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