ESP TOYOTA CAMRY 1999 Service Repair Manual

AUTOMATIC TRANSAXLECOMPONENT PARTS ±
AX±32
COMPONENT PARTS
GENERAL NOTES
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar±looking parts of different subassemblies being on your work-
bench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next com-
ponent group. If a component group cannot be assembled because parts are being ordered, be sure
to keep all parts of that group in a separate container while proceeding with disassembly, inspection,
repair and assembly of other component groups.
Recommended fluid for the automatic transaxle:
DEXRON ® @@@@@: [g 2]
GENERAL CLEANING NOTES:
1. All disassembled parts should be washed clean and any fluid passages and holes blown through with
compressed air.
2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spray-
ing automatic transmission fluid or kerosene in your face.
3. The recommended automatic transaxle fluid or kerosene should be used for cleaning.
PARTS ARRANGEMENT:
1. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs,
and reassembly.
2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at
least 15 minutes before assembly.
GENERAL ASSEMBLY:
1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O±rings should be replaced.
3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
5. Check thrust bearings and races for wear or damage. Replace if necessary.
6. Use petroleum jelly to keep parts in place.
AX0EY±02

AUTOMATIC TRANSAXLECOMPONENT PARTS REMOVAL ±
AX±33
GENERAL NOTES
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar±looking parts of different subassemblies being on your work-
bench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next compo-
nent group. If a component group cannot be assembled because parts are being ordered, be sure to keep
all parts of that group in a separate container while proceeding with disassembly, inspection, repair and
assembly of other component groups.
Recommended fluid for the automatic transaxle: ATF D±@@@@@: [g 2] or DEXRON®@@@@@: [g
3](DEXRON®@@@@@: [g 2])
1. GENERAL CLEANING NOTES:
(a) All disassembled parts should be washed clean and any fluid passages and holes blown through with
compressed air.
(b) When using compressed air to dry parts, always aim away from yourself to prevent accidentally spray-
ing automatic transaxle fluid or kerosene in your face.
(c) The recommended automatic transaxle fluid or kerosene should be used for cleaning.
2. PARTS ARRANGEMENT:
(a) After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs,
and reassembly.
(b) When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
(c) New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at
least fifteen minutes before assembly.
3. GENERAL ASSEMBLY:
(a) All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
(b) All gaskets and rubber O±rings should be replaced.
(c) Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
(d) If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
(e) Check thrust bearings and races for wear or damage. Replace if necessary.
(f) Use petroleum jelly to keep parts in place.
AX02T±07

AUTOMATIC TRANSAXLECOMPONENT PARTS REMOVAL ±
AX±33
GENERAL NOTES
The instructions here are organized so that you work on only one component group at a time.
This will help avoid confusion from similar±looking parts of different subassemblies being on your work-
bench at the same time.
The component groups are inspected and repaired from the converter housing side.
As much as possible, complete the inspection, repair and assembly before proceeding to the next compo-
nent group. If a component group cannot be assembled because parts are being ordered, be sure to keep
all parts of that group in a separate container while proceeding with disassembly, inspection, repair and
assembly of other component groups.
Recommended fluid for the automatic transaxle: ATF D±@@@@@: [g 2] or DEXRON®@@@@@: [g
3](DEXRON®@@@@@: [g 2])
1. GENERAL CLEANING NOTES:
(a) All disassembled parts should be washed clean and any fluid passages and holes blown through with
compressed air.
(b) When using compressed air to dry parts, always aim away from yourself to prevent accidentally spray-
ing automatic transaxle fluid or kerosene in your face.
(c) The recommended automatic transaxle fluid or kerosene should be used for cleaning.
2. PARTS ARRANGEMENT:
(a) After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs,
and reassembly.
(b) When disassembling a valve body, be sure to keep each valve together with the corresponding spring.
(c) New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at
least fifteen minutes before assembly.
3. GENERAL ASSEMBLY:
(a) All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
(b) All gaskets and rubber O±rings should be replaced.
(c) Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the
groove correctly.
(d) If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced.
(e) Check thrust bearings and races for wear or damage. Replace if necessary.
(f) Use petroleum jelly to keep parts in place.
AX02T±07

BO0MA±01
BO6675
N19058
H01884
Adhesive TapeAdhesive Tape
N22643
± BODYBODY OUTSIDE MOULDING
BO±41
2389 Author: Date:
INSTALLATION
1. HEAT BODY MOUNTING SURFACE
(a) Using a heat light, heat the body mounting surface to
40 ± 60 °C (104 ± 140 °F).
NOTICE:
Do not heat body excessively.
(b) Remove the adhesive tape from the body.
(c) Wipe off stains with cleaner.
2. CLEAN MOULDING
If reusing the moulding:
(a) Using a heat light, heat the moulding to 20 ± 30 °C (68 ±
86 °F).
NOTICE:
Do not heat moulding excessively.
(b) Remove the adhesive tape from the moulding.
(c) Wipe off stains with cleaner.
(d) Apply a new adhesive tape to moulding as shown in the
illustration.
3. INSTALL MOULDING
(a) Using a heat light, heat the body and moulding.
Body: 40 ± 60 °C (104 ± 140 °F)
Moulding: 20 ± 30 °C (68 ± 86 °F)
NOTICE:
Do not heat moulding excessively.
(b) Lift moulding release sheet from face of moulding.
NOTICE:
When the moulding release sheet is removed, make sure
that no dirt or dust can get onto the uncoated area.
(c) Align the bosses with their corresponding holes in the
body, and press firmly on the moulding. Refer to the il-
lustration for the front fender moulding application proce-
dures.
NOTICE:
Do not apply excessive force onto the moulding, but steady
pressure with your thumbs.

H01983
Code Shape Size
Code Shape Size
Code Shape Size
A
D
G
J
M
PBC
EF
HI
K
NL
O L = 16 (0.63) ù = 5.2 (0.21)mm (in.)
L = 16 (0.63) ù = 6.0 (0.24)
L = 20 (0.79) ù = 6.0 (0.24)
L = 20 (0.79) ù = 6.0 (0.24)
L = 10 (0.39) ù = 5.0 (0.20)
L = 20 (0.79) ù = 5.2 (0.21)
L = 22 (0.87) ù = 8.0 (0.31)
L = 20 (0.79) ù = 6.0 (0.24)
L = 20 (0.79) ù = 6.0 (0.24)
L = 18 (0.79) ù = 6.0 (0.24)
L = 14 (0.55) ù = 5.0 (0.20)
L = 12 (0.47) ù = 5.0 (0.20)
L = 18 (0.17) ù = 8.0 (0.31)8 x 1.256 x 1.00
6 x 1.00 BO±74
± BODYINSTRUMENT PANEL
2422 Author: Date:
HINT:
Screw shapes and size are indicated in the table below. The code (ºAº±ºPº) correspond to those indicated
on the previous page.

CL036±01
Q10085
Filler Cap
Float
Reservoir
TankSlotted Spring Pin

Grommet
Clutch Line
15 (155, 11)
Master Cylinder Body

Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torqueSpringPiston
Push RodSnap Ring WasherBootClip
12 (120, 9)
Lock NutClevisClevis Pin CL±4
± CLUTCHCLUTCH MASTER CYLINDER
1783 Author: Date:
CLUTCH MASTER CYLINDER
COMPONENTS

± DIAGNOSTICSENGINE (5S±FE)
DI±15
250 Author: Date:
(b) TOYOTA Enhanced Signals.
TOYOTA hand±held tester displayMeasurement ItemNormal Condition*1
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 2.9 ~ 5.1 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 25 ~ 62 %
STARTER SIGStarter SignalCranking: ON
CTP SIGClosed Throttle Position SignalThrottle fully closed: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SIGPark/Neutral Position Switch SignalP or N position: ON
ELECTCL LOAD SIGElectrical Load SignalDefogger S/W ON: ON
STOP LIGHT SWStop Light Switch SignalStop light switch ON: ON
PS OIL PRESS SWPower Steering Oil Pressure Switch SignalTurn steering wheel: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL#1, CYL#2, CYL#3, CYL#4Abnormal revolution variation for each cylinder0 %
IGNITIONTotal number of ignition for every 1,000 revolu-
tions0 ~ 2,000 rpm
EGR SYSTEMEGR system operating conditionIdling: OFF
FUEL PUMPFuel Pump SignalIdling: ON
A/C CUT SIGA/C Cut SignalA/C S/W OFF: ON
A/C MAG CLUTCHA/C Switch SignalA/C ON: ON
EVAP (PURGE) VSVEVAP VSV SignalVSV operating: Avove 30 %
VAPOR PRESS VSVVapor Pressure VSV SignalVSV operating: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 ~ 1.2 V
O2 LR B1, S1 *2
Heated Oxygen Sensor Lean Rich Bank 1 Sen-
sor 1: Response time for oxygen sensor output to
switch from lean to rich
Idling after warming up: 0 ~ 1,000 msec.
O2 RL B1, S1 *2
Heated Oxygen Sensor Rich Lean Bank 1 Sen-
sor 1: Response time for oxygen sensor output to
switch from rich to lean
Idling after warming up: 0 ~ 1,000 msec.
*1: If no conditions are specifically stated for ºldlingº, it means the shift lever is at N or P position, the A/C
switch is OFF and all accessory switches are OFF.
*2: Except California Specification vehicles.

DI00I±09
DI±16
± DIAGNOSTICSENGINE (5S±FE)
251 Author: Date:
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below. For details of each code, turn to the page referred to under the ''See Page '' for the respec-
tive ''DTC No.'' in the DTC chart.
SAE Controlled:
DTC No.
(See Page)Detection ItemTrouble AreaMIL*1Memory
P0105
(DI±29)
Manifold Absolute
Pressure/Barometric
Pressure Circuit
MalfunctionOpen or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM

P0106
(DI±33)Manifold Absolute Pressure
Circuit Range/Performance
ProblemManifold absolute pressure sensor
Vacuum line
P0110
(DI±35)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor (built into mass air flow meter)
ECM

P0115
(DI±41)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM

P0116
(DI±47)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI±49)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM

P0121
(DI±54)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
Range/Performance Problem
Throttle position sensor
*2
P0125
(DI±61)
Insufficient Coolant Temp. for
Closed Loop Fuel Control
(Except California Spec.)Open or short in heated oxygen sensor (bank 1 sensor 1)
circuit
Heated oxygen sensor (bank 1 sensor 1)
ECM

*3
P0125
(DI±55)
Insufficient Coolant Temp. for
Closed Loop Fuel Control
(Only for California Spec.)Open or short in A/F sensor circuit
A/F sensor
ECM

*2
P0130
(DI±66)Heated Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
*2
P0133
(DI±71)
Heated Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
*2
P0135
(DI±75)
Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 1)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
 ECM

*1: 


MIL lights up
*
2: Except California specification vehicles
*
3: Only for California specification vehicles

± DIAGNOSTICSENGINE (5S±FE)
DI±19
254 Author: Date:
DTC No.
(See Page)Detection ItemTrouble AreaMIL*1Memory
P0500
(DI±145)Vehicle Speed Sensor
Malfunction
Combination meter
Open or short in No.1 vehicle speed sensor circuit
No.1 vehicle speed sensor
ECM

P0505
(DI±148)Idle Control System
Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C switch circuit
Air intake (hose loose)
ECM

*1: 


MIL lights up
2. MANUFACTURER CONTROLLED
DTC No.
(See Page)Detection ItemTrouble AreaMIL*1Memory
*2
P1130
(DI±152)A/F Sensor Circuit
Range/Performance MalfunctionOpen or short in A/F sensor circuit
A/F sensor
ECM

*2
P1133
(DI±157)A/F Sensor Circuit Response
MalfunctionA/F sensor
*2
P1135
(DI±161)A/F Sensor Heater Circuit
MalfunctionOpen or short in heater circuit of A/F sensor
A/F sensor heater
ECM

P1300
(DI±163)Igniter Circuit Malfunction (No.1)
Open or short in IGF or IGT circuit from igniter to ECM
Ignition coil (No.1)
ECM

P1310
(DI±163)Igniter Circuit Malfunction (No.2)
Open or short in IGF or IGT circuit from igniter to ECM
Ignition coil (No.2)
ECM

P1335
(DI±169)Crankshaft Position Sensor Cir-
cuit Malfunction
(During engine running)Open short in crankshaft position sensor circuit
Crankshaft position sensor
ECM
±
*3
P1520
(DI±170)Stop Light Switch Signal Mal-
functionShort in stop light switch signal circuit
Stop light switch
ECM

P1600
(DI±173)ECM BATT MalfunctionOpen in back up power source circuit
ECM
*3
P1780
(DI±175)Park/Neutral Position Switch
MalfunctionShort in park/neutral position switch circuit
Park/neutral position switch
ECM

*1: 


MIL lights up
*
2: Only for California Specification vehicles
*
3: Only for A/T models

± DIAGNOSTICSENGINE (5S±FE)
DI±71
306 Author: Date:
DTC P0133 Heated Oxygen Sensor Circuit Slow Re-
sponse (Bank 1 Sensor 1) (Ex. CA Spec.)
CIRCUIT DESCRIPTION
Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on
page DI±55.
DTC No.DTC Detecting ConditionTrouble Area
P0133
Response time for heated oxygen sensor's voltage output to
change from rich to lean, or from lean to rich, is 1 sec. or more
during idling after engine is warmed up
(2 trip detection logic)

Heated oxygen sensor

Fuel trim malfunction
HINT:
Sensor 1 refers to the sensor closer to the engine body.
INSPECTION PROCEDURE
HINT:
Read freeze frame data using TOYOTA hand±held tester or OBD II scantool. Because freeze frame records
the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining
whether the vehicle was running or stopped, the engine warmed up or not, the air±fuel ratio lean or rich, etc.
at the time of the malfunction.
1 Are there any other codes (besides DTC P0133) being output?
YES Go to relevant DTC chart.
NO
DI4NF±01