Page 330 of 4770

2. INSPECT DRIVE AND DRIVEN ROTORS
A. Inspect rotor body clearance
Using a thickness gauge, measure the clearance be±
tween the driven rotor and body.
Standard body clearance:
0.10 ± 0.16 mm (0.0039 ± 0.0063 in.)
Maximum body clearance:
0.20 mm (0.0079 in.)
If the body clearance is greater than maximum, re±
place the rotors as a set. If necessary, replace the oil
pump assembly.
B. Inspect rotor tip clearance
Using a thickness gauge, measure the clearance be±
tween the drive and driven rotor tips.
Standard tip clearance:
0.04 ± 0.16 mm (0.0016 ± 0.0063 in.)
Maximum tip clearance:
0.20 mm (0.0079 in.)
If the tip clearance is greater than maximum, replace
the rotors as a set.
OIL PUMP INSPECTION
1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If it doesn't, replace the relief valve. If necessary,
replace the oil pump assembly.2. REMOVE DRIVE AND DRIVEN ROTORS
Remove the 2 bolts, pump body cover, O±ring, the
drive and driven rotors.
± 5S±FE ENGINELUBRICATION SYSTEMEG1±280
Page 492 of 4770
11
BODY
A crash impact absorbing structure for side collisions is adopted in addition to that for frontal and rear collisions. The body
is made highly rigid and lightweight through the optimized allocation of materials and the generous application of
high±strength sheet steel, etc. Furthermore, the vehicle creates less noise and vibration through the use of advanced noise
insulation technology, and the application of anti±corrosion sheet steel produces a highly rust±resistant body.
Body Shell
Impact Absorbing Structure for Side Collision
Page 494 of 4770
13
EXTERIOR
EXTERIOR EQUIPMENT
BUMPER
The Super Olefin Polymer, a material that is light, scratch resistant and highly recyclable, has been adopted in the
front bumper.
Urethane bumper has been adopted for the rear bumper for weight reduction.
LIGHTS
1. Front Lights
The headlight, parking light, and turn signal light
have been concentrated to improve the visibility
from other vehicles, while also reducing weight.
The headlight uses HB2 (H4) type bulb to provide
excellent night±time visibility.
A light auto turn±off system is standard
equipment for all models.
The daytime running light system is standard
equipment on models for Canada.
Page 511 of 4770

32ENGINEÐ5S±FE ENGINE
MAJOR DIFFERENCES
Major differences between the new 5S±FE engine and previous engine are listed below.
Item
Features
Engine ProperThe squish area of the combustion chamber in the cylinder head has been
optimised to improve torque in the low±to mid±speed range.
Cooling SystemAn aluminum radiator core is used for weight reduction.
Intake and Exhaust System
The ports of the manifold have been extended to improve torque in the low±
to mid±speed range.
The exhaust manifold is made of stainless steel plates for improve engine per-
formance and weight reduction.
Through the optimized allocation of the exhaust pipe supports, the number of
supports has been reduced from 5 to 4, thus reducing the noise and vibration
which are transmitted to the vehicle body.
Fuel SystemA fuel returnless system has been adopted to prevent the internal temperature
of the fuel tank from rising and to reduce evaporative emissions.
Ignition SystemThe DIS (Direct Ignition System) contributes to the powerful high output by
providing a powerful spark to the engine.
Engine MountingTo reduce noise and vibration and to improve drivability, the allocation of the
engine mounts*1 and their characteristics have been revised.
Engine Control System
The injection pattern for engine starting have changed form the 2 group
injection type to sequential multiport injection type.
In place of the oxygen sensor (bank 1, sensor 1), a new air fuel ratio sensor has
been adopted. *
2
The power steering idle±up control has been changed from the system using
an air control valve to the one using a pressure switch and an IAC valve.
Emission Control System
The EGR valve body has been changed from cast iron to aluminum alloy for
weight reduction.
A TWC (Three±Way Catalytic Converter) that is integrated with a stainless
steel exhaust manifold has been adopted.*
2
The TWC, which was previously installed below the exhaust manifold has
been discontinued.*3
*1: Only for Automatic Transaxle Models.
*
2: Only for California Specification Models.
*
3: Except for California Specification Models.
Page 513 of 4770
34ENGINEÐ5S±FE ENGINE
2. Exhaust Manifold
A stainless steel exhaust manifold is used for improving the engine performance and for reducing weight.
On the California specification model, the stainless steel exhaust maniflod and the TWC (Three±Way Catalytic
Converter) have been integrated to improve the warm±up performance of the TWC, thus reducing exhaust emissions.
FUEL SYSTEM
1. Fuel Returnless System
The new Camry has adopted a fuel returnless system to reduce evaporative emissions. With the pressure regulator
housed inside the fuel tank, this system eliminates the return of fuel from the engine area. This prevents the internal
temperature of the fuel tank from risisng, and reduced evaporative emissions.
Page 525 of 4770

46ENGINEÐ1MZ±FE ENGINE
MAJOR DIFFERNCES
Major differences between the new 1MZ±FE engne and previous engine are listed below.
Item
Outline
Cooling SystemAn aluminum radiator core is used for weight reduction.
Intake and Exhaust System
Through the optimized allocation of the exhaust pipe supports, the number
number of supports has been reduced from 5 to 4, thus reducing the noise
and vibration which are transmitted to the vehicle body.
Fuel SystemA fuel returnless system has been adopted to prevent the internal temperature
of the fuel tank from rising, and to reduce evaporative emissions.
Engine MountingThe characteristics of the engine mounts, torque rod, and absorber have been
optimized to reduce noise and vibration.
Engine Control System
A communication circuit has been provided between the ECM and the
ABS & TRAC ECU in conjunction with the adoption of the TRAC
(Traction Control) system.*
The fuel pressure control has been discontinued in conjunction with the
adoption of the fuel returnless system.
Instead of using the IDL signal input from the throttle position sensor,
the ECM now uses the VTA signal to detect the completely closed state of
the throttle valve.
A new EGR system which uses a EGR valve position sensor is used.
A communication method of the ECM and the hand±held tester has been
changed from the SAEJ1962 to the ISO 9141±2.
*: Applicable only to Vehicle Equipped with the TRAC System.
Page 539 of 4770
60CHASSISÐBRAKES
BRAKES
DESCRIPTION
The ventilated disc brake is used for front brake on all models.
The rear drum brake is used on the 5S±FE engine model, and the rear solid disc brake is used on the 1MZ±FE engine
model.
The ABS is provided on the 5S±FE engine CE grade model as an option and on other models as standard.
An ABS actuator has been changed to the 2±position solenoid valve type actuator.
A compact and lightweight ABS & TRAC system, in which the ABS and TRAC functions are integrated, is made
available as an option on the LE and XLE grade models with the 1MZ±FE engine.
A portless and portless type master cylinder is used on the models with ABS & TRAC system.
The center lever type parking brake is adopted on all models.
Page 564 of 4770
89BODYÐLIGHTWEIGHT AND HIGHLY RIGID BODY
BODY
LIGHTWEIGHT AND HIGHLY RIGID BODY
The body of the new Camry is made highly rigid and lightweight through refinement of the shap and construction
of each part, improved joint rigidity, and increased use of high strength sheet steel.
HIGH STRENGTH SHEET STEEL
Light and highly rigid high strength sheet steel is used for the hood, door panels and members.