Toyota Celica 2005 Betriebsanleitung

INTRODUCTION

MAINTENANCE

PREPARATION

SERVICE SPECIFICATION

DIAGNOSTICS

ENGINE MECHANICAL

EMISSION CONTROL

SFI

COOLING

LUBRICATION

IGNITION

STARTING

CHARGING

CLUTCH

MANUAL TRANSAXLE (C56)

MANUAL TRANSAXLE (C60)

AUTOMATIC TRANSAXLE (U240E)

AUTOMATIC TRANSAXLE (U341E)

SUSPENSION AND AXLE

BRAKE

STEERING

SUPPLEMENTAL RESTRAINT SY STEM (SRS)

BODY ELECTRICAL

BODY

AIR CONDITIONING

2005 CELICA REPAIR MANUAL

2005 CELICA (RM1131U)

IN00U−97

N17080

Filler Cap

Float

Reservoir

zGrommet

Clip

Slotted Spring Pin

: Specified torque

zNon−reusable part

Cylinder

Piston

Push Rod

Washer

Snap Ring

Boot

zGasket

Lock Nut

Clevis Pin

Clevis

N·m (kgf·cm, ft·lbf)

12 (120, 9)

15 (155, 11)

−INTRODUCTION HOW TO USE THIS MANUAL

IN−1

2005 CELICA (RM1131U)

HOW TO USE THIS MANUAL

GENERAL INFORMATION

1. INDEX

An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you

in finding your way through the manual, the section title and major heading are given at the top of every page.

2. PRECAUTION

At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained

in that section.

Read these precautions before starting any repair task.

3. TROUBLESHOOTING

TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the

cause. The fundamentals of how to proceed with troubleshooting are described on page IN−20.

Be sure to read this before performing troubleshooting.

4. PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-

cial Service Materials) which should be prepared before beginning the operation and explains the purpose

of each one.

5. REPAIR PROCEDURES

Most repair operations begin with an overview illustration. It identifies the components and shows how the

parts fit together.

Example:

Illustration:

what to do and where

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a)

Task heading : what to do

SST 09350−30020 (09350−06120)

Set part No. Component part No.

Detailed text : how to do task

(b)

Piston stroke: 1.40 1.70 mm (0.0551  0.0669 in.)

Specification

Place SST and a dial indicator onto the overdrive brake pis-

ton as shown in the illustration.

Measure the stroke applying and releasing the compressed

air (392  785 kPa, 4  8 kgf/cm2or 57 114 psi) as shown

in the illustration.

IN−2

−INTRODUCTION HOW TO USE THIS MANUAL

2005 CELICA (RM1131U)

The procedures are presented in a step−by−step format:

SThe illustration shows what to do and where to do it.

SThe task heading tells what to do.

SThe detailed text tells how to perform the task and gives other information such as specifications

and warnings.

Example:

This format provides the experienced technician with a FAST TRACK to the information needed. The upper

case task heading can be read at a glance when necessary, and the text below it provides detailed informa-

tion. Important specifications and warnings always stand out in bold type.

6. REFERENCES

References have been kept to a minimum. However, when they are required you are given the page to refer

to.

7. SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the

procedure to look up your specifications. They are also found in Service Specifications section for quick ref-

erence.

8. CAUTIONS, NOTICES, HINTS:

SCAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other

people.

SNOTICES are also presented in bold type, and indicate the possibility of damage to the components

being repaired.

SHINTS are separated from the text but do not appear in bold. They provide additional information to

help you perform the repair efficiently.

9. SI UNIT

The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of

Unit), and alternately expressed in the metric system and in the English System.

Example:

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

IN0CN−25

B02923

B02924

1ZZ−FE engine:

2ZZ−GE engine:

−INTRODUCTION IDENTIFICATION INFORMATION

IN−3

2005 CELICA (RM1131U)

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER

1. VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped on the vehicle

identification number plate and the certification label, as shown

in the illustration.

A: Vehicle Identification Number Plate

B: Certification Label

2. ENGINE SERIAL NUMBER

The engine serial number is stamped on the engine block, as

shown in the illustration.

IN0CO−31

FI1066

Z11554

Seal Lock Adhesive

IN−4

−INTRODUCTION REPAIR INSTRUCTIONS

2005 CELICA (RM1131U)

REPAIR INSTRUCTIONS

GENERAL INFORMATION

BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

(b) During disassembly, keep parts in the appropriate order

to facilitate reassembly.

(1) Before performing electrical work, disconnect the

negative (−) terminal cable from the battery.

(2) If it is necessary to disconnect the battery for in-

spection or repair, first disconnect the negative (−)

terminal cable.

(3) When disconnecting the terminal cable, to prevent

damage to battery terminal, loosen the cable nut

and raise the cable straight up without twisting or

prying it.

(4) Clean the battery terminals and cable ends with a

clean shop rag. Do not scrape them with a file or oth-

er abrasive objects.

(5) Install the cable ends to the battery terminals after

loosening the nut, and tighten the nut after installa-

tion. Do not use a hammer to tap the cable ends

onto the terminals.

(6) Be sure the cover for the positive (+) terminal is

properly in place.

(d) Check hose and wiring connectors to make sure that they

are connected securely and correctly.

(e) Non−reusable parts

(1) Always replace cotter pins, gaskets, O−rings, oil

seals, etc. with new ones.

(2) Non−reusable parts are indicated in the component

illustrations by the ”z” symbol.

(f) Precoated parts

Precoated parts are bolts, nuts, etc. that are coated with

a seal lock adhesive at the factory.

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

caused to move in any way, it must be recoated with

the specified adhesive.

(2) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then apply

the specified seal lock adhesive to the bolt, nut or

threads.

BE1367

Medium Current Fuse and High Current Fuse

Equal Amperage Rating

V00076

AbbreviationPart NameSymbolIllustration

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

CIRCUIT BREAKER

FUSE

M−FUSE

H−FUSE

−INTRODUCTION REPAIR INSTRUCTIONS

IN−5

2005 CELICA (RM1131U)

(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.

(g) When necessary, use a sealer on gaskets to prevent

leaks.

(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

(i) Use of special service tools (SST) and special service ma-

terials (SSM) may be required, depending on the nature

of the repair. Be sure to use SST and SSM where speci-

fied and follow the proper work procedure. A list of SST

and SSM can be found in Preparation section in this

manual.

(j) When replacing fuses, be sure the new fuse has the cor-

rect amperage rating. DO NOT exceed the rating or use

one with a lower rating.

IN0253

WRONG CORRECT

IN0252

WRONG CORRECT

IN−6

−INTRODUCTION REPAIR INSTRUCTIONS

2005 CELICA (RM1131U)

(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-

er locations (See page IN−8).

SCancel the parking brake on the level place and

shift the transmission in Neutral (or N position).

SWhen jacking up the front wheels of the vehicle at

first place stoppers behind the rear wheels.

SWhen jacking up the rear wheels of the vehicle at

first place stoppers before the front wheels.

SWhen either the front or rear wheels only should be

jacked up, set rigid racks and place stoppers in front

and behind the other wheels on the ground.

SAfter the vehicle is jacked up, be sure to support it

on rigid racks . It is extremely dangerous to do any

work on a vehicle raised on a jack alone, even for

a small job that can be finished quickly.

(l) Observe the following precautions to avoid damage to the

following parts:

(1) Do not open the cover or case of the ECU unless

absolutely necessary. (If the IC terminals are

touched, the IC may be destroyed by static electric-

ity.)

(2) To disconnect vacuum hoses, pull off the end, not

the middle of the hose.

(3) To pull apart electrical connectors, pull on the con-

nector itself, not the wires.

(4) Be careful not to drop electrical components, such

as sensors or relays. If they are dropped on a hard

floor, they should be replaced and not reused.

(5) When steam cleaning an engine, protect the elec-

tronic components, air filter and emission−related

components from water.

(6) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

IN0002

Example:

−INTRODUCTION REPAIR INSTRUCTIONS

IN−7

2005 CELICA (RM1131U)

(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals

from bending.

(8) When using a vacuum gauge, never force the hose

onto a connector that is too large. Use a step−down

adapter for adjustment. Once the hose has been

stretched, it may leak air.

(m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to

identify how they should be reconnected to.

(2) After completing a job, double check that the vacu-

um hoses are properly connected. A label under the

hood shows the proper layout.

(n) Unless otherwise stated, all resistance is measured at an

ambient temperature of 20°C (68°F). Because the resis-

tance may be outside specifications if measured at high

temperatures immediately after the vehicle has been run-

ning, measurement should be made when the engine has

cooled down.

IN0CP−25

B02925

Front

JACK POSITION

Front

Rear

CAUTION :

PANTOGRAPH JACK POSITION

SUPPORT POSITION

Safety stand and swing arm type lift

When jacking−up the rear and front, make

sure the car is not carrying any extra weight.

Front crossmember

Rear axle beam

IN−8

−INTRODUCTION REPAIR INSTRUCTIONS

2005 CELICA (RM1131U)

VEHICLE LIFT AND SUPPORT LOCATIONS

B02926

PLATE TYPE LIFT

Attachment C

HINT :

Left and right set position

Front and rear set position

Place the vehicle over the center of the lift.

SAlign the cushion gum ends of the plate

with the attachment lower ends (A, C).

SAlign the attachment upper end (B) with the

front jack supporting point (L).

Attachment dimensions

85 mm (3.35 in.)

100 mm (3.94 in.)

70 mm (2.76 in.)

200 mm (7.87 in.)

−INTRODUCTION REPAIR INSTRUCTIONS

IN−9

2005 CELICA (RM1131U)

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