Toyota Camry 2007-2009 Service Manual - Introduction

INTRODUCTION – HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

GENERAL INFORMATION

1. GENERAL DESCRIPTION

(a) This manual is written in accordance with SAE

J2008. (1) Diagnosis (2) Removing / Installing, Replacing, Disassembling

/ Reassembling, Checking and Adjusting

(3) Final Inspection

(b) The following procedures are omitted from this

manual. However, these procedures must be performed. (1) Use a jack or lift to perform operations (2) Clean all removed parts (3) Perform a visual check

2. INDEX

(a) An alphabetical INDEX section is provided at the

end of the manual as a reference to help you find the item to be repaired.

3. PREPARATION

(a) Use of Special Service Tools (SST) and Special

Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in the "Preparation" section of this manual.

4. REPAIR PROCEDURES

(a) A component illustration is placed under the title

where necessary.

(b) Non-reusable parts, grease application areas,

precoated parts and torque specifications are noted in the component illustrations. The following illustration is an example.

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INTRODUCTION – HOW TO USE THIS MANUAL

Example:

Float

Slotted Spring Pin

15 (155,11)

Cylinder

N*m (kgf*cm, ft.*lbf)

Non-reusable part

Filter Cap

Reservoir Tank

: Specified torque

Grommet

12 (120,9)

Piston

Gasket

Washer

Push Rod

non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using an illustration. In these cases, torque, oil and other information are described in the illustration.

(d) Only items with key points are described in the text.

What to do and other details are explained using illustrations next to the text. Both the text and illustrations are accompanied by standard values and notices.

Illustration What to do and where to do it Task heading What work will be performed Explanation text How to perform the task

Also has information such as specifications and warnings, which are written in boldface text

Clevis Pin

Clip

Clevis

Lock Nut

Boot

Snap Ring

N017080E11

(e) Illustrations of similar vehicle models are sometimes

used. In these cases, minor details may be different from the actual vehicle.

(f) Procedures are presented in a step-by-step format.

5. SERVICE SPECIFICATIONS

(a) SPECIFICATIONS are presented in boldface text

throughout the manual. The specifications are also found in the "Service Specifications" section for reference.

6. TERM DEFINITIONS

CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs.

INTRODUCTION – HOW TO USE THIS MANUAL

7. INTERNATIONAL SYSTEM OF UNITS

(a) The units used in this manual comply with the

International System of Units (SI UNIT) standard. Units from the metric system and the English systems are also provided. Example:

Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

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INTRODUCTION – IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND SERIAL NUMBERS

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1. VEHICLE IDENTIFICATION NUMBER

(a) The vehicle identification number is stamped on the

vehicle body and on the certification label, as shown in the illustration.

Vehicle Identification Number

Certification Label

2AZ-FE:

2GR-FE:

2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER

(a) The engine serial number is stamped on the

cylinder block of the engine as shown in the illustration.

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INTRODUCTION – IDENTIFICATION INFORMATION

IN–5

(b) The transaxle serial number is stamped on the

housing as shown in the illustration.

E351E Transaxle Serial Number

U250E Transaxle Serial Number

U660E Transaxle Serial Number

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INTRODUCTION – REPAIR INSTRUCTION

REPAIR INSTRUCTION

PRECAUTION

1. BASIC REPAIR HINT

(a) HINTS ON OPERATIONS

1 Attire • Always wear a clean uniform.

• Hat and safety shoes must be worn.

2 Vehicle protection Prepare a grille cover, fender cover, seat cover and floor mat before starting the

operation.

3 Safety operation • When working with 2 or more persons, be sure to check safety for one another.

• When working with the engine running, make sure to provide ventilation for exhaust fumes in the workshop.

• If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety equipment and take extra care not to injure yourself or others.

• When jacking up the vehicle, be sure to support the specified location with a safety stand.

• When lifting up the vehicle, use appropriate safety equipment.

4 Preparation of tools and

measuring gauge

5 Removal and installation,

disassembly and assembly operations

Before starting operation, prepare a tool stand, SST, gauge, oil and parts for replacement.

• Diagnose with a thorough understanding of proper procedures and of the reported problem.

• Before removing the parts, check the general condition of the assembly and for deformation and damage.

• When the assembly is complicated, take notes. For example, note the total number of electrical connections, bolts, or hoses removed. Add matchmarks to insure reassembly of components in the original positions. T emporarily mark hoses and their fittings if needed.

• Clean and wash the removed parts if necessary and assemble them after a thorough check.

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INTRODUCTION – REPAIR INSTRUCTION

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6 Removed parts • Place the removed parts in a separate box to avoid mixing them up with the new parts

or contaminating the new parts.

• For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in this manual.

• Retain the removed parts for customer inspection, if requested.

(b) JACKING UP AND SUPPORTING VEHICLE

(1) Care must be taken when jacking up and

supporting the vehicle. Be sure to lift and support the vehicle at the proper locations.

(1) Precoated parts are bolts and nuts that are

coated with a seal lock adhesive at the factory.

(2) If a precoated part is retightened, loosened or

moved in any way, it must be recoated with the specified adhesive.

(3) When reusing a precoated part, clean off the old

adhesive and dry the part with compressed air.

Seal Lock Adhesive

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Then apply new seal lock adhesive appropriate to that part.

(4) Some seal lock agents harden slowly. You may

have to wait for the seal lock adhesive to harden.

(d) GASKETS

(1) When necessary, use a sealer on gaskets to

prevent leaks.

(e) BOLTS, NUTS AND SCREWS

(1) Carefully follow all the specifications for

tightening torques. Always use a torque wrench.

INCORRECT

CORRECT

(f) FUSES

(1) When inspecting a fuse, check that the wire of

the fuse is not broken.

(2) When replacing fuses, be sure that the new fuse

has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

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Illustration Symbol Part Name Abbreviation

FUSE FUSE

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Illustration Symbol Part Name Abbreviation

INTRODUCTION – REPAIR INSTRUCTION

MEDIUM CURRENT FUSE M-FUSE

HIGH CURRENT FUSE H-FUSE

FUSIBLE LINK FL

CIRCUIT BREAKER CB

(g) CLIPS

(1) The removal and installation methods of typical

clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during work, always replace the damaged clip with a new one.

INTRODUCTION – REPAIR INSTRUCTION

Shape (Example) Removal/Installation

Remove clips with clip remover or pliers.

Remove fasteners with clip remover or screwdriver.

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Remove clips with wide scraper to prevent panel damage.

Remove clips by pushing center pin through and prying out shell.

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Shape (Example) Removal/Installation

INTRODUCTION – REPAIR INSTRUCTION

Remove clips by unscrewing center pin and prying out shell.

Remove clips by prying out pin and then prying out shell.

(h) CLAWS

(1) The removal and installation methods of typical

claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the damaged claws with a new caps or covers.

Shape (Example) Illustration Procedures

1. Using a screwdriver, detach the claws and remove the cap or covers.

INTRODUCTION – REPAIR INSTRUCTION

Shape (Example) Illustration Procedures

1. Using a screwdriver, detach the claws and remove the cap or covers.

(i) REMOVAL AND INSTALLATION OF VACUUM

HOSES

INCORRECT

CORRECT

(1) To disconnect a vacuum hose, pull and twist

from the end of the hose. Do not pull from the middle of the hose as this may damage the hose.

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(2) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected.

(3) After completing any hose related repairs,

double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.

(4) When using a vacuum gauge, never force the

hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a stepdown adapter if necessary.

(j) TORQUE WHEN USING TORQUE WRENCH

WITH EXTENSION TOOL

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INTRODUCTION – REPAIR INSTRUCTION

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(1) Use the formula below to calculate special

torque values for situations where SST or an extension tool is combined with the torque wrench.

Formula:

T' = L2/(L1 + L2) * T

T' Reading of torque wrench {N*m

(kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {c m

(in.)} L2 Length of torque wrench {cm (in.)}

NOTICE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this manual, the actual torque will be excessive and parts will be damaged.

2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

The CAMRY is equipped with a Supplemental Restraint System (SRS).

CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully.

(a) GENERAL NOTICE

(1) As malfunctions of the SRS are difficult to

confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery.

INTRODUCTION – REPAIR INSTRUCTION

(2) Work must be started at least 90 seconds after

the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. The SRS is equipped with a back-up power source. If work is started within 90 seconds af ter turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

CAUTION: Never use a back-up power source (battery or other) to avoid erasing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.

(3) In minor collisions where the SRS does not

deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle. (See page RS-352 for steering pad) (See page RS-399 for front passenger airbag assembly) (See page RS-371 for driver side knee airbag assembly) (See page RS-432 for front seat side airbag assembly) (See page RS-426 for curtain shield airbag assembly) (See page SB-23 for front seat outer belt assembly)

(4) Never use SRS parts from another vehicle.

When replacing parts, use new parts.

(5) Before repairs, remove the airbag sensor

assemblies if impacts are likely to be applied to the sensor during repairs.

(6) Never disassemble and attempt to repair all

airbag sensor assemblies and all airbag assemblies.

1. Steering pad

2. Front passenger airbag assembly

3. Driver side knee airbag assembly

4. Front seat side airbag assembly

5. Curtain shield airbag assembly

6. Front seat outer belt assembly

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Marks

INTRODUCTION – REPAIR INSTRUCTION

(7) Replace the airbag sensor assemblies and the

airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.

(8) Do not directly expose the airbag sensor

assembly or airbag assembly to hot air or flames.

(9) Use a voltmeter/ohmmeter with high impedance

(minimum=10 kΩ) for troubleshooting electrical circuits.

(10)Information labels are attached to the SRS

components. Follow the instructions on the labels.

(11)After work on the SRS is completed, check the

SRS warning light.

(b) SPIRAL CABLE

(1) The steering wheel must be fitted correctly to the

steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See page RS-366).

(1) Always place a removed or new steering pad

C107194E01

surface upward as shown in the illustration. Placing the horn button with the pad surface facing down could cause a serious accident if the airbag inflates. Also, do not place anything on top of the horn button.

Example:

CORRECT

INCORRECT

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Example:

INTRODUCTION – REPAIR INSTRUCTION

(2) Never measure the resistance of the airbag

squib. This may cause the airbag to inflate, which could cause serious injury.

(3) Grease or detergents of any kind should not be

applied to the horn button.

(4) Store the horn b utton assembly in an area where

the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the

vehicle, disconnect the airbag ECU connectors (4 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.

(6) When disposing of the vehicle or the horn button

assembly by itself, the airbag should be deployed using SST before disposal (See page

RS-352). Activate the airbag in a safe place

away from electrical noise.

(d) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always place a removed or new front passenger

airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag inflation direction facing down could cause a serious accident if the airbag inflates.

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Z013950E02

Example:

CORRECT

INCORRECT

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INTRODUCTION – REPAIR INSTRUCTION

(2) Never measure the resistance of the airbag

squib. This may cause the airbag to inflate, which could cause serious injury.

Example:

Z013951E02

(3) Grease or detergents of any kind should not be

applied to the front passenger airbag assembly.

(4) Store the airbag assembly in an area where the

ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the

(6) When disposing of the vehicle or the airbag

assembly unit by itself, the airbag should be deployed using SST before disposal (See page

RS-399). Activate the airbag in a safe place

away from electrical noise.

(e) DRIVER SIDE KNEE AIRBAG ASSEMBLY

(1) Always place a removed or new knee airbag

assembly with the airbag inflation direction facing upward. Placing the airbag assembly with the airbag inflation direction facing downward could cause a serious accident if the airbag inflates.

Example:

CORRECT

INCORRECT

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Example:

INTRODUCTION – REPAIR INSTRUCTION

(2) Never measure the resistance of the airbag

squib. This may cause the airbag to inflate, which could cause serious injury.

(3) Grease or detergents of any kind should not be

applied to the knee airbag assembly.

(4) Store the knee airbag assembly where the

ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the

vehicle, disconnect the airbag ECU connectors (2 pins). These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.

(6) When disposing of a vehicle or knee airbag

assembly unit by itself, the airbag should be inflated using SST before disposal (See page

RS-371). Activate the airbag in a safe place

away from electrical noise.

(f) FRONT SEAT SIDE AIRBAG ASSEMBLY

(1) Always place a removed or new front seat side

airbag assembly with the airbag inflation direction facing up.

(2) Never measure the resistance of the airbag

squib. This may cause the airbag to inflate, which could cause serious injury.

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Example:

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(3) Grease or detergents of any kind should not be

applied to the front seat side airbag assembly.

(4) Store the airbag assembly in an area where the

ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

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Example:

INTRODUCTION – REPAIR INSTRUCTION

CORRECT

(5) When using electric welding anywhere on the

(6) When disposing of a vehicle or the airbag

assembly unit by itself, the airbag should be deployed using SST before disposal (See page

RS-432). Activate the airbag in a safe place

away from electrical noise.

(g) CURTAIN SHIELD AIRBAG ASSEMBLY

(1) Always place a removed or new curtain shield

airbag assembly in a clear plastic bag, and keep it in a safe place.

INCORRECT

Example:

Clear Plastic Bag

D100325E02

CAUTION: The plastic bag is not reusable. NOTICE: Never disassemble the curtain shield airbag assembly.

(2) Never measure the resistance of the airbag

squib. This may cause the airbag to inflate, which could cause serious injury.

D030931E01

(3) Grease or detergents of any kind should not be

applied to the curtain shield airbag assembly.

(4) Store the airbag assembly in an area where the

ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.

Example:

INTRODUCTION – REPAIR INSTRUCTION

(5) When using electric welding anywhere on the

(6) When disposing of a vehicle or the airbag

assembly unit by itself, the airbag should be deployed using SST before disposal (See page

RS-426). Activate the airbag in a safe place

away from electrical noise.

(h) FRONT SEAT OUTER BELT ASSEMBLY AND

REAR SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) (1) Never measure the resistance of the seat outer

belt. This may cause the pretensioner of the seat belt to activate, which could cause serious injury.

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(2) Never disassemble the seat outer belt. (3) Never install the seat outer belt on another

vehicle.

(4) Store the seat outer belt in an area where the

ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.

(5) When using electric welding anywhere on the

(6) When disposing of a vehicle or the seat outer

belt unit by itself, the seat outer belt should be activated before disposal (See page SB-23). Activate the seat outer belt in a safe place away from electrical noise.

(7) As the seat outer belt is hot after being activated,

allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the seat outer belt.

(8) Grease, detergents, oil or water should not be

applied to the front seat outer belt.

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