TOYOTA CAMRY 1999 Service Repair Manual

A07362
Gray
Brown
No.1
No.2
No.3
No.4
A07361
California
A07359
S05990
(b)
(c)(d)
A07360
(e)
(f)
EM±60
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1232 Author: Date:
(m) Connect the 4 injector connectors.
HINT:
The No.1 and No.3 injector connectors are brown, and the No.2
and No.4 injector connectors are gray.
16. California:
INSTALL AIR HOSE FOR AIR ASSIST SYSTEM
Connect the air hose to the cylinder head port.
17. INSTALL INTAKE MANIFOLD
(a) Install a new gasket and the intake manifold with the 6
bolts and 2 nuts. Uniformly tighten the bolts and nuts in
several passes.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(b) Connect the MAP sensor vacuum hose to the gas filter.
(c) Connect the brake booster vacuum hose to the intake
manifold.
(d) Connect the PCV hose to the intake manifold.
(e) Connect the 2 ground wires to the intake manifold with the
2 bolts.
(f) Connect the knock sensor 1 connector.

S05982
SST
Fulcrum
Length
A07365
A07363
A07364
Clamp
Connector
A01564(b)(c)(d)
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±61
1233 Author: Date:
18. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Temporarily connect the fuel inlet hose with 2 new gas-
kets and fuel pulsation damper.
(b) Using SST, tighten the fuel pulsation damper.
SST 09612±24014 (09617±24011)
Torque:
34 N´m (350 kgf´cm, 25 ft´lbf)
29 N´m (300 kgf´cm, 21 ft´lbf) for use with SST
HINT:
Use a torque wrench with a fulcrum length of 30 cm (1.181 in.).
19. INSTALL ENGINE WIRE
(a) Install the 2 engine wire clamps to the 2 brackets on the
front side of the intake manifold.
(b) Install the engine wire clamp to the bracket on the LH side
of the intake manifold.
20. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket, the EGR valve, EGR pipe and vacu-
um modulator assembly with the union nut, 2 nuts and
bolt.
Torque:
13.3 N´m (136 kgf´cm, 10 ft´lbf) for nut
61.2 N´m (624 kgf´cm, 45 ft´lbf) for union nut
(b) Install the hose clamp to the bracket on the intake man-
ifold.
(c) Install the VSV for the EGR with the bolt.
(d) Connect the VSV connector for the EGR.
21. INSTALL INTAKE MANIFOLD STAY
Install the intake manifold stay with the bolt and nut.
Torque: 39 N´m (398 kgf´cm, 29 ft´lbf)
22. INSTALL WATER OUTLET
(a) Install a new gasket and the water outlet with the 2 nuts.
Torque: 15 N´m (150 kgf´cm, 11 ft´lbf)
(b) Connect the radiator hose to the water outlet.
(c) Connect the water bypass pipe hose to the water outlet.
(d) Connect the heater water hose to the water outlet.
(e) Connect the ECT sensor connector.
(f) Connect the ECT sender gauge connector.
23. CONNECT OIL PRESSURE SWITCH CONNECTOR
24. CONNECT NOISE FILTER CONNECTOR

S05548
Wire
Clamp
S05297
Clamp
Sensor
Connector
S05281
EM±62
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1234 Author: Date:
25. INSTALL IGNITION COILS AND NO.2 INTAKE MAN-
IFOLD STAY ASSEMBLY
(a) TMC Made:
Install the 2 ignition coils and manifold stay assembly with
the 2 nuts and 2 bolts.
Torque:
21 N´m (214 kgf´cm, 15 ft´lbf) for 12 mm head
42 N´m (428 kgf´cm, 31 ft´lbf) for 14 mm head
(b) TMMK Made:
Install the 2 ignition coils and manifold stay assembly with
the nut and 3 bolts.
Torque:
21 N´m (214 kgf´cm, 15 ft´lbf) for 12 mm head
42 N´m (428 kgf´cm, 31 ft´lbf) for 14 mm head
(c) Install the wire clamp to the manifold stay.
(d) Connect the 4 high±tension cords to the spark plugs.
(e) Install the 4 high±tension cords to the 2 clamps on the cyl-
inder head cover.
(f) Connect the 2 ignition coil connectors.
26. INSTALL THROTTLE BODY (See page SF±34)
27. INSTALL EXHAUST MANIFOLD
(a) California:
Install the A/F sensor connector for the wiring side to the
bracket to the LH engine hanger.
(b) Except California:
Install the heated oxygen sensor for the wiring side to the
bracket to the LH engine hanger.
(c) Attach the exhaust manifold to the front exhaust pipe.
(d) Install a new gasket, the exhaust manifold, No.2 and No.3
exhaust manifold heat insulators assembly with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(e) Install the wire clamp.
(f) California:
Connect the A/F sensor connector.
(g) Except California:
Connect the heated oxygen sensor (bank 1 sensor 1)
connector.
(h) Install the No.1 exhaust manifold stay with the 2 bolts.
Torque: 42 N´m (425 kgf´cm, 31 ft´lbf)

S05300
TMC
Made
TMMK
Made
S05282
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±63
1235 Author: Date:
(i) TMC Made:
Install the No.2 exhaust manifold stay with the 2 nuts.
Torque:
42 N´m (425 kgf´cm, 31 ft´lbf) for manifold side
58 N´m (591 kgf´cm, 43 ft´lbf) for block side
(j) TMMK Made:
Install the No.2 exhaust manifold stay with the bolt and
nut.
Torque:
42 N´m (425 kgf´cm, 31 ft´lbf) for manifold side
41.5 N´m (423 kgf´cm, 31 ft´lbf) for block side
(k) Install the No.1 exhaust manifold heat insulator with the
3 (California) or 5 (Except California) bolts.
(l) Install 3 new nuts holding the front exhaust pipe to the ex-
haust manifold.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
28. INSTALL GENERATOR (See page CH±16)
29. INSTALL AIR CLEANER CASE (See page EM±75)
30. FILL WITH ENGINE COOLANT
31. START ENGINE AND CHECK FOR LEAKS
32. RECHECK ENGINE COOLANT LEVEL AND OIL LEV-
EL

EM0YV±01
A02195
Radiator Reservoir Hose
Generator Drive BeltUpper Radiator
Hose
Support BracketFront Exhaust Pipe PS Oil Pressure Switch
ConnectorBattery TrayBattery
PS Pump Drive Belt
PS Pump
Support Stay Upper Radiator Support
Lower Radiator Hose
A/C Compressor
Cylinder Block Insulator
LH Front Fender Apron Seal
Oil Cooler Hose (A/T)
Cruise Control ActuatorEVAP Hose
Air Filter Upper Radiator
Support
EVAP Hose Hood
PCV Hose
Support
Bracket  Gasket

 Non±reusable part Gasket
Clamp
N´m (kgf´cm, ft´lbf)
62 (630, 46)
56 (570, 41)

: Specified torque
Washer Hose
for Windshield
No.1 Electric
Cooling Fan
Connector
ECT Switch
Connector No.2 Electric
Cooling Fan
ConnectorRadiator
Assembly
A/C Compressor
ConnectorLower Radiator
Support
RH Front Fender
Aplon Seal
Cruise
Control
Actuator
Connector
Battery
Hold±Down
ClampAir Cleaner
Case
VSV
Connector
for EVAP
EVAP
Hose
IAT Sensor
Connector
Air
Cleaner
Cap
EM±64
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1236 Author: Date:
ENGINE UNIT
COMPONENTS

A01565
Engine Wire Clamp
Brake Booster
Vacuum Hose
DLC1
Ground Strap
Connector
Generator
Wire
Wire
Clamp
Generator
ConnectorMAP Sensor
Vacuum HoseMAP Sensor
Connector
Fuel Inlet Hose
Engine
Wire
Starter
Connector
Starter
CableEngine
Wire
ProtectorGround
Cable (M/T)
Ground Strap Connector Wire
Clamp
Ground
Cable (A/T)
Heater
Hose
A01658
No.2 Instrument Panel
Under Cover
Cowl Side Trim Front Door Inside Scuff Plate
Engine Wire
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±65
1237 Author: Date:

A02188
Engine Moving Control Rod
Engine and
Transaxle Assembly
Front Engine
Mounting Insulator
RH Drive Shaft
Lower Suspension ArmLH Drive Shaft No.2 RH Engine
Mounting BracketRear Engine
mounting
Insulator
Transaxle
Shift
Control
Cable
(A/T)
Tie Rod End
Lock CapTransaxle Shift
Control Cable
Clutch Release Cylinder and Tube Engine Wire
Starter M/T
N´m (kgf´cm, ft´lbf)
64 (650, 47)
64 (650, 47)
127 (1,300, 94)
52 (530, 38)
64 (650, 47)
66 (670, 49)
49 (500, 36)
64 (650, 47)
64 (650, 47)
64 (650, 47)
294 (3,000, 217)
TMC Made
80 (820, 59)
TMMK Made
44 (450, 32) for Silver Color
66 (670, 49) for Green Color
: Specified torque
 Non±reusable part
EM±66
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1238 Author: Date:

S05316
M/T
Engine
No.2 Exhaust
Manifold Stay
(TMMK Made)
(TMC Made)
Exhaust Pipe Bracket
Oil Pan
Insulator
No.1 Exhaust
Manifold Stay
Back±Up Light Switch ConnectorNo.2 Rear End Plate Flywheel
LH Stiffener Plate
Clutch Disk
Clutch Cover
Engine Wire
VSS Connector
Wire Clamp
Ground Strap
Transaxle No.1 Rear End PlateIntake Manifold
Stay RH Stiffener Plate
N´m (kgf´cm, ft´lbf)

Precoated partx 8
88 (900, 65)
19 (195, 14)
64(650, 47)
64(650, 47)
64(650, 47)64(650, 47)


: Specified torquex 6
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±67
1239 Author: Date:

A02187
A/T
Engine
No.2 Exhaust
Manifold Stay
(TMC Made)
Exhaust Pipe Bracket
Oil Pan
InsulatorLH Stiffener Plate
Engine Wire
VSS Connector
Wire Clamp
Ground Strap No.1 Rear End PlateIntake Manifold
Stay RH Stiffener Plate
N´m (kgf´cm, ft´lbf)

Precoated partx 8 (TMMK Made)
No.2 Rear End Plate
Transaxle No.1 Exhaust
Manifold Stay
PNP Switch
Connector
StarterThrottle Cable Clamp
Solenoid Connector
Front SpacerDrive Plate
Rear Spacer
Throttle Cable
Solenoid Connector x 6
83 (850, 61)27 (280, 20)
66 (670, 48)
66 (670, 20)
66 (670, 48)
66 (670, 48)



: Specified torque
EM±68
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
1240 Author: Date:

EM08F±04
S05251
± ENGINE MECHANICAL (5S±FE)ENGINE UNIT
EM±69
1241 Author: Date:
REMOVAL
1. REMOVE HOOD
2. REMOVE FRONT FENDER APRON SEALS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER CAP
(a) Disconnect the IAT sensor connector.
(b) Disconnect the VSV connector for the EVAP
(c) Disconnect the PCV hose from the cylinder head cover.
(d) Disconnect the EVAP hose from the throttle body.
(e) Disconnect the EVAP hose from the VSV.
(f) Disconnect the 2 clamps, and disconnect the air cleaner
cap from the air cleaner case.
(g) Loosen hose clamp, and disconnect the air cleaner hose
from the throttle body.
(h) Remove the air cleaner cap and hose assembly.
7. REMOVE AIR CLEANER CASE
(a) Remove the air filter.
(b) Remove the 3 bolts and air cleaner case.
8. REMOVE BATTERY AND TRAY
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR (See page CO±18)
11. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts holding the support stay to the sup-
port bracket.
(b) Remove the 2 bolts holding the support bracket to the
front frame.
(c) Remove the 2 bolts and 2 nuts holding the front exhaust
pipe to the center exhaust pipe.
(d) Remove the 3 nuts holding the front exhaust pipe to the
exhaust manifold.
(e) Remove the front exhaust pipe and 2 gaskets.
(f) Remove the nut and support bracket.
12. DISCONNECT CONNECTORS, WIRES, CABLES,
CLAMPS AND HOSES
(a) Disconnect the generator wire.
(b) Disconnect the generator connector.
(c) Disconnect the wire clamp from the generator.
(d) Disconnect the starter cable.
(e) Disconnect the starter connector.
(f) Disconnect the DLC1 from the bracket.