engine TOYOTA CELICA 2002 T230 / 7.G Repair Manual

’02MY CELICA U (L/O 0108)
1872002 MY CELICA_U (OM20792U)
If you perform maintenance by yourself,
be sure to follow the correct procedure
given in this section.
You should be aware that improper or in-
complete servicing may result in operating
problems.
Performing doityourself maintenance
during the warranty period may affect your
warranty coverage. Read the separate
Toyota Warranty statement for details and
suggestions.
This section gives instructions only for
those items that are relatively easy for an
owner to perform. As explained in Section
6, there are still a number of items that
must be done by a qualified technician
with special tools.
For information on tools and parts for do
ityourself maintenance, see “Parts and
tools”.
Utmost care should be taken when work-
ing on your vehicle to prevent accidental
injury. Here are a few precautions that
you should be especially careful to ob-
serve:CAUTION
When the engine is running, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold, power steering
fluid reservoir and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the engine is hot, do not remove
the coolant reservoir cap or air re-
lease valve or loosen the drain
plugs to prevent burning yourself.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Doityourself service
precautions

’02MY CELICA U (L/O 0108)
1882002 MY CELICA_U (OM20792U)
Be extremely cautious when work-
ing on the battery. It contains poi-
sonous and corrosive sulfuric acid.
Warning: Battery posts, terminals
and related accessories contain lead
and lead compounds, chemicals
known to the State of California to
cause cancer and reproductive
harm. Wash hands after handling.
NOTICE
Remember that battery and ignition
cables carry high currents or volt-
ages. Be careful of accidentally
causing a short circuit.
 Add only demineralized or distilled
water to fill the radiator. And if you
spill some of the coolant, be sure
to wash it off with water to prevent
it from damaging the parts or paint.
 Do not allow dirt or anything else
to fall through the spark plug holes.
 Do not pry the outer electrode of a
spark plug against the center elec-
trode.
Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.
 Do not reuse iridiumtipped spark
plugs by cleaning or regapping.
 Do not overfill automatic transmis-
sion fluid, or the transmission
could be damaged.
 Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
 Be careful not to scratch the glass
surface with the wiper frame.
 When closing the engine hood,
check to see that you have not for-
gotten any tools, rags, etc.
Front
Rear
Positioning the jack

’02MY CELICA U (L/O 0108)
1892002 MY CELICA_U (OM20792U)
When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustrations.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start or run the engine while
your vehicle is supported by the
jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the transmission in “P”
(automatic) or reverse (manual).
Block the wheels on the opposite
side of the jack up point if neces-
sary.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
put an object on or under the jack.
NOTICE
Make sure to place the jack correctly,
or your vehicle may be damaged.
Here is a list of parts and tools you will
need on performing doityourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
Engine oil API grade SJ
“EnergyConserving”, SL
“EnergyConserving” or ILSAC
multigrade having viscosity proper for
your climate
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE ENGINE COOLANT
LEVEL
Parts (if level is low):
“TOYOTA Long Life Coolant” or equiva-
lent
See Section 72 for details about cool-
ant type selection.
Demineralized or distilled water
Tools:
Funnel (only for adding coolant)
Parts and tools

’02MY CELICA U (L/O 0108)
1912002 MY CELICA_U (OM20792U)
DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level192
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the engine coolant level el193
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the radiator and condenser r194
. . . . . . . . . . . . . . . . . . . . . . . .
Checking brake fluid 195
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
Checking power steering fluid 195
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking tire pressure 196
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. .
Checking and replacing tires 197
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rotating tires 198
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . . . . . .
Installing snow tires and chains 199
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing wheels 200
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . . . .
Aluminum wheel precautions 201
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 2

’02MY CELICA U (L/O 0108)
1922002 MY CELICA_U (OM20792U)
Low level Full level
Add oil O.K. Too full
With the engine at operating tempera-
ture and turned off, check the oil level
on the dipstick. 1. To get a true reading, the vehicle should be on a level spot. After turning
off the engine, wait a few minutes for
the oil to drain back into the bottom of
the engine.
2. Pull out the dipstick, and wipe it clean with a rag.
3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be
correct.
4. Pull the dipstick out and look at the oil level on the end.
CAUTION
Be careful not to touch the hot ex-
haust manifold.
If the oil level is below or only slightly
above the low level, add engine oil of
the same type as already in the engine.
Remove the oil filler cap and add engine
oil in small quantities at a time, checking
the dipstick.
The approximate quantity of oil needed to
fill between the low level and the full level
on the dipstick is indicated below for ref-
erence.
When the level reaches within the correct
range, install the f iller cap handtight.
Oil quantity, L (qt., lmp. qt.): 1ZZFE engine 1.3 (1.4, 1.1)
2ZZGE engine 1.5 (1.6, 1.3)
NOTICE
 Avoid overfilling, or the engine
could be damaged.
 Check the oil level on the dipstick
once again after adding the oil.
ENGINE OIL SELECTION
Use API grade SJ “EnergyConserving”,
SL “EnergyConserving” or ILSAC multi-
grade engine oil.
Recommended viscosity (SAE):
5W-30 Preferred
Temperature range anticipated before
next oil change
SAE 5W30 is the best choice for your
vehicle, for good fuel economy, and
good starting in cold weather.
If you use SAE 10W30 engine oil in
extremely low temperatures, the engine
may become difficult to start, so SAE
5W30 engine oil is recommended.
Checking the engine oil level

’02MY CELICA U (L/O 0108)
1932002 MY CELICA_U (OM20792U)
API service symbol
ILSAC certification mark
Oil identification marks
Either or both API registered marks are
added to some oil containers to help
you select the oil you should use.
The API Service Symbol is located any-
where on the outside of the container.
The top portion of the label shows the oil
quality by API (American Petroleum
Institute) designations such as SL. The
center portion of the label shows the SAE
viscosity grade such as SAE 5W30.
“EnergyConserving” shown in the lower
portion, indicates that the oil has
fuelsaving capabilities.
The ILSAC (International Lubricant Stan-
dardization and Approval Committee) Certi-
fication Mark is displayed on the front of
the container.Look at the seethrough coolant reser-
voir when the engine is cold. The cool-
ant level is satisfactory if it is between
the “FULL” and “LOW” lines on the
reservoir. If the level is low, have your
Toyota dealer add ethyleneglycol type
coolant for proper corrosion protection
of aluminum components.
The coolant level in the reservoir will vary
with engine temperature. However, if the
level is on or below the “LOW” line, you
should have your Toyota dealer add cool-
ant.
Always use ethyleneglycol type coolant
for a proper corrosion protection of alumi-
num components. See information in the
next column.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, drain cock and water
pump.
If you can find no leak, have your Toyota
dealer test the cap pressure and check
for leaks in the cooling system.
Checking the engine coolant
level

’02MY CELICA U (L/O 0108)
1942002 MY CELICA_U (OM20792U)
CAUTION
To prevent burning yourself, do not
remove the coolant reservoir cap or
air release valve when the engine is
hot.
Coolant type selection
Use of improper coolants may damage
your engine cooling system. Your coolant
must contain ethyleneglycol type coolant
for a proper corrosion protection of your
engine that contains aluminum compo-
nents. Use “TOYOTA Long Life Coolant”
or equivalent.
In addition to preventing freezing and sub-
sequent damage to the engine, this type
of coolant will also prevent corrosion. Fur-
ther supplemental inhibitors or additives
are neither needed nor recommended.
Read the coolant container for information
on freeze protection. Follow the manufac-
turer’s directions for how much to mix
with plain water (preferably demineralized
water or distilled water). The total capacity
of the cooling system is given in Section
8. We recommend to use 50% solution for
your Toyota, to provide protection down to
about 35
C (31 F). When it is extreme-
ly cold, to provide protection down to
about 50 C (58 F), 60% solution is rec-
ommended. Do not use more than 70%
solution for better coolant performance.NOTICE
Do not use alcohol type antifreeze or
plain water alone.
If any of the above parts are extremely
dirty or you are not sure of their condi-
tion, take your vehicle to Toyota dealer.
CAUTION
To prevent yourself from burning, be
careful not to touch the radiator or
condenser when the engine is hot.
NOTICE
To prevent damage to the radiator
and condenser, do not perform the
work by yourself.
Checking the radiator and
condenser

’02MY CELICA U (L/O 0108)
1952002 MY CELICA_U (OM20792U)
To check the fluid level, simply look at
the seethrough reservoir. The level
should be between the “MAX” and
“MIN” lines on the reservoir.
It is normal for the brake fluid level to go
down slightly as the brake pads wear. So
be sure to keep the reservoir filled.
If the reservoir needs frequent refilling, it
may indicate a serious mechanical prob-
lem. If the level is low, add SAE J1703 or
FMVSS No.116 DOT 3 brake fluid to the
brake reservoir.
Remove and replace the reservoir cap by
hand. Fill the brake fluid to the dotted
line. This brings the fluid to the correct
level when you put the cap back on.
Use only newly opened brake fluid. Once
opened, brake fluid absorbs moisture from
the air, and excess moisture can cause a
dangerous loss of braking.
CAUTION
Take care when filling the r
eservoir
because brake fluid can harm your
eyes and damage painted surfaces. If
fluid gets in your eyes, flush your
eyes with clean water immediately. If
you still feel uncomfortable with your
eyes, go to the doctor.
NOTICE
If you spill the fluid, be sure to wash
it off with water to prevent it from
damaging the parts or paint.
If hot
O.K. Close Open
If hot add If cold
add
If cold O.K.
Check the fluid level through the reser-
voir. If necessary, add automatic trans-
mission fluid DEXRON
II or III.
If the vehicle has been driven around 80
km/h (50 mph) for 20 minutes (a little
more in frigid temperatures), the fluid is
hot (60 °C—80 °C or 140 °F—175 °F). You
may also check the level when the fluid
is cold (about room temperature,
10 °C—30 °C or 50 °F—85 °F) if the engine
has not been run for about five hours.
Checking brake fluid Checking power steering fluid

’02MY CELICA U (L/O 0108)
2052002 MY CELICA_U (OM20792U)
NOTICE
Be sure the engine and all accesso-
ries are off before performing main-
tenance.
 When checking the battery, remove
the ground cable from the negative
terminal (“” mark) first and rein-
stall it last.
 Be careful not to cause a short cir-
cuit with tools.
 Take care no solution gets into the
battery when washing it.
Ty p e A
Green Dark Clear or
light yellow
Ty p e B Blue White Red
CHECKING BY INDICATOR
Check the battery condition by the indi-
cator color.
Indicator color
ConditionTy p e ATy p e B
GreenBlueGood
DarkWhite
Charging
necessary. Have
battery checked
by your Toyota
dealer.
Clear orlight
yellow
Red
Have battery
checked by your
Toyota dealer.
During recharging, the battery is pro-
ducing hydrogen gas.
Therefore, before recharging:
1. If recharging with the battery installed on the vehicle, be sure to disconnect
the ground cable.
2. Be sure the power switch on the re- charger is off when connecting the
charger cables to the battery and when
disconnecting them.
CAUTION
Always charge the battery in an un-
confined area. Do not charge the
battery in a garage or closed room
where there is not sufficient ventila-
tion.
Only do a slow charge (5 A or
less). Charging at a quicker rate is
dangerous. The battery may ex-
plode, causing personal injuries.
NOTICE
Never recharge the battery while the
engine is running. Also, be sure all
accessories are turned off.
—Checking battery c ondition Battery recharging pr ecautions

’02MY CELICA U (L/O 0108)
2082002 MY CELICA_U (OM20792U)
NOTICE
Do not use engine antifreeze or any
other substitute because it may dam-
age your vehicle’s paint.
The following illustrations show how to
gain access to the bulbs. When replacing
a bulb, make sure the ignition switch and
light switch are off. Use bulbs with the
wattage ratings given in the table.
CAUTION
To prevent yourself from burning,
do not replace the light bulbs while
they are hot.
Halogen bulbs have pressurized gas
inside and require special handling.
They can burst or shatter if
scratched or dropped. Hold a bulb
only by its plastic or metal case.
Do not touch the glass part of a
bulb with bare hands.
The inside of the lens of exterior lights
such as headlights may temporarily fog up
when the lens becomes wet in the rain or
in a car wash. This is not a problem
because the fogging is caused by the
temperature difference between the outside
and inside of the lens, just like the
windshield fogged up in the rain. However,
if there is a large drop of water on the
inside of the lens, or if there is water
pooled inside the light, contact your
Toyota dealer.
NOTICE
Only use a bulb of the listed type.
Light bulbsBulbNo.WTy p e
Headlights
(low beam)—55A
Headlights
(high beam)900565B
Front fog light—55C
Parking lights—5D
Front turn signal
lights—21E
Front side marker
lights—5D
Rear turn signal
lights—21D
Stop/tail lights—21/5D
Backup lights—18D
License plate lights—5D
Interior light
(with moon roof)—10E
Interior light
(without moon roof)—8F
Replacing light bulbs—