This is the Highly Detailed factory service repair manual for the2002 TOYOTA CELICA, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.2002 TOYOTA CELICA Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Introduction Maintenance Preparation Service Specifications Diagnositics 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 File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to have2002 TOYOTA CELICA Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting! 8

1. TOYOTA
REPAIR
MANUAL
• MAINTENANCE
• PREPARATION
• SPECIFICATIONS
•DIAGNOSTICS
Pub. No. RM744U1 VOLUME 1

2. 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 thatthe publications below have also been prepared as relevant service manuals forthe compo-
nents and systems in this vehicles.
r Manual Name
• U240E Automatic Transaxte Repair Manual (Aug., 1999)
•; U340E, U341E Automatic Transaxle Repair Manual (Aug., 1999)
• 2000 CELICA Electrical Wiring Diagram
•,2000CELICANewCarFeatures
Pub. No.
RM740U
RM735U
EWD399U
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 repro-
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Jul. 14,1999 01-990714-00

3. NOTE: The screen toned sections below are in VOLUME 2
(Pub. No. RM744U2).
INTRODUCTION
MAINTENANCE
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
erjyrs
f.uife*»;K
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il
i®s»*^jtta^ri3<-MS^
AIR
ALPHABETICAL INDEX If

4. NOTE:ThescreentonedsectionsbelowareinVOLUME1
(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

5. ENGINE MECHANICAL
CO/HC EM-1
COMPRESSION EM-3
VALVE CLEARANCE EM-4
IGNITION TIMING EM-13
IDLE SPEED EM-14
TIMING CHAIN EM-15
CYLINDER HEAD EM-36
ENGINE UNIT EM-70
CYLINDER BLOCK EM-85J
EXHAUST SYSTEM EM-115

6. EM-1
ENGINE MECHANICAL - CO/HC
CO/HC EMOSJ-OS
INSPECTION
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 SE-
CONDS
CO/HC Meter
4. 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 mea-
surement order prescribed by the applicable local regulations.

7. 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 neces-
sary.
CO HC
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
(Fluctuating HC reading)
1. Vacuum leaks:
• 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

8. EM-3
ENGINE MECHANICAL - COMPRESSION
H037
COMPRESSION EMOSK-05
INSPECTION
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 pos-
sible.
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.
• 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)

9. EM-4
ENGINE MECHANICAL - VALVE CLEARANCE
VALVECLEARANCE BJlSQ-OI
ADJUSTMENT
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE CYLINDER HEAD COVER
(See page EM-18)
1ZZ-FE:
A01044
2. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark "0" of the timing chain cover.
(b) Check that the point marks of the camshaft timing sprock-
ets 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.
2ZZ-GE:
3. INSPECT VALVE CLEARANCE
(a) Gheck only the valves indicated.
• Using a feeler gauge, measure the clearance be-
tween 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.)

10. ENGINE MECHANICAL - VALVE CLEARANCE
EM-5
1Z2-FE:
2Z2-GE:
Valve Lifter
A10366
A10411
A10412
YA01053
(b) Turn the crankshaft 1 revolution (360°) and align the mark
as above (See procedure in step 2).
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
4. 1ZZ-FE:
ADJUSTVALVECLEARANCE
(a) Set the No. 1 cylinder to the TDC/compression (See pro-
cedure in step 2).
(b) Place matchmarks on the timing chain and camshaft tim-
ing sprockets.
(c) Remove the 2 bolts and chain tensioner.
(d) 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 illustra-
tion.
NOTICE:
• Be careful not to drop anything inside the timing
chain cover.
• Do not allowthe chain to come into contactwith water
or dust.
(f) Remove the valve lifters.

11. EM-6
ENGINE MECHANICAL - VALVE CLEARANCE
A01082
(g) 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 pos-
sible 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 cam-
shaft on the adjusting valve points upward.
SST
(2) Using SST, press down the valve.
(3) 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.

12. 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 in41 size in incrementsof0.020 mm (0.0008
in.), from 2.000 mm (0.0787 in.) to 2.800 mm (0.1102 in.).

13. 1ZZ-FE: Valve Lifter Selection Chart (Intake)
m
^"". Installed lifter thickness
^^^ mm (in )
Measured clearance ^-^^
mm (in.) ^s
*v^
0.000 - 0.030 (0.0000 - 0.001 2)
0.031 -0.050(0.0012-0.0020)
0.051 - 0.070 (0.0020 - 0 0028)
0.071 - 0.090 (0.0028 - 0.0035)
0.081 - 0 1 10 (0.0036 - O.OO43)
0111-0.130(00044-00061)
0.131 -0.149(0.0052-0.0059)
0. 1 50 - 0.250 (0.0059 - 0,0098)
0.251 - 0.270 (0,0099 - 0.0106)
0.271 - 0.2SO (0.0107 - 0.01 1 4)
0.291 -0.310 (0.0115 - 0.0122)
0.311 -0.330 (0,0122 -0.0130)
0.331 -0.350(0.0130-0.0138)
0.351 -0370(0.0138-0,0146)
0.371 - 0.390 (0.0146 - 0.0154)
0.391 - 0.410 (0.0154 - 0.0161)
0.411-0.430(0.0162-0,0169)
0.431 - 0.450 (0.0170 - 0,0177)
0.451 - 0 470 (0.0178 - 0.0185)
0.491 - 0.510 (0.01 93 - 0.0201)
0.51 1 - 0.530 (0.0201 - 0.0209)
0.531-0.550(0.0209-0.0217)
0.351 - 0.570 (0.021 7 - 0.0224)
0.571 - 0.590 (0.0225 - 0.0232]
0.5B1 - 0.610 {0.0233 - 0.0240)
0611 -0.630(0.0241 -0.0248)
0.651 - 0.670 (0.0256 - 0.0264)
0.691 -0,710(0.0272-0.0280)
0,7 1 1 - Q 730 {0.0280 - 0.0287)
0 731 - 0.760 (0.0288 - 0.0295)
0.751 - 0,770 {0.0296 - 0.0303)
0.771 -0.790(0.0304-0.0311)
0.791-0.610(0.0311-0.0319)
0.811 -0.830(0.0319-0.0327)
0,831 - 0.850 (0,0327 - 0.0335)
0.851 - 0.870 (0.0335 - 0.0343)
0.871 - 0.800 {0.0343 - 0.0350)
ft AOI ft oin in n*»Ki niwuii
0.9 1 1 - 0.9X (0.0359 - 0.0366)
a
1
12
14
15
18
20
22
24
26
28
30
32
36
38
40
42
44
46
48
52
06
58
60
62
«4
66
68
70
72
74
74
74
g
S
a
06
14
16
18
20
22
24
26
28
30
32
34
38
40
42
44
46
48
50
54
68
BO
62
64
66
68
70
72
74
74
74
00(0.2008
iri
06
06
16
18
20
22
24
26
28
3D
32
34
36
40
42
44
46
48
SO
52
56
60
62
64
66
68
70
72
74
74
74
20(0.2016
in'
06
08
06
16
20
22
24
26
28
30
32
34
36
38
42
44
46
48
50
52
54
58
62
64
66
66
70
72
74
74
74
40(0.2024
iri
06
06
08
08
20
22
24
28
28
30
32
34
38
38
40
44
46
48
50
62
54
55
60
64
66
68
70
72
74
74
74
a
S
Iri
06
06
06
OB
10
22
24
26
28
30
32
34
36
38
40
42
48
48
50
52
54
58
58
62
86
68
70
72
74
74
74
a
a
0
06
08
06
08
10
12
24
26
28
30
32
34
36
38
40
42
44
48
50
52
64
66
58
50
64
68
70
72
74
7*
74
a
08
06
08
10
12
14
26
28
30
32
34
36
38
40
42
44
46
60
52
54
56
58
60
62
66
70
72
74
74
74
5510(0.2051
06
06
08
10
12
14
16
26
30
32
34
36
38
40
42
44
46
48
62
64
66
SB
60
62
64
SB
72
74
74
74
|
05
06
08
10
12
14
16
28
30
32
34
36
38
40
42
44
45
46
52
54
B6
58
60
62
64
88
72
74
74
74
a
08
08
10
12
14
16
16
30
32
34
36
38
40
42
44
46
48
50
54
56
58
50
62
64
66
70
74
74
5.240(02063
06
08
10
12
14
16
18
30
32
34
36
38
40
42
44
46
46
50
54
56
68
60
62
64
E6
70
74
74
2.
06
10
12
16
18
20
32
34
36
38
40
42
44
46
48
50
52
66
58
60
62
64
66
58
72
74
5.260(0.2071
08
10
12
16
18
20
32
34
36
38
40
42
44
46
48
50
52
56
58
60
52
64
66
68
72
74
5.270(0.2075
10
12
14
18
20
22
34
36
38
40
42
44
46
46
SO
52
54
58
80
62
64
6G
68
70
5.280(0.2079)
10
12
14
18
20
22
34
36
38
40
42
44
46
48
50
62
54
58
60
62
64
66
68
70
a
12
14
16
20
22
24
38
38
40
42
44
46
48
50
52
54
66
60
62
64
66
66
70
72
5.300(0.2087)
12
14
16
20
22
24
38
38
40
42
44
46
48
50
52
54
56
60
62
64
66
68
70
72
5.310(05091)
14
16
18
20
22
24
26
38
40
42
44
46
48
50
52
54
56
58
52
64
66
68
70
72
74
a
1
14
16
18
20
22
24
26
38
40
42
44
48
48
60
52
54
56
SB
62
64
66
68
70
72
74
74
a
I
16
18
20
as
24
26
28
40
42
44
48
48
50
52
54
56
68
60
64
66
68
70
72
74
74
§
zolores
16
18
20
22
24
26
26
40
42
44
46
48
60
52
54
56
58
60
64
66
68
70
72
74
74
S
5.350(0.2
18
20
22
24
28
28
30
42
44
46
48
50
52
54
53
58
60
82
66
68
70
72
74
74
S
5.360(0.2
18
20
22
24
26
28
30
42
44
46
48
50
52
54
56
58
60
62
66
68
70
72
74
74
?
5.370(0.2
20
22
24
28
28
30
32
44
46
46
50
52
64
56
56
80
82
84
68
70
72
74
74
3
a
1
20
22
24
26
28
30
32
44
46
48
50
52
54
5G
58
60
62
64
68
70
72
74
74
S
a
22
24
26
28
30
32
34
46
48
50
62
54
56
58
60
82
64
66
70
72
74
74
if
5.400(0.2
22
24
28
28
30
32
34
46
46
50
52
54
56
58
eo
62
64
66
70
72
74
74
f
5.410(0.2
24
26
26
30
32
34
36
48
50
52
54
56
58
60
62
64
66
6Q
72
74
74
S
5.420(0.2
24
26
28
30
32
34
36
48
50
52
54
56
68
60
62
84
66
68
72
74
74
S
5.430(0.2
26
28
30
32
34
36
38
50
52
54
66
58
60
62
94
66
68
70
74
74
¥
a
1
iri
26
28
30
32
34
36
38
50
52
54
66
58
60
62
64
66
68
70
74
74
?
a
28
30
32
34
36
38
40
52
54
56
68
60
62
84
68
68
70
72
74
S
5.460(0.2
28
30
32
34
36
38
40
52
54
56
58
60
62
64
86
86
70
72
74
S
<M
a
g
iri
30
32
34
36
38
40
42
54
56
56
60
62
84
66
68
70
72
74
in
5.480(0.2
30
32
34
36
38
40
42
54
66
58
60
62
64
66
68
70
72
74
5
5.490(0.2
32
34
36
38
40
42
44
56
58
60
62
64
66
68
70
72
74
Intake vave 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.
8
5.500(0.2
32
34
36
38
40
42
44
56
SB
60
62
64
66
88
70
72
74
8
0
iri
34
36
36
40
42
44
46
58
60
62
64
66
88
70
72
74
74
C f
a i
m i
34 3
36 31
38 4
40 4
42 4
44 4
46 4
58 6
60 6
62 6
64 6
66 6
88 7
70 7
72 ^
74 7
Lifter
No.
06
08
10
12
14
16
18
20
22
24
26
26
5
i a
i 1
6 35
3 38
0 40
I 42
4 44
6 46
8 48
0 60
2 62
4 64
« 66
8 68
0 70
2 72
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17. EM-12
ENGINE MECHANICAL VALVE CLEARANCE
6. 1ZZ-FE:
REINSTALL CAMSHAFT
(a) Reinstall the valve lifters (See page EM-61).
(b) Align the crankshaft pulley groove with the timing mark "0"
of the timing chain cover.
(c) Hold the timing chain, and place the intake camshaft and
timing sprocket assembly.
(d) Align the matchmarks on the timing chain and camshaft
timing sprocket.
(e) Reinstall the camshaft and timing sprocket assemblies
(Seepage EM-65).
A10387
(f) Check that the point marks of the camshaft timing sprock-
ets are in straight line on the timing chain cover surface
as shown in the illustration.
(g) Check that the matchmarks on the timing chain and cam-
shaft timing sprockets.
(h) Install the chain tensioner (See page EM-25).
(i) Recheck the valve clearance (See procedure in step 3).
(j) Check the valve timing (See page EM-25).
7. REINSTALL CYLINDER HEAD COVER
(See page EM-25)

18. EM-13
ENGINE MECHANICAL - IGNITION TIMING
IGNITION TIMING EM15FMM
INSPECTION
1. WARM UP ENGINE
Allowthe engine to warm up to normal operating temperature.
TOYOTA Hand-Held Tester
D07259
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
scantooloperator'sforfurtherdetails.
3. CONNECT TIMING LIGHT TO ENGINE
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

19. EM-14
ENGINE MECHANICAL - IDLE SPEED
IDLESPEED EM05N-0
INSPECTION
1. INSTALL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All vacuum lines properly connected
(e) SFI system wiring connectors fully plugged
(f) All operating accessories switched OFF
(g) Ignition timing check correctly
(h) Transmission in neutral position
(i) Air conditioning switched OFF
TOYOTAHand-HeldTester
D072S9
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCANTOOL
(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

20. ENGINE MECHANICAL - TIMING CHAIN
EM-15
TIMING CHAIN
COMPONENTS
Upper Front Fender Apron Seal
Drive Belt
PS Oil Pressure
Switch Connector
PS Pump
Upper Radiator Support
Seal
Generator
Connector
1ZZ-FE: I 52(530.38)
RH Engine Mounting
Insulator
2ZZ-GE:
RH Engine Mounting | 52(530,38)
Insulator
RH Engine Under Cover
N-m (kgf-cm, ft-lbf) : Specified torque
A10352

21. EM-16
ENGINE MECHANICAL - TIMING CHAIN
1ZZ-FE:
RH Engine Mounting Bracket
Belt Tensioner
Timing Chain Cover
Timing Chain Tensioner
Front Crankshaft
Oil Seal
No. 2 Cylinder Head Cover
Wire Harness
Protector
Crankshaft
Pulley x 6
Water Pump
Chain Tensioner
Slipper
Crankshaft Position
Sensor
* Gasket Camshaft Timing
Sprocket
Chain ^
r -gym
I ^
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

22. ENGINE MECHANICAL - TIMING CHAIN
EM-17
2ZZ-GE:
RH Engine Mounting Bracket
Wire Harness Protector
No. 2 Cylinder Head
Cover
PCV Hose
Driver Belt * 4
Tensioner Ignition Coil (w/ Igniter).
9.0(90,80in.-lbf)
Timing Chain Cover
Timing Chain
Tensioner
Cylinder Head
CoverFront Crankshaft
Oil Seal
Crankshaft Position
Sensor
*• Gasket
Crankshaft Pulley_
'"
Camshaft Timing Sprocket
„---' IWater
Water Pump Pulley_. Timing Chain
[-'"
Valve Timing
Controller Assembl
No. 1
Ventilation
Pipe
Chain Tensioner
Slipper
Oil
Guide
Chain Vibration Dumper
Crank Angle Sensor Plate
Crankshaft Timing Sprocket
*O-Ring
N-m (kgf-cm, ft-lbf) : Specified torque
Non-reusable part
A10353

23. 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.
A01045
A10381
7. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.
HINT:
Place a wooden block between the jack and engine.
(b) 1ZZ-FE:
Removethe 4bolts, 2 nuts and RH engine mounting insu-
lator.
(c) 2ZZ-GE:
Remove the 5 bolts, 2 nuts and RH engine mounting insu-
lator.
8. 1ZZ-FE:
REMOVECYLINDERHEADCOVER
(a) Remove the 4 bolts and No. 2 cylinder head cover.
(b) Remove the 4 ignition coils (See page IG-6).
(c) Disconnect the 2 PCV hoses from the cylinder head.

24. EM-19
ENGINE MECHANICAL - TIMING CHAIN
Itoase
M0387
(d) Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head
cover and gasket.
9. 2ZZ-GE:
REMOVECYLINDERHEADCOVER
(a) Remove the 4 bolts and No. 2 cylinder head cover.
(b) Remove the ignition coils (See page IG-6).
(c) Disconnect the 2 PCV hoses from the cylinder head cov-
er.
(d) Remove the 2 nuts, bolt and disconnect the No. 3 ventila-
tion hose from the No. 1 ventilation pipe.
(e) Remove the No. 1 ventilation pipe and gasket.
(f) Remove the 9 bolts, wire harness protector, cylinder head
cover and gasket.
(g) Remove the O-ring from the cylinder head cover.
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 sprock-
ets 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.

25. EM-20
ENGINE MECHANICAL - TIMING CHAIN
SST
SST
SST
600298
A07317
yA10389
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.
HINT:
If necessary, remove the pulley with SST.
SST 09950-50012 (09951-05010, 09952-05010,
09953-05020,09954-05020)
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)
17.
(a)
(b)
(c)
1ZZ-FE:
REMOVE TIMING CHAIN COVER
Remove the 11 bolts and nut.
Using a tone wrench socket (E8), remove the stud bolt.
Remove the timing chain cover by prying the portions be-
tween the cylinder head and cylinder block with a screw-
driver.
NOTICE:
Be careful not to damage the contact surfaces ofthe timing
chain cover, cylinder head and cylinder block.

26. EM-21
ENGINE MECHANICAL - TIMING CHAIN
A10390
ft
B00302
N A10371
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.
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.
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 as-
sembly.

27. EM-22
ENGINE MECHANICAL - TIMING CHAIN
122.6 mm
EM2378
INSPECTION
1. INSPECT TIMING CHAIN AND TIMING SPROCKETS
(a) 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 se-
lected at random.
(b) Wrap the chain around the timing sprocket.
(c) Using a vernier calipers, measure the timing sprocket di-
ameter with the chain.
NOTICE:
Vernier calipers must contact the chain rollers for measur-
ing.
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.
1ZZ-FE:
2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRA-
TIONDAMPER
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.

28. EM-23
ENGINE MECHANICAL - TIMING CHAIN
Raise
Move
A07221
3. INSPECT CHAIN TENSIONER
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised with your finger.
(b) 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.
4. INSPECT OIL JET (See page LU-11)

29. ENL-24
ENGINE MECHANICAL - TIMING CHAIN
B00179
SST
B00178
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.
(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.
Cut Position
A01149
(b) 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 screw-
driver tip.
B00177
(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

30. EM-25
ENGINE MECHANICAL - TIMING CHAIN
A10438
INSTALLATION
1. INSTALL VALVE TIMING CONTROLLER ASSEMBLY
AND CAMSHAFT TIMING SPROCKET
(a) Apply engine oil in the range from the tip of the intake
camshaft to 16 mm from that tip.
(b) Align the timing mark on the value timing controller as-
sembly with the knock pin, and install the value timing
controller assembly to the cam shaft.
NOTICE:
Do not push valve timing controller assembly to the cam-
shaft 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.
A10371
(d) Temporarily install the timing sprocket bolt.
(e) 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)
o 2. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the hexagonal wrench head portion of the cam-
shafts, and align the point marks of the camshaft timing
sprockets.
Set Key
B00280
(b) Using a crankshaft pulley bolt, Turn the crankshaft and
set the set key on the crankshaft upward.

31. EM-26
ENGINE MECHANICAL - TIMING CHAIN
1ZZ-FE:
2ZZ-GE:
N
B00281
Timing
Mark
B00282
Mark Mark
Timing Mark A10395
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)
4. INSTALL TIMING CHAIN AND CRANKSHAFT TIMING
SPROCKET
(a) Install the timing chain on the crankshaft timing sprocket
with the yellow color link aligned with the timing mark on
the crankshaft timing sprocket.
HINT:
If necessary, install the sprocket with SST.
SST 09223-22010
(b) 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.
(c) 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.

32. EM-27
ENGINE MECHANICAL - TIMING CHAIN
Cylinder Head
Stopper
A10402
(d) Check that the tension between the intake camshaft tim-
ing 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.
A01047
6. INSTALL CRANK ANGLE SENSOR PLATE
Install the plate with the "F" mark facing forward.

33. EM-28
ENGINE MECHANICAL - TIMING CHAIN
Seal Width
1.5 mm
Chain
Cover
Groove
Cylinder
Head
Groove
7 mm
.mm
B
12mm
6mm
A07223
7. 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 ap-
plication. Otherwise the material must be removed
and reapplied.
Immediately remove nozzle from the tube and rein-
stall cap.
A104Q3
(c) Apply seal packing to 2 locations as shown in the illustra-
tion.
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 ap-
plication. Otherwise the material must be removed
and reapplied.
• Immediately remove nozzle from the tube and rein-
stall cap.

34. EM-29
ENGINE MECHANICAL - TIMING CHAIN
B
A1137t
(d) 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:
• 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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