TOYOTA CAMRY 1999 Service Repair Manual

EM2082
A06614
Push Front Mark
(Cavity)
Front
N01001
Front Mark
(Protrusion)
Z19381
EM±110
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1282 Author: Date:
9. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.
10. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
11. INSTALL CONNECTING ROD CAP NUTS
HINT:

The cap nuts are tightened in 2 progressive steps (steps
(b) and (d)).

If any one of the connecting rod bolts is broken or de-
formed, replace it.
(a) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.
(b) Install and alternately tighten the 2 cap nuts in several
passes.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
If any one of the cap nuts does not meet the torque specifica-
tion, replace the connecting rod bolt and cap nut as a set.

S02826
Front 90°Painted Mark
90°
S05945
Pulley
Set
Key
Cylinder
Block Top
Surface
P01478
P00716
P00733
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±111
1283 Author: Date:
(c) Mark the front of the cap nut with the paint.
(d) Retighten the cap nuts 90° as shown.
(e) Check that the painted mark is now at a 90° angle to the
front.
(f) Check that the crankshaft turns smoothly.
12. CHECK CONNECTING ROD THRUST CLEARANCE
(See page EM±86)
13. INSTALL ENGINE BALANCER
(a) Turn the crankshaft, and set the No.1 cylinder TDC as
shown in the illustration.
(b) Set the balance shafts so that the punch marks of the bal-
ance shafts are aligned with the grooves of the
No.2 housing.
(c) Wipe clean the installation surface of the spacer.
(d) Place the spacers on the cylinder block.
HINT:
When replacing the crankshaft and/or balance shaft, use the
thickest spacers.
(e) Place the engine balancer on the cylinder block.
(f) Check that punch marks shown in the illustration of the
balance shafts are aligned with the grooves of the No.2
housing.

S04614
1
Pull 53
426
P01477
Z19357
13
2 EM±112
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1284 Author: Date:
(g) While pulling the center part of the engine balancer in the
direction of the arrow, uniformly tighten the 6 bolts in sev-
eral passes, in the sequence shown.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(h) Recheck that the punch marks of the balance shafts are
aligned with the grooves of the No.2 housing.
14. CHECK AND ADJUST BACKLASH OF CRANKSHAFT
GEAR AND NO.1 BALANCE SHAFT GEAR
(See page EM±86)
15. INSTALL REAR OIL SEAL RETAINER
Install a new gasket and the retainer with the 6 bolts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
16. INSTALL WATER PUMP, WATER BYPASS PIPE AND
OIL COOLER (w/ OIL COOLER) ASSEMBLY
(a) Install a new O±ring to the water pump cover.
(b) Install the water pump, water bypass pipe and oil cooler
(w/ oil cooler) assembly with the 3 bolts. Tighten the bolts
in the sequence shown.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
(c) Install the generator drive belt adjusting bar with the bolt.
Torque: 22 N´m (224 kgf´cm, 16 ft´lbf)
(d) w/ Oil Cooler:
Install the oil cooler. (See page LU±18)
17. INSTALL OIL FILTER (See page LU±2)
18. INSTALL KNOCK SENSOR 1 (See page SF±57)
19. INSTALL PS PUMP BRACKET
Install the PS pump bracket with the 3 bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
20. INSTALL OIL PUMP AND OIL PAN
(a) Install the oil pump and oil pan. (See page LU±13)
(b) Install the crankshaft position sensor connector to the
generator drive belt adjusting bar.
21. INSTALL OIL DIPSTICK
22. INSTALL CYLINDER HEAD ASSEMBLY
(a) Install the cylinder head assembly. (See page EM±33)
(b) Install the 2 bolts holding the water bypass pipe to the cyl-
inder head.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(c) Install the VSV for EGR to the cylinder head with the bolt.
(d) Connect the knock sensor 1 connector.
(e) Connect the crankshaft position sensor connector.

± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±113
1285 Author: Date:
(f) Install the wire clamp to the generator drive belt adjusting
bar.
(g) Connect the IAC valve water bypass hose to the water by-
pass pipe.
(h) Connect the water bypass hose (from the water bypass
pipe) to the water outlet.
(i) Install the camshafts. (See page EM±53)
(j) Install the cylinder head cover.
(1) Install the cylinder head cover. (See page EM±53)
(2) Connect the PCV hose to the intake manifold.
(k) Install the No.3 timing belt cover with the 3 bolts.
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
23. INSTALL TIMING BELT AND PULLEYS
(See page EM±23)
24. DISCONNECT ENGINE FROM ENGINE STAND

EM08M±03
A07369
Heated Oxygen Sensor (Bank 1 Sensor 2)
HINT:
Before installing oxygen sensor, twist
sensor wire counterclockwise 3 and 1/2
turns.
After installing oxygen sensor, check that
sensor wire is not twisted. If it is twisted,
remove oxygen sensor and reinstall it.
Heat Insulator
Bracket
RingTailpipe
 Gasket
Center Exhaust Pipe
Heated Oxygen Sensor
(Bank 1 Sensor 2)
TWC (Except California)
Rear TWC (California)
Front Exhaust Pipe Bracket
StayBracket
N´m (kgf´cm, ft´lbf)
 Non±reusable part Gasket
 Gasket
Heat Insulator Heat Insulator
Heat Insulator

56 (570, 41)
44 (450, 32)
62 (630, 46)
56 (570, 41)
Bracket
: Specified torqueRing



19 (195, 14)
33 (330, 24)
33 (330, 24)
33 (330, 24)
EM±114
± ENGINE MECHANICAL (5S±FE)EXHAUST SYSTEM
1286 Author: Date:
EXHAUST SYSTEM
COMPONENTS

EM04I±04
S04994
CO/HC Meter
± ENGINE MECHANICAL (1MZ±FE)CO/HC
EM±1
1287 Author: Date:
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine at normal operating temperature
(b) Air cleaner installed
(c) All pipes and hoses of air induction system connected
(d) All accessories switched OFF
(e) All vacuum lines properly connected
HINT:
All vacuum hoses for EGR systems, etc. should be 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
SECONDS
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
HINT:
When doing the 2 mode (idle and 2,500 rpm) test, these mea-
surement order prescribed by the applicable local regulations.

EM±2
± ENGINE MECHANICAL (1MZ±FE)CO/HC
1288 Author: Date:
If the CO/HC concentration dose not comply with regulations,
troubleshoot in the order given below.
See the table below for possible causes, then inspect and cor-
rect the applicable causes if necessary.
COHCProblemsCauses
NormalHighRough idle1. Faulty ignitions:

Incorrect timin
g
Incorrect timing

Fouled, shorted or improperly gapped plugs

Open or crossed hi
gh±tension cords
Oen or crossed high±tension cords
2. Incorrect valve clearance
3 Leaky EGR valve
3 Leaky EGR valve
4.Leaky intake and exhaust valves
5.Leaky cylinder
LowHighRough idle1. Vacuum leaks:LowHighRough idle
(
Filtrating HC reading)
1. Vacuum leaks:

PCV hose(Filtrating HC reading)
PCV hose

EGR valve
EGR valve

Intake manifold
Intake manifold

Air intake chamber
Air intake chamber

Throttle bodyThrottle body

IAC valveIAC valve

Brake booster lineBrake booster line
2. Lean mixture causing misfire
HighHighRough idle
(Black smoke from exhaust)1. Restricted air filter
2. Faulty SFI system

Faulty pressure regulator

Defective ECT sensor

Faulty ECM

Faulty injectors

Faulty throttle position sensor

Faulty MAF meter

EM04J±03
P19471Compression Gauge
± ENGINE MECHANICAL (1MZ±FE)COMPRESSION
EM±3
1289 Author: Date:
COMPRESSION
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 COILS AND HIGH±TENSION
CORDS (See page IG±7)
3. REMOVE SPARK PLUGS
Using a 16 mm plug wrench, remove the 6 spark plugs.
4. CHECK 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:
1,500 kPa (15.3 kgf/cm
2, 218 psi)
Minimum pressure: 1,000 kPa (10.2 kgf/cm
2, 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 15 psi) or less
(e) If the cylinder compression in 1 or 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 COILS AND HIGH±TENSION
CORDS (See page IG±8)

EM04K±04
P18805
P13074
RH EX
RH IN
LH IN
LH EX 13
6
23
1
6
2Front EM±4
± ENGINE MECHANICAL (1MZ±FE)VALVE CLEARANCE
1290 Author: Date:
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE RH FENDER APRON SEAL
2. DRAIN ENGINE COOLANT
3. REMOVE V±BANK COVER
(a) Using a 5 mm hexagon wrench, remove the 2 nuts.
(b) Disconnect the 2 clips, and remove the cover.
4. REMOVE HIGH±TENSION CODE SET
(See page IG±7)
5. REMOVE AIR INTAKE CHAMBER ASSEMBLY
(See page EM±32)
6. REMOVE IGNITION COILS
7. DISCONNECT RADIATOR HOSE FROM WATER
OUTLET
8. REMOVE CYLINDER HEAD COVERS
(See page EM±32)
9. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 (IN and EX) are
loose.
If not, turn the crankshaft 1 revolution (360°) and align the mark
as above.
10. INSPECT VALVE CLEARANCE
(a) Check only those valves indicated in the illustration.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record out of specification valve clearance mea-
surements. They will be used later to determine the
required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 ± 0.25 mm (0.006 ± 0.010 in.)
Exhaust0.25 ± 0.35 mm (0.010 ± 0.014 in.)

P13072
RH IN
LH IN
LH EX RH EX 5
3
435
4 22Front
P13073
RH IN
LH IN
LH EX RH EX
5 1
4
65
4 1
6 Front
P12919
Upward
Notch
± ENGINE MECHANICAL (1MZ±FE)VALVE CLEARANCE
EM±5
1291 Author: Date:
(b) Turn the crankshaft 2/3 of a revolution (240°), and check
only the valves indicated in the illustration. Measure the
valve clearance. (See step (a))
(c) Turn the crankshaft a further 2/3 of a revolution (240°),
and check only the valves indicated in the illustration.
Measure the valve clearance. (See step (a))
11. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the camshaft so that the cam lobe for the valve
to be adjusted faces up.
(2) Turn the valve lifter with a screwdriver so that the
notches are perpendicular to the camshaft.