Toyota Camry 1983-1996 Repair Guide

Diagnosis and Testing

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ON VEHICLE INSPECTION SPARK TEST



2S-ELC, 3S-FE and 5S-FE Engines

See Figures 1, 2, 3 and 4

DO NOT use this test for the 1994-95 5S-FE California or any 1996 models.

  1. Tag and disconnect the spark plug wires from the spark plugs.
  2.  
  3. Remove the spark plugs and install the spark plug wires to each spark plug.
  4.  
  5. Ground (do not hold spark plug) the spark plug; check if spark occurs while engine is being cranked.
  6.  

Crank the engine for no more than 2 seconds at a time to prevent flooding the engine with gasoline.

  1. If good spark does not occur, follow the correct diagnostic flow chart (engine and year) and necessary service procedures.
  2.  



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Fig. Fig. 1: Spark test chart-1983-90 2S-ELC and 3S-FE engines



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Fig. Fig. 2: Spark test chart-1991 3S-FE engine



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Fig. Fig. 3: Spark test chart-1992-93 5S-FE engine



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Fig. Fig. 4: Spark test chart-1994-95 US 5S-FE engine

2VZ-FE, 3VZ-FE and 5S-FE Engines

See Figures 5, 6, 7 and 8

Use this test for the 1994-95 5S-FE California and 1996 5S-FE models.

  1. Disconnect the coil wire from distributor. Hold the coil wire end about 1 / 2 inch (12.5mm) from a good body ground; check if spark occurs while engine is being cranked.
  2.  

Crank the engine for no more than 2 seconds at a time to prevent flooding the engine with gasoline.

  1. If good spark does not occur, follow the correct diagnostic flow chart (engine and year) and necessary service procedures.
  2.  



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Fig. Fig. 5: Spark test chart-2VZ-FE engine



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Fig. Fig. 6: Spark test chart-3VZ-FE engine



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Fig. Fig. 7: Spark test chart-1994-95 California 5S-FE engine



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Fig. Fig. 8: Spark test chart-1996 5S-FE engine

SIGNAL GENERATOR AIR-GAP INSPECTION



2S-ELC and 3S-FE Engines

See Figures 9, 10 and 11

The air gap in the distributor should be check periodically. Distributor air gap may only be checked and can only be adjusted by component replacement.

Remove the hold-down bolts from the top of the distributor gap.

  1. Remove the distributor cap from the housing without disconnecting the ignition wires.
  2.  
  3. Pull the ignition rotor (not the signal rotor) straight up and remove it. If the contacts are worn, pitted or burnt, replace it. Do not file the contacts.
  4.  
  5. Remove the dust shield.
  6.  
  7. Turn the crankshaft (a socket wrench on the front pulley bolt may be used to do this) until a tooth on the signal rotor aligns with the projection of the pick-up coil.
  8.  
  9. Using a non-ferrous feeler gauge (brass, copper or plastic) measure the gap between the signal rotor and the pick-up coil projection. DO NOT USE AND ORDINARY METAL FEELER GAUGE! The gauge should just touch either side of the gap (snug fit). The acceptable range for the air gap is 0.008-0.016 inch (0.20-0.40mm).
  10.  



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Fig. Fig. 9: Measure the air gap in this position with a non-ferrous feeler gauge-Canadian 2S-ELC and 3S-FE engines



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Fig. Fig. 10: Measure the air gap in this position with a non-ferrous feeler gauge-U.S.2S-ELC and 1987-89 3S-FE engines



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Fig. Fig. 11: Measure the air gap in this position with a non-ferrous feeler gauge-1990-91 3S-FE engine

  1. On all US models, if the air gap is not within specifications, replace the IIA distributor housing. On Canadian models, replace the breaker plate and pick-up coil assembly.
  2.  
  3. Check to make sure the housing gasket is in position on the housing.
  4.  
  5. Install the rotor and dust shield.
  6.  
  7. Install the distributor cap with attached wiring. Attach the cap to the housing and tighten the hold-down bolts.
  8.  

2VZ-FE and 3VZ-FE Engines

See Figures 12 and 13

  1. Remove the distributor cap.
  2.  
  3. Use SST 09240-00020 or equivalent wire gauge set on G1 and G2 and a non-ferrous feeler gauge (use paper, brass or plastic gauge) on NE pick-up. Measure the air gap between the signal rotor and pick-up coil projection. Measure the gap between the signal rotor and the pick-up coil projection, by using). The acceptable range for the air gap is:

    2VZ-FE engines-0.008-0.016 inch (0.20-0.40mm)
     
    3VZ-FE engines-0.008-0.020 inch (0.20-0.50mm).
     

  4.  



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Fig. Fig. 12: Measure the air gap in these locations-2VZ-FE engine



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Fig. Fig. 13: Measure the air gap in these locations-3VZ-FE engine

  1. If the air gap is not within specifications, replace the IIA distributor housing.
  2.  

5S-FE Engine
1992-96 EXCEPT 1994-95 CALIFORNIA

See Figures 14 and 15

  1. Remove the distributor cap.
  2.  
  3. Measure the gap between the signal rotor and the pick-up coil projection, by using a non-ferrous feeler gauge (use paper, brass or plastic gauge). Or use SST 09240-00020 wire gauge set.
  4.  



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Fig. Fig. 14: Measuring the air gap-1992-96 except 1994-95 California 5S-FE engine



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Fig. Fig. 15: Measuring the air gap-1996 5S-FE engine

  1. The air gap should be 0.008-0.0016 inch (0.2-0.4mm).
  2.  
  3. If the air gap is not correct, replace the distributor housing.
  4.  

1994-95 CALIFORNIA

See Figure 16

  1. Remove the distributor cap.
  2.  
  3. Use SST 09240-00020 or equivalent wire gauge set on G1 and G2 and a feeler gauge on NE pick-up. Measure the air gap between the signal rotor and pick-up coil projection.
  4.  
  5. The air gap should read 0.008-0.020 inch (0.20-0.50mm).
  6.  



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Fig. Fig. 16: Measuring the air gap-1994-95 California 5S-FE engine

  1. If the air gap is not within specifications, replace the distributor housing assembly.
  2.  

SIGNAL GENERATOR (PICK-UP) RESISTANCE TEST



3S-FE Engine

See Figure 17

  1. Using a suitable ohmmeter, check the resistance cold between terminals G1 and G- and NE and G- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be 140-180 ohms (1987-90 and 205-255 ohms (1991)
  4.  
  5. If the resistance is not correct, replace the distributor housing assembly.
  6.  



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Fig. Fig. 17: Terminal identification of the pick-up coil-3S-FE engine

5S-FE Engine
1992-93 MODELS

See Figure 18

  1. Using a suitable ohmmeter, check the resistance cold between terminals G and G- and NE and NE- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be 185-265 ohms at G and G-, and 370-530 ohms at NE and NE-.
  4.  
  5. If the resistance is not correct, replace the distributor housing.
  6.  



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Fig. Fig. 18: Measuring the resistance between terminals of the pick-up coil-1992-93 5S-FE engine

1994-95 MODELS EXCEPT CALIFORNIA

See Figure 19

  1. Using a suitable ohmmeter, check the resistance cold between terminals G and G- and NE and NE- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be 185-275 ohms at G and G-, and 370-550 ohms at NE and NE-.
  4.  
  5. If the resistance is not correct, replace the distributor housing.
  6.  



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Fig. Fig. 19: Measuring the resistance between terminals of the pick-up coil-1994-95 5S-FE engine except California

1994-95 CALIFORNIA MODELS

See Figure 20

  1. Using a suitable ohmmeter, check the resistance cold between terminals G1 and G-, G2 and G- then NE and G- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be:

    G1 and G--125-200 ohms
     
    G2 and G--125-200 ohms
     
    NE and G--155-250 ohms
     

  4.  
  5. If the resistance is not correct, replace the distributor housing.
  6.  



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Fig. Fig. 20: Measuring the resistance between terminals of the pick-up coil-1994-95 5S-FE engine California models

1996 MODELS

See Figure 21

  1. Using a suitable ohmmeter, check the resistance of the signal generator.
  2.  
  3. Pick up coil resistance should be 135-220 ohms.
  4.  
  5. If the resistance is not correct, replace the distributor housing assembly.
  6.  



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Fig. Fig. 21: Measuring the resistance between terminals of the pick-up coil-1996 5S-FE engine

2VZ-FE Engine

See Figure 22

  1. Using a suitable ohmmeter, check the resistance cold between terminals G1 and G-, G2 and G- then NE and G- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be:

    G1 and G--140-180 ohms
     
    G2 and G--140-180 ohms
     
    NE and G--140-180 ohms
     

  4.  
  5. If the resistance is not correct, replace the distributor housing.
  6.  



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Fig. Fig. 22: Terminal identification of the pick-up coil-2VZ-FE engine

3VZ-FE Engine

See Figure 23

  1. Using a suitable ohmmeter, check the resistance cold between terminals G1 and G-, G2 and G- then NE and G- of the signal generator.
  2.  
  3. The signal generator (pick-up coil) resistance cold should be:

    G1 and G--125-190 ohms
     
    G2 and G--125-190 ohms
     
    NE and G--155-240 ohms
     

  4.  
  5. If the resistance is not correct, replace the distributor housing.
  6.  



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Fig. Fig. 23: Terminal identification and testing of the pick-up coil-3VZ-FE engine

VACUUM ADVANCE



1983-85 and Canadian Models

See Figure 24

Inspect the vacuum advance by disconnecting the vacuum hose and attaching a vacuum pump to the diaphragms. Apply vacuum and check that the advancer moves freely. It does not respond to the test, replace the advancer.



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Fig. Fig. 24: Testing the vacuum advance-1983-85 models and Canadian models

GOVERNOR ADVANCE



1983-85 and Canadian Models

See Figure 25

Inspect the governor advance by turning the rotor shaft counterclockwise, then release it and check that the rotor turns slightly clockwise. Check that the rotor shaft is not excessively loose.



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Fig. Fig. 25: Testing the governor advance-1983-85 models and Canadian models

 
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