TOYOTA CAMRY 1999 Service Repair Manual

SS09Q±01
± SERVICE SPECIFICATIONSCLUTCH
SS±43
206 Author: Date:
CLUTCH
SERVICE DATA
Pedal height from asphalt sheet 1MZ±FE161.8 ± 171.8 mm (6.370 ± 6.764 in.)
Pedal height from asphalt sheet 5S±FE156.8 ± 166.8 mm (6.173 ± 6.567 in.)
Push rod play at pedal top1.0 ± 5.0 mm (0.039 ± 0.197 in.)
Pedal freeplay5.0 ± 15.0 mm (0.197 ± 0.591 in.)
Clutch start switch ON±OFF Stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runout Max.0.8 mm (0.031 in.)
Flywheel runoutMax.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)
Diaphragm spring finger wear Max. width5.0 mm (0.197 in.)
Diaphragm spring tip non±alignmentMax.0.5 mm (0.020 in.)

SS09R±01
SS±44
± SERVICE SPECIFICATIONSCLUTCH
207 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder installation nut121209
Clutch line1515511
Release cylinder installation bolt121209
Bleeder plug8.48574 in.´lbf
Cruise control actuator bracket x Body131309
Starter x Transaxle3940029
Clutch accumulator installation bolt2121015
Clutch accumulator installation nut2727020
Release fork support 1MZ±FE4748035
Release fork support 5S±FE3940029
Clutch cover x Flywheel1919514

SS09O±01
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E153)
SS±45
208 Author: Date:
MANUAL TRANSAXLE (E153)
SERVICE DATA
Input shaft
3rd & 4th gears journal diameterMin.
5th gear journal diameterMin.
RunoutMax.
35.950 mm (1.4154 in.)
27.950 mm (1.1004 in.)
0.05 mm (0.0020 in.)
Output shaft
1st & 2nd gears journal diameterMin.
RunoutMax.
38.950 mm (1.5335 in.)
0.06 mm (0.0024 in.)
Oil pump clearance
Rotor body STD
Max.
Rotor tip STD
Max.
Rotor side STD
Max.
0.10 ± 0.16 mm (0.0039 ± 0.0063 in.)
0.30 mm (0.0118 in.)
0.08 ± 0.15 mm (0.0031 ± 0.0059 in.)
0.30 mm (0.0118 in.)
0.03 ± 0.08 mm (0.0012 ± 0.0031 in.)
0.15 mm (0.0059 in.)
Gear thrust clearance
1st & 3rd STD
Max.
2nd STD
Max.
4th STD
Max.
5th STD
Max.
0.10 ± 0.35 mm (0.0039 ± 0.0138 in.)
0.40 mm (0.0157 in.)
0.10 ± 0.45 mm (0.0039 ± 0.0177 in.)
0.50 mm (0.0197 in.)
0.10 ± 0.55 mm (0.0039 ± 0.0217 in.)
0.60 mm (0.0236 in.)
0.10 ± 0.57 mm (0.0039 ± 0.0224 in.)
0.65 mm (0.0256 in.)
Gear radial clearance
1st & 4th STD
2nd & 3rd STD
5th STD
1st, 2nd, 3rd, 4th & 5thMax.
0.009 ± 0.051 mm (0.0004 ± 0.0020 in.)
0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
0.009 ± 0.050 mm (0.0004 ± 0.0020 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance
1st, 4th & 5th Min.
2nd & 3rdMin.
0.8 mm (0.031 in.)
0.7 mm (0.028 in.)
Drive in depth
Control shaft cover oil seal
Select inner lever slotted spring pin
No.1 shift inner lever slotted spring pin
No.2 shift inner lever slotted spring pin
0 ± 1.0 mm (0 ± 0.039 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
Input shaft snap ring thickness Mark
No.2 clutch hub H
J
K
L
M
N
P
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)

SS±46
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E153)
209 Author: Date:
Input shaft snap ring thickness Mark
No.3 clutch hub a
b
c
d
e
f
g
h
j
Ball bearing 1
2
3
4
5
6
7
8
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0729 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0847 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
Output shaft snap ring thickness Mark
No.1 clutch hub A
B
C
D
E
F
G
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
2.90 mm (0.1142 in.)
2.95 mm (0.1161 in.)
3.00 mm (0.1181 in.)
3.05 mm (0.1201 in.)
3.10 mm (0.1220 in.)
Differential pinion to side gear backlash STD0.05±0.20 mm (0.0020±0.0079 in.)
Differential side gear thrust washer thickness
0.80 mm (0.0315 in.)
0.90 mm (0.0354 in.)
1.00 mm (0.0394 in.)
1.10 mm (0.0433 in.)
1.20 mm (0.0472 in.)
1.30 mm (0.0512 in.)
1.40 mm (0.0551 in.)
Differential case side bearing preload (at starting)
New bearing (Output shaft preload plus)
Reused bearing (Output shaft preload plus)
0.2 ± 0.3 N´m (1.8 ± 3.5 kgf´cm, 1.6 ± 3.0 in.´lbf)
0.1 ± 0.2 N´m (1.1 ± 2.2 kgf´cm, 1.0 ± 1.9 in.´lbf)
Differential side bearing adjusting shim thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)

± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E153)
SS±47
210 Author: Date:
Output shaft bearing preload (at starting)
New bearing
Reused bearing
0.8 ± 1.6 N´m (8 ± 16 kgf´cm, 6.9 ± 13.9 in.´lbf)
0.5 ± 1.0 N´m (5 ± 10 kgf´cm, 4.3 ± 8.7 in.´lbf)
Output shaft rear bearing adjusting shim thickness Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
1.30 mm (0.0512 in.)
1.35 mm (0.0531 in.)
1.40 mm (0.0551 in.)
1.45 mm (0.0571 in.)
1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0728 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)

SS09P±01
SS±48
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E153)
211 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head A
(See page MX±4) 14 mm head B64
46
37650
470
38047
34
27
Cruise control actuator x Body (w/ Cruise control)131309
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Clutch acummulator x Transaxle Bolt
Nut21
26210
27015
20
Clutch line bracket x Transaxle121209
Front wheel1031,05076
Exhaust pipe support stay3333024
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe5657041
No.1 exhaust pipe support bracket x Front suspension member3333024
Stabilizer bar link x Stabilizer bar3940029
Stabilizer bar bracket x Front suspension member1919514
PS gear assembly x Front suspension member1811,850134
Front engine absorber x Transaxle4849035
RH exhaust manifold stay2020014
Front engine mounting insulator x Front suspension member Silver bolt
Green bolt44
66450
67033
48
LH engine mounting insulator x Front suspension member8082059
LH engine mounting bracket x Transaxle6465047
Rear engine mounting insulator x Front suspension member6667048
Steering return pipe x Front suspension member101007
Front suspension member with lower suspension arm Bolt A
Bolt B
(See page MX±4) Nut C181
32
361,850
330
370134
24
27
Flywheel housing under cover x Transaxle7.88069 in.´lbf
Shift cable grommet retainer x Body4.95043 in.´lbf
Shift lever assembly x Body121209
No.2 selecting bellcrank with selecting bellcrank support2020014
Shift and select lever shaft lock bolt4950036
Shift and select lever shaft assembly x Transmission case2020014
Transmission case cover x Transmission case2930022
Breather plug4950036
Output shaft lock nut1231,25090
Shift fork and shift head set bolt2424017
Rear bearing retainer x Transmission case4243031
Straight screw plug2525018
Straight screw plug (Reverse restrict pin)131309
Reverse idler gear shaft lock bolt2930022
Transmission case x Transaxle case2930022
Transmission oil pipe x Transaxle case1717513
Reverse shift arm bracket assembly x Transaxle case1717513

± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (E153)
SS±49
212 Author: Date:
Transmission oil pump assembly x Transaxle case1717513
Transaxle case receiver x Transaxle case7.47565 in.´lbf
Clutch release fork support4748035
Control lever housing support bracket x Transaxle case1717513
Vehicle speed sensor1717513
Clutch release line bracket x Transaxle case1717513
Back±up light switch4041030
Filler and drain plug4950036
No.1 and No.2 oil receiver pipe x Transmission case1717513
Transmission oil cooler sub±assembly x Elbow3435025
Elbow x Transaxle case2727520
Transmission oil pump case x Oil pump cover101058
Transaxle case cover x Transaxle case5455040
Differential left case x Differential right case6364046
Ring gear set bolt1241,26091

SS09M±01
SS±50
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (S51)
213 Author: Date:
MANUAL TRANSAXLE (S51)
SERVICE DATA
Input shaft roller bearing journal diameterMin.29.970 mm (1.799 in.)
Input shaft 3rd gear journal diameterMin.33.090 mm (1.3028 in.)
Input shaft 4th gear journal diameterMin.32.470 mm (1.2783 in.)
Input shaft 5th gear journal diameterMin.26.970 mm (1.0618 in.)
Input shaft runoutMax.0.05 mm (0.0020 in.)
Output shaft roller bearing journal diameterMin.31.970 mm (1.2587 in.)
Output shaft 1st gear journal diameterMin.37.970 mm (1.4949 in.)
Output shaft 2nd gear journal diameterMin.31.990 mm (1.2594 in.)
Output shaft runoutMax.0.05 mm (0.0020 in.)
Gear thrust clearance 1st STD0.10 ± 0.29 mm (0.0039 ± 0.0114 in.)Gear thrust clearance 1st STD
Max.
0.10 0.29 mm (0.0039 0.0114 in.)
0.35 mm (0.0138 in.)
Gear thrust clearance 2nd STD0.20 ± 0.44 mm (0.0079 ± 0.0173 in.)Gear thrust clearance 2nd STD
Max.
0.20 0.44 mm (0.0079 0.0173 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 3rd STD0.10 ± 0.25 mm (0.0039 ± 0.098 in.)Gear thrust clearance 3rd STD
Max.
0.10 0.25 mm (0.0039 0.098 in.)
0.30 mm (0.0118 in.)
Gear thrust clearance 4th STD0.20 ± 0.45 mm (0.0079 ± 0.0177 in.)Gear thrust clearance 4th STD
Max.
0.20 0.45 mm (0.0079 0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 5th STD0.20 ± 0.40 mm (0.0079 ± 0.0157 in.)Gear thrust clearance 5th STD
Max.
0.20 0.40 mm (0.0079 0.0157 in.)
0.45 mm (0.0177 in.)
Gear radial clearance 1st, 2nd, 3rd, and 4th STD
Max.0.009 ± 0.053 mm (0.0004 ± 0.0021 in.)
0.070 mm (0.0028 in.)
Gear radial clearance 5th STD
Max.0.009 ± 0.050 mm (0.0004 ± 0.0020 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance 1st, 3rd and 4th Min.0.6 mm (0.024 in.)
Synchronizer ring to gear clearance 2nd Min.0.7 mm (0.028 in.)
Differential case side bearing preload (at starting)(For use with SST)0.8 ± 1.6 N´m (8 ± 16 kgf´cm, 6.9 ± 13.9 in.´lbf)
Differential pinion to side gear backlash0.05 ± 0.20 mm (0.0020 ± 0.0079 in.)
Drive in depthDrive in depth
Input shaft front oil seal

0 ± 0.5 mm
(0 ± 0.020 in.) In ut shaft front oil seal
Reverse restrict pin slotted spring pin
0 ± 0.5 mm (0 ± 0.020 in.)
13.5 ± 0.5 mm (0.531 ± 0.020 in.) Reverse restrict in slotted s ring in
Shift and select lever shaft slotted spring pin
13.5 ± 0.5 mm (0.531 ± 0.020 in.)
23.5 ± 1.0 mm (0.925 ± 0.039 in.)
Differential side gear thrust washer thickness0 95 mm (0 0374 in )Differential side gear thrust washer thickness0.95 mm (0.0374 in.)
1 00 mm (0 0394 in )
1.00 mm (0.0394 in.)
1 05 mm (0 0413 in )1.05 mm (0.0413 in.)
1 10 (0 0433 i )1.10 mm (0.0433 in.)()
1.15 mm (0.0453 in.)()
1.20 mm (0.0472 in.)

± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (S51)
SS±51
214 Author: Date:
Input shaft snapring thicknessInput shaft snap ring thickness
No.2 clutch hub Mark 1

1.95 ± 2.00 mm (0.0768 ± 0.0787 in.)
No.2 clutch hub Mark 1
Mark 2
1.95 2.00 mm (0.0768 0.0787 in.)
2.00 ± 2.05 mm (0.0787 ± 0.0807 in.)
Mark 3
Mk4
()
2.05 ± 2.10 mm (0.0807 ± 0.0827 in.)
2 10 2 15 (0 0827 0 0846 i )Mark 4
Mark 5
2.10 ± 2.15 mm (0.0827 ± 0.0846 in.)
215±220mm(00846 ± 0 0866 in )Mark 5
M
ark 6
2.15 ± 2.20 mm (0.0846 ± 0.0866 in.)
2.20 ± 2.25 mm (0.0866 ± 0.0886 in.)Mark 6
No.3 clutch hub Mark 13
2.20 ± 2.25 mm (0.0866 ± 0.0886 in.)
2.20 ± 2.25 mm (0.0866 ± 0.0886 in.) No.3 clutch hub Mark 13
Mark 14
2.20 2.25 mm (0.0866 0.0886 in.)
2.25 ± 2.30 mm (0.0886 ± 0.0906 in.)
Mark 15
Mk16
()
2.30 ± 2.35 mm (0.0906 ± 0.0925 in.)
2 35 2 40 (0 0925 0 0945 i )Mark 16
Mark 17
2.35 ± 2.40 mm (0.0925 ± 0.0945 in.)
240±245mm(00945 ± 0 0965 in )Mark 17
Mark 182.40 ± 2.45 mm (0.0945 ± 0.0965 in.)
2.45 ± 2.50 mm (0.0965 ± 0.0984 in.)Mark 18
Mark 19
2.45 ± 2.50 mm (0.0965 ± 0.0984 in.)
2.50 ± 2.55 mm (0.0984 ± 0.01004 in.)Mark 19
Mark 20
2.50 2.55 mm (0.0984 0.01004 in.)
2.55 ± 2.60 mm (0.1004 ± 0.01024 in.)
Mark 21
Mark 22
()
2.60 ± 2.65 mm (0.1024 ± 0.01043 in.)
2 65 2 70 mm (0 1043 0 01063 in )Mark 22
Mark 23
2.65 ± 2.70 mm (0.1043 ± 0.01063 in.)
270±2 75 mm (0 1063±0 01083 in )Mark 23
Mark 24
2.70 ± 2.75 mm (0.1063 ± 0.01083 in.)
2.75 ± 2.80 mm (0.1083 ± 0.01102 in.)Mark 24
Mark 25
2.75 ± 2.80 mm (0.1083 ± 0.01102 in.)
2.80 ± 2.85 mm (0.1102 ± 0.01122 in.)Mark 25
Mark 26
2.80 2.85 mm (0.1102 0.01122 in.)
2.85 ± 2.90 mm (0.1122 ± 0.01142 in.)
Mark 27
Rear bearing Mark A
2.90 ± 2.95 mm (0.1142 ± 0.01161 in.)
2 15 2 20 mm (0 0846 0 0866 in ) Rear bearing Mark A
Mark B
2.15 ± 2.20 mm (0.0846 ± 0.0866 in.)
220±2 25 mm (0 0866±0 0886 in )Mark B
Mark C
2.20 ± 2.25 mm (0.0866 ± 0.0886 in.)
2.25 ± 2.30 mm (0.0886 ± 0.0906 in.)Mark C
Mark D
2.25 ± 2.30 mm (0.0886 ± 0.0906 in.)
2.30 ± 2.35 mm (0.0906 ± 0.0925 in.)Mark D
Mark E
2.30 2.35 mm (0.0906 0.0925 in.)
2.35 ± 2.40 mm (0.0925 ± 0.0945 in.)
Differential side bearing adjusting shim thicknessDifferential side bearing adjusting shim thickness
Mark 1

1 90 mm (0 0748 in )Mark 1
Mark 2
1.90 mm (0.0748 in.)
1 95 mm (0 0768 in )Mark 2
Mark 31.95 mm (0.0768 in.)
2 00 mm (0 0787 in )
Mark 3
Mark 42.00 mm (0.0787 in.)
2 05 mm (0 0807 in )
Mark 4
Mark 52.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
Mark 5
Mark 6
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)Mark 6
Mark 7
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)Mark 7
Mark 8
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)Mark 8
Mark 9
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)Mark 9
Mark 10
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)Mark 10
Mark 11
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)Mark 11
Mark 12
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)Mark 12
Mark 13
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
Mark 14
()
2.55 mm (0.1004 in.)
Mark 15
()
2.60 mm (0.1024 in.)
Mark 16
()
2.65 mm (0.1043 in.)
Mark 172.70 mm (0.1063 in.)
Mark 18
Mk
2.75 mm (0.1083 in.)
(i)Mark 192.80 mm (0.1102 in.)

SS09N±01
SS±52
± SERVICE SPECIFICATIONSMANUAL TRANSAXLE (S51)
215 Author: Date:
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head6465047Transaxle x Engine 17 mm head
14 mm head
64
46
650
470
47
34
Cruise control actuator x Body (w/ Cruise control)131309
Starter x Transaxle3737828
Clutch release cylinder x Transaxle121209
Clutch line bracket x Transaxle Bolt A121209Clutch line bracket x Transaxle Bolt A
(See page MX±4) Bolt B
12
6.9
120
70
9
61 in.´lbf
Manifold stay Front side4242531
Manifold stay Rear side3940029
Front wheel1031,05076
Exhaust pipe bracket Bolt1919514Exhaust ie bracket Bolt
Nut
19
33
195
330
14
24
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe5657041
No.1 exhaust pipe support bracket x Front suspension member3333024
Stabilizer bar link x Stabilizer bar3940029
Stabilizer bar bracket x Front suspension member1919514
PS gear assembly x Front suspension member1811,850134
Front engine mounting insulator x Front suspension member Silver bolt4445033Front engine mounting insulator x Front sus ension member Silver bolt
Green bolt
44
66
450
670
33
48
LH engine mounting insulator x Front suspension member8082059
LH engine mounting bracket x Transaxle6465047
Rear engine mounting insulator x Front suspension member6667048
Steering return pipe x Front suspension member101007
Front suspension member with lower suspension arm Bolt A1811,850134Front sus ension member with lower sus ension arm Bolt A
Bolt B
181
32
1,850
330
134
24Bolt B
(See page MX±4) Nut C
32
36
330
370
24
27
LH stiffener plate3738027
RH stiffener plate3940029
Rear end plate9.39582 in.´lbf
Shift cable grommet retainer x Body4.95043 in.´lbf
Shift lever assembly x Body121209
Transmission case x Transaxle case2930022
Transmission case x Case cover2930022
Transmission case protector1818513
Rear bearing retainer4243031
Output shaft front bearing lock plate1818513
Transaxle case receiver set bolt7.47565 in.´lbf
5th driven gear lock nut1231,25090
Reverse idler shaft lock bolt2930022
Control shaft cover3737527
Control shift lever x Lever shaft6.46556 in.´lbf
Ring gear x Differential case8385061
Selecting bellcrank x Transmission case3738027