Toyota Camry 1997–2001 Repair Manual Set (P/N RM654U1/RM654U2)

The repair chapters provide the working procedures, while the wiring manual, change documentation, and bulletins support system identification and fault diagnosis. Use the model code, engine, transaxle, production source, and installed system to select the correct procedure.

Coverage limits: The core repair content is for the 1999 Camry; the other model years are supported by change documentation and selected repair extracts rather than a complete repair manual for each year. Other Toyota models appear in cross-model bulletins and reference tables, without complete repair-manual coverage.

The CNG features material explains construction and operation. The dedicated CNG repair supplement RM683U and wiring manual EWD371U are referenced but are not included.

Searchable PDFs and Limited Bookmark Navigation

Search, navigation, and wiring detail: Text search is available in all 41 PDFs. Embedded bookmarks are present in the five New Car Features files and the collision manual; the A/C chapter has a single bookmark. The remaining files have no embedded bookmarks. Dense wiring pages require zooming to read small connector numbers and wire codes.

The ZIP contains 41 printable PDFs totaling 4,349 pages, including front matter, section dividers, blank pages, and 13 supplementary information pages in the maintenance guide. The repair material is split across 25 PDFs; the other 16 PDFs contain the supporting publications and extracts listed above.

Engine, Transaxle, Electrical, and Collision Coverage

The following selected content highlights outline the main workshop areas rather than reproduce the full contents. Other topics include starter-motor and alternator overhaul.

• Engine repair: Step-by-step procedures for timing-belt service, valve-clearance adjustment, cylinder-head overhaul, engine removal, and cylinder-block inspection for the 5S-FE and 1MZ-FE.

• Transaxle and clutch service: A140E/A541E internal overhaul, S51/E153 manual-transaxle repair, clutch service, and automatic-transaxle road, stall, hydraulic-pressure, and manual-shift testing.

• Brakes and chassis: Denso and Bosch ABS, ABS/TRAC, hydraulic bleeding, wheel alignment, hubs, drive shafts, struts, control arms, and power-steering pump and rack repair.

• Electrical diagnosis: OBD II fault tracing, SRS, immobilizer, theft deterrent, wireless locks, and cruise control, with relay locations, wiring routes, connector views, and ground-point diagrams.

• Cooling, fuel, and ignition: Water-pump and radiator service, lubrication-system work, emission-control checks, ignition testing, and SFI component inspection.

• A/C, body, and collision repair: Refrigerant recovery, evacuation, charging, leak checks, compressor and HVAC service, doors, glass, roof, seats, belts, panel replacement, and body measurements.

The repair sections are suited to experienced technicians who can use electrical test equipment, diagnostic tools, and the specified Toyota SSTs; the introduction presents the procedures for an experienced technician.

Fault Isolation and Field-Service Information

The diagnostic section explains normal and check modes, freeze-frame data, two-trip detection logic, fail-safe operation, symptom confirmation, terminal checks, and circuit inspection. These procedures connect a reported symptom or trouble code with tests of the relevant sensors, actuators, wiring, and control unit.

The bulletin collection adds field information on EVAP and air-fuel-ratio sensor codes, single-cylinder misfires, brake noise, sliding-roof diagnosis, door-glass displacement, mirror wind noise, and trunk leaks. Bulletin-specific VIN ranges and production changes distinguish the affected configurations.

Transaxle Internals and Factory Reference Data

The automatic-transaxle material extends to oil pumps, clutch packs, brakes, planetary assemblies, overdrive units, valve bodies, and differentials, with inspection, reassembly, and final checks.

Service Specifications and Preparation consolidate torque tables, fluid capacities, pressure-test data, wear limits, alignment values, electrical test specifications, refrigerant information, and tool requirements. Identified SSTs include valve-clearance set 09248-55040, automatic-transmission tool set 09350-32014, transmission oil-pressure gauge set 09992-00095, and A/C service tool set 07110-58060.

Model Changes and CNG System Construction

The New Car Features documents distinguish CE, LE, and XLE grades, U.S. and Canadian configurations, and TMC- and TMMK-built vehicles. They describe emissions, SRS, immobilizer, brake, body, and mid-cycle changes.

For SXV23L-AEPNCA, the CNG material describes the combustion chamber and pistons, valve mechanism, two-way exhaust control, pressure regulator, shutoff valves, delivery pipe, gaseous injectors, oxygen and air-fuel-ratio sensor control, ECM functions, and revised fuel-tank and rear-floor construction.

Drawings and Repair Precautions

Illustrations include the 5S-FNE fuel-system layout and pressure-regulator section, two-way exhaust control diagram, automatic-transaxle exploded views, ABS/TRAC system diagrams, Overall Electrical Wiring Diagram, and collision cut-location and three-dimensional measuring drawings.

The engine chapters warn that twisting, reversing, contaminating, or using the timing belt to hold a camshaft pulley can damage the belt. The 5S-FE cylinder-head section also explains how uneven camshaft removal can damage the head’s thrust area and cause camshaft seizure or breakage.

The SRS material addresses diagnostic-code preservation before battery disconnection and the backup-power delay associated with unintended deployment. Collision repair is limited to the illustrated cut-and-join locations to preserve body strength; painting is outside that manual’s scope.

A Preview of Cold Valve-Clearance Specifications

For the 5S-FE, the valve-clearance inspection section specifies 0.19–0.29 mm at the intake valves and 0.28–0.38 mm at the exhaust valves, measured with the engine cold. Adjusting-shim selection charts accompany the inspection and adjustment procedures.

The corresponding cold clearances for the 1MZ-FE are 0.15–0.25 mm intake and 0.25–0.35 mm exhaust. Its separate charts support shim selection for that engine.

Safety note: SRS, CNG and gasoline fuel systems, refrigerant, brake hydraulics, welding, and work under a raised vehicle require the specified isolation, recovery, ventilation, support equipment, and trained handling.