spark plugs replace TOYOTA CAMRY 1999 Service Repair Manual

A00434
± DIAGNOSTICSENGINE (5S±FE)
DI±93
328 Author: Date:
2 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Disconnect the high±tension cord from the spark plug.
(b) Remove the spark plug.
CHECK:
(a) Check the plug type.
(b) Check the electrode for carbon deposits.
(c) Check the electrode gap.
OK:
(a) Platinum±tipped spark plugs with twin ground
electrodes.
Recommended spark plug:
ND made: PK20TR11
NGK made: BKR6EKPB±11
(b) No large carbon deposit present.
Not wet with gasoline or oil.
(c) Electrode gap: 1.1 mm (0.043 in.)
PREPARATION:
(a) Install the spark plug to the high±tension code.
(b) Disconnect the injector connector.
(c) Ground the spark plug.
CHECK:
Check if spark occurs while the engine is being cracked.
NOTICE: To prevent excess fuel being injected from the in-
jectors during this test, don't crank the engine for more
than 5 ~ 10 seconds at a time.
OK:
Spark jumps across electrode gap.
NG Replace or check ignition system
(See page IG±1).
OK

EM07Z±03
S05289
(c)
(d) (e)
S05590
Turn
P03443
1 11 122
33 EM±4
± ENGINE MECHANICAL (5S±FE)VALVE CLEARANCE
1176 Author: Date:
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE CYLINDER HEAD COVER
(a) Disconnect the 4 high±tension cords from the clamps on
the cylinder head cover.
(b) Disconnect the 4 high±tension cords from the spark
plugs.
(c) Disconnect the PCV hose from the intake manifold.
(d) Disconnect the PCV hose from the cylinder head cover.
(e) Disconnect the engine wire clamp from the mounting bolt
of the No.2 timing belt cover.
(f) Remove the cylinder head cover. (See page EM±33)
2. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 are tight.
If not, turn the crankshaft one revolution (360°) and align the
mark as above.
3. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out±of±specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.19 ± 0.29 mm (0.007 ± 0.011 in.)
Exhaust0.28 ± 0.38 mm (0.011 ± 0.015 in.)
(b) Turn the crankshaft one revolution (360°) and align the
mark as above.

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

Replace the camshaft position sensor.CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
Resistance: Cold Hot
835 ± 1,400 W1,060 ± 1,645 W
CHECK IGT SIGNAL FROM ECM
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
Resistance: Cold Hot
1,630 ± 2,740 W2,065 ± 3,225 W
TRY ANOTHER IGNITERReplace the crankshaft position sensor.
Check wiring between ECM and igniter, and
then try another ECM.
OK
OK
OKBAD
BAD
BAD
OK
Continued from the previous page
DENSO made:
Wabash made:1,690 ± 2,560 W2,145 ± 3,010 W
B00848
P24453
WRONG
CORRECT
P24457
IG±2
± IGNITION (1MZ±FE)IGNITION SYSTEM
1696 Author: Date:
2. INSPECT HIGH±TENSION CORDS
(a) Remove the V±bank cover.
(b) Disconnect the high±tension cords from the spark plugs.
(1) Using needle±nose pliers, disconnect the cord
clamp from the engine wire protector.
(2) Disconnect the high±tension cords from the spark
plugs.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(3) Disconnect the high±tension cords from the clamp.
(c) Disconnect the high±tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high±tension cord at the grommet.
NOTICE:

Pulling on or bending the cords may damage the con-
ductor inside.

Do not wipe any of the oil from the grommet after the
high±tension cord is disconnected.

P24458HolderGrommet
S00813
CORRECT WRONG
Clearance
IG0147
Megger
Ground
S03776
IG±4
± IGNITION (1MZ±FE)IGNITION SYSTEM
1698 Author: Date:
(g) Connect the high±tension cords to the ignition coils.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and ignition coil as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(h) Connect the high±tension cords to the spark plugs.
(i) Install the V±bank cover.
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) Remove the high±tension cords set. (See step 2)
(b) Remove the ignition coils.
(c) 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 (e).
HINT:
If a megger is not available, the following simple method of in-
spection provides fairly accurate results.
(d) Simple Method:
(1) Quickly race the engine to 4,000 rpm 5 times.
(2) Remove the spark plug. (See step (e))
(3) Visually check the spark plug.
If the electrode is dry ... OK
If the electrode is wet ... Proceed to step (f)
(4) Install the spark plug. (See step (i))

P13225
16 mm Plug
Wrench
P25746
DENSO PK20TR11 NGK BKR6EKPB11
P20584
IG0152
± IGNITION (1MZ±FE)IGNITION SYSTEM
IG±5
1699 Author: Date:
(e) Using a 16 mm plug wrench, remove the 6 spark plugs
from the RH and LH cylinder heads.
(f) Check the spark plug for thread damage and insulator
damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSO madePK20TR11
NGK madeBKR6EKPB11
(g) 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.
(h) 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.
(i) Using a 16 mm plug wrench, install the 6 spark plugs to
the RH and LH cylinder heads.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
(j) Install the ignition coils.
(k) Install the high±tension cords set. (See step 2)
4. INSPECT IGNITION COILS
(a) Disconnect the high±tension cords from the ignition coils.
(b) Disconnect the ignition coil connectors.

MA00L±01
P00495
Outside
Inside
± MAINTENANCEENGINE
MA±5
48 Author: Date:
ENGINE
INSPECTION
1. REPLACE TIMING BELT
5S±FE: (See page EM±17)
1MZ±FE: (See page EM±15)
2. INSPECT DRIVE BELTS
5S±FE: (See page CH±1)
1MZ±FE: (See page CH±1)
3. REPLACE SPARK PLUGS
5S±FE: (See page IG±1)
1MZ±FE: (See page IG±1)
4. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty or
oily.
(b) Clean the air filter with compressed air.
First blow from the inside thoroughly, then blow off the outside
of the air filter.
5. REPLACE AIR FILTER
Replace the air filter with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER
5S±FE: (See page LU±2)
1MZ±FE: (See page LU±3)
7. REPLACE ENGINE COOLANT
5S±FE: (See page CO±2)
1MZ±FE: (See page CO±2)
8. 1MZ±FE:
INSPECT CHARCOAL CANISTER
(See page EC±6)
9. REPLACE GASKET IN FUEL TANK CAP
5S±FE: (See page EC±6)
1MZ±FE: (See page EC±6)
10. INSPECT FUEL LINES AND CONNECTIONS
5S±FE: (See page EC±6)
1MZ±FE: (See page EC±6)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
5S±FE: (See page EC±15)
1MZ±FE: (See page EC±17)
12. ADJUST VALVE CLEARANCE
5S±FE: (See page EM±4)
1MZ±FE: (See page EM±4)

MA00L±02
P00495
Outside
Inside
± MAINTENANCEENGINE
MA±1
42 Author: Date:
ENGINE
INSPECTION
1. REPLACE TIMING BELT (See Pub. No. RM654U, page
EM±17)
2. INSPECT DRIVE BELTS (See Pub. No. RM654U, page
CH±1)
3. REPLACE SPARK PLUGS (See page IG±1)
4. INSPECT AIR CLEANER FILTER
(a) Visually check that the air filter is not excessively dirty or
oily.
(b) Clean the air cleaner filter with compressed air.
First blow from the inside thoroughly, then blow off the
outside of the air cleaner filter.
5. REPLACE AIR CLEANER FILTER
Replace the air filter with a new one.
6. REPLACE ENGINE OIL AND OIL FILTER (See Pub. No.
RM654U, page LU±2)
7. REPLACE ENGINE COOLANT (See Pub. No. RM654U,
page CO±2)
8. INSPECT FUEL PRESSURE REGULATOR RES-
ERVOIR (See page SF±6)
9. INSPECT FUEL FILTER (See page SF±3)
10. REPLACE FUEL FILTER (See page SF±5)
11. INSPECT FUEL LINES AND CONNECTIONS
Visually check for loose connections, sharp bends or damage.
12. INSPECT FUEL TANK BAND (See page SF±18)
13. INSPECT FUEL TANK
(a) Check for fuel leaks (See page SF±1).
(b) Check the fuel tank mounting (See page SF±18).
14. REPLACE FUEL TANK (See page SF±18)
15. INSPECT EXHAUST PIPES AND MOUNTINGS (See
Pub. No. RM654U, page EC±15)
16. ADJUST VALVE CLEARANCE (See page EM±4)

B06352
S05976
Upward
Turn
Connector
B06351
Gray
Brown No.1
No.2
No.3
No.4
S05289
(b)
(c) (d) SF±26
± SFI (5S±FE)INJECTOR
1459 Author: Date:
(h) Attach the 4 injectors and delivery pipe assembly to the
cylinder head.
(i) Temporarily install the 2 bolts holding the delivery pipe to
the cylinder head.
(j) Check that the injectors rotate smoothly.
HINT:
If injectors do not rotate smoothly, the probable cause is incor-
rect installation of O±rings. Replace the O±rings.
(k) Position the injector connector upward.
(l) Tighten the 2 bolts holding the delivery pipe to the cylinder
head.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(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.
2. INSTALL CYLINDER HEAD COVER
(a) Install the cylinder head cover. (See page EM±53)
(b) Connect the PCV hose to the intake manifold.
(c) Connect the PCV hose to the cylinder head cover.
(d) Install the engine wire clamp to the mounting bolt of the
No.2 timing belt cover.
(e) Connect the 4 high±tension cords to the spark plugs.
(f) Install the 4 high±tension cords to the clamps on the cylin-
der head cover.
3. CHECK FOR FUEL LEAKS (See page SF±1)