless Door Lock Control System Inspection894
Inspect Wireless Door Lock Transmitter Operation894
Check Battery Capacity895
Inspect Wireless Door Lock Control Receiver Circuit896
Replace Transmitter (Lithium) Battery898
Replace Door Control Receiver and Transmitter899
Sliding Roof System Location904
Sliding Roof System Inspection905
Power Mirror Control System Location906
Power Mirror Control System Inspection907
Audio System Description909
Radio Wave Band909
Service Area909
Reception Problems909
Noise Problems910
Diagnosis Code List917
Radio Troubleshooting918
Radio Not Operating When Power Switch Turned to "On"919
Audio System Location937
Inspect Radio Receiver Assembly Circuit938
Antenna Location940
Clock Troubleshooting943
Clock Loses or Gains Time944
Horn System Location946
Inspect Horn Switch947
Inspect Horn Operation947
Inspect Horn Relay Continuity948
Body950
Clip Replacement952
Front Bumper Components955
Rear Bumper Components956
Headlight Components957
Remove Headlight958
Hood Adjustment960
Front Door Components961
Front Door Disassembly962
Remove Regulator Handle962
Remove Lower Frame Bracket Garnish962
Remove No, 2 Door Inside Handle Bezel962
Remove Door Trim963
Remove Door Side Airbag Sensor963
Remove Front Door Weatherstrip964
Remove Front Door Belt Moulding964
Remove Upper Window Stops965
Remove Door Glass965
Remove Window Regulator965
Remove Window Regulator from Motor966
Remove Speaker966
Remove Door Glass Female Stabilizer967
Remove Front Lower Frame967
Remove Front Door No. 2 Weatherstrip967
Remove Door Lock967
Remove Outside Handle968
Inspect Front Door Glass969
Front Door Adjustment970
Adjust Front Door Glass970
Back Door Components973
Back Door Disassembly974
Remove Back Door Trim Board974
Remove Rear Wiper Arm974
Remove Rear Wiper Motor974
Remove Control Cable975
Remove Back Door Lock975
Remove Key Cylinder975
Remove Outside Back Door Garnish975
Adjust Door in Left/Right and Vertical Directions976
Adjust Door in Forward/Rearward and Yertical Directions976
Adjust Door Lock Striker976
Adjust Lower Stopper976
Back Door Reassembly977
Back Door Stay Replacement978
Remove Back Door Stay978
Front Wiper and Washer Components979
Front Wiper and Washer Removal980
Remove Wiper Arms980
Remove Cowl Top Ventilator Louver980
Remove Wiper Motor and Link Assembly980
Front Wiper and Washer Inspection981
Inspect Washer Nozzle981
Front Wiper and Washer Adjustment982
Adjust Front Washer Nozzle982
Front Wiper and Washer Installation983
Install Wiper Motor983
Install Wiper Motor and Link Assembly983
Install Cowl Top Ventilator Louver983
Rear Wiper and Washer Components984
Rear Wiper and Washer Removal985
Remove Rear Washer Nozzle985
Rear Wiper and Washer Inspection986
Rear Wiper and Washer Installation987
Roof Drip Side Moulding Components989
Roof Drip Side Moulding Removal990
Roof Drip Side Moulding Installation991
Clean Body Mounting Surface991
Clean Moulding991
Install Roof Drip Side Moulding991
Install Roof Side Rail Weatherstrip992
Roof Side Moulding Components993
Roof Side Moulding Removal994
Roof Side Moulding Installation995
Clean Contract Surface of Body995
Apply Adhesive996
Install Moulding996
Side Mudguard Components997
Windshield Components998
Windshield Removal999
Remove Front Pillar Garnish999
Remove Map Light Assembly999
Remove Inner Rear View Mirror999
Remove Winoshield Outside Moulding1000
Remove Windshield Glass1000
Windshield Installation1001
Clean and Shape Contact Surface of Body1001
Clean Removed Glass1001
Install New Dams1002
Position Glass1002
Clean Contact Surface of Glass1002
Coat Contact Surface of Body with Primer1002
Coat Contact Surface of Glass with Primer1003
Install Windshield Glass and Moulding1003
Inspect for Leak and Repair1004
Install Wiper Arms1004
Quarter Window Glass Components1006
Quarter Window Glass Removal1007
Remove Door Scuff Plate1007
Remove Luggage Compartment Tray1007
Remove Rear Deck Trim Cover1007
Remove Quarter Trim Panel1008
Remove Roof Side Inner Garnish1008
Remove Roof Side Rail Weatherstrip1008
Remove Quarter Window Glass1009
Quarter Window Glass Installation1011
Clean and Shape Contact Surface of Body Panel1011
Clean Contact Surface of New Glass1011
Install New Spacers1011
QUARTER WINDOW Glass1012
Back Door Glass Components1015
Back Door Glass Removal1016
Remove Center Stop Light1016
Remove Back Door Glass1016
Back Door Glass Installation1017
Install New Dams and Outside Lower Moulding1017
Install Rear Wiper Arm1019
Sliding Roof On-Vehicle Inspection1020
Inspect Sliding Roof Glass Alignment1020
Sliding Roof Components1021
Sliding Roof Removal1022
Sliding Roof Disassembly1023
Remove Sunshade Stoppers1023
Remove Front Housing Frame1023
Remove Drive Cable1023
Sliding Roof Adjustment1024
Sliding Roof Reassembly1025
Sliding Roof Installation1026
Instrument Panel Components1027
Instrument Panel Removal1030
Instrument Panel Disassembly1034
Instrument Panel Reassembly1035
Roof Headlining Components1037
Roof Headlining Removal1039
Remove Deck Trim Side Panel1039
Front Seat Components1043
Front Seat B0-921043
Front Seat Removal1044
Remove Seat Track Covers1044
Remove Front Seat1044
Front Seat Disassembly1045
Front Seat Reassembly1048
Install Reclining Connecting Pipe1048
Install Seat Cushion Assembly1048
Install Front Seat Inner Belt1048
Install Seatback Cover1049
Install Seatback Assembly1049
Front Seat Installation1051
Rear Seat Components1052
Rear Seat Removal1053
Rear Seat Disassembly1054
Rear Seat Reassembly1055
Install Seat Cushion Coyer1055
Install Seatback Frame1055
Rear Seat Installation1056
Seat Belt Components1057
Rear Seat1057
Seat Belt Inspection1058
Seat Belt Pretensioner Removal1060
Seat Belt Pretensioner Inspection1062
Seat Belt Pretensioner Disposal1063
Seat Belt Pretensioner Activation When Scrapping Vehicle1064
Seat Belt Pretensioner Replacement1068
Seat Belt Pretensioner Installation1069
Air Conditioning1070
Air Conditioning System Precaution1072
Supplemental Restraint System (Srs)1073
Air Conditioning System On-Vehicle Inspection1074
Inspect Refrigerant Volume1074
Inspect Refrigerant Pressure with Manifold Gauge Set1075
Inspect Idle-Up Speed1079
Inspect for Leakage of Refrigerant1080
Air Conditioning System Evacuating1081
Evacuate Air from Refrigeration System1081
Air Conditioning System Charging1082
Install Charging Cylinder1082
Inspect Refrigeration System for Leaks1082
Charge Refrigerant into Refrigerant System1083
Air Conditioning System Location1084
Air Conditioning System Troubleshooting1085
Drive Belt On-Vehicle Inspection1087
Drive Belt Removal1088
Drive Belt Installation1089
Manifold Gauge Set1090
Set on1090
Set off1091
Refrigerant Line On-Vehicle Inspection1092
Refrigerant Line Location1093
Refrigerant Line Replacement1094
Air Conditioning Unit On-Vehicle Inspection1095
Air Conditioning Unit Components1096
Air Conditioning Unit Removal1097
Air Conditioning Unit Inspection1099
Inspect Evaporator1099
Inspect Heater Radiator1099
Air Conditioning Unit Installation1100
Blower Unit Components1101
Blower Unit Removal1102
Remove Blower Unit1102
Blower Unit Disassembly1103
Remove Air Refiner Filter1103
Remove Blower Motor1103
Blower Unit Reassembly1104
Blower Unit Installation1105
Compressor and Magnetic Clutch On-Vehicle Inspection1106
Inspect Compressor for Metallic Sound1106
Inspect Compressor Lock Sensor Resistance1106
Inspect Magnetic Clutch Operation1106
Compressor and Magnetic Clutch Components1107
Compressor and Magnetic Clutch Removal1108
Compressor and Magnetic Clutch Disassembly1109
Remove Pressure Plate1109
Remove Rotor1109
Remove Stator1110
Compressor and Magnetic Clutch Reassembly1111
Install Pressure Plate1112
Inspect Magnetic Clutch Clearance1112
Compressor and Magnetic Clutch Installation1113
Condenser On-Vehicle Inspection1114
Inspect Condenser Fins for Blockage or Damage1114
Inspect Condenser and Fittings for Leakage1114
Condenser Components1115
Condenser Removal1116
Remove Liquid Tube and Discharge Hose1116
Remove Radiator Upper Mountings1116
Condenser Replacement1117
Replace Dryer from Modulator1117
Condenser Installation1118
Blower Motor Inspection1119
Inspect Blower Motor Operation1119
Install Blower Motor1119
Blower Resistor Inspection1120
Thermistor Inspection1121
Remove Thermistor1121
Install Thermistor1121
Pressure Switch On-Vehicle Inspection1122
Inspect Pressure Switch Operation1122
Pressure Switch Removal1123
Pressure Switch Installation1124
Heater Main Relay Inspection1125
Magnetic Clutch Relay Inspection1126
Condenser Fan On-Vehicle Inspection1128
Condenser Fan Components1129
Air Conditioning Amplifier On-Vehicle Inspection1131
Inspect Aic Amplifier Circuit1131
Heater Control Assembly On-Vehicle Inspection1136
Inspect Heater Control Dials Operation1136
Heater Control Assembly Components1137
Heater Control Assembly Removal1138
Heater Control Assembly Inspection1139
Inspect Bulb1139
Inspect Aic Indicator Operation1139
Inspect Dimming Operation1139
Inspect Aic Switch Continuity1140
Inspect Defroster Mode Switch Operation1140
Heater Control Assembly Installation1141
Connect A/C Control Cables1142
Engine Coolant Temperature (ECT) Switch Inspection1143
Air Refiner Filter Replacement1144
Install Air Refiner Filter1144
Alphabetical Index1146

Toyota Celica 2000 - Repair Manual

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