Toyota Celica 1993 AT200 series Betriebsanleitung

@ToYoTA

REPAI

MANUAL

FOR

CHASSIS

& BODY

FOREWORD

This

repairmanual

has

been

prepared

to provide

information

covering

general

service

repa

irsforthechassis

andbodyof

the

TOYOTA

CELICA,

Aooltcable

models: AT2O0

series

ST2O2.

204series

Forthe service

specifications

and repair

plocedure

of the

above

modelother

than

those

listedinthis

manual,

refertothe

following

manuals.

Allinformation

inthis

manual

isbased

onthe

latest

product

information

at the

time

of publication,

However,spectfica-

tions

and

procedures

are

sublectto change

without

notice

TOYOTAMOTOR CORPORATION

o 1995 TOYOTA

MOTORCORPORATION

AIrightsresefved.

Thisbook

maynotbe

repro-

duced

orcopied,

inwhole

or in paft,

withoutthe

wr tten permrssion

of Toyota Motor Cofporation.

Manual

Name Pub.

7A-FE

Engine

Repair

Manual RM325E

3S-FE

Engine

ReparrManual RM395E

3S-GE

Engine

RepairManual RM396E

35-GE,35-GTE,55-FE

Eng

ineRepair RM164E

Manual

SS-FE

Engine

Repair

Manual RM267E

Supplement

A14OE

Automatic

Transaxle

Repair RM248E

Manual

Celica

Electrical

Wiring

Diagram EWDI98Y

Celica

New

CarFeatures NCF103E

INTRODUCTION

CLUTCH

C52

MANUAL

TRANSAXLE

S54

MANUAL

TRANSAXLE

E56

MANUAL

TRANSAXLE

AUTOMATIC

TRANSAXLE

SUSPENSION

AND

AXLE

BRAKE

SYSTEM

STEERING

SUPPLEMENTAL

RESTRAINT

SYSTEM

BODY

ELECTRICAL

SYSTEM

BODY

AIR

CONDITIONING

SYSTEM

ELECTRICAL

WIRING

DIAGRAMS

$fifiiliffiffi,frffI

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*$nxilifqfr

ffi$Jiritilrl

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tN-1

INTRODUCTION

HOWTOUSE

TH|SMANUAL .........'.......

lN-

tDENTtFtCAT|ON

TNFORMATTON

......'......

lN-

GENERAL

REPAIRINSTRUCTIONS

,.......'".

IN-

PRECAUTTON .'.'.......'.....

VEHICLE

LIFTANDSUPPORT

LOCATTONS ...............'.

lN-

ABBREVIATIONSUSED

INTHIS

MANUAL ....................

|N-

STANDARO

BOLT

TOROUE

SPEC|F|CAT|ONS ...........

|N-

;ffi

lN-2 INTRODUCTION

_ HOWTO

USE

THISMANUAL

HOW

USE

THISMANUAL

INDEX

An INDEX

providad

onthe

first

page

of each

sectionto guideyou

to theitemto be

repaired.

To assist

you infinding

your

waythrough

the manual,

th€ Section

Titleand

majorheading

are

ffio given

at thetop of 6very

Page.

rffiil["

4'-1C

GENERALDESCRIPTION

At the boginning

of each

section,

a General

Description

is given

that p6rtains

to all

repair

operations

contained

inthats6ction.

Read

these

pr6cautions

bofors

starting

anyrspalr

task.

TROUBLESHOOTING

tablesareincluded

foreachsystem

to help

you

diagnose

the

problem

and

findthecause.

Besureto read

thisbefore

performing

troubleshooting.

PREPARATION

Preparation

liststheSST

(Special

Service

Tools).

recommanded

tools,equipment,

lubricant

and

SSM

(special

ServiceMaterials)

whichshould

prepared

before

beginning

the

operationand

explains

the

purpose

of each

one.

REPAIR

PROCEDURES

Most repairoperations

begin

with an overview

illustration.

lt identifies

the components

and

shows

how

the parts

fit togethar.

Example:

_-.c-rf-.,

( -'- -l - --frlrer uao

-_:7

a- -Float

a Grommet

ulevrs

"rJ

Lock

CliP

Cl€vis

Nut

Gasket

(,A\

t)v/

to//

Boot

)Ring

Tank

,"..

(Nl

*YY

snar

Rod

N.rn(ksi;"annn : specified

torque

a Non-reusable

part

Cylinder

tN-3

INTRODUCTION

- HOWTOUSE

THISMANUAL

The

procedures

ara

presented

ina step-by-stop format:

o The

illustration

showswhatto do andwhsrsto do it.

r The

taskheadingtslls

whatto do.

. The detailedtext tells how to perform

the task and gives

other informationsuch as

sp6cificatio

nsandwarn

ings.

Examols:

Ttsk ha,dlng :

REFERENCES

References

havebeenkoptto a

^.^a r^ ra{.r t^

piston

a3showd

inthe illustration'

minimum.However,

when

theyarerequired

you

are

given

the

Thisformatorovides

theexoerienced

technician

witha FASTTRACK

to theinformation

needed.

The upper

casetask heading

can be read

at a glance

when necessary,

andthe text belowit

orovides

d6tailedinformation.

lmportant

specifications

and

warningsalways

standout in bold

pe.

SPECIFICATIONS

Specifications

a16

prssented

inbold

typethroughout

thetext

whereneeded.

You never

haveto

leavethe

procedure

tolookup

your

specifications.

They

arealso

foundattheend

of eachsection,

for

quick

reference.

rrs*

lN-4 INTRODUCTION

_ HOWTOUSETHISMANUAL

CAUTIONS,NOTICES,

HINTS:

. CAUTIONSar€

presented

inboldtype,

andindicatethereisa possibility

of injuryto youor

other06oolo.

. NOTICESare also

presontod

in bold

typ6,and indicatothe possibility

of damageto the

componentsbeing

repaired.

r HINTS

are separatedfrom the text but do not appearin bold.

They provide

additional

information

to help

youperform

therepairefficiently.

SIUNIT

TheUNITS

given

thismanualare

primarily

expressedaccordingto the

Sl UNIT

(lnternational

System

of Unit),andalternatoly

expressedinthemetric

system

andintho EnglishSystem.

Example:

Torque:30N.m

(310

kgf

.cm,

22ft.lbf

)

INTRODUCTION

- IDENTIFICATION

INFORMATION

IDENTIFICATION

INFORMATION

VEHICLE

IDENTIF]CATION

NUMBER

Thevehicle

identification

number

is stamp€don th€

vehicle

identification

number

plate

andmanufacture's

late.

A. Vehicle

ldentification

NumberPlate

B. Manufacture's

Plate

ENGlNESERIAL

NUMBER

Theengine

serialnumber

is stampedon the engine

block

asshown.

7A-FEEngine

55-FE

35-FE,3S-GEEngines

tN-6 INTRODUCTION

_ GENERALREPAIRINSTRUCTIONS

,-€F

SealLock

Adhesive

GENERALREPAIRINSTRUCTIONS

1. Usefender,

seatandfloorcoversto teeptfrevd-fficie

cleanand

prevent

damage.

2. During

disassembly,keep parts in the appropriata

orderto facilitatereassemblv.

3. Observethefollowing:

(a) Beforeperforming

electricalwork, disconnect

thenegative

terminalcablefromthebattery.

(b) lf it is necessaryto disconnsctthe batteryfor

inspectionorrepair,alwaysdisconnsctthecable

fromthenegative

(-)terminal

whrchis

grounded

to thevehiclebodv

damageto th€ batteryterminal

post,

loosentheterminalnut

andraise

thecable

strar-

ght upwithouttwistingor prying

it.

(d) Clean

thebatteryterminal

posts

andcabletermi-

nalswith a cleanshoprag.Donot scrapethem

with afileorotharabrasiveobjects.

(a) Install

thecableterminalto thebattery

post

with

the nut loose,and

tightenthe nutafterinstalla-

tion.

Do not usea hammarto taothe terminal

onto

the post.

(f) Besu16

thecoverforthe positive(*) terminalis

properly

inplace.

4. Checkhoseandwiringconnactorsto makesurethat

theyarssgcureandcorrect.

5. Non

- reusable

parts

(a) Alwaysreplacecotter

pins.

gask6ts,

- ringsand

oilsealsetc.with newonos.

(b) Non-rausabla

parts

a16

indicated

inthe

compo-

nentillustrationsbyths"1" symbol.

A Pra^^ira.l n.rtc

Precoated parts are bolts and nuts, etc. that are

coatedwith a seallock adhesiveat the factorv.

(a) lf a precoated part is retightened.loosened or

caused

to move in any way, it must be recoated

with the soecifiedadhesive.

tN-7

INTRODUCTION

_ GENERAL

REPAIR

INSTRUCTIONS

(b) When

r€using

precoated

parts,

cleanoff theold

adhesive

and dry with compressed

air. Then

apply

thespecified

seal

lockadhesive

to thsbolt,

nutorth

rsads.

parts

are

indicatedinthe component

*^"l'

l"J::::l;:lJ

: J;:lTnooJ

u,*"*

reventrTi.ry..ff

leaks.

Carefully

observs

allspacifications

for bolt

tightening

torquss.

Always

use

a torqua

wrench.

Useof special

servicetools

(SST)

andspecial

service

materials

(SSM)

may be required,

depending

on the

natureof the rspair.Be sureto uss SSTand SSM

where

specified

and follow the proper

work proce-

dure.

A list

of SST

andSSM

can be foundin ths

preparation

partat the front of each

section

in this

man

ual.

10. Whenreplacing

fuses,besurs

thenew

fusehas

the

corr€ct

amperago

rating.DO

NOTexceod

therating

ussone

with a lowerrating.

Fuse

and High Current

AmperageRating

I lrii 'l

f,.rFa'nfl

TL- - 11

Medium

Current

Equal

l;1ji\-,.1

pI Fr r.l

c-)

l|;t l;t I

t"f

L]LJ 8E1367

lllustraiion Symbol Part Nam€ Abb16vi8tion

8E5594

------\_'z'rc-

tN0365

FUSE FUSE

8E5595

---4-

1N0366

MEDIUM

CURRENT

FUSE M.FUSE

a€5596

--@-

rNo367

HIGH

CURRENT

FUSE H-FUSE

885597

-_@-

lNo367

FUSIBLE

LINK FL

4E5598

CIRCU

IT BR

EAKER CB

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