Toyota Celica 1993 AT200 series Operating instructions

@ToYoTA
REPAI
R
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.
No
a
a
o
a
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
a
a
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
$fifiiliffiffi,frffI
.
.Hffi.ffiffiffi
*$nxilifqfr
ffi$Jiritilrl
il#{*ffi
ffi:Hffi
ffi,ff
tHsllrltffi
,'#ffi
i'ffi-,ffiffi
riHstu#ll

tN-1
INTRODUCTION
HOWTOUSE
TH|SMANUAL .........'....... lN-
tDENTtFtCAT|ON
TNFORMATTON
......'......
lN-
GENERAL
REPAIRINSTRUCTIONS
,.......'".
IN-
PRECAUTTON .'.'.......'.....
IN
-
VEHICLE
LIFTANDSUPPORT
LOCATTONS ...............'.
lN-
ABBREVIATIONSUSED
INTHIS
MANUAL ....................
|N-
STANDARO
BOLT
TOROUE
SPEC|F|CAT|ONS ...........
|N-
;ffi
b
10
12
t4

lN-2 INTRODUCTION
_ HOWTO
USE
THISMANUAL
HOW
TO
USE
THISMANUAL
INDEX
An INDEX
is
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
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
be
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
I
"rJ
I
^l
)s
i\
q
,l
I
Lock
CliP
I
I
WR
I
Cl€vis
Nut
Gasket
I
I
/1
(,A\
t)v/
to//
al
Boot
I
I
o
)Ring
Tank
,"..
(Nl
*YY
ll
I
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
ty
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
in
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
p
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
(c) To prevent
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,
O
- 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
8.
o
(b) When
r€using
precoated
parts,
cleanoff theold
adhesive
and dry with compressed
air. Then
apply
thespecified
seal
lockadhesive
to thsbolt,
nutorth
rsads.
(c) Precoated parts
are
indicatedinthe component
*^"l'
l"J::::l;:lJ
: J;:lTnooJ
u,*"*
to
p
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
or
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

tN-8 INTRODUCTION
_ GENERAL
REPAIRINSTRUCTIONS
11.
Car€mustbe
takenwhen
jacking
up
andsupporting
thevehicle.
86sur6to liftandsupport
thevehicle
at
theprop6r
locations
(See
page
lN
- 12).
(a) lf thevehicle
isto be
jacked
uponly
at th6front
or rearsnd,
besursto blockths wheelsat the
opposite
endinorder
to ensura
safety.
(b) Afterth6
vehicleis
jacked
up.be
sureto support
it onstands.
lt isextremely
dangerousto doany
workon
avehicleraised
ona
jack
alone.
evenfor
asmall
job
that
canbefinished
quickly.
Observe
thefollowing
precautions
toavoid
damaga
to
thofollowing
pa
rts:
(a) Donot
openthe
coverorcase
of theECU
unless
absolutolynecessary.
(lf
thelCterminals
aretou-
ched,thelC
maybedestroyed
bystaticelectric-
ity.)
Todisconnect
vacuum
hoses.
pull
onthesnd,
not
themiddleof the hose.
To pullapart
electrical
connoctors,
pullon the
connectoritself,
notthewires.
Ba carefulnot to drop electrrcal
componants.
suchassensors
orrelays.
lf theyare
droppedon
a hardfloor.they should
be replaced
and not
reusod.
When
steamcleaning
anengine.
protoct
thedis-
tributor,
airfilter,and
VCVfromwater.
Neverusaanimpact
wrench
to remove
or install
tomperature
switch6s
ortemperature
ssnsors.
Whenchecking
continuity
atthewire
connector,
ins6rtthe
toster
probe
carefully
to prsvent
termi-
nals
frombending.
Whenusing
a vacuum
gauge,
nev6rforce
ths
hosaonto a connoctor
that is too large.
Usea
stsp-down adapterinstead.
Once
the hose
has
beenstretched,
it mayleak.
Tag
hosesbefore
disconnecting
them:
(a) When
disconnecting
vacuum
hoses,
usetags
to
identify
howthoy
should
bereconnectod.
(b) After completing
a job, double
checkthat the
vacuumhoses
ars properly
connected.
A label
under
thehoodshows
thepropsr
layout.
IN
12.
WRONG CORRECT
.L -'
'...'
:- ./
,//).=:=-- )-1"
e- ':*
/'" /z
(b)
(c)
(d)
(e)
(f)
(sl
(h)
CORRECT
P4-l--l
"" ll
ll
WRONG
pl6
A
?
M

INTRODUCTION
- GENERALREPAIR
INSTRUCTIONS
14. Unless
otherwise
stat€d,allresistance
ismeasured
at
anambient
tomperature
of 20'C (68"F).
Becausethe
rosistance
may
beoutsidespscifications
if measured
at hightempsratures
immediatelyafter the vehicle
has been running,measuroments
should be made
whenthe6nginehascooled
down.

tN-10 INTRODUCTION
_ PRECAUTION
PRECAUTION
FORVEHICLES
EOUIPPED
WITH
SRS
AIRBAG
TheTOYOTACELICA
is equippedwith an SRS
(Supplemental
RestraintSystem)airbag
as an
option.
,:.
. . Failureto carryoutservice
operationsinthecorrsct
s6quonce
couldcausetheSRSto unexpect-
ITI
rrr edly
deployduringservicing,
possibly
leadingto aseriousaccident.
Further.ifamistakeismadeinservicing
theSRS,itis
possible
theSRSmay
failto op6ratewhen
required.
Before
performing
servicing
(including
removalor installationof parts,
inspectionor replace-
ment),besureto readthe
followingitemscarefully.
thenfollow
thocorrect
procedure
described
inthisman
ual.
Locationof Components
Se
nsor
Lock
Release
Bolt
AirbagSensor
Steering
WheelPad SteeringWheel
R097r2

tN-11
INTRODUCTION
_ PRECAUTION
'I
. Neverdisassemble
thesteeringwheel
pad
assembly.
2. Do
notsubject
thesteeringwheel
pad
to shocks
or bring
magnetsclose
to it.
3. Do
notexpose
thest€ering
wheel
pad
to high
temperatures
orfire.
4. lf grease,
cleaner,oilor water
gets
onths steoringwheel
pad,
promptly
wipeit off with a dry
cloth.
5. Donotdrop
thesteeringwheel
pad. Never
usea steering
wheel
pad
whichhasbeen
dropped.
6. Neverinstall
thesteeringwheel
and
pad
inanothervehicle.
7. Whenthe steering
wheel
pad
is removed,
store
it on a stable,
flat place
with the pad surface
facingupwards.
Never
place
anythingontop
ofthe
pad.
8. When
workonthe
vehiclewill
produce
toostronga
shock.first
Ioosenthesensor
lockrelease
boltuntil
it turnsfreelyand
perform
the
workaftersensor
lockoccurs.
9. Evenincases
wherethevehicle
isina low- impactaccident
wharothe
airbagisnotactivated,
always
checkthepad surface
andairbag
sonsor
part. lf dents.cracks or deformation
isvisibla,
replacethe
SRSwithanew
assembly.
10. When
disposingof
thevehicleorsteering
wheel,always
deploy
theSRS
first.
11. Thedeployed
inflatorinsrde
thsste6ring
wheel
pad
is
hot,sodispose
of itafterit has
naturally
cooleddown
to ambienttemperature.
Never
applywatsr
to coolit down.
FOR
VEHICLESEOUIPPED
WITH
A CATALYTIC
CONVERTER
CAUTION: ll large amounts of unburned
gasoline
flow into the converter, it may overheat and create
a fire hazard.
To prevent this. observethe following precautions
and explain them to your customer.
1. Useonlyunleaded
gasoline.
2. Avoidprolonged
idling.
Avoidrunning
theengineat
idlespeodformore
than20minutas.
3. Avoidspark
jump test.
(a) Performspark
jump
testonly
whenabsolutely
necessary.
Performthistest
asrapidlyas
possible.
(b) Whiletesting,
n6ver
racethe€ngtne.
4. Avoid
prolonged
enginecompression
measurement.
Enginecompression
testsmustbe
doneasrapidly
as
possible.
5- Donot runengine
whenfueltank isnearlyempty.
Thismaycause
theengineto misfireandcreate
anextra
loadontheconverter.
6. Avoid coasting
with ignitionturnedoff andprolonged
braking.
7. Do not dispose
of usedcatalyst
along
with parts contaminated
with gasoline or oil.

lN-12 rNTRoDUcrroN
- vEHtcLE
LIFTAND
suppoRT
LocATloNS
VEHICLE
LIFT
ANDSUPPORT
LOCATIONS
JACK POSITION
Front.............,....
Front
crossmember
Rear...................Rearaxle
beam
CAUTION: Before
jacking-up
therearand
front,
makesurethe car
is
not carryingany extra weight'
PANTOGRAPH
JACKPOSITION
SUPPORT
POSITION o
ffi
Saietystandandswing armtype lift
Nr
0005

rN-13
INTRODUCTION
- ABBREVIATIONS
USED
INTHIS
MANUAL
ABBREVIATIONS
USED
INTHIS
MANUAL
ABS Anti-Lock BrakoSvstgm
ALR AutomsticLocking
Rotractor
APPROX. Approximat6ly
A/-l Automatic
Transaxle
ATF Automatic
TransaxloFluid
CircuitBrosk€r
compactDisc
cRs Child
RestrsjntSystem
ECU El€ctronic
Control
Unit
Em6rgency
Locking
Retractor
FTFI Electronic
Turning
Rsdio
EX Exhaust
Ex. Exc6pt
FIPG Form€din PloceGask6t
Fusiblo
Link
tl Front
H
- Fuso High
Current
Fuso
IG lgnition
JB Junction
Block
rFn LightEmitting
Oiode
LH L6ft-Hand
LSO LimitodSlip
Ditforential
Max. Marimum
Multipurpos6
M/r Manual
Transaxl€
o/D Ov6rdriv€
P&BV Proportioning
andBy-p656 Vavg
PS Pow€r
Steering
RH Right*Hand
sRs Suppl6m6ntal
R66traintSystom
ssM Spoci6l
Sorvice
Matorials
ssT Spocial
Sorvico
Tool6
SID St6ndard
sw Switch
TEtvl
P. Temp€raturo
without

tN-14 INTRODUCTION
- STANOARDBOLTTOROUE
SPECIFICATIONS
STANDARDBOLTTOROUESPECIFICATIONS
HOWTO DETERMINEBOLT
STRENGTH
Mark Class Mark Class
Hexagon
headbolt 4-
6-
7
8-
9-
10-
Bolt
- headNo.
4f
5T
6T
7r
8T
9T
107
'I
1T
studbolt
4I
No mark 4r
Grooved
6T
hexa9on
llange bolt
w/ washer
hexagon bolt
No mark 4r
rlexagon
headbolt 2
protruding
lines 5T
Hexagon
{lange
bolt
hexagonbolt
2
prolrudrng
ltnes 6T Weldedbolt
41
||
exagon
headbolt 3
prorruorn9
lrnes 7r
trexagon
headbolt 4
protrudrng
lrnes 8T

rN-15
INTRODUCTION
_ STANDARD
BOLTTOROUESPECIFICATIONS
SPECIFIEDTOROUEFOB
STANOARD
BOLTS
Class Oiamete,
mm Pitch mm
Sp€citiedtorque
,n
head
bolt
cm tt.lbt 69onflang€boh kot.cm ft.lbt
N.m N.m
6
B
10
12
14
1
1.25
1.25
LC
LC
5 55 48 in.lbf
12.5 130 I
26 260 19
41 480 35
74 760 55
115 1,150 83
6 60 52 in.lbf
14 145 10
29 290 21
53 540 39
84 850 61
5T
6
8
10
12
16
'l
1.25
1.25
1.5
1.5
o.c oc 5b rn..tDt
15.5 160 12
32 330 24
59 600 43
91 930 61
140 1,400 101
7.5 75 65 in..lbf
11.5 115 13
36 360 26
65 670 48
100 1
,050 76
6T
6
8
10
12
to
1
1.25
1.25
1.25
1.5
1.5
8 80 69 in..lbt
'19 195 14
39 400 29
71 730 53
110 1,100 80
170 1.750 121
9 90 78in..lbt
21 210 15
44 440 32
80 810 59
125 1,250 90
6
B
10
12
16
,l
1.25
1.25
t.5
10.5 110 8
25 260 19
52 530 38
95 970 10
145 1,500 108
230 2,300 166
12 120 9
28 290 21
58 590 43
105 ],050 76
165 1,700 123
8T 8 10
1a
1.25
1.25
1.25
29 300 22
61 620 45
110 1,100 80
33 330 24
68 690 50
120 1,250 90
9T 10
12
1.25
1
.25
34 340 25
lo 110 51
125 1,300 94
3't 380 21
78 790 57
140 1,450 105
107 8 10 38 390 28
7a 800 58
140 1,450 105
42 430 31
88 890 64
155 1,600 116
117 8 10
12
42 430 31
87 890 64
155 1,600 116
47 480 35
97 990 '7 2
175 1,800 '130

- MEMO
-

cL-l
CLUTCH
DESCR|PT|ON..... . .....".
CL- 2
PREPARATTON ... .........CL- 4
TRoUBLESHOOTTNG
.......'.....'............
CL- 5
CLUTCH
SYSTEM
BLEEDING
,..'....''"...."
CL- 6
CLUTCH
PEDAL.. .., .......
CL- 7
CLUTCHMASTERCYLINDER
...........'......
CL- 9
CLUTCH
RELEASECYLINDER
.. ....
. ,.....
CL- 13
cLUrcH
uNrT '.....
.....c1-
18
SERVTCE
SpEClFlCATtONS...'..'..
.........,..
CL- 22
ffi