Remove Install Overhaul

2002 Toyota MR2
2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder
2002 ENGINE PERFORMANCE
Removal, Overhaul & Installation - 4-Cylinder
INTRODUCTION
NOTE: Before performing removal, overhaul and installation procedures, check for any
related Technical Service Bulletins (TSBs).
WARNING: On Prius, read service precautions before proceeding with service

procedure. See SERVICE PRECAUTIONS .
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle.
Removal, overhaul and installation procedures are covered in this article. If component removal and installation
is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.
SERVICE PRECAUTIONS
PRIUS
WARNING: When performing any inspection or service procedure on this vehicle,

ensure following service precautions are followed to prevent personal
injury or death due to the extremely high voltage.
The following service precautions must be followed:
z Ensure ignition is off and ignition key is removed from ignition before performing any inspection or
service procedure in engine compartment, as engine may automatically start and shut off when ignition is
on and READY light is illuminated. READY light is displayed just above the shift lever position
indicator on instrument cluster at center of instrument panel.
z Read all service and warning labels in engine compartment before performing any procedures in engine
compartment.
z All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring
harness that contains Orange connectors.
z High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution
labels on them. DO NOT touch these components.
z If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and
wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring
harness, connectors or components. Service plug is located on service plug assembly at driver's side front
corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a
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2002 Toyota MR2
location in which no one may install service plug while technician is working on the vehicle.
z If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is
removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when
touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and
in good condition and that no holes exist in insulated gloves by applying air to insulated glove before
touching any high-voltage wiring harness, connectors or components.
z DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short
circuit.
z If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness
connector is wrapped with tape to prevent wiring harness connector from contacting any surface.
z If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-
voltage system is being serviced.
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2002 Toyota MR2
Fig. 1: Locating Service Plug & Service Plug Assembly (Prius)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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PROGRAMMING
POWER SUN ROOF REINITIALIZATION PROCEDURE
Camry
NOTE: Following procedure should be performed if battery is disconnected and

reconnected, or battery is discharged and recharged to provide proper
automatic operation and jam protection operation of power sun roof.
1. Ensure ignition is on. Depress and hold TILT UP side of power sun roof switch until power sun roof tilts
all the way upward and then tilts downward a little. Power sun roof switch is located on headliner, just in
front of power sun roof.
2. Check proper operation of open/closing and tilt up/down function for power sun roof using power sun
roof switch. Power sun roof should operate anytime ignition is on, or for 43 seconds after ignition is off
provided both front doors are closed. It will stop operating if any front door is opened. Depressing SLIDE
OPEN side of power sun roof switch for one second should open power sun roof. Depressing TILT UP
side of power sun roof switch for one second should close power sun roof. To tilt power sun roof upward,
depress and hold TILT UP side of power sun roof switch for one second. To tilt power sun roof
downward, depress and hold SLIDE OPEN side of power sun roof switch for one second.
Celica
NOTE: Following procedure should be performed if battery is disconnected and

reconnected, or battery is discharged and recharged to provide proper
automatic operation and jam protection operation of power sun roof.
Close power sun roof using power sun roof switch and continue to depress power sun roof switch briefly after
power sun roof is fully closed. Power sun roof switch is located on headliner, just in front of power sun roof.
AIR INDUCTION SYSTEMS

ACOUSTIC CONTROL INDUCTION SYSTEM VACUUM SWITCHING VALVE
NOTE: Acoustic Control Induction System (ACIS) Vacuum Switching Valve (VSV) may
also be referred to as intake air control valve system VSV.
Removal & Installation (Celica)
Acoustic Control Induction System (ACIS) VSV is located on lower side of air cleaner case. See Fig. 2 .
Remove necessary components for access to ACIS VSV. Remove ACIS VSV. To install, reverse removal
procedure.
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Fig. 2: Locating Acoustic Control Induction System Vacuum Switching Valve & Components (Celica)
COMPUTERIZED ENGINE CONTROLS
NOTE: When battery is disconnected, vehicle computer and memory systems may lose
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memory data. Driveability problems may exist until computer systems have
completed a relearn cycle.
NOTE: On Camry and Celica, it may be possible that power sun roof may not operate
properly if battery is disconnected and reconnected, or battery is discharged
and recharged. If power sun roof does not operate properly, perform power sun
roof reinitialization procedure. See appropriate POWER SUN ROOF
REINITIALIZATION PROCEDURE under PROGRAMMING.
ENGINE CONTROL MODULE
NOTE: On Camry, Camry Solara, Highlander, MR2 and RAV4, an engine immobilizer
system may be used. On models equipped with engine immobilizer system, if
Engine Control Module (ECM) is replaced, ECM must be programmed with
proper ignition key code for engine immobilizer system. Models equipped with
engine immobilizer system may be identified by looking at the ignition key. On
models equipped with engine immobilizer system, the top of the ignition key is
thicker than a standard ignition key, as a transponder chip is incorporated into
the top of the ignition key. For programming procedures, see COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate
ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.
Removal & Installation (Camry, Camry Solara, Celica, ECHO, Highlander, RAV4 & Tacoma)
Ensure ignition is off. Remove necessary components to access Engine Control Module (ECM). Remove ECM.
See ECM LOCATION table. To install, reverse removal procedure.
Removal & Installation (Corolla)
Ensure ignition is off. Note location of Engine Control Module (ECM). See ECM LOCATION table. Remove
lower center finish panel and necessary components for access to ECM. See Fig. 3 . Remove ECM. To install,
reverse removal procedure.
Removal & Installation (MR2)
Ensure ignition is off. Note location of Engine Control Module (ECM). See ECM LOCATION table. Remove
luggage compartment lids, luggage compartments, quarter trim panels, lower trim covers, partition board and
cover for access to ECM. See Fig. 4 . For additional information on removal of luggage compartment
components, see FUEL PUMP under FUEL SYSTEMS. Remove ECM. To install, reverse removal procedure.
Removal & Installation (Prius)
WARNING: Read service precautions before proceeding with service procedure. See
SERVICE PRECAUTIONS .
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Ensure ignition is off. Remove necessary components to access Engine Control Module (ECM). Remove ECM.
See ECM LOCATION table. To install, reverse removal procedure.
ECM LOCATION
Model (1)
Location
Camry & Camry Behind Glove Box
Solara
Celica In Engine Compartment, Below Cover, Just In Front Of Battery, Next To Driver's
Side Strut Tower
Corolla Behind Stereo On Instrument Panel, Just In Front Of Center Console
ECHO & Highlander Behind Glove Box
MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment
Prius Behind Glove Box
RAV4 Behind Passenger's Side Kick Panel, Just Below Instrument Panel
Tacoma Behind Glove Box
(1) For illustration of ECM location, see THEORY & OPERATION article.
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Fig. 3: Locating Engine Control Module & Components (Corolla)

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Fig. 4: Locating Engine Control Module & Components (MR2)

ENGINE SENSORS & SWITCHES

ACCELERATOR PEDAL POSITION SENSOR
Removal & Installation (Camry)
Accelerator pedal position sensor is located near top of accelerator pedal. Service information is not available
from manufacturer.
Removal & Installation (Camry Solara)
1. Accelerator pedal position sensor is located near top of accelerator pedal and must be replaced along with
accelerator pedal as an assembly. See Fig. 5 . Disconnect electrical connector at accelerator pedal position
sensor. Remove accelerator pedal bracket retaining bolts and accelerator pedal along with accelerator
pedal position sensor.
2. To install, reverse removal procedure. Tighten accelerator pedal bracket retaining bolts to specification.
See TORQUE SPECIFICATIONS .
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Fig. 5: Locating Accelerator Pedal Position Sensor (Camry Solara)

Removal & Installation (MR2 With Sequential Manual Transaxle)
There are 2 types of manual transaxles used. On models with a standard type manual transaxle, the driver
operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is
electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift
lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists
of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. For
servicing of accelerator pedal position sensor, see THROTTLE BODY under FUEL SYSTEMS.
WARNING: Read service precautions before proceeding with service procedure.

See SERVICE PRECAUTIONS .
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1. Accelerator pedal position sensor is located near top of accelerator pedal and must be replaced along with
accelerator pedal as an assembly. See Fig. 6 . Disconnect electrical connector at accelerator pedal position
sensor. Remove accelerator pedal retaining bolts and accelerator pedal along with accelerator pedal
position sensor.
2. To install, reverse removal procedure. Tighten accelerator pedal retaining bolts to specification. See
TORQUE SPECIFICATIONS .
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Fig. 6: Locating Accelerator Pedal Position Sensor (Prius)

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A/C COMPRESSOR LOCK SENSOR
Removal & Installation (Camry, Camry Solara With Manual A/C, Celica, Highlander, MR2 & RAV4)
A/C compressor lock sensor is located near front of A/C compressor with electrical connector located near
generator. Service information is not available from manufacturer. It may be necessary to replace A/C
compressor along with A/C compressor lock sensor as an assembly. Consult local parts department for parts
availability. For servicing of A/C compressor, see appropriate article in AIR CONDITIONING & HEATING.
A/C EVAPORATOR TEMPERATURE SENSOR
Removal & Installation (Camry With Manual A/C & Camry Solara With Manual A/C)
A/C evaporator temperature sensor is located in evaporator case, next to evaporator core. For servicing of A/C
evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING.
AIR/FUEL SENSOR
NOTE: Air/Fuel (A/F) sensor may also be referred to as Air/Fuel (A/F) ratio sensor.
Removal & Installation (Camry, Camry Solara, Highlander & RAV4)
1. On Camry and Camry Solara, a heated Air/Fuel (A/F) sensor is mounted on exhaust manifold above
catalytic converter. On Highlander and RAV4, there are 2 heated A/F sensors mounted on exhaust
manifold above catalytic converter. On all models, disconnect electrical connector for A/F sensor.
Remove heat insulator for access to A/F sensor. Unscrew A/F sensor from exhaust manifold.
2. To install, reverse removal procedure. Tighten A/F sensor to specification (if available). See TORQUE
SPECIFICATIONS .
Removal & Installation (Tacoma)
1. Heated Air/Fuel (A/F) sensor is mounted on exhaust pipe in front of catalytic converter. Disconnect
electrical connector for A/F sensor. Remove retaining nuts, A/F sensor and gasket from exhaust pipe.
2. To install, reverse removal procedure using NEW gasket. Tighten A/F sensor retaining nuts to
specification. See TORQUE SPECIFICATIONS .
AIRFLOW METER
NOTE: Airflow meter may be referred to as Mass Airflow (MAF) meter.
Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

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Ensure ignition is off. Disconnect electrical connector at airflow meter. Airflow meter is bolted to upper cap on
air cleaner assembly. Remove bolts, airflow meter and "O" ring. To install reverse removal procedure using
NEW "O" ring.
1. Ensure ignition is off. Disconnect electrical connector at airflow meter. Airflow meter is located between
air intake hose and upper cap on air cleaner assembly and is mounted on upper cap on air cleaner
assembly.
2. Disconnect necessary hoses for removal of upper cap on air cleaner assembly. Loosen clamp on air intake
hose at airflow meter. Loosen retaining clips that retain upper cap on air cleaner assembly.
3. Remove upper cap on air cleaner assembly with airflow meter from air cleaner assembly. Remove airflow
meter retaining nuts, airflow meter and gasket from upper cap.
4. To install, reverse removal procedure using NEW gasket. Tighten airflow meter retaining nuts to
BRAKELIGHT SWITCH
NOTE: Brakelight switch may also be referred to as stoplight switch.
1. Remove necessary components for access to brakelight switch. Brakelight switch is located near top of
brake pedal. Disconnect electrical connector at brakelight switch. Loosen lock nut on brakelight switch.
Remove brakelight switch from mounting bracket.
2. Install brakelight switch in mounting bracket. Install electrical connector on brakelight switch. Depress
brake pedal .20-.39" (5.0-10.0 mm) and hold in this position. Rotate brakelight switch inward until
stoplights go off. Tighten lock nut. Release brake pedal.
3. Depress brake pedal .20-.39" (5.0-10.0 mm) and ensure brakelights come on. Release brake pedal. Ensure
brakelights go off.
Removal & Installation (Camry Solara, Corolla, ECHO, Highlander, MR2, Prius & RAV4

brake pedal. Disconnect electrical connector at brakelight switch. Loosen lock nut on brakelight switch.
Remove brakelight switch from mounting bracket.
2. Install brakelight switch in mounting bracket. Install electrical connector on brakelight switch. Depress
brake pedal .20-.59" (5.0-15.0 mm) and hold in this position. Rotate brakelight switch inward until
stoplights go off. Tighten lock nut. Release brake pedal.
3. Depress brake pedal .20-.59" (5.0-15.0 mm) and ensure brakelights come on. Release brake pedal. Ensure
brakelights go off.
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brake pedal. Disconnect electrical connector at brakelight switch. Rotate brakelight switch
counterclockwise and remove brakelight switch from mounting bracket.
2. Install brakelight switch in mounting bracket until brakelight switch contacts the cushion. Rotate
brakelight switch clockwise approximately 1/4 turn to install brakelight switch in mounting bracket.
Using feeler gauge, measure clearance between cushion and brakelight switch to determine the protrusion
of the rod on brakelight switch. See Fig. 7 . Clearance should be .020-.102" (.50-2.60 mm). Depress brake
pedal and ensure brakelights come on. Release brake pedal. Ensure brakelights go off.
Fig. 7: Measuring Clearance At Brakelight Switch (Celica)

Brakelight switch is located near top of brake pedal. Service information is not available from manufacturer.
CAMSHAFT POSITION SENSOR

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NOTE: On Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius and
RAV4, camshaft position sensor may also be referred to Variable Valve Timing
(VVT) sensor.
Removal & Installation
See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.
CRANKSHAFT POSITION SENSOR
See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS.
EGR GAS TEMPERATURE SENSOR
Removal & Installation (Tacoma 2.7L 4-Cyl. 3RZ-FE)
1. Disconnect electrical connector at EGR gas temperature sensor. EGR gas temperature sensor is located
near EGR valve. See Fig. 8 .
2. It may be necessary to remove EGR valve for access to EGR gas temperature sensor. See EGR VALVE
under EMISSION SYSTEMS & SUB-SYSTEMS. Remove EGR gas temperature sensor. To install,
reverse removal procedure.
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Fig. 8: Locating EGR Gas Temperature Sensor (Tacoma 2.7L 4-Cyl. 3RZ-FE)
ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation (Camry, Camry Solara, Corolla, Highlander, RAV4 & Tacoma)
1. Ensure ignition is off. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See
ENGINE COOLANT TEMPERATURE SENSOR LOCATION table.
2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW
gasket. Tighten ECT sensor to specification (if available). See TORQUE SPECIFICATIONS . Fill
cooling system.
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1. Ensure ignition is off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils
and valve cover. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See
gasket. Reinstall No. 2 cylinder head cover. Fill and bleed cooling system. See COOLING SYSTEM
BLEEDING under COOLING SYSTEM.
Removal & Installation (ECHO)
1. Ensure ignition is off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils
and valve cover. Remove air cleaner assembly for access to Engine Coolant Temperature (ECT) sensor.
See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. Disconnect electrical
connector at ECT sensor.
gasket. Reinstall air cleaner assembly and No. 2 cylinder head cover. Fill cooling system.
1. Ensure ignition is off. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See
gasket. Tighten ECT sensor to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling
system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.
ENGINE COOLANT TEMPERATURE SENSOR LOCATION

Model Location
Camry & Camry On Flywheel End Of Cylinder Head & Contains Dark Gray Electrical Connector
Solara With Green/Yellow & Brown Wires
Celica On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With
Green & Brown Wires
Corolla On Flywheel End Of Cylinder Head & Contains Dark Gray Electrical Connector
With White & Brown Wires
ECHO On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With
Red/Blue & Brown Wires
Highlander On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical
Connector With White/Blue & White Wires
MR2 On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical
Connector With Red/Blue & Brown Wires
RAV4 On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical
Connector With White & Brown Wires
Tacoma On Coolant Housing At Rear Of Cylinder Head & Contains Dark Gray 2-Pin
Electrical Connector With Green/Red & Blue/Black Wires
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WARNING: Service procedure should only be performed by authorized dealer.
ECT sensor is located on flywheel end of cylinder head and contains a Dark Gray 2-pin electrical connector
with White and Brown wires. Manufacturer states that converter and inverter assembly must be removed for
access to ECT sensor. The converter and inverter assembly are involved with the high-voltage system used on
this vehicle and service procedure should only be performed by authorized dealer.
HEATED OXYGEN SENSOR
NOTE: On Camry, Camry Solara, Highlander, RAV4 and Tacoma, an Air/Fuel (A/F)
sensor is used. For servicing of A/F sensor, see AIR/FUEL SENSOR .
Removal & Installation (All Models)

1. Servicing of heated oxygen sensor is just primarily an unbolt and bolt-on procedure. For heated oxygen
sensor location, see HEATED OXYGEN SENSOR LOCATION table. It may be necessary to remove
heat insulator for access to heated oxygen sensor. On MR2, it may be necessary to remove air cleaner
assembly for access to heated oxygen sensor on exhaust pipe assembly.
2. On all models, disconnect electrical connector for heated oxygen sensor. Remove retaining nuts or
unscrew heated oxygen sensor. Remove heated oxygen sensor and gasket (if equipped). To install,
reverse removal procedure using NEW gasket (if equipped). Tighten heated oxygen sensor or retaining
nuts to specification (if available). See TORQUE SPECIFICATIONS .
HEATED OXYGEN SENSOR LOCATION

Model Location
Camry & Camry On Exhaust Pipe After Catalytic Converter
Solara
Celica, Corolla & One On Exhaust Pipe In Front Of Catalytic Converter & One On Exhaust Pipe After
ECHO Catalytic Converter
Highlander Two Oxygen Sensors Are Mounted On Exhaust Manifold Below Catalytic
Converters
MR2 Two Oxygen Sensors Are Mounted On Exhaust Manifold Above Catalytic
Converters & One On Exhaust Pipe Behind Catalytic Converter
Prius One On Exhaust Pipe In Front Of Catalytic Converter & One On Exhaust Pipe After
Catalytic Converter
RAV4 Two Oxygen Sensors Are Mounted On Exhaust Manifold Below Catalytic
Converters
Tacoma On Exhaust Pipe After Catalytic Converter
IGNITION SWITCH
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Ignition switch is located at bottom of upper steering column bracket. See Fig. 9 . If necessary to remove
steering column for access to ignition switch, see appropriate STEERING COLUMNS article in STEERING.
Remove screws and ignition switch. To install, reverse removal procedure.
Fig. 9: Locating Typical Ignition Switch

KNOCK SENSOR
NOTE: Knock sensor may also be referred to as knock sensor No. 1.

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Knock sensor is located on side of cylinder block, just below intake manifold. See Fig. 10 . Service information
is not available from manufacturer. It may be necessary to remove engine with transaxle to gain access for
removal of intake manifold. For engine removal, see appropriate article in ENGINES. It may be necessary to
remove intake manifold for access to knock sensor. Use Socket (SST 09816-30010) when servicing knock
sensor. Tighten knock sensor and intake manifold bolts/nuts (if removed) to specification. See TORQUE
SPECIFICATIONS .
Fig. 10: Locating Knock Sensor (Camry & Highlander)

Removal (Camry Solara)
1. Knock sensor is located on side of cylinder block. See Fig. 11 . Manufacturer states to remove engine
with transaxle for access to knock sensor. See appropriate article in ENGINES.
2. Disconnect necessary hoses for removal of intake manifold with throttle body. Remove engine wiring
harness from engine wiring harness clamp. Remove bolts/nuts, engine wiring harness brackets, intake
manifold with throttle body, gasket and intake manifold insulator. See Fig. 11 . Using Socket (SST
09816-30010), remove knock sensor from cylinder block.
Installation
Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install intake
manifold, reverse removal procedure using NEW gasket. Tighten intake manifold bolts/nuts to specification.
See TORQUE SPECIFICATIONS . Reinstall engine.
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Fig. 11: Locating Knock Sensor & Identifying Intake Manifold & Components (Camry Solara)
Removal (Celica)
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1. Manufacturer states throttle body and intake manifold must be removed for access to knock sensor.
Knock sensor is located on side of cylinder block. See Fig. 12 and Fig. 13 . Remove throttle body. See
THROTTLE BODY under FUEL SYSTEMS.
2. Remove coolant reservoir and air cleaner case. Disconnect necessary hoses for removal of intake
manifold. On 1.8L 2ZZ-GE models, remove bolts/nuts and intake manifold support from rear of intake
manifold. On all models, remove bolts/nuts, intake manifold and gasket from cylinder head.
3. Disconnect electrical connector at knock sensor. On 1.8L 1ZZ-FE models, using Socket (SST 09816-
30010), remove knock sensor from cylinder block. On 1.8L 2ZZ-GE models, note position electrical
connector fitting on knock sensor in relation to the cylinder block for installation reference. Remove
knock sensor retaining nut from stud at center of knock sensor. See Fig. 13 . Remove knock sensor from
stud on cylinder block.
Installation
1. On 1.8L 1ZZ-FE models, install and tighten knock sensor to specification. See TORQUE
SPECIFICATIONS . On 1.8L 2ZZ-GE models, install knock sensor on stud on cylinder block. Ensure
electrical connector fitting on knock sensor is positioned in original location in relation to the cylinder
block. Install and tighten knock sensor retaining nut to specification. See TORQUE
SPECIFICATIONS . On all models, reinstall electrical connector on knock sensor. To install remaining
components, reverse removal procedure using NEW gaskets.
2. On 1.8L 2ZZ-GE models, note intake manifold bolt/nut identification before tightening intake manifold
bolts/nuts to specification. See Fig. 14 . On all models, ensure gasket for throttle body is installed with
protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten
bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See
COOLING SYSTEM BLEEDING under COOLING SYSTEM.
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Fig. 12: Locating Knock Sensor & Identifying Intake Manifold & Components (Celica 1.8L 1ZZ-
FE)
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Fig. 13: Locating Knock Sensor & Identifying Intake Manifold & Components (Celica 1.8L 2ZZ-
GE)
Fig. 14: Identifying Intake Manifold Bolts/Nuts (Celica 1.8L 2ZZ-GE)

Removal (Corolla)
Knock sensor is located on side of cylinder block. See Fig. 15 . Remove throttle body. See THROTTLE
BODY under FUEL SYSTEMS.
2. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See
Fig. 15 . Disconnect necessary electrical connectors so engine wiring harness protector and engine wiring
harness may be disconnected from engine wiring harness brackets. See Fig. 15 .
3. Remove bolts and disconnect engine wiring harness protector and engine wiring harness from engine
wiring harness brackets. Disconnect necessary hoses for removal of intake manifold. Remove bolts from
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intake manifold support. Remove bolts/nuts, engine wiring harness brackets, intake manifold and gasket
from cylinder head.
4. Disconnect electrical connector at knock sensor. Using Socket (SST 09816-30010), remove knock sensor
from cylinder block.
Installation
Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install remaining
components, reverse removal procedure using NEW gaskets. Ensure gasket for throttle body is installed with
protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts
to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
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Fig. 15: Locating Knock Sensor & Identifying Intake Manifold & Components (Corolla)
Removal (ECHO)
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Knock sensor is located on side of cylinder block. See Fig. 16 . Remove throttle body. See THROTTLE
BODY under FUEL SYSTEMS.
2. Remove coolant filler and No. 2 cylinder head cover located on top of engine, above ignition coils and
valve cover (if necessary) for access to intake manifold. See Fig. 16 . Disconnect necessary hoses for
removal of intake manifold. Remove bolts/nuts, intake manifold and gasket from cylinder head.
Installation
components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Fill cooling system.
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Fig. 16: Locating Knock Sensor & Identifying Intake Manifold & Components (ECHO)
Removal & Installation (Highlander)
Knock sensor is located on side of cylinder block, just below intake manifold. See Fig. 10 . Service information
is not available from manufacturer. It may be necessary to remove engine with transaxle to gain access for
removal of intake manifold. For engine removal, see appropriate article in ENGINES. It may be necessary to
remove intake manifold for access to knock sensor. Use Socket (SST 09816-30010) when servicing knock
sensor. Tighten knock sensor and intake manifold bolts/nuts (if removed) to specification. See TORQUE
SPECIFICATIONS .
Removal (MR2)
1. Knock sensor is located on side of cylinder block. See Fig. 17 . Manufacturer states to remove engine and
transaxle for access to knock sensor. See appropriate article in ENGINES.
2. Disconnect coolant hoses from throttle body and vacuum hoses from intake manifold. Remove engine
wiring harness from engine wiring harness brackets. Remove bolts/nuts, engine wiring harness brackets,
intake manifold with throttle body and gasket. Using Socket (SST 09817-16011), remove knock sensor
Installation
See TORQUE SPECIFICATIONS . Reinstall engine. Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING under COOLING SYSTEM.
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Fig. 17: Locating Knock Sensor & Identifying Typical Intake Manifold & Components (MR2)
Removal (Prius)
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Knock sensor is located on side of cylinder block. See Fig. 18 .
2. Ensure service plug is removed from service plug assembly. See SERVICE PRECAUTIONS . Remove
throttle body. See THROTTLE BODY under FUEL SYSTEMS. Remove engine oil dipstick and tube
with "O" ring if necessary for access to intake manifold.
3. Remove bolts/nuts, intake manifold and gasket from cylinder head. Disconnect electrical connector at
knock sensor. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation
components, reverse removal procedure using NEW gaskets and "O" ring on dipstick tube. Tighten bolts/nuts to
specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM
BLEEDING under COOLING SYSTEM.
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Fig. 18: Locating Knock Sensor & Identifying Intake Manifold & Components (Prius)
Removal (RAV4)
1. Knock sensor is located on side of cylinder block. See Fig. 19 . Manufacturer states to remove engine and
transaxle for access to knock sensor. See appropriate article in ENGINES.
2. Disconnect necessary hoses, electrical connectors and engine wiring harness for removal of intake
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manifold with throttle body. Remove bolts/nuts, intake manifold with throttle body, gasket and intake
manifold insulator. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation
See TORQUE SPECIFICATIONS . Reinstall engine.
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Fig. 19: Locating Knock Sensor & Identifying Intake Manifold & Components (RAV4)
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1. Remove starter and fuel filter mounting bolts to access knock sensor. Knock sensor is located on side of
cylinder block. See Fig. 20 .
3. To install, reverse removal procedure. Tighten knock sensor, fuel filter mounting bolts and starter bolts to
Fig. 20: Locating Knock Sensor (Tacoma)

PARK/NEUTRAL POSITION SWITCH
NOTE: Park/Neutral Position (PNP) is used only on A/T models.
Removal (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander & RAV4)
1. The Park/Neutral Position (PNP) switch is located on side of transaxle. See Fig. 21 . Remove necessary
components for access to PNP switch.
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2. Disconnect electrical connector at PNP switch. Disconnect shift cable on transaxle for access to PNP
switch. Remove nut, washer and control lever from transaxle.
3. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut,
lock plate, PNP switch retaining bolts and PNP switch.
Installation
1. Using NEW lock plate, install PNP switch on transaxle. Install and tighten PNP switch retaining nut and
PNP switch retaining bolts to specification. See TORQUE SPECIFICATIONS . Bend over tab on lock
plate against PNP switching retaining nut.
2. Reinstall control lever, washer and nut on PNP switch. Tighten nut for control lever to specification. See
TORQUE SPECIFICATIONS . Reconnect shift cable on control lever. Check that engine starts only
with shift lever in Park and Neutral. If PNP switch adjustment is required, go to next step.
3. Ensure parking brake is applied. Place shift lever in Neutral. It may be necessary to remove control lever
for access to PNP switch retaining bolts. Loosen PNP switch retaining bolts.
4. Rotate PNP switch so neutral base line aligns with the groove. See Fig. 22 -Fig. 26 . Tighten PNP switch
retaining bolts to specification. See TORQUE SPECIFICATIONS .
5. Ensure continuity exists between specified terminals on PNP switch in relation to shift lever position. See
PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in SYSTEM &
COMPONENT TESTING - 4-CYLINDER article. Reinstall electrical connector.
Fig. 21: Locating Typical Park/Neutral Position Switch & Components

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Fig. 22: Adjusting Park/Neutral Position Switch (Camry, Camry Solara, Highlander & RAV4)
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Fig. 23: Adjusting Park/Neutral Position Switch (Celica 1.8L 1ZZ-FE & ECHO)
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Fig. 24: Adjusting Park/Neutral Position Switch (Celica 1.8L 2ZZ-GE)

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Fig. 25: Adjusting Park/Neutral Position Switch (Corolla With 3-Speed A/T)
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Fig. 26: Adjusting Park/Neutral Position Switch (Corolla With 4-Speed A/T)
Removal (Tacoma)
1. The Park/Neutral Position (PNP) switch is located on side of transmission. See Fig. 21 . Remove front
exhaust pipe with heat insulator (if necessary) and disconnect transmission oil cooler line for access to
PNP switch.
2. Remove transmission oil cooler line elbow with "O" ring for access to PNP switch (if necessary).
Disconnect electrical connector at PNP switch.
3. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut,
lock plate, PNP switch retaining bolt and PNP switch.
Installation
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1. Using NEW lock plate, install PNP switch on transmission. Install and tighten PNP switch retaining nut
and PNP switch retaining bolt to specification. See TORQUE SPECIFICATIONS . Bend over tab on
lock plate against PNP switching retaining nut.
2. Using NEW "O" ring, install transmission oil cooler line elbow (if removed) and tighten to specification.
See TORQUE SPECIFICATIONS . Install transmission oil cooler line (if removed) and tighten nut to
3. Check that engine starts only with shift lever in Park and Neutral. If PNP switch adjustment is required,
go to next step.
4. Ensure parking brake is applied. Place shift lever in Neutral. Loosen PNP switch retaining bolt. Rotate
PNP switch so neutral base line aligns with the groove. See Fig. 27 and Fig. 28 . Tighten PNP switch
retaining bolt to specification. See TORQUE SPECIFICATIONS .
5. Ensure continuity exists between specified terminals on PNP switch in relation to shift lever position. See
PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in SYSTEM &
COMPONENT TESTING - 4-CYLINDER article. Reinstall electrical connector.
Fig. 27: Adjusting Park/Neutral Position Switch (Tacoma 2.4L 2RZ-FE)

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Fig. 28: Adjusting Park/Neutral Position Switch (Tacoma 2.7L 3RZ-FE)

POSITIVE TEMPERATURE COEFFICIENT HEATER
Positive Temperature Coefficient (PTC) heater is located in the heater core. See Fig. 29 . For servicing of PTC
heater, see appropriate HEATER SYSTEMS article in AIR CONDITIONING & HEATING.
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Fig. 29: Locating Positive Temperature Coefficient Heater (ECHO)

POWER STEERING PRESSURE SENSOR
NOTE: Power steering pressure sensor may also be referred to as power steering oil
pressure sensor.
1. Power steering pressure sensor is located on side of power steering pump and contains a 3-pin electrical
connector. Disconnect electrical connector at power steering pressure sensor. Remove power steering
pressure sensor with "O" ring from power steering pump.
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2. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF before
installing power steering pressure sensor. Tighten power steering pressure sensor to specification. See
TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.
POWER STEERING PRESSURE SWITCH
NOTE: Power steering pressure switch may also be referred to as power steering oil
pressure switch.
CAUTION: When servicing power steering pressure switch, use care not to drop
power steering pressure switch or switch may be damaged.
Removal & Installation (Camry, Camry Solara, Celica, Highlander & RAV4)
1. Power steering pressure switch is screwed into side of power steering pump, near pressure hose fitting. It
may be necessary to remove power steering pump for access to power steering pressure switch.
Disconnect electrical connector at power steering pressure switch. Remove power steering pressure
switch with "O" ring (if equipped) from power steering pump.
2. To install, reverse removal procedure using NEW "O" ring (if equipped). Coat "O" ring with Dexron-III
ATF before installing power steering pressure switch. Tighten power steering pressure switch to
specification. See TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.
Removal & Installation (Corolla)
1. Power steering pressure switch is screwed into end of union bolt that secures pressure hose on power
steering pump. Disconnect electrical connector at power steering pressure switch. Remove power steering
pressure switch.
2. To install, reverse removal procedure. Tighten power steering pressure switch to specification. See
TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.
Service information is not available from manufacturer.
THROTTLE POSITION SENSOR
NOTE: On MR2, there are 2 types of throttle bodies and TP sensors used depending on
type of transaxle used. On models with a standard type manual transaxle, the
driver operates the clutch and shifts the transaxle. On models with sequential
manual transaxle, the transaxle is electronically controlled and the clutch is
operated and transaxle is shifted hydraulically by moving the shift lever forward
or backward. Sequential manual transaxle may be identified by shift lever
pattern which consists of "R", "N", "S" and "+" in place of the conventional type
shift lever pattern and no clutch pedal is used.
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Removal & Installation (Camry & Camry Solara)
Throttle Position (TP) sensor is incorporated into the throttle body. Service information is not available from
manufacturer.
Removal & Installation (Celica, Corolla, ECHO, MR2 With Standard Type Manual Transaxle, RAV4 & Tacoma)
Throttle Position (TP) sensor is mounted on throttle body. Service information is not available from
manufacturer.
1. Throttle Position (TP) sensor is mounted on throttle body. Manufacturer lists procedure with throttle body
removed. If necessary to remove throttle body for access to TP sensor, see THROTTLE BODY under
FUEL SYSTEMS. Remove retaining screws and TP sensor from throttle body.
2. To install, ensure throttle valve on throttle body is fully closed. Position TP sensor at 45 degrees so it
aligns with shaft on throttle valve and install on throttle body. See Fig. 30 . Rotate TP sensor to the right
45 degress. Install and tighten retaining screws.
Fig. 30: Installing Throttle Position Sensor (Highlander)

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Removal & Installation (MR2 With Sequential Manual Transaxle & Prius)
For servicing of Throttle Position (TP) sensor, see THROTTLE BODY under FUEL SYSTEMS.
VACUUM SENSOR FOR HYDROCARBON ADSORBER CATALYST SYSTEM
Vacuum for sensor for Hydrocarbon Adsorber Catalyst (HCAC) system is located at passenger's side front
corner of the engine and contains Black 3-pin connector with Brown, Violet/White and Yellow/Red wires. See
Fig. 31 . Servicing of vacuum sensor is just primarily an unbolt and bolt-on procedure.
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Fig. 31: Locating Vacuum Sensor For HCAC System (Prius)

VAPOR PRESSURE SENSOR
For servicing of vapor pressure sensor, see VAPOR PRESSURE SENSOR under EMISSION SYSTEMS &
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SUB-SYSTEMS.
VARIABLE VALVE TIMING SENSOR
NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft
position sensor.
For VVT sensor servicing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.
VEHICLE SPEED SENSOR
Vehicle speed sensor is mounted on transaxle and contains a Black 3-pin electrical connector with Blue, Pink
and Red/Blue wires. Service information is not available from manufacturer.
Removal (Camry Solara, Celica, Corolla, ECHO & RAV4)
1. Vehicle speed sensor is mounted on transaxle and contains a 3-pin electrical connector. See Fig. 32 .
Remove necessary components for access to vehicle speed sensor. Disconnect electrical connector at
vehicle speed sensor.
2. Remove retaining bolt and vehicle speed sensor with "O" ring from transaxle. If necessary to remove
drive gear assembly from vehicle speed sensor, remove retaining clip from outside of vehicle speed
sensor. Retaining clip is located just below "O" ring groove on vehicle speed sensor. Remove drive gear
from vehicle speed sensor.
Installation
To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF (A/T models)
or gear oil (M/T models) before installing on vehicle speed sensor. Tighten retaining bolt to specification. See
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Fig. 32: Locating Typical Vehicle Speed Sensor (Camry Solara, Celica, Corolla, ECHO & RAV4)
Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to skid control
Electronic Control Unit (ECU). Skid control ECU converts input signals from wheel speed sensors to a 4-pulse
input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular
waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by
using input signal.
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Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to Anti-Lock
Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed
sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal
to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines
vehicle speed by using input signal.
Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to brake Electronic
Control Unit (ECU) for the Anti-Lock Brake System (ABS). Brake ECU converts input signals from wheel
speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input
signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM
determines vehicle speed by using input signal.
Removal (Tacoma)
1. Vehicle speed sensor is mounted near rear of transmission or transfer case and contains a 3-pin electrical
connector with Blue, Green/Red and Pink wires. See Fig. 33 .
2. Disconnect electrical connector at vehicle speed sensor. Remove retaining bolt and vehicle speed sensor
with "O" ring. Remove drive gear from vehicle speed sensor (if necessary).
Installation
To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF (A/T models)
or gear oil (M/T models) before installing on vehicle speed sensor. Tighten retaining bolt to specification. See
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Fig. 33: Locating Typical Vehicle Speed Sensor (Tacoma)

COOLING SYSTEM
COOLING SYSTEM BLEEDING
NOTE: On Celica, MR2 and Prius, whenever cooling system is drained, special cooling
system bleeding procedure must be performed. On all other models, no special
cooling system bleeding procedure is required.
Celica
1. This procedure assumes cooling system has been completely drained by loosening radiator drain plug on
bottom of radiator and engine drain plug on coolant drain union located on driver's side rear corner of
cylinder block.
2. Remove front fender apron seal and upper radiator support seal for access to coolant reservoir. See Fig.
12 . Remove coolant reservoir bolts and coolant reservoir hose retaining clamp bolts. Raise and support
coolant reservoir and secure to hood latch assembly.
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3. Remove cooling system bleeder plug. This is a thumb-type plug on top of coolant reservoir, near coolant
reservoir cap. Add approximately 4 qts. (3.7L) of 50/50 mixture of distilled water and coolant to coolant
reservoir until coolant level is at FULL mark on coolant reservoir. DO NOT use plain water or alcohol
based coolant. Continue to add water/coolant mixture as necessary. If cooling system does not require
approximate refill capacity to maintain coolant in coolant reservoir at the FULL mark, air exists in system
or system was not properly drained. See COOLING SYSTEM APPROXIMATE REFILL
CAPACITY (CELICA) table.
4. If cooling system will not take additional coolant, squeeze lower radiator hose several times while using
your finger to block cooling system bleeder plug opening. Continue to do this while slowly adding
coolant. Start engine with coolant reservoir cap and cooling system bleeder plug removed. Ensure A/C is
turned off. Operate engine until cooling fan comes on and goes off one time. Add additional coolant to
coolant reservoir as necessary.
5. Install cooling system bleeder plug. Install and tighten coolant reservoir cap about 2 1/2 turns until "click"
sound is heard. Increase engine speed to 3000 RPM for 5 seconds and then allow engine to idle for 5
seconds. Repeat this procedure for at least 15 minutes. Shut engine off and allow engine to completely
cool. With engine completely cooled, coolant level in coolant reservoir should be between LOW and
FULL marks. The next time engine operates and is at normal operating temperature, coolant level in
coolant reservoir should be above the FULL mark.
6. Reinstall coolant reservoir, front fender apron seal and upper radiator support seal. Check for coolant
leaks.
COOLING SYSTEM APPROXIMATE REFILL CAPACITY (CELICA)

Engine Application Qts. (L)
1.8L 1ZZ-FE
A/T 5.9 (5.6)
MT 6.0 (5.7)
1.8L 2ZZ-GE
A/T 6.1 (5.8)
M/T 6.2 (5.9)
MR2
1. Remove tool box and luggage compartment trim cover. See Fig. 34 . Connect air bleed hoses to heater
coolant valve air drain plug and radiator air drain plug. See Fig. 35 . Suspend opposite end of air bleed
hoses from the hood. Ensure air bleed hoses are not pinched or restricted. Rotate heater coolant valve air
drain plug and radiator air drain plug counterclockwise to open position.
2. Slowly add a 50/50 mixture of distilled water and coolant to coolant reservoir so that coolant lever in
coolant reservoir remains at least 1/2 full all the time while adding coolant to coolant reservoir. Coolant
reservoir is located at driver's side rear corner of engine compartment. See Fig. 35 . DO NOT use plain
water or alcohol based coolant. Approximate capacity is 11.0 qts. (10.4L). Air should bleed from air
bleed hoses on heater coolant valve air drain plug and radiator air drain plug. Ensure coolant level in both
air bleed hoses and coolant reservoir are at the same level. See Fig. 35 .
3. If coolant level in air bleed hoses is lower than level at coolant reservoir, air still exists in cooling system.
Check for pinched or restricted air bleed hoses and repeat step 2 . When proper coolant level is obtained
in air bleed hoses, close heater coolant valve air drain plug and radiator air drain plug. Install cap on
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coolant reservoir until "click" sound is heard and cap is in the lock position. Remove air bleed hoses.
4. Start engine and ensure air is bleeding into coolant reservoir. Warm engine to normal operating
temperature. Check that coolant level in coolant reservoir is above the FULL mark. Shut engine off and
allow engine to completely cool. Ensure coolant level in coolant reservoir is between LOW and FULL
marks. Add coolant if necessary. Reinstall luggage compartment trim cover and tool box.
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Fig. 34: Locating Tool Box & Luggage Compartment Trim Cover (MR2)
Fig. 35: Installing Air Bleed Hoses & Locating Coolant Reservoir (MR2)
Prius
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1. Slowly add a 50/50 mixture of distilled water and coolant to radiator. DO NOT use plain water or alcohol
based coolant. Approximate capacity is 5.2 qts. (4.9L).
2. Install radiator cap. Start engine and allow engine to idle. Accelerate engine and then engine allow to idle.
Repeat this procedure several times for approximately 2 minutes. Shut engine off. Remove radiator cap
and check coolant level. Coolant level should be even with rim of radiator filler neck. If coolant level
decreases when pinching the upper or lower radiator hose closed several times, add coolant as necessary.
Once correct coolant level is obtained, install radiator cap and go to next step.
3. It is necessary to put transit in inspection mode so engine will run continuously. To put transit in
inspection mode, perform the following steps within 60 seconds:
z Ensure ignition is off and then turn ignition on.
z Ensure transaxle is in Park and then fully depress accelerator pedal 2 times.
z Place transaxle in Neutral and then fully depress accelerator pedal 2 times.
z Place transaxle back in Park and then fully depress accelerator pedal 2 times.
4. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate
inspection mode operation. See Fig. 36 . Master warning light may also be referred to as hybrid system
error warning light.
5. Start engine and operate engine until cooling fan starts to turn with engine speed less than 2500 RPM.
Shut engine off immediately after cooling fan starts to turn. Allow engine to cool until engine coolant
temperature is less than 122°F (50°C). Remove radiator cap and recheck coolant level.
6. If proper coolant level exists, shut engine off. Go to next step. If coolant level has dropped, add coolant
and repeat steps 3 -6 . Once proper coolant level exists, shut engine off. Go to next step.
7. Air must be bleed from heater water pump which circulates coolant through the heater core. The heater
water pump may also be referred to as water pump motor (A/C). Turn ignition on with engine off. Place
blower speed control dial in LO position and temperature control dial to MAX HOT position. Operate
heater water pump until constant coolant flow sound exists at heater core. Ensure there is no sound of air
in the coolant flow. Once constant sound of coolant flow exists through heater core, fill coolant reservoir
to the maximum level.
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Fig. 36: Locating Master Warning Light (Prius)

IGNITION SYSTEMS
CAMSHAFT POSITION SENSOR
NOTE: On Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius and
RAV4, camshaft position sensor may also be referred to Variable Valve Timing
(VVT) sensor.
Removal & Installation (Camry & Highlander)
Camshaft position sensor is located on end of cylinder head at flywheel end of engine. See Fig. 37 . Service
information is not available from manufacturer except for camshaft position sensor bolt torque specification.
See TORQUE SPECIFICATIONS .
Removal & Installation (Camry Solara, Celica, Corolla, ECHO, MR2 & RAV4)
1. Note location of camshaft position sensor. See CAMSHAFT POSITION SENSOR LOCATION table.
See Fig. 37 -Fig. 42 . On Celica and MR2, remove No. 2 cylinder head cover located on top of engine,
above ignition coils and valve cover for access to camshaft position sensor. On MR2, remove suspension
upper brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower.
2. On all models, disconnect electrical connector at camshaft position sensor. Remove bolt and camshaft
position sensor with "O" ring (if equipped) from cylinder head.
3. To install, reverse removal procedure using NEW "O" ring (if equipped). Tighten camshaft position
sensor bolt to specification. See TORQUE SPECIFICATIONS . On MR2, tighten suspension upper
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brace bolt/nut to specification. See TORQUE SPECIFICATIONS .
CAMSHAFT POSITION SENSOR LOCATION

Application Location
Camry Solara, ECHO & On End Of Cylinder Head At Flywheel End Of Engine
RAV4
Celica, Corolla & MR2 Just Above Intake Manifold On Cylinder Head, At Flywheel End Of
Engine
Fig. 37: Locating Typical Camshaft Position Sensor (Camry, Camry Solara & Highlander)
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Fig. 38: Locating Camshaft Position Sensor (Celica 1.8L 1ZZ-FE & Corolla)
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Fig. 39: Locating Camshaft Position Sensor (Celica 1.8L 2ZZ-GE)

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Fig. 40: Locating Camshaft Position Sensor (ECHO)

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Fig. 41: Locating Camshaft Position Sensor (MR2)

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Fig. 42: Locating Camshaft Position Sensor (RAV4)

WARNING: Service procedure should only be performed by authorized dealer.
Camshaft position sensor is located on end of cylinder head at flywheel end of engine and contains a Black 2-
pin electrical connector with Green and Red wires. Manufacturer states that converter and inverter assembly
must be removed for access to camshaft position sensor. See CONVERTER AND INVERTER ASSEMBLY
in HYBRID VEHICLE CONTROL SYSTEM article.
1. Camshaft position sensor is located on cylinder head, just in front of intake manifold. See Fig. 43 .
2. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. Disconnect electrical
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connector at camshaft position sensor. Remove bolt and camshaft position sensor from cylinder head.
3. To install, reverse removal procedure. Tighten camshaft position sensor bolt to specification. See
Fig. 43: Locating Camshaft Position Sensor (Tacoma)

CRANKSHAFT POSITION SENSOR
Removal & Installation (Camry, Camry Solara & Highlander)
1. Crankshaft position sensor is located on side of timing chain cover. See Fig. 44 . Remove necessary
components for access to crankshaft position sensor. Disconnect electrical connector for crankshaft
position sensor. Remove bolt and crankshaft position sensor.
2. To install, reverse removal procedure. Tighten crankshaft position sensor bolt to specification. See
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Fig. 44: Locating Crankshaft Position Sensor (Camry, Camry Solara & Highlander)
Removal (Celica)
1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 .
Manufacturer states throttle body and intake manifold must be removed for access to crankshaft position
sensor.
2. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. Remove coolant reservoir and
air cleaner case. Disconnect necessary hoses for removal of intake manifold. On 1.8L 2ZZ-GE models,
remove bolts/nuts and intake manifold support from rear of intake manifold. On all models, remove
bolts/nuts, intake manifold and gasket from cylinder head.
3. Disconnect electrical connector for crankshaft position sensor. Remove bolts and crankshaft position
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sensor.
Installation
1. Install crankshaft position sensor. Install and tighten crankshaft position sensor bolts to specification. See
TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using
NEW gaskets.
2. On 1.8L 2ZZ-GE models, note intake manifold bolt/nut identification before tightening intake manifold
bolts/nuts to specification. See Fig. 14 . On all models, ensure gasket for throttle body is installed with
protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten
bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See
COOLING SYSTEM BLEEDING under COOLING SYSTEM.
Fig. 45: Locating Typical Crankshaft Position Sensor (Celica, Corolla, MR2 & RAV4)
Removal (Corolla)
1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 .
Manufacturer states throttle body and intake manifold must be removed for access to crankshaft position
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sensor. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS.
2. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See
Fig. 15 . Disconnect necessary electrical connectors so engine wiring harness protector and engine wiring
harness may be disconnected from engine wiring harness brackets. See Fig. 15 .
3. Remove bolts and disconnect engine wiring harness protector and engine wiring harness from engine
wiring harness brackets. Disconnect necessary hoses for removal of intake manifold. Remove bolts from
intake manifold support. Remove bolts/nuts, engine wiring harness brackets, intake manifold and gasket
from cylinder head. Disconnect electrical connector for crankshaft position sensor. Remove bolts and
crankshaft position sensor.
Installation
Install crankshaft position sensor. Install and tighten crankshaft position sensor bolts to specification. See
TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW
gaskets. Ensure gasket for throttle body is installed with protrusion area facing proper direction. See
THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Fill cooling system.
1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 46 . Raise and
support vehicle. Remove passenger's side lower engine cover for access to crankshaft position sensor.
Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position
sensor.
TORQUE SPECIFICATIONS . Reinstall passenger's side lower engine cover.
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Fig. 46: Locating Typical Crankshaft Position Sensor (ECHO & Prius)
support vehicle. Remove lower engine cover. A/C compressor must be removed for access to crankshaft
position sensor.
2. Rotate automatic belt tensioner clockwise as viewed from front of engine to release tension from
accessory drive belt. Remove accessory drive belt. Remove bolts and A/C compressor with hoses
attached for access to crankshaft position sensor. Disconnect electrical connector for crankshaft position
sensor. Remove bolt and crankshaft position sensor with "O" ring.
3. To install, reverse removal procedure using NEW "O" ring. Tighten crankshaft position sensor bolt and
A/C compressor bolts to specification. See TORQUE SPECIFICATIONS .
support vehicle. Remove passenger's side lower engine cover. Disconnect electrical connector for
crankshaft position sensor. Remove bolt and crankshaft position sensor.
TORQUE SPECIFICATIONS . Reinstall passenger's side lower engine cover.
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Removal & Installation (RAV4)
support vehicle. Remove lower engine cover for access to crankshaft position sensor.
2. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position
sensor with "O" ring. To install, reverse removal procedure using NEW "O" ring. Tighten crankshaft
position sensor bolt to specification. See TORQUE SPECIFICATIONS .
1. Crankshaft position sensor is located near crankshaft pulley, just above oil pan on driver's side of engine.
See Fig. 47 . Raise and support vehicle. Remove lower engine cover.
2. Disconnect negative battery cable. Disconnect electrical connectors at generator. Remove accessory drive
belt, generator and generator mounting bracket. Disconnect electrical connector at crankshaft position
sensor. Remove bolts and crankshaft position sensor with "O" ring.
3. To install, reverse removal procedure using NEW "O" ring. Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
Fig. 47: Locating Crankshaft Position Sensor (Tacoma)

IGNITION COIL
Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO & Highlander)
1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils for access to ignition
coil. Disconnect electrical connector at ignition coil mounted on valve cover.
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2. Note location of ignition coil for installation reference. Remove ignition coil bolt and ignition coil from
valve cover.
3. To install, reverse removal procedure. Tighten ignition coil bolt to specification. See TORQUE
SPECIFICATIONS .
1. Remove suspension upper brace. Suspension upper brace fits between strut towers and is bolted to top of
each strut tower. Remove No. 2 cylinder head cover located on top of engine, above ignition coils for
access to ignition coil. Disconnect electrical connector at ignition coil mounted on valve cover.
2. Note location of ignition coil for installation reference. Remove ignition coil bolt, ignition coil and dust
seal from valve cover.
3. To install, reverse removal procedure. Tighten ignition coil bolt and suspension upper brace bolt/nut to
1. Remove air cleaner assembly on top of engine for access to ignition coil. Disconnect electrical connector
at ignition coil mounted on valve cover.
valve cover.
SPECIFICATIONS .
1. Remove upper cap on air cleaner assembly for access to ignition coil. Disconnect electrical connector at
ignition coil mounted on valve cover.
valve cover.
SPECIFICATIONS .
1. Remove necessary components for access to ignition coil mounted on valve cover. Disconnect electrical
connector at ignition coil. Note location of ignition coil for installation reference. Remove ignition coil
bolt and ignition coil from valve cover.
SPECIFICATIONS .
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FUEL SYSTEMS
FUEL SYSTEM PRESSURE RELEASE
WARNING: ALWAYS release fuel pressure before disconnecting any fuel injection-
related component. DO NOT allow fuel to contact engine or electrical
components.
Camry
1. Ensure ignition is off. Remove circuit opening relay from fuse/relay box. See Fig. 48 . Fuse/relay box is
located at driver's side front corner of engine compartment.
2. Start engine and allow engine to idle until engine stalls. Attempt to start engine again to ensure engine
will not start. Turn ignition off. Disconnect negative battery cable. Remove fuel tank cap to release any
pressure from fuel tank.
3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly
loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is
released, fuel system components may be serviced.
4. Reinstall circuit opening relay and negative battery cable. Start engine and check operation of
Malfunction Indicator Light (MIL) on instrument panel with engine running. MIL is displayed as engine
icon on instrument panel. It may be possible that Diagnostic Trouble Code (DTC) P0171 may have been
stored in Engine Control Module (ECM) and MIL may be illuminated with engine running due to the lean
condition caused by operating engine with circuit opening relay removed. If MIL is illuminated, DTCs
must be cleared from ECM. See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-
DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article.
NOTE: It may be possible that power sun roof may not operate properly after
battery was disconnected. If power sun roof does not operate properly,
perform power sun roof reinitialization procedure. See appropriate POWER
SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.
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Fig. 48: Locating Circuit Opening Relay (Camry)

Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

1. On all models, disconnect electrical connector for fuel pump. See FUEL PUMP ELECTRICAL
CONNECTOR LOCATION table. This is electrical connector for fuel pump and fuel gauge sending
unit. Electric fuel pump is located in the fuel tank.
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FUEL PUMP ELECTRICAL CONNECTOR LOCATION

Application Connector Location
Camry Solara, Celica, Corolla & Under Cover Plate, Below Rear Seat Cushion
ECHO
Highlander Under Cover Plate, Below Driver's Side & Passenger's Side Rear
Seats
MR2 (1) Under Cover Plate, Below Luggage Compartment Boxes Behind
The Seats
Prius Under Cover Plate, Below Rear Seat Cushion
RAV4 Under Cover Plate, Below Driver's Side Rear Seat
Tacoma On Top Of Fuel Tank, At Fuel Pump
(1) For additional information for removal of luggage compartment boxes, see FUEL PUMP .
2. Start engine and allow engine to idle until engine stalls. Turn ignition off. Disconnect negative battery
cable.
3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly
loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is
released, fuel system components may be serviced. Reinstall electrical connector for fuel pump and
negative battery cable.
NOTE: On Celica, it may be possible that power sun roof may not operate
properly after battery was disconnected. If power sun roof does not
operate properly, perform power sun roof reinitialization procedure. See
appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under
PROGRAMMING.
FUEL FILTER
Manufacturer does not list procedure for servicing of external fuel filters. Fuel filter(s) may be used on the fuel
pump assembly. For servicing of fuel filter(s) on fuel pump assembly, see FUEL PUMP .
FUEL FILTER ON FUEL PUMP
For servicing of fuel filter(s) on fuel pump assembly, see FUEL PUMP .
FUEL PUMP
NOTE: When servicing fuel pump, use care to cover all fuel line fittings and
connections to prevent dirt from entering fuel pump or fuel lines.
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Removal (Camry)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .

2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done.
Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel
gauge sending unit. Electric fuel pump is located in fuel tank.
3. Ensure area around disconnect fitting and fuel supply line on top of fuel pump is clean. Remove retaining
clip from disconnect fitting on fuel supply line at top of fuel pump. See Fig. 49 . Disconnect fuel supply
line from top of fuel pump. DO NOT bend or twist fuel supply line or disconnect fitting during removal.
Use care not to damage the nylon fuel supply line and disconnect fitting during removal, as there are "O"
rings inside the disconnect fitting.
4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Remove fuel pump
assembly and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel
gauge sending unit when removing fuel pump.
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Fig. 49: Locating Retaining Clip, Disconnect Fitting, Fuel Supply Line & Fuel Pump Retaining Plate
(Camry & Highlander)
Disassembly & Reassembly
1. Using screwdriver, release snap fit areas on No. 2 fuel suction support and remove No. 2 fuel suction
support from bottom of fuel pump. See Fig. 50 . Remove rubber cushion from bottom of fuel pump.
2. Remove fuel pressure regulator with "O" ring. See Fig. 50 . Disconnect lead wire at fuel pump. Remove
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fuel pump with fuel filter from fuel filter assembly. See Fig. 50 . Using small screwdriver, remove
retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from bottom of fuel pump.
3. Using screwdriver, release snap fit areas on fuel suction plate subassembly and separate fuel suction plate
subassembly from fuel filter assembly. See Fig. 50 . If necessary to remove fuel gauge sending unit,
unlock fuel gauge sending unit. Slide fuel gauge sending unit downward and remove.
4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring.
Coat "O" ring with gasoline before installing. Ensure fuel gauge sending unit is fully locked in place by
pushing fuel gauge sending unit downward.
Installation
To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel tank bolts to
specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel supply line at
fuel pump and retaining clip is properly installed and fuel supply line cannot be pulled from fuel pump
assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL
SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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Fig. 50: Exploded View Of Fuel Pump & Components (Camry)


gauge sending unit. Electric fuel pump is located in the fuel tank.
3. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Ensure area around
disconnect fitting on fuel line at fuel pump is clean. Depress both sides of retainer and pull fuel line with
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disconnect fitting from outlet tube on the fuel pump. See Fig. 51 .
4. Remove fuel pump retaining plate-to-fuel tank bolts. Remove fuel pump retaining plate, fuel pump and
gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending
unit when removing fuel pump.
Fig. 51: Disconnecting Fuel Line At Fuel Pump (Camry Solara)

1. Note location of fuel pump mounting bracket. See Fig. 52 . Using screwdriver, release snap fit areas on
fuel pump mounting bracket and remove fuel pump mounting bracket with round fuel filter from fuel
pump. See Fig. 53 .
2. Disconnect electrical connector at fuel pump. Disconnect fuel gauge sending unit wire from bottom of
fuel pump mounting bracket. Using screwdriver, release snap fit areas on fuel pump in proper sequence
and remove cover bracket and rubber cushion from bottom of fuel pump. See Fig. 53 .
3. Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. See Fig. 52 .
Remove fuel filter from fuel pump. To reassemble, reverse disassembly procedure using NEW retaining
clip on fuel filter.
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Installation
1. Using NEW gasket, install fuel pump in fuel tank. Tighten fuel pump retaining plate-to-fuel tank bolts to
CAUTION: DO NOT reuse old retainer when installing fuel line on outlet tube at
fuel pump. Always use a NEW retainer.
2. Ensure areas are clean before installing fuel line at fuel pump. Apply light coat of engine oil on tip of
outlet tube at fuel pump to allow for ease of disconnect fitting and fuel line installation. Using NEW
retainer, install fuel line on outlet tube at fuel pump until "click" sound is heard. DO NOT reuse old
retainer. Pull on fuel line to ensure fuel line is properly locked on the fuel pump.
3. To install remaining components, reverse removal procedure. Tighten fuel pump protector cover bolts to
4. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS
in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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Fig. 52: Exploded View Of Fuel Pump & Components (Camry Solara)
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Fig. 53: Removing Fuel Pump & Cover Bracket (Camry Solara)
Removal (Celica)

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gauge sending unit. Electric fuel pump is located in the fuel tank. Disconnect electrical connector at vapor
pressure sensor. See Fig. 54 .
3. Ensure area around emission tube and fuel line at fuel pump is clean. Remove retaining clip from fuel line
at fuel pump. See Fig. 54 . Disconnect fuel line from fuel pump. Disconnect emission tube.
Fig. 54: Locating Emission Tube, Fuel Line, Retaining Clip & Vapor Pressure Sensor (Celica)
1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 55 . Remove
rubber cushion.
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2. Disconnect lead wire for fuel gauge sending unit. Press lock on main fuel filter and slide fuel gauge
sending unit from main fuel filter. See Fig. 56 . Main fuel filter may also be referred to as fuel pump
filter. Using screwdriver, remove No. 1 fuel suction support from main fuel filter. See Fig. 57 . Use care
not to damage No. 1 fuel suction support and main fuel filter during removal.
3. Disconnect lead wire from fuel pump and No. 1 fuel suction support. Remove retaining clip and vapor
pressure sensor from No. 1 fuel suction support. Remove fuel pump from main fuel filter. Remove fuel
pressure regulator with "O" ring from main fuel filter. Using small screwdriver, remove retaining clip that
holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump.
4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring
on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Install
fuel gauge sending unit on main fuel filter so fuel gauge sending unit installation distance between float
fulcrum and No. 1 fuel suction support is 5.91" (150.0 mm). See Fig. 58 .
Installation
1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel tank
bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel
line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump
assembly.
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Fig. 55: Exploded View Of Fuel Pump & Components (Celica)

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Fig. 56: Removing Fuel Gauge Sending Unit (Celica)

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Fig. 57: Removing No. 1 Fuel Suction Support (Celica)

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Fig. 58: Measuring Fuel Gauge Sending Unit Installation Distance (Celica)
Removal (Corolla)

gauge sending unit. Electric fuel pump is located in fuel tank.
3. Ensure area around fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See
Fig. 59 . Disconnect fuel line from fuel pump.
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Fig. 59: Removing Retaining Clip At Fuel Line (Corolla)

rubber cushion. Remove fuel pressure regulator with "O" ring from main fuel filter.
CAUTION: Use care when removing retaining clip as not to damage the No. 1
fuel suction support.
2. Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel
filter from fuel pump. DO NOT damage No. 1 fuel suction support when removing retaining clip.
3. Using small screwdriver, pry No. 1 fuel suction support from fuel pump mounting bracket and fuel gauge
sending unit. Use care not to damage No. 1 fuel suction support and fuel pump mounting bracket. Fuel
pump mounting bracket may also be referred to as fuel suction plate.
4. Remove fuel filter cushion from bottom of main fuel filter. Fuel filter cushion may also be referred to as
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No. 2 fuel filter cushion. Remove main fuel filter with fuel pump from fuel pump mounting bracket.
Disconnect electrical connector from fuel pump. Remove fuel pump from main fuel filter.
5. To reassemble, reverse disassembly procedure using NEW "O" ring on fuel pressure regulator and NEW
retaining clip on fuel filter. Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation
assembly.
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Fig. 60: Exploded View Of Fuel Pump & Components (Corolla)

Removal (ECHO)

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gauge sending unit. Electric fuel pump is located in the fuel tank. Disconnect electrical connector at vapor
3. Ensure area around emission tube and fuel line at fuel pump is clean. Remove retaining clip from fuel line
at fuel pump. See Fig. 61 . Disconnect fuel line from fuel pump. Disconnect emission tube.
Fig. 61: Locating Emission Tube, Fuel Line, Retaining Clip & Vapor Pressure Sensor (ECHO)
rubber cushion and fuel pressure regulator with "O" ring.
2. Disconnect electrical connector for fuel gauge sending unit. Using screwdriver, remove No. 1 fuel suction
support from fuel filter. See Fig. 63 . Use care not to damage No. 1 fuel suction support during removal.
Remove "O" ring from No. 1 fuel suction support. Disconnect lead wire from fuel pump.
3. Remove retaining clip and vapor pressure sensor from No. 1 fuel suction support. Remove fuel pump
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with "O" ring from fuel filter. Remove "O" ring from fuel pump.
4. To reassemble, reverse disassembly procedure using NEW "O" rings. Coat "O" rings with gasoline before
installing.
Installation
assembly.
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Fig. 62: Exploded View Of Fuel Pump & Components (ECHO)

Fig. 63: Removing No. 1 Fuel Suction Support (ECHO)

Removal (Highlander)

2. Remove driver's side and passenger's side rear seats and cover plate on floor panel for access to fuel
pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical
connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank.
3. Ensure area around disconnect fitting and fuel supply line on top of fuel pump is clean. Remove retaining
clip from disconnect fitting on fuel supply line at top of fuel pump. See Fig. 49 . Disconnect fuel supply
line from top of fuel pump. DO NOT bend or twist fuel supply line or disconnect fitting during removal.
Use care not to damage the nylon fuel supply line and disconnect fitting during removal, as there are "O"
rings inside the disconnect fitting.
4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Lift fuel pump
assembly upward and disconnect necessary fuel line and then remove fuel pump assembly from fuel tank.
Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing
fuel pump.
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2. Remove fuel pressure regulator with jet pump assembly and "O" ring. See Fig. 64 . Using small
screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from
fuel pump.
support from fuel pump mounting bracket. See Fig. 64 . Disconnect fuel pump electrical connector from
top of fuel pump. Remove fuel pump with main fuel filter. Remove fuel pump from main fuel filter. If
necessary to remove fuel gauge sending unit from fuel pump mounting bracket, disengage fuel gauge
sending unit. Slide fuel gauge sending unit downward and remove from fuel pump mounting bracket.
4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O"
rings. Coat "O" ring with gasoline before installing. Ensure fuel gauge sending unit is fully seated in fuel
pump mounting bracket.
Installation
To install, reverse removal procedure. Ensure areas are clean before installing fuel supply line at fuel pump and
retaining clip is properly installed and fuel supply line cannot be pulled from fuel pump assembly. Operate fuel
pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC
DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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Fig. 64: Exploded View Of Fuel Pump & Components (Highlander)

Removal (MR2)
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2. Apply tape to end of screwdriver to prevent scratching interior components. Using screwdriver, remove
door opening scuff plates, lower trim covers and quarter trim covers. See Fig. 4 . Remove luggage
compartment lids, luggage compartment boxes and cover plate on floor panel for access to fuel pump if
not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector
for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank.
3. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Disconnect electrical
connector at vapor pressure sensor. See Fig. 65 . Ensure area around emission tube and fuel line at fuel
pump is clean. Remove retaining clip from fuel line at fuel pump. See Fig. 65 . Disconnect fuel line from
fuel pump. Disconnect emission tube.
4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Remove fuel pump
assembly with gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel
gauge sending unit when removing fuel pump.
Fig. 65: Locating Vapor Pressure Sensor, Retaining Clip, Disconnect Fitting, Fuel Line & Fuel
Pump Retaining Plate (MR2)
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rubber cushion from bottom of fuel pump.
2. Disconnect lead wire from bottom of No. 1 fuel suction support. No. 1 fuel suction support may also be
referred to as fuel suction plate. Using screwdriver, release snap fit areas on No. 1 fuel suction support
and remove No. 1 fuel suction support from main fuel filter. See Fig. 67 . Use care not to damage No. 1
fuel suction support and main fuel filter. Main fuel filter may also be referred to as fuel filter assembly.
3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Remove fuel
pump from main fuel filter. See Fig. 66 . Using small screwdriver, remove retaining clip that holds fuel
filter on bottom of fuel pump. Remove fuel filter from fuel pump. Remove fuel pressure regulator with
"O" ring from top of main fuel filter. See Fig. 66 . Remove "O" ring from fuel pressure regulator.
Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation
1. To install, reverse removal procedure using NEW gasket. Ensure fuel pump assembly is positioned so
reference mark aligns with specified bolt hole and emission tube fitting is pointing toward front of
vehicle. See Fig. 68 .
2. Tighten fuel pump retaining plate-to-fuel tank bolts and fuel pump protector cover bolts to specification.
See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and
retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. Operate fuel
DIAGNOSTIC PROCEDURES - 4-CYLINDER article. Reinstall luggage compartment components.
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Fig. 66: Exploded View Of Fuel Pump & Components (MR2)

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Fig. 67: Removing No. 1 Fuel Suction Support (MR2)

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Fig. 68: Installing Fuel Pump Assembly (MR2)

Removal (Prius)
1. It may be necessary to replace fuel pump and fuel tank as an assembly. Consult local parts department for
parts availability. To remove fuel tank, release fuel pressure. See FUEL SYSTEM PRESSURE
RELEASE .
3. Raise and support vehicle. Remove exhaust pipe assembly and tailpipe for access to fuel tank. Drain
gasoline from fuel tank into approved container. Disconnect fuel filler tube and any remaining hoses for
fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank retaining bolts and fuel
tank.
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Installation
To install, reverse removal procedure using NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel tank
retaining bolts and exhaust pipe-to-exhaust manifold bolts to specification. See TORQUE
SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under
FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
Removal (RAV4)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove driver's side rear seat
and cover plate on floor panel for access to electrical connector for fuel pump if not previously done.
2. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel
gauge sending unit. Electric fuel pump is located in fuel tank. Disconnect electrical connector at vapor
3. Ensure area around fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See
Fig. 69 . Disconnect fuel line from fuel pump. Remove fuel pump retaining plate-to-fuel tank bolts and
fuel pump retaining plate.
4. Lift fuel pump assembly upward and disconnect fuel line from fuel pressure regulator and then remove
fuel pump assembly with gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump
and fuel gauge sending unit when removing fuel pump.
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Fig. 69: Locating Retaining Clip, Fuel Line, Fuel Pump Retaining Plate & Vapor Pressure Sensor
(RAV4)
rubber cushion from bottom of fuel pump.
2. Disconnect lead wire from bottom of No. 1 fuel suction support. No. 1 fuel suction support may also be
referred to as fuel suction plate. Using screwdriver, release snap fit areas on No. 1 fuel suction support
and remove No. 1 fuel suction support from main fuel filter. See Fig. 71 . Use care not to damage No. 1
fuel suction support and main fuel filter. Main fuel filter may also be referred to as fuel filter assembly.
pump from main fuel filter. See Fig. 70 . Using small screwdriver, remove retaining clip that holds fuel
filter on bottom of fuel pump. Remove fuel filter from fuel pump. Remove fuel pressure regulator with
"O" ring from top of main fuel filter. See Fig. 70 . Remove "O" ring from fuel pressure regulator.
Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation
1. To install, reverse removal procedure using NEW gasket. Ensure fuel pump assembly is positioned so
reference mark aligns with specified bolt hole and fuel pump is properly positioned in fuel tank. See Fig.
72 .
2. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE
SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is
properly installed and fuel line cannot be pulled from fuel pump assembly. Operate fuel pump and check
for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC
PROCEDURES - 4-CYLINDER article.
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Fig. 70: Exploded View Of Fuel Pump & Components (RAV4)

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Fig. 71: Removing No. 1 Fuel Suction Support (RAV4)

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Fig. 72: Installing Fuel Pump Assembly (RAV4)

Removal (Tacoma)

2. Electric fuel pump is located in fuel tank. Fuel tank must be removed for servicing of fuel pump. Raise
and support vehicle. Remove necessary covers for access to fuel tank. Drain gasoline from fuel tank into
approved container.
3. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with
transmission jack. Remove fuel tank straps. Slightly lower fuel tank for access to fuel supply and fuel
return lines at the fuel pump.
4. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel
gauge sending unit. Disconnect electrical connector from vapor pressure sensor. See Fig. 73 .
5. Ensure area around fuel supply and fuel return lines on top of fuel pump is clean. Disconnect fuel supply
and fuel return lines from top of fuel pump. Remove fuel tank. Remove fuel pump mounting bracket-to-
fuel tank bolts. Remove fuel pump assembly and gasket from fuel tank. Use care not to damage fuel filter
on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.
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1. Disconnect electrical connector on lead wire from the fuel pump. See Fig. 73 . Pull bottom of fuel pump
from fuel pump mounting bracket.
2. Disconnect fuel hose at top of fuel pump. Remove fuel pump with rubber cushion from fuel pump
mounting bracket. Remove rubber cushion from bottom of fuel pump. Using small screwdriver, remove
retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. To
reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter.
Installation
1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump mounting bracket-to-fuel
tank bolts to specification. See TORQUE SPECIFICATIONS .
2. Operate fuel pump and check for fuel leaks before installing fuel tank. See FUEL PUMP OPERATION
under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. Before
installing fuel tank, ensure insulator cushions are installed in proper areas on top of fuel tank. See Fig.
74 .
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Fig. 73: Exploded View Of Fuel Pump & Components (Tacoma)

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Fig. 74: Locating Insulator Cushions On Fuel Tank (Tacoma)

FUEL PRESSURE REGULATOR
1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 50 . Remove fuel
pump from fuel tank. See FUEL PUMP .
3. Remove fuel pressure regulator with "O" ring. See Fig. 50 . Remove "O" ring from fuel pressure
regulator.
4. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with gasoline before installing
fuel pressure regulator. Reinstall fuel pump.
2. Remove round fuel filter retaining screw and round fuel filter with "O" ring from fuel pressure regulator.
See Fig. 75 .
3. Remove fuel pressure regulator retaining screw. Remove fuel pressure regulator with "O" ring from fuel
pump mounting bracket. Remove "O" ring from fuel pressure regulator.
Installation
To install, reverse removal procedure using NEW "O" rings. Coat "O" ring with gasoline before installing fuel
pressure regulator and round fuel filter. Tighten fuel pressure regulator retaining screw and round fuel filter
retaining screw to specification. See TORQUE SPECIFICATIONS . Reinstall fuel pump.
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Fig. 75: Locating Fuel Pressure Regulator (Camry Solara)

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2. Using screwdriver, remove No. 1 fuel suction support from main fuel filter. See Fig. 57 . Use care not to
damage No. 1 fuel suction support during removal. Disconnect lead wire from fuel pump and No. 1 fuel
suction support. Remove fuel pressure regulator with "O" ring from main fuel filter.
3. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator. Coat "O" ring with
gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal & Installation (Corolla & ECHO)
1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 60 and Fig. 62 .
Remove fuel pump from fuel tank. See FUEL PUMP .
2. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 60 and Fig. 62 .
Remove rubber cushion. Remove fuel pressure regulator with "O" ring.
1. Fuel pressure regulator contains the jet pump assembly and is located on fuel pump assembly in the fuel
tank. See Fig. 64 . Remove fuel pump from fuel tank. See FUEL PUMP .
Remove fuel pressure regulator with jet pump assembly and "O" ring. Remove "O" ring from fuel
pressure regulator with jet pump assembly.
3. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator with jet pump
assembly. Coat "O" ring with gasoline before installing fuel pressure regulator with jet pump assembly.
Reinstall fuel pump.
2. Disconnect lead wire from bottom of No. 1 fuel suction support. Using screwdriver, release snap fit areas
on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 67 .
Use care not to damage No. 1 fuel suction support and main fuel filter.
pressure regulator with "O" ring from top of main fuel filter. See Fig. 66 . Remove "O" ring from fuel
pressure regulator.
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Fuel pressure regulator is located on fuel pump assembly in the fuel tank. Manufacturer does not provide
information for servicing of fuel pressure regulator. It may be necessary to replace fuel pressure regulator along
with fuel pump and fuel tank as an assembly. Consult local parts department for parts availability. For servicing
of fuel pump and fuel tank as an assembly, see FUEL PUMP .
2. Disconnect lead wire from bottom of No. 1 fuel suction support. Using screwdriver, release snap fit areas
on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 71 .
Use care not to damage No. 1 fuel suction support and main fuel filter.
3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Disconnect tube
on fuel pressure regulator from clamp. Remove fuel pressure regulator with "O" ring from top of main
fuel filter. See Fig. 70 . Remove "O" ring from fuel pressure regulator.
Removal (Tacoma)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect air hose and fuel
return hose from fuel pressure regulator. Fuel pressure regulator is located on end of fuel rail at front of
engine.
2. Remove bolts and fuel pressure regulator with "O" ring from fuel rail. Remove "O" ring from fuel
pressure regulator.
Installation
1. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with gasoline before installing
fuel pressure regulator in fuel rail.
2. Tighten fuel pressure regulator bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel
FUEL RAILS & FUEL INJECTORS
Removal (Camry)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper cap on air cleaner
assembly with air cleaner hose. Remove No. 2 cylinder head cover located on top of engine, above
ignition coils and valve cover. See Fig. 76 .
2. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See Fig. 77 . Fuel pipe goes from end
of fuel rail to fuel pipe fitting. Ensure area around fuel pipe and disconnect fitting is clean.
CAUTION: Use care when disconnecting fuel pipe, as some residual fuel
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pressure may still exist in the fuel system.
3. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 77 . Remove
ventilation hose No. 2. See Fig. 76 . Remove engine wiring harness for access to fuel rail and fuel
injectors. Note location of electrical connectors on fuel injectors for installation reference. Disconnect
electrical connectors at fuel injectors.
CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall
from fuel rail.
4. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the
2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from
fuel injector. Grommet may also be referred to as an insulator.
Installation
1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline
before installing "O" ring on fuel injector.
2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting
motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing
downward, toward intake manifold and the 2 spacers are installed on cylinder head before installing fuel
rail.
3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed.
Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O"
ring installation and replace "O" ring on fuel injector.
4. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold. Tighten
fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . To install
remaining components, reverse removal procedure. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe
to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Operate fuel pump
and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC
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Fig. 76: Exploded View Of Fuel Rail & Components (Camry & Camry Solara)
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Fig. 77: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Camry)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove No. 2 cylinder head
cover located on top of engine, above ignition coils and valve cover. See Fig. 76 .
2. Remove ventilation hose No. 2. See Fig. 76 . Ventilation hose No. 2 may also be referred to as PCV hose.
Remove engine wiring harness for access to fuel rail and fuel injectors. Note location of electrical
connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors.
from fuel rail.
2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from
fuel injector.
Installation
rail. Coat grommet contact surfaces with gasoline before installing fuel rail with fuel injectors.
fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . To install
remaining components, reverse removal procedure. Operate fuel pump and check for fuel leaks. See
FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-
CYLINDER article.
Removal (Celica & Corolla)
cover located on top of engine, above ignition coils and valve cover. See Fig. 78 and Fig. 79 .
2. Remove fuel pipe clamp from end of fuel pipe at end of fuel rail. Perform STEP 1 in illustration. See Fig.
80 and Fig. 81 . Ensure area around fuel pipe and disconnect fitting is clean.
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3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform
STEP 2 in illustration. See Fig. 80 and Fig. 81 . Note location of electrical connectors on fuel injectors
for installation reference. Disconnect electrical connectors at fuel injectors.
from fuel rail.
4. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 78 and Fig. 79 . Remove fuel rail-to-
cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from
cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation
toward valve cover and the 2 spacers are installed on cylinder head before installing fuel rail. Coat
grommet contact surfaces with gasoline before installing fuel rail with fuel injectors.
4. Ensure electrical connector on each fuel injector is facing toward valve cover. Tighten fuel rail-to-
cylinder head bolts and fuel pipe clamp-to-cylinder head bolt to specification. See TORQUE
SPECIFICATIONS . Install No. 2 cylinder head cover.
CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe
fitting. Always use a NEW retainer.
5. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel
pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard.
DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting.
6. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION
under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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Fig. 78: Exploded View Of Fuel Rail & Components (Celica)

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Fig. 79: Exploded View Of Fuel Rail & Components (Corolla)

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Fig. 80: Disconnecting Fuel Pipe From Fuel Pipe Fitting (Celica)
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Fig. 81: Disconnecting Fuel Pipe From Fuel Pipe Fitting (Corolla)
Removal (ECHO)
cover located on top of engine, above ignition coils and valve cover, ignition coils, valve cover and
gasket. See Fig. 82 .
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2. Remove fuel pipe clamp from end of fuel pipe at end of fuel rail. Perform STEP 1 in illustration. See Fig.
83 . Ensure area around fuel pipe and disconnect fitting is clean.
3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform
STEP 2 in illustration. See Fig. 83 . Note location of electrical connectors on fuel injectors for installation
reference. Disconnect electrical connectors at fuel injectors.
from fuel rail.
4. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 82 . Remove fuel rail-to-cylinder head
bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head.
Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation
SPECIFICATIONS .
5. Apply sealant at specified areas on cylinder head before installing gasket and valve cover. See Fig. 84 .
Using NEW seal washers, install valve cover bolts/nuts. Tighten valve cover bolts/nuts to specification in
sequence. See TORQUE SPECIFICATIONS . See Fig. 85 . Install ignition coils and tighten ignition
coil bolts to specification. See TORQUE SPECIFICATIONS . Install No. 2 cylinder head cover.
7. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION
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Fig. 82: Exploded View Of Fuel Rail & Components (ECHO)

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Fig. 83: Disconnecting Fuel Pipe From Fuel Pipe Fitting (ECHO)
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Fig. 84: Identifying Valve Cover Sealant Application Areas (ECHO & Prius)
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Fig. 85: Valve Cover Bolt/Nut Tightening Sequence (ECHO & Prius)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper cap on air cleaner
assembly with air cleaner hose. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See
Fig. 86 .
2. Ensure area around fuel pipe and disconnect fitting is clean. Depress both tabs and pull fuel pipe with
disconnect fitting from fuel pipe fitting. See Fig. 86 .
3. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical
connectors at fuel injectors. Remove clamps and engine wiring harness for access to fuel rail.
from fuel rail.
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2002 Toyota MR2
2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and insulator from
fuel injector.
Installation
1. To install, reverse removal procedure using NEW insulators and "O" rings. Coat "O" ring with gasoline
rail.
fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . Install fuel pipe on
fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel
pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL
SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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Fig. 86: Exploded View Of Fuel Rail & Components (Highlander)

Removal (MR2)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove suspension upper brace
and No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig.
87 .
2. Remove PCV hose and engine wiring harness for access to fuel rail. Note location of electrical connectors
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on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors.
from fuel rail.
2 spacers and 4 grommets from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring
from fuel injector.
Installation
toward valve cover and the 2 spacers and 4 grommets are installed on cylinder head before installing fuel
rail.
cylinder head bolts and suspension upper brace bolts/nuts to specification. See TORQUE
SPECIFICATIONS .
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Fig. 87: Exploded View Of Fuel Rail & Components (MR2)

Removal (Prius)
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1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove air cleaner assembly on
top of engine for access to ignition coils and valve cover. Remove ignition coils, valve cover and gasket.
See Fig. 88 .
2. Ensure area around fuel pipe at end of fuel rail and disconnect fitting is clean. See Fig. 89 .
3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig.
89 .
connectors at fuel injectors.
from fuel rail.
5. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 88 . Remove fuel rail-to-cylinder head
bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head.
Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation
SPECIFICATIONS .
5. Apply sealant at specified areas on cylinder head before installing gasket and valve cover. See Fig. 84 .
Using NEW seal washers, install valve cover bolts/nuts. Tighten valve cover bolts/nuts to specification in
sequence. See TORQUE SPECIFICATIONS . See Fig. 85 . Install ignition coils and tighten ignition
coil bolts to specification. See TORQUE SPECIFICATIONS .
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7. Reinstall air cleaner assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP
OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER
article.
Fig. 88: Exploded View Of Fuel Rail & Components (Prius)

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Fig. 89: Locating Fuel Pipe, Disconnect Fitting & Disconnecting Fuel Pipe From Fuel Pipe Fitting
(Prius)
Removal (RAV4)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect PCV hose from valve
cover for access to fuel rail. See Fig. 90 .
2. Remove air cleaner assembly for access to fuel rail. Note location of electrical connectors on fuel
injectors for installation reference. Disconnect electrical connectors at fuel injectors.
from fuel rail.
2 spacers and 4 grommets from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring
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2002 Toyota MR2
from fuel injector.
Installation
away from valve cover and the 2 spacers and 4 grommets are installed on cylinder head before installing
fuel rail.
4. Ensure electrical connector on each fuel injector is facing away from valve cover. Tighten fuel rail-to-
cylinder head bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check
for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC
PROCEDURES - 4-CYLINDER article.
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Fig. 90: Exploded View Of Fuel Rail & Components (RAV4)

Removal (Tacoma)
1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove air cleaner hose and
intake air connector for access to fuel rail and fuel injectors. See Fig. 91 .
connectors at fuel injectors. Disconnect air hose and fuel return hose from fuel pressure regulator.
3. Remove union bolt with gaskets and disconnect fuel inlet pipe from fuel rail. See Fig. 91 .
from fuel rail.
4. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors. Remove 4 insulators from
spacers on cylinder head. See Fig. 92 . Remove fuel injectors from fuel rail. Remove "O" ring and
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grommet (except Calif. emission vehicles only) from fuel injector. See Fig. 91 .
Installation
1. To install, reverse removal procedure using NEW grommets, "O" rings, insulators and gaskets. Coat "O"
ring with gasoline before installing "O" ring on fuel injector. Coat fuel rail "O" ring contact area with
gasoline before installing fuel injector on fuel rail.
2. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel
injector is facing toward intake manifold and the 4 insulators are installed on spacers on the cylinder
head. See Fig. 92 .
3. With fuel rail installed, loosely install fuel rail-to-cylinder head bolts. Ensure fuel injectors rotate
smoothly. If fuel injectors fail to rotate smoothly, check for improper "O" ring installation and replace
"O" ring on fuel injector.
4. Ensure electrical connector on each fuel injector is facing toward intake manifold. Tighten fuel rail-to-
cylinder head bolts and fuel inlet pipe-to-fuel rail union bolt to specification. See TORQUE
SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION
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Fig. 91: Exploded View Of Fuel Rail & Components (Tacoma)

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Fig. 92: Locating Insulators (Tacoma)

THROTTLE BODY
Removal & Installation (Camry & Camry Solara)
1. Drain cooling system. Remove upper cap on air cleaner assembly with air cleaner hose. Disconnect
coolant hoes, vacuum hose and electrical connector at throttle body. Remove bolts, throttle body and
gasket from intake manifold.
2. Manufacturer does not provide information for servicing of throttle control motor and Throttle Position
(TP) sensor. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is
installed so protrusion (if equipped) aligns with groove on intake manifold. See Fig. 93 . Tighten throttle
body bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
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Fig. 93: Installing Gasket For Throttle Body (Camry, Camry Solara, Highlander & RAV4)
Removal (Celica & Corolla)
1. Drain cooling system. On Celica, remove No. 2 cylinder head cover located on top of engine, above
ignition coils and valve cover. See Fig. 78 . On all models, remove upper cap on air cleaner assembly
with air cleaner hose.
2. Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove
bolts/nuts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control
(IAC) valve and gasket from bottom of throttle body (if necessary).
Installation
1. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is installed with
protrusion facing proper direction. See Fig. 94 and Fig. 95 .
2. Tighten throttle body bolts/nuts to specification. See TORQUE SPECIFICATIONS . On Celica, fill and
bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM. On Corolla,
fill cooling system.
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Fig. 94: Installing Gasket For Throttle Body (Celica)

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Fig. 95: Installing Gasket For Throttle Body (Corolla)

1. Drain cooling system. Remove air cleaner hose that fits between throttle body and air cleaner assembly.
Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove
bolts/nuts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control
(IAC) valve and gasket from bottom throttle body (if necessary).
2. To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to
specification. See TORQUE SPECIFICATIONS . Fill cooling system.
1. Drain cooling system. Remove upper cap on air cleaner assembly with air cleaner hose. Disconnect
control cable(s), coolant hoses, vacuum hose and electrical connectors at throttle body. Remove bolts,
throttle body and gasket from intake manifold.
2. Remove retaining screws, Idle Air Control (IAC) valve and gasket from bottom of throttle body (if
necessary). Remove retaining screws and Throttle Position (TP sensor) from throttle body (if necessary).
Installation
1. To install, reverse removal procedure using NEW gasket. If installing TP sensor, ensure throttle valve on
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throttle body is fully closed. Position TP sensor at 45 degrees to so it aligns with shaft on throttle valve
and install on throttle body. See Fig. 30 . Rotate TP sensor to the right 45 degress and install and tighten
retaining screws.
2. Ensure gasket for throttle body is installed so protrusion aligns with groove on intake manifold. See Fig.
93 . Tighten throttle body bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling
system.
Removal & Installation (MR2 With Standard Type Manual Transaxle)
NOTE: On MR2 there are 2 types of throttle bodies used depending on type of transaxle
used. On models with a standard type manual transaxle, the driver operates the
clutch and shifts the transaxle. On models with sequential manual transaxle, the
transaxle is electronically controlled and the clutch is operated and transaxle is
shifted hydraulically by moving the shift lever forward or backward. Sequential
manual transaxle may be identified by shift lever pattern which consists of "R",
"N", "S" and "+" in place of the conventional type shift lever pattern and no
clutch pedal is used.
1. Drain cooling system. Remove suspension upper brace. Suspension upper brace fits between strut towers
and is bolted to top of each strut tower. Remove air cleaner hose that fits between throttle body and air
cleaner assembly.
bolts/nuts, throttle body and gaskets from intake manifold. Remove retaining screws, Idle Air Control
(IAC) valve and gasket from bottom of throttle body (if necessary).
3. To install, reverse removal procedure using NEW gaskets. Ensure gaskets for throttle body are installed
in proper sequence, as 2 gaskets are used and that protrusion on the one gasket is properly positioned. See
Fig. 96 .
4. Tighten throttle body bolts/nuts and suspension upper brace bolts/nuts to specification. See TORQUE
SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under
COOLING SYSTEM.
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Fig. 96: Installing Gaskets For Throttle Body (MR2)

Removal (MR2 With Sequential Manual Transaxle)
1. Drain cooling system. Remove suspension upper brace. Suspension upper brace fits between strut towers
and is bolted to top of each strut tower. Remove air cleaner hose that fits between throttle body and air
cleaner assembly.
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bolts/nuts, throttle body support bracket near bottom of throttle body, throttle body and gaskets from
intake manifold. Throttle Position (TP) sensor and accelerator pedal position sensor may be serviced.
Throttle control motor is nonserviceable. If throttle control motor is defective, throttle body must be
replaced.
Disassembly
1. If necessary to remove TP sensor, remove TP sensor retaining screws and TP sensor from throttle body.
See Fig. 97 . Use care not to drop or damage TP sensor.
2. If necessary to remove accelerator pedal position sensor, remove retaining bolts and accelerator pedal
position sensor from throttle body. See Fig. 97 . Use care not to drop or damage accelerator pedal
position sensor.
Fig. 97: Locating Accelerator Pedal Position Sensor, Throttle Position Sensor & Throttle Control
Motor (MR2 With Sequential Manual Transaxle)
Reassembly
1. To install accelerator pedal position sensor, install accelerator pedal position sensor on throttle body.
Tighten accelerator pedal position sensor bolts to specification. See TORQUE SPECIFICATIONS .
2. To check accelerator pedal position sensor operation after installation on throttle body, install electrical
connector on accelerator pedal position sensor. Connect Toyota hand-held tester or scan tool to data link
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connector No. 3. See Fig. 98 .

3. Turn ignition on. DO NOT depress accelerator pedal or rotate accelerator pedal position sensor after
turning ignition on. Using hand-held tester or scan tool, check that ACCEL POS#1 (VPA) voltage of the
CURRENT DATA is .3-.9 volt. This is the standard accelerator pedal position sensor voltage. Turn
ignition off. Disconnect electrical connector at accelerator pedal position sensor.
4. To install TP sensor, ensure throttle valve opening on throttle body is about 4 degrees. Install TP sensor
on throttle body so it is at position No. 1 (15 degrees) and loosely install TP sensor retaining screws. See
Fig. 99 . Rotate TP sensor counterclockwise to position No. 2 until it contacts throttle valve and slightly
tighten TP sensor retaining screws. See Fig. 99 .
NOTE: Ensure electrical connector is not installed on accelerator pedal position

sensor when checking TP sensor adjustment.
5. To check TP sensor adjustment after installation on throttle body, install electrical connector on TP
sensor. Ensure electrical connector is NOT installed on accelerator pedal position sensor. Connect Toyota
hand-held tester or scan tool to data link connector No. 3. See Fig. 98 . Turn ignition on. DO NOT
depress accelerator pedal or rotate accelerator pedal position sensor after turning ignition on when
adjusting TP sensor.
6. Using hand-held tester or scan tool, read the throttle valve opening which is displayed as a percentage.
Throttle valve opening may be read by accessing THROTTLE POS under CURRENT DATA on hand-
held tester or scan tool.
7. While reading throttle valve opening, rotate TP sensor clockwise and counterclockwise until throttle
valve opening is 15.2 percent, as this is the center of the standard throttle valve opening of 14.4-16.0
percent. Tighten TP sensor retaining screws to specification. See TORQUE SPECIFICATIONS . When
TP sensor retaining screws are tightened, this may cause the throttle valve opening to change. Ensure
throttle valve opening remains at 15.2 percent after TP sensor retaining screws are tightened. Readjust TP
sensor if necessary.
8. Ensure throttle valve on throttle body is fully closed. Using hand-held tester or scan tool, read the throttle
valve opening again. With throttle valve fully closed, throttle valve opening should be 10-14 percent.
9. If throttle valve opening is not within specification with throttle valve fully closed, repeat steps 5 through
8 until correct throttle valve opening is obtained. Turn ignition off. Remove hand-held tester or scan tool.
Disconnect electrical connector at TP sensor.
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Fig. 98: Locating Data Link Connector No. 3 (MR2 With Sequential Manual Transaxle)
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Fig. 99: Installing Throttle Position Sensor (MR2 With Sequential Manual Transaxle)
Installation
1. To install, reverse removal procedure using NEW gaskets. Ensure gaskets for throttle body are installed
in proper sequence, as 2 gaskets are used and that protrusion on the one gasket is properly positioned. See
Fig. 96 .
2. Tighten throttle body bolts/nuts, throttle body support bracket bolts and suspension upper brace bolts/nuts
to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING
SYSTEM BLEEDING under COOLING SYSTEM.
Removal (Prius)
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Drain cooling system. Remove air cleaner assembly on top of engine for access to throttle body. Disconnect
coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gasket
from intake manifold. Throttle Position (TP) sensor may be serviced. Throttle control motor is nonserviceable.
If throttle control motor is defective, throttle body must be replaced.
1. If necessary to remove TP sensor, remove TP sensor retaining screws and TP sensor from throttle body.
See Fig. 100 . Use care not to drop or damage TP sensor.
2. To install TP sensor, ensure throttle valve opening on throttle body is about 3.5 degrees. Install TP sensor
on throttle body so it is at position No. 1 (15 degrees) and loosely install TP sensor retaining screws. See
Fig. 101 . Rotate TP sensor counterclockwise to position No. 2 until it contacts throttle valve and slightly
tighten TP sensor retaining screws. See Fig. 101 .
NOTE: Ensure electrical connector is not installed on throttle control motor when
checking TP sensor adjustment.
3. To check TP sensor adjustment after installation on throttle body, install electrical connector on TP
sensor. Ensure electrical connector is NOT installed on throttle control motor. Connect Toyota hand-held
tester to data link connector No. 3. See Fig. 102 . Turn ignition on. DO NOT depress accelerator pedal
after turning ignition on when adjusting TP sensor.
4. Using hand-held tester, read the throttle valve opening which is displayed as a percentage. Throttle valve
opening may be read by accessing THROTTLE POS under CURRENT DATA on hand-held tester.
5. While reading throttle valve opening, rotate TP sensor counterclockwise until throttle valve opening is
14.8 percent, as this is the center of the standard throttle valve opening of 14.0-15.6 percent. Tighten TP
sensor retaining screws to specification. See TORQUE SPECIFICATIONS . When TP sensor retaining
screws are tightened, this may cause the throttle valve opening to change. Ensure throttle valve opening
remains at 14.8 percent after TP sensor retaining screws are tightened. Readjust TP sensor if necessary.
6. Ensure throttle valve on throttle body is fully closed. Using hand-held tester, read the throttle valve
opening again. With throttle valve fully closed, throttle valve opening should be 10-14 percent.
7. If throttle valve opening is not within specification with throttle valve fully closed, repeat steps 5 and 6
until correct throttle valve opening is obtained. Turn ignition off. Remove hand-held tester. Disconnect
electrical connector at TP sensor.
Installation
To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to specification. See
TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING
under COOLING SYSTEM.
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Fig. 100: Locating Throttle Position Sensor & Throttle Control Motor (Prius)
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Fig. 101: Installing Throttle Position Sensor (Prius)

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Fig. 102: Locating Data Link Connector No. 3 (Prius)

1. Drain cooling system. Remove air cleaner hose that fits between throttle body and air cleaner assembly.
Disconnect control cable(s), coolant hoses, vacuum hose and electrical connectors at throttle body.
Remove bolts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control
(IAC) valve and gasket from side of throttle body (if necessary).
2. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is installed so
protrusion on gasket aligns with groove on intake manifold. See Fig. 93 . Tighten throttle body bolts to
specification. See TORQUE SPECIFICATIONS . Fill cooling system.
1. Drain cooling system. Remove air cleaner hose and intake air connector. See Fig. 91 .
2. Disconnect control cable(s), PCV hose, air hose, vacuum hoses and electrical connectors at throttle body.
Remove bolts/nuts, throttle body and gasket from intake manifold. Disconnect remaining coolant hoses
from bottom of throttle body. Remove throttle body. Remove screws, Idle Air Control (IAC) valve and
gasket from bottom of throttle body (if necessary).
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3. To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to
specification. See TORQUE SPECIFICATIONS . Fill cooling system
IDLE AIR CONTROL VALVE
Removal & Installation (Celica, Corolla, ECHO, Highlander, MR2 With Standard Type Manual Transaxle, RAV4 &
Tacoma)
Idle Air Control (IAC) valve is located on throttle body. See THROTTLE BODY for servicing of IAC valve.
EMISSION SYSTEMS & SUB-SYSTEMS

CANISTER CLOSED VALVE VACUUM SWITCHING VALVE
Removal & Installation (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma)
Canister Closed Valve Vacuum Switching Valve (CCV VSV) servicing procedure is just primarily an unbolt
and bolt-on procedure. For illustration of CCV VSV, see EMISSION SYSTEMS & SUB-SYSTEMS in
SYSTEM & COMPONENT TESTING - 4-CYLINDER article.
Canister Closed Valve Vacuum Switching Valve (CCV VSV) is located on charcoal canister. See Fig. 103 .
Charcoal canister is located near fuel tank. Remove charcoal canister. Remove bracket for access to CCV VSV
if necessary. See Fig. 103 . Remove screw and CCV VSV with "O" ring from charcoal canister. To install,
reverse removal procedure using NEW "O" ring.
Fig. 103: Locating Canister Closed Valve Vacuum Switching Valve (ECHO)
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2002 Toyota MR2
Removal (Prius)
1. Canister Closed Valve Vacuum Switching Valve (CCV VSV) is located on top of fuel tank. See Fig.
104 . Fuel tank must be removed for access to CCV VSV. Release fuel pressure. See FUEL SYSTEM
PRESSURE RELEASE .
tank.
4. Disconnect necessary hoses and electrical connectors for removal of CCV VSV and fresh air valve.
Remove bolt and separate fresh air valve from CCV VSV. See Fig. 104 . Remove bolts for CCV VSV
and remove CCV VSV along with trap filter and seal packing. Remove bolts and separate CCV VSV
from trap filter.
Installation
To install, reverse removal procedure using NEW seal packing on trap filter and gasket on exhaust pipe at
exhaust manifold. Tighten fuel tank retaining bolts and exhaust pipe-to-exhaust manifold bolts to specification.
See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP
OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
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2002 Toyota MR2
Fig. 104: Locating Canister Closed Valve Vacuum Switching Valve, Fresh Air Valve & Trap Filter
(Prius)
CHARCOAL CANISTER
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2002 Toyota MR2

Charcoal canister is located near fuel tank. For illustration of charcoal canister location, see EMISSION
SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Service
information is not available from manufacturer.
EGR GAS TEMPERATURE SENSOR
Removal & Installation (Tacoma 2.7L 4-Cyl. 3RZ-FE)
See EGR GAS TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES.
EGR VACUUM SWITCHING VALVE
Removal & Installation (Tacoma 2.7L 3RZ-FE)
EGR Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and bolt-on procedure.
EGR VSV is located on bracket, near throttle body and contains Green 2-pin electrical connector with
White/Red and Red/Black wires.
EGR VALVE
Removal & Installation (Tacoma 2.7L 3RZ-FE)
EGR valve servicing procedure is just primarily an unbolt and bolt-on procedure using a NEW gasket. Tighten
EGR valve retaining nuts and EGR pipe bolts/nuts to specification. See TORQUE SPECIFICATIONS .
EVAP VACUUM SWITCHING VALVE

EVAP Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and bolt-on procedure.
See EVAP VACUUM SWITCHING VALVE LOCATION table. For illustration of EVAP VSV location,
see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER
article.
EVAP VACUUM SWITCHING VALVE LOCATION

Camry On Air Cleaner Housing & Contains Blue or Black 2-Pin Electrical Connector With
Black/White & Black/Red Wires
Camry On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical
Helpmelearn
2002 Toyota MR2
Solara Connector With Black/White & Black/Red Wires

Celica On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector
With Green/Orange & Black/White Wires
Corolla On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector
With Blue/Black & Black Wires
ECHO On Bracket At Side Of Air Cleaner Housing & Contains Blue 2-Pin Electrical Connector
With Black/Yellow & White/Green Wires
Highlander On Rear Of Air Cleaner Housing & Contains Blue 2-Pin Electrical Connector With
Black/White & Black/Red Wires
MR2 On Air Intake Hose, Near Air Cleaner Assembly & Contains Blue 2-Pin Electrical
Connector With Black/Red & White Wires
Prius At Passenger's Side Front Corner Of Engine Compartment, Near Air Intake Hose &
Contains Blue 2-Pin Electrical Connector With Red/Blue & Black Wires
RAV4 On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical
Connector With Black/Red & Pink Wires
Tacoma On Bracket Bolted To Inside Of Driver's Side Front Fender Panel & Contains Black 2-Pin
Electrical Connector With White/Green & White/Red Wires
FRESH AIR VALVE
Fresh air valve is located on top of fuel tank. See Fig. 104 . For servicing of fresh air valve, see CANISTER
CLOSED VALVE VACUUM SWITCHING VALVE .
HYDROCARBON ADSORBER CATALYST VACUUM SWITCHING VALVE
Hydrocarbon Adsorber Catalyst (HCAC) Vacuum Switching Valve (VSV) servicing procedure is just primarily
an unbolt and bolt-on procedure. HCAC VSV is located on bracket bolted to timing chain end of engine and
uses a Brown 2-pin electrical connector with Black and Black/White wires. See Fig. 105 .
Helpmelearn
2002 Toyota MR2
Fig. 105: Locating Hydrocarbon Adsorber Catalyst Vacuum Switching Valve (Prius)
PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE
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2002 Toyota MR2
Removal & Installation (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma)
Pressure switching valve Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and
bolt-on procedure. See PRESSURE SWITCHING VALVE VSV LOCATION table. For illustration of
pressure switching valve VSV location, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM &
COMPONENT TESTING - 4-CYLINDER article.
PRESSURE SWITCHING VALVE VSV LOCATION

Camry On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Connector With Violet & Black/Red Wires
Camry On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Solara Connector With White/Red & Red Wires
Celica On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Connector With Green/Orange & Black/White Wires
Corolla On Bracket At Charcoal Canister Near Fuel Tank & Contains Black 2-Pin Electrical
Connector With Red & Black Wires
Highlander On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Connector With White & Green/Yellow Wires
MR2 Below Driver's Side Luggage Compartment, On Bracket At Charcoal Canister Near Fuel
Tank & Contains Blue 2-Pin Electrical Connector With Blue/White & Black/Red Wires
RAV4 On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Connector With Green/Orange & Black/Red Wires
Tacoma On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical
Connector With Green/Black & White/Red Wires
PURGE FLOW SWITCHING VALVE VACUUM SWITCHING VALVE
1. Purge flow switching valve Vacuum Switching Valve (VSV) is located on bracket at charcoal canister on
top of fuel tank and contains Blue 2-pin electrical connector with Black and Black/Red wires. See Fig.
106 . Manufacturer states fuel tank must be removed for access to purge flow switching valve VSV.
Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
tank.
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2002 Toyota MR2
4. Disconnect necessary hoses and electrical connector for removal of purge flow switching valve VSV.
Remove retaining bolts and purge flow switching valve. To install, reverse removal procedure using
NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel tank retaining bolts and exhaust pipe-to-
exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and
check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC
Fig. 106: Locating Purge Flow Switching Valve Vacuum Switching Valve (Prius)
TRAP FILTER
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2002 Toyota MR2
Trap filter is located on top of fuel tank. See Fig. 104 . For servicing of trap filter, see CANISTER CLOSED
VALVE VACUUM SWITCHING VALVE .
VAPOR PRESSURE SENSOR
Removal & Installation (Camry & Highlander)
Information is not available from manufacturer.
Removal & Installation (Camry Solara & Corolla)
Service information is not available from manufacturer. On Camry Solara, vapor pressure sensor is located on
charcoal canister near fuel tank and contains Black 3-pin electrical connector with Blue/Red, Brown and Yellow
wires. On Corolla, vapor pressure sensor is located on charcoal canister near fuel tank and contains Black 3-pin
electrical connector with Brown, Blue and Yellow wires. For illustration of vapor pressure sensor location, see
EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER
article.
Removal & Installation (Celica & ECHO)
Vapor pressure sensor is located on top of fuel pump. See Fig. 54 and Fig. 61 . Remove rear seat cushion and
cover plate on floor panel for access to vapor pressure sensor. Disconnect electrical connector at vapor pressure
sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip and vapor pressure sensor. To
install reverse removal procedure.
1. Vapor pressure sensor is located on top of fuel pump. See Fig. 65 . Apply tape to end of screwdriver to
prevent scratching interior components. Using screwdriver, remove door opening scuff plates, lower trim
covers and quarter trim covers. See Fig. 4 . Remove luggage compartment lids, luggage compartment
boxes and cover plate on floor panel for access to vapor pressure sensor.
2. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Disconnect electrical
connector at vapor pressure sensor. Ensure area around vapor pressure sensor is clean. Remove retaining
clip located just below the vapor pressure sensor. Remove vapor pressure sensor. To install reverse
removal procedure.
Removal (Prius)
Helpmelearn
2002 Toyota MR2
1. Vapor pressure sensor is located at top corner of fuel tank. See Fig. 107 . Manufacturer states fuel tank
must be removed for access to vapor pressure sensor. Release fuel pressure. See FUEL SYSTEM
PRESSURE RELEASE .
tank.
4. Disconnect electrical connector at vapor pressure sensor. Ensure area around vapor pressure sensor is
clean. Remove retaining clip and vapor pressure sensor from mounting flange. Use care not to scratch
vapor pressure sensor or vapor pressure sensor sealing surfaces. DO NOT use tools to remove vapor
pressure sensor. Vapor pressure sensor should be removed from mounting flange by-hand.
Installation
1. If mounting flange was removed from fuel tank, using NEW seal packing, install mounting flange in fuel
tank. Ensure vapor pressure sensor and vapor pressure sensor sealing surfaces are clean and no scratches
exist. Install vapor pressure sensor. Ensure vapor pressure sensor is fully seated in mounting flange.
2. Install retaining clip. Ensure retaining clip is fully seated in rim of vapor pressure sensor. Check that
vapor pressure sensor cannot be pulled from mounting flange. To install remaining components, reverse
removal procedure using NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel tank retaining
bolts and exhaust pipe-to-exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS .
Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS
Helpmelearn
2002 Toyota MR2
Fig. 107: Locating Vapor Pressure Sensor (Prius)

Vapor pressure sensor is located on top of fuel pump. See Fig. 69 . Remove driver's side rear seat and cover
plate on floor panel for access to vapor pressure sensor. Disconnect electrical connector at vapor pressure
sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip and vapor pressure sensor. To
install reverse removal procedure.
Vapor pressure sensor is located on top of fuel pump. See Fig. 73 . Servicing information is not available from
manufacturer.
Helpmelearn
2002 Toyota MR2
VARIABLE VALVE LIFT SYSTEM

VARIABLE VALVE LIFT OIL CONTROL VALVE
NOTE: Variable Valve Lift (VVL) oil control valve may also be referred to as VVL Oil
Control Valve (OCV) or camshaft timing oil control valve (VVL) and is used with
VVL system. VVL system may also be referred to as Variable Valve Timing Lift
Intelligent (VVTL-I or VVTL-i) system.
Removal & Installation (Celica 1.8L 2ZZ-GE)
1. Variable Valve Lift (VVL) oil control valve is located at intake manifold side of cylinder head, near
flywheel end of engine. See Fig. 110 . Remove No. 2 cylinder head cover located on top of engine, above
ignition coils and valve cover, front fender apron seal and upper radiator support seal. See Fig. 12 .
2. Disconnect electrical connector at VVL oil control valve. Remove retaining bolt and VVL oil control
valve with "O" ring from housing on rear of cylinder head. To install, reverse removal procedure using
NEW "O" ring. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .
VARIABLE VALVE TIMING SYSTEM

VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE
NOTE: Variable Valve Timing (VVT) camshaft timing oil control valve may also be
referred to as oil control valve for VVT, VVT Oil Control Valve (OCV) or camshaft
timing oil control valve VVT.

1. Variable Valve Timing (VVT) camshaft timing oil control valve is located at intake manifold side of
cylinder head, near timing chain end of engine. See Fig. 108 -Fig. 113 . Remove No. 2 cylinder head
cover (if equipped) which is located on top of engine, above ignition coils and valve cover for access to
VVT camshaft timing oil control valve.
2. On Celica, remove front fender apron seal, upper radiator support seal, generator and ventilation tube for
access to VVT camshaft timing oil control valve. See Fig. 12 . On ECHO, remove generator bracket for
access to VVT camshaft timing oil control valve. On MR2, remove suspension upper brace. Suspension
upper brace fits between strut towers and is bolted to top of each strut tower. On Prius, remove air cleaner
assembly on top of engine for access to VVT camshaft timing oil control valve.
3. On all models, disconnect electrical connector at VVT camshaft timing oil control valve. Remove
retaining bolt and VVT camshaft timing oil control valve with "O" ring from cylinder head. To install,
reverse removal procedure using NEW "O" ring. Tighten retaining bolt to specification (if available). See
Helpmelearn
2002 Toyota MR2
Fig. 108: Locating Typical Variable Valve Timing Camshaft Timing Oil Control Valve (Camry,
Camry Solara, Highlander & RAV4)
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2002 Toyota MR2
Fig. 109: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (Celica 1.8L 1ZZ-
FE)
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2002 Toyota MR2
Fig. 110: Locating Variable Valve Lift Oil Control Valve & Variable Valve Timing Camshaft
Timing Oil Control Valve (Celica 1.8L 2ZZ-GE)
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2002 Toyota MR2
Fig. 111: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (Corolla)
Helpmelearn
2002 Toyota MR2
Fig. 112: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (ECHO)
Helpmelearn
2002 Toyota MR2
Fig. 113: Locating Typical Variable Valve Timing Camshaft Timing Oil Control Valve (MR2 &
Prius)
VARIABLE VALVE TIMING SENSOR
NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft
position sensor.
Helpmelearn
2002 Toyota MR2
For VVT sensor servicing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (CAMRY)
Application Ft. Lbs. (N.m)
A/F Sensor (1)
ECT Sensor 15 (20)

Fuel Rail-To-Cylinder Head Bolt 15 (20)
Heated Oxygen Sensor 32 (43)
Intake Manifold Bolt/Nut 22 (30)
Knock Sensor 29 (39)
Power Steering Pressure Switch 15 (20)
Throttle Body Bolt 22 (30)
Vehicle Speed Sensor Retaining Bolt (1)
INCH Lbs. (N.m)

Camshaft Position Sensor Bolt 80 (9.0)
Control Lever Nut 112 (12.7)
Crankshaft Position Sensor Bolt 80 (9.0)
Fuel Pump Retaining Plate-To-Fuel Tank Bolt 31 (3.5)
Ignition Coil Bolt 80 (9.0)
PNP Switch Retaining Bolt 48 (5.4)
PNP Switch Retaining Nut 61 (6.9)
VVT Camshaft Timing Oil Control Valve Retaining Bolt 80 (9.0)
(1) Information is not available from manufacturer.
TORQUE SPECIFICATIONS (CAMRY SOLARA)

A/F Sensor 32 (43)
ECT Sensor 15 (20)
INCH Lbs. (N.m)
Accelerator Pedal Bracket Retaining Bolt 80 (9.0)
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2002 Toyota MR2

Fuel Pressure Regulator Retaining Screw 18 (2.0)
Fuel Pump Protector Cover Bolt 35 (4.0)
Round Fuel Filter Retaining Screw 18 (2.0)
Vehicle Speed Sensor Retaining Bolt 49 (5.5)
TORQUE SPECIFICATIONS (CELICA)

ECT Sensor (1)
Fuel Rail-To-Cylinder Head Bolt

1.8L 1ZZ-FE 14 (19)
1.8L 2ZZ-GE 21 (29)
Intake Manifold Bolt/Nut
1.8L 1ZZ-FE 14 (19)
1.8L 2ZZ-GE (2)
Intake Manifold Support Bolt/Nut

1.8L 2ZZ-GE 18 (24)
Knock Sensor
1.8L 1ZZ-FE 29 (39)
Knock Sensor Retaining Nut
1.8L 2ZZ-GE 15 (20)
Throttle Body Bolt/Nut
1.8L 1ZZ-FE 15 (20)
1.8L 2ZZ-GE 16 (22)
INCH Lbs. (N.m)
Fuel Pipe Clamp-To-Cylinder Head Bolt 80 (9.0)
Helpmelearn
2002 Toyota MR2
Vehicle Speed Sensor Retaining Bolt

A/T 49 (5.5)
M/T 97 (11.0)
VVL Oil Control Valve Retaining Bolt
1.8L 2ZZ-GE 75 (8.5)
VVT Camshaft Timing Oil Control Valve Retaining Bolt
1.8L 1ZZ-FE 66 (7.5)
1.8L 2ZZ-GE 75 (8.5)
(2) Tighten bolts/nuts "A" to 20 ft. lbs. (27 N.m) and bolt "B" to 34 ft. lbs. (46 N.m). See Fig. 14 .
TORQUE SPECIFICATIONS (COROLLA)

ECT Sensor (1)

Heated Oxygen Sensor-To-Exhaust Pipe Behind Catalytic Converter 32 (43)
Heated Oxygen Sensor-To-Exhaust Pipe Retaining Nut 32 (43)
Intake Manifold Support Bolt 14 (19)
Throttle Body Bolt/Nut 15 (20)
A/T 12 (16)
M/T (2)
INCH Lbs. (N.m)

VVT Camshaft Timing Oil Control Valve Retaining Bolt (1)

(2) Tighten retaining bolt to 97 INCH lbs. (11.0 N.m).
TORQUE SPECIFICATIONS (ECHO)

Helpmelearn
2002 Toyota MR2

ECT Sensor (1)

Power Steering Pressure Sensor 15 (20)
INCH Lbs. (N.m)
Valve Cover Bolt/Nut (2) 89 (10.1)
A/T 62 (7.0)
M/T 97 (11.0)
(2) Tighten to specification in sequence. See Fig. 85 .
TORQUE SPECIFICATIONS (HIGHLANDER)

A/F Sensor (1)
ECT Sensor 15 (20)

Heated Oxygen Sensor (1)

INCH Lbs. (N.m)
Helpmelearn
2002 Toyota MR2
Fuel Pump Retaining Plate-To-Fuel Tank Bolt (1)

TORQUE SPECIFICATIONS (MR2)

A/C Compressor Bolt 18 (24)
ECT Sensor 15 (20)
Suspension Upper Brace Bolt 54 (73)
Suspension Upper Brace Nut 59 (80)
Throttle Body Support Bracket Bolt (1) 36 (49)
INCH Lbs. (N.m)
Accelerator Pedal Position Sensor Bolt (1) 48 (5.4)
Fuel Pump Protector Cover Bolt 30 (3.4)
TP Sensor Retaining Screw (1) 18 (2.0)
(1) Applies only to models with sequential manual transaxle.
TORQUE SPECIFICATIONS (PRIUS)

Accelerator Pedal Retaining Bolt 12 (16)
Exhaust Pipe-To-Exhaust Manifold Bolt 46 (62)
Fuel Tank Retaining Bolt 29 (39)
Helpmelearn
2002 Toyota MR2

INCH Lbs. (N.m)
TP Sensor Retaining Screw 15 (1.7)
Valve Cover Bolt/Nut (1) 89 (10.1)
(1) Tighten to specification in sequence. See Fig. 85 .
TORQUE SPECIFICATIONS (RAV4)

A/F Sensor 32 (43)
ECT Sensor 15 (20)
A/T (1)
M/T 13 (18)
INCH Lbs. (N.m)
(1) Tighten retaining bolt to 49 INCH lbs. (5.5 N.m).
TORQUE SPECIFICATIONS (TACOMA)

A/F Sensor Retaining Nut 15 (20)
ECT Sensor 15 (20)
EGR Pipe Bolt/Nut
Helpmelearn
2002 Toyota MR2
2.7L 3RZ-FE 14 (19)

EGR Valve Retaining Nut
2.7L 3RZ-FE 14 (19)
Fuel Filter Mounting Bolt 15 (20)
Fuel Inlet Pipe-To-Fuel Rail Union Bolt 22 (30)
Generator Mounting Bracket-To-Timing Chain Cover Bolt
Large Bolt 55 (75)
Small Bolt 13 (18)
Heated Oxygen Sensor-To-Exhaust Pipe Retaining Nut 15 (20)
Starter Bolt 29 (39)
Transmission Oil Cooler Line Elbow 25 (34)
Transmission Oil Cooler Line Nut 25 (34)
Vehicle Speed Sensor Retaining Bolt (1)
INCH Lbs. (N.m)

Airflow Meter Retaining Nut 75 (8.5)
Fuel Pressure Regulator Bolt 78 (8.8)
Fuel Pump Mounting Bracket-To-Fuel Tank Bolt 31 (3.5)
PNP Switch Retaining Bolt
2.4L 2RZ-FE 48 (5.4)
2.7L 3RZ-FE 115 (13.0)
PNP Switch Retaining Nut
2.4L 2RZ-FE 35 (4.0)
2.7L 3RZ-FE 61 (6.9)
(1) On A/T models, tighten retaining bolt to 12 ft. lbs. (16 N.m) on 2WD models or 102 INCH lbs. (11.5
N.m) on 4WD models. On M/T models, tighten retaining bolt to 115 INCH. lbs. (13.0 N.m) on 2WD
models or 102 INCH lbs. (11.5 N.m) on 4WD models.
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2002 Toyota MR2

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2002 ENGINE PERFORMANCE

Removal, Overhaul & Installation - 4-Cylinder

WARNING: On Prius, read service precautions before proceeding with service

CAUTION: When battery is disconnected, vehicle computer and memory systems

WARNING: When performing any inspection or service procedure on this vehicle,

The following service precautions must be followed:

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius)

NOTE: Following procedure should be performed if battery is disconnected and

NOTE: Following procedure should be performed if battery is disconnected and

AIR INDUCTION SYSTEMS

Removal & Installation (Celica)

COMPUTERIZED ENGINE CONTROLS

ENGINE CONTROL MODULE

Removal & Installation (Corolla)

Removal & Installation (MR2)

Removal & Installation (Prius)

Fig. 3: Locating Engine Control Module & Components (Corolla)

Fig. 4: Locating Engine Control Module & Components (MR2)

ENGINE SENSORS & SWITCHES

Removal & Installation (Camry)

Removal & Installation (Camry Solara)

Fig. 5: Locating Accelerator Pedal Position Sensor (Camry Solara)

Removal & Installation (MR2 With Sequential Manual Transaxle)

Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure.

Fig. 6: Locating Accelerator Pedal Position Sensor (Prius)

A/C COMPRESSOR LOCK SENSOR

A/C EVAPORATOR TEMPERATURE SENSOR

Removal & Installation (Camry, Camry Solara, Highlander & RAV4)

Removal & Installation (Tacoma)

NOTE: Airflow meter may be referred to as Mass Airflow (MAF) meter.

WARNING: On Prius, read service precautions before proceeding with service

Removal & Installation (Tacoma)

NOTE: Brakelight switch may also be referred to as stoplight switch.

Removal & Installation (Camry)

WARNING: On Prius, read service precautions before proceeding with service

Removal & Installation (Celica)

Fig. 7: Measuring Clearance At Brakelight Switch (Celica)

Removal & Installation (Tacoma)

CAMSHAFT POSITION SENSOR

Removal & Installation

See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.

CRANKSHAFT POSITION SENSOR

Removal & Installation

See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS.

EGR GAS TEMPERATURE SENSOR

Removal & Installation (Tacoma 2.7L 4-Cyl. 3RZ-FE)

ENGINE COOLANT TEMPERATURE SENSOR

Removal & Installation (Celica)

Removal & Installation (ECHO)

Removal & Installation (MR2)

ENGINE COOLANT TEMPERATURE SENSOR LOCATION

Removal & Installation (Prius)

WARNING: Service procedure should only be performed by authorized dealer.

HEATED OXYGEN SENSOR

Removal & Installation (All Models)