TOYOTA CAMRY 1999 Service Repair Manual

S06045
AISIN Made
MAHLE MadeRH Piston
LH Piston Front Mark
(2 Cavities)
Front Mark
(1 cavity)Front
Front
Front
FrontRH Piston
LH Piston Front Mark
(1 cavity)
Front Mark
(1 cavity)
P12699
P12801
Front
Protrusion EM±106
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1392 Author: Date:
11. INSTALL PISTON AND CONNECTING ROD
ASSEMBLES
Using a piston ring compressor, push the correctly numbered
piston and connecting rod assemblies into each cylinder with
the front mark of the piston facing forward.
HINT:
The shape of the piston varies for the RH and LH banks. The
RH piston is marked with ºRº, the LH piston with ºLº.
12. PLACE CONNECTING ROD CAP ON CONNECTING
ROD
(a) Match the numbered connecting rod cap with the con-
necting rod.
(b) Align the pin dowels of the connecting rod cap with the
pins of the connecting rod, and install the connecting rod.
(c) Check that the protrusion of the connecting rod cap is fac-
ing in the correct direction.
13. INSTALL CONNECTING ROD CAP BOLTS
HINT:

The connecting rod cap bolts are tightened in 2 progres-
sive steps (steps (b) and (d)).

If any of the connecting rod cap bolts is broken or de-
formed, replace it.

P12697
P25743
Painted Mark
Front90°
90°
P12911
Seal Width
2 ± 3 mm A
BA
B
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
EM±107
1393 Author: Date:
(a) Apply a light coat of engine oil on the threads and under
the heads of the connecting rod cap bolts.
(b) Install and alternately tighten the 2 connecting rod cap
bolts in several passes.
Torque: 24.5 N´m (250 kgf´cm, 18 ft´lbf)
If any of the connecting rod cap bolts does not meet the torque
specification, replace the connecting rod cap bolts.
(c) Mark the front of the connecting cap bolts with paint.
(d) Retighten the cap bolts by 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.
14. CHECK CONNECTING ROD THRUST
CLEARANCE (See page EM±83)
15. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil seal
retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the oil packing (FIPG) material from the gasket sur-
faces 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 oil seal retainer as shown in the
illustration.
Seal packing: Part No. 08826±00080 or equivalent

Install a nozzle that has been cut to a 2 ± 3 mm (0.08
± 0.12 in.) opening.

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.
(c) Install the oil seal retainer with the 6 bolts Uniformly tight-
en the bolt in several passes, in the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
16. INSTALL EGR COOLER
Install a new gasket and the EGR cooler with the 3 bolts and 2
nuts.
Torque: 9 N´m (90 kgf´cm, 78 in.´lbf)

P12477
Seal Packing
Z09223
Seal Width
3 ± 5 mmA
BA
B EM±108
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1394 Author: Date:
17. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826±00100 or equivalent
(b) Install the drain union.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
HINT:
After applying the specified torque, rotate the drain union clock-
wise until its drain port is facing downward.
18. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the seal plate
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.

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 seal plate as shown in the il-
lustration.
Seal packing: Part No. 08826±00100 or equivalent

Install a nozzle that has been cut to a 3 ± 5 mm (0.12
± 0.20 in.) opening.

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.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
19. INSTALL OIL FILTER UNION
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
20. INSTALL OIL FILTER (See page LU±15)
21. INSTALL OIL PUMP (See page LU±15)
22. INSTALL NO.1 OIL PAN (See page LU±15)
23. INSTALL OIL STRAINER (See page LU±15)
24. INSTALL NO.2 OIL PAN (See page LU±15)
25. INSTALL WATER PUMP (See page CO±8)
26. INSTALL WATER INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water in-
let housing and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

P12909
Seal Width 3 ± 5 mm
Z14261
1
23
45 6
7
89
10
P12389
SST
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
EM±109
1395 Author: Date:

Using a non±residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water inlet housing as shown in
the illustration.
Seal packing: Part No. 08826±00100 or equivalent

Install a nozzle that has been cut to a 3 ± 5 mm (0.12
± 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.
(c) Install the water inlet housing with the 8 bolts and 2 nuts.
Uniformly tighten the bolts and nuts, in several passes, in
the sequence shown.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)
(d) Install the engine wire band.
(e) Install the engine wire clamp.
27. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors.
SST 09816±30010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Connect the 2 knock sensor connectors.
28. INSTALL NO.2 IDLER PULLEY BRACKET
Torque: 28 N´m (290 kgf´cm, 21 ft´lbf)
29. INSTALL A/C COMPRESSOR HOUSING BRACKET
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)

P00601
Adhesive
A05416
1
2 34 5
67
8
EM±110
± ENGINE MECHANICAL (1MZ±FE)CYLINDER BLOCK
1396 Author: Date:
30. INSTALL OIL PRESSURE SWITCH
(See page LU±1)
31. INSTALL GENERATOR, BRACKET AND
ADJUSTING BAR ASSEMBLY
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
32. INSTALL CYLINDER HEAD (See page EM±57)
33. INSTALL TIMING PULLEYS AND BELT
(See page EM±21)
34. REMOVE ENGINE STAND
35. A/T:
INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833±00070, THREE BOND 1324
or equivalent
(b) Install the front spacer, drive plate and rear plate on the
crankshaft.
(c) Install and uniformly tighten the 8 bolts, in several passes,
in the sequence shown.
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)
36. M/T:
INSTALL FLYWHEEL (See step 35)
Torque: 83 N´m (850 kgf´cm, 61 ft´lbf)

EM0YU±01
A06653
 Gasket
 Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Gasket


BracketFront Exhaust Pipe Bracket
StayHeat Insulator Center Exhaust Pipe Gasket Heat InsulatorHeat Insulator
Heated Oxygen Sensor
(Bank 1 Sensor 2)TailpipeRing
Ring
33 (330, 24)
Heat Insulator
Heated Oxygen Sensor (Bank 1 Sensor 2)

Before installing the oxygen sensor, twist
the sensor wire counterclockwise 3 and
1/2 turns.
If it is twisted, remove the oxygen sensor
and reinstall it.
After installing the sensor wire is not twisted. California A/T
Bracket
HINT:
56 (570, 41)
19 (195, 14)
21 (210, 15)
62 (630, 46)
33 (330, 24)33 (330, 24)
56 (570, 41)
Stay
Front Exhaust Pipe (Type A)
Type B
44 (450, 33)
 Gasket
± ENGINE MECHANICAL (1MZ±FE)EXHAUST SYSTEM
EM±111
1397 Author: Date:
EXHAUST SYSTEM
COMPONENTS

A06652
 Gasket
 Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torque Gasket

 Gasket
Bracket
Stay
Front Exhaust Pipe (A/T) BracketBracket
Stay
21 (210, 15)
Heat Insulator Center Exhaust Pipe Gasket Heat InsulatorHeat Insulator
Heated Oxygen Sensor
(Bank 1 Sensor 2)TailpipeRing
Ring
33 (330, 24)
Heat Insulator
Heated Oxygen Sensor (Bank 1 Sensor 2)

Before installing the oxygen sensor, twist
the sensor wire counterclockwise 3 and
1/2 turns.
If it is twisted, remove the oxygen
sensor and reinstall it.
After installing the sensor wire is notExcept California A/T
HINT:
56 (570, 41)
19 (195, 14)
62 (630, 46)
33 (330, 24)33 (330, 24)
56 (570, 41)
twisted.
Front Exhaust Pipe
M/T
44 (450, 33)
EM±112
± ENGINE MECHANICAL (1MZ±FE)EXHAUST SYSTEM
1398 Author: Date:

IG0DB±01
SPARK TEST
CHECK CONNECTION OF IGNITION COIL WITH
CHECK RESISTANCE OF HIGH±TENSION CORDS
CHECK POWER SUPPLY TO IGNITION COILS WITH
1. Turn ignition switch to ON.
2. Check that there is battery positive voltage at ignition
CHECK RESISTANCE OF IGNITION COILS
Resistance:
SecondaryCold Hot
9.7 ± 16.7 kW12.4 ± 19.6 kW
CHECK RESISTANCE OF SENSORS
Resistance: Cold Hot
Camshaft position sensor
Crankshaft position sensor835 ± 1,400 W
985 ± 1,600 W1,060 ± 1,645 W
1,265 ± 1,890 W
CHECK IGT SIGNAL FROM ECM
TRY ANOTHER IGNITERIGNITER CONNECTORS
(See step 2)
Maximum resistance: 25 kW per cord
IGNITERS
coil positive (+) terminal.
(See step 4)
(See steps 5 and 6)
(See page DI±22) NO
OK
OK
OK
OK
OK
BAD
BAD
BAD
BAD
BAD
BAD
Connect securely.
Replace cord(s).
Check wiring between ignition switch to ignition
Replace ignition coil(s) with igniter(s).
Replace sensor(s).
Check wiring between ECM and igniters, and coils with igniters.
then try another ECM.
± IGNITION (5S±FE)IGNITION SYSTEM
IG±1
1683 Author: Date:
IGNITION SYSTEM
ON±VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in these sentences express the temperature of the coils themselves. ºColdº is from
±10°C (14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to 100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high±tension cord from the spark plug.
(2) Remove the spark plug.
(3) Install the spark plug to the high±tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors during this test, crank the engine for no more
than 5 ± 10 seconds at time.
If the spark does not occur, do the test as follows:

S05295
CORRECT
WRONG
S05542
Ohmmeter
IG0147
Megger
Ground
S03776
IG±2
± IGNITION (5S±FE)IGNITION SYSTEM
1684 Author: Date:
2. INSPECT HIGH±TENSION CORDS
(a) Remove the high±tension cords.
Disconnect the high±tension cords at the rubber boot. Do
not pull on the high±tension cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(b) Using an ohmmeter, measure the high±tension cord re-
sistance.
Maximum resistance: 25 kW per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high±tension cord.
(c) Reinstall the high±tension cords.
3. INSPECT SPARK PLUGS
NOTICE:

Never use a wire brush for cleaning.

Never attempt to adjust the electrode gap on a used
spark plug.

Spark plugs should be replaced every 100,000 km
(60,000 miles).
(a) Disconnect the high±tension cords from the spark plugs.
(b) Inspect the electrode.
Using a megger (insulation resistance meter), measure
the insulation resistance.
Standard correct insulation resistance:
10 MW or more
If the resistance is less than specified, proceed to step (d).
HINT:
If a megger is not available, the following simple method of in-
spection provides fairly accurate results.
Simple Method:

Quickly race the engine to 4,000 rpm 5 times.

Remove the spark plug. (See step (c))

Visually check the spark plug.
If the electrode is dry ... OK
If the electrode is wet ... Proceed to step (d)

Reinstall the spark plug. (See step (g))

S05308
16 mm Plug
Wrench
P20584
IG0152
B06373
Ohmmeter
± IGNITION (5S±FE)IGNITION SYSTEM
IG±3
1685 Author: Date:
(c) Using a 16 mm plug wrench, remove the 4 spark plugs.
(d) Visually check the spark plug for thread damage and insu-
lator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSO madePK20TR11
NGK madeBKR6EKPB11
(e) Inspect the electrode gaps.
Maximum electrode gap for used spark plug:
1.3 mm (0.051 in.)
If the gap is greater than maximum, replace the spark plug.
Correct electrode gap for new spark plug:
1.1 mm (0.043 in.)
NOTICE:
If adjusting the gap of a new spark plug, bend only the base
of the ground electrode. Do not touch the tip. Never attempt
to adjust the gap on the used plug.
(f) Clean the spark plugs.
If the electrode has traces of wet carbon, allow it to dry and then
clean with a spark plug cleaner.
Air pressure: Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(g) Using a 16 mm plug wrench, install the 4 spark plugs.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
(h) Reconnect the high±tension cords from the spark plugs.
4. INSPECT IGNITION COILS WITH IGNITERS
(a) Disconnect the high±tension cords from the ignition coils.
(b) Inspect the secondary coil resistance.
Using an ohmmeter, measure the resistance between the
high±tension terminals.
Secondary coil resistance:
Cold9.7 ± 16.7 kW
Hot12.4 ± 19.6 kW