Toyota - Camry - Workshop Manual - 1999 - 1999

DI–1 DIAGNOSTICS – ENGINE (5S–FE) ENGINE (5S–FE) DI00F–08 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 2 Customer Problem Analysis P. DI–2 Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3 P. DI–3 If the display indicates a communication fault in the tool, inspect DLC3 P. DI–3 3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P. DI–3 4 Clear DTC and Freezed Frame Data P. DI–3 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI–3 7 Problem Symptom Confirmation If the engine does not start perform steps 10 and 12 first Malfunction occurs. 9 10 DTC Check P. DI–3 Normal Basic Inspection P. DI–3 12 14 8 Malfunction code. 11 DTC Chart P. DI–16 Problem Symptoms Table P. DI–28 Parts Inspection 15 Malfunction does not occur. Symptom Simulation P. IN–21 13 Circuit Inspection P. DI–29 Check for Intermittent Problems P. DI–3 Identification of Problem 16 Adjustment, Repair 17 Confirmation Test End Author: Date: 236 DI–2 DIAGNOSTICS – ENGINE (5S–FE) DI00G–05 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveaability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Back fire Other No complete combustion High ( rpm) Low ( Muffler explosion (after–fire) rpm) Surging Others Datas Problem Occurred Constant Other Condition When Problem Occurs Problem Frequency Sometimes ( times per day/month) Weather Fine Cloudy Rainy Snowy Outdoor Temperature Hot Warm Cool Cold (approx. Place Highway Rough road Engine Temperature Engine Operation Cold Suburbs Other Warming up Inner city After warming up Just after starting ( Starting Driving Constant speed A/C switch ON/OFF Other Condition of MIL Normal Mode (Precheck) Once only Various/Other °F/ °C) Uphill Downhill Any temperature min.) Idling Acceleration Other Racing Deceleration Remains on Sometimes light up Does not light up Normal Malfunction code(s) (code Freezed frame data ( ) Malfunction code(s) (code Freezed frame data ( ) ) DTC Inspection Check Mode Normal Author: ) Date: 237 DI–3 DIAGNOSTICS – ENGINE (5S–FE) DI00H–08 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand– held tester, and read off various data output from the vehicle’s ECM.
FI0534 TOYOTA Hand–Held Tester DLC3 S05331 OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system / components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory. (See page DI–16) If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automarially but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect the OBD II scan tool or TOYOTA hand–held tester to Data Link Connector 3 (DLC3) on the vehicle. The OBD II scan tool or TOYOTA hand–held tester also enables you to erase the DTCs and check freezed frame data and various forms of engine data (For operating instructions, see the OBD II scan tool’s instruction book.) DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits. (See DTC chart on page DI–16) Author: Date: 238 DI–4 DIAGNOSTICS – ENGINE (5S–FE)
The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTCs use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily. (TOYOTA hand–held tester only) (See page DI–3)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory.(1st trip) If the same malfunction is detected again during the second drive test, this second detection causes the MIL to light up.(2nd trip) (However, the IG switch must be turned OFF between the 1st trip and the 2nd trip.)
Freeze frame data: Freeze frame data records the engine condition when a misfire (DTCs P0300 ∼ P0304) or fuel trim malfunction (DTCs P0171, P0172) or other malfunction (first malfunction only), is detected. Because freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
Priorities for troubleshooting: If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart, these should be followed. If no instructions are given troubleshoot DTCs according to the following priorities. (1) DTCs other than fuel trim malfunction (DTCs P0171, P0172), EGR (DTCs P0401, P0402), and misfire (DTCs P0300 ∼ P0304). (2) Fuel trim malfunction (DTCs P0171, P0172), and EGR (DTCs P0401, P0402). (3) Misfire (DTCs P0300 ∼ P0304). Author: Date: 239 DI–5 DIAGNOSTICS (b) – ENGINE (5S–FE) Check the DLC3 The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141–2 format. N09214 Terminal No. Connection / Voltage or Resistance Condition 7 Bus  Line / Pulse generation During transmission 4 Chassis Ground ↔ Body Ground /1 Ω or less Always 5 Signal Ground ↔ Body Ground /1 Ω or less Always 16 Battery Positive ↔ Body Ground /9 ∼ 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) S05347 INSPECT DIAGNOSIS (Normal Mode) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–2). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand–held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester. Author: Date: 240 DI–6 DIAGNOSTICS (2) (3) (4) – ENGINE (5S–FE) Connect the OBD II scan tool or TOYOTA hand– held tester to DLC3 under the instrument panel lower pad. Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand–held tester switch ON. Use the OBD II scan tool or TOYOTA hand–held tester to check the DTCs and freezed frame data and note them down. (For operating instructions, see the OBD II scan tool’s instruction book.) See page DI–3 to confirm the details of the DTCs. (5) NOTICE:
When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand–held tester) to check the DTCs, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, perform the following either action.
Turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM.
Check the 1st trip DTC using Mode 7 (Continuous Test Results) for SAE J1979. (c) Clear the DTC. The DTCs and freezed frame data will be erased by either action. (1) Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased. Author: Date: 241 DI–7 DIAGNOSTICS – ENGINE (5S–FE) 3. INSPECT DIAGNOSIS (Check Mode) HINT: TOYOTA hand–held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. (a) Check the DTC. (1) Initial conditions
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in P or N position
Air conditioning switched OFF (2) Turn ignition switch OFF. (3) Prepare the TOYOTA hand–held tester. (4) Connect the TOYOTA hand–held tester to the DLC3 under the instrument panel lower pad. (5) Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. (6) Flashing ON OFF 0.13 Second FI3605 Switch the TOYOTA hand–held tester normal mode to check mode. (Check that the MIL flashes.) NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or LOCK during check mode, the DTCs and freezed frame data will be erased. (7) Start the engine. (The MIL goes out after the engine start.) (8) Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTCs and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode. So all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. Author: Date: 242 DI–8 DIAGNOSTICS – ENGINE (5S–FE) 4. FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. DTC No. Fail–Safe Operation Fail–Safe Deactivation Conditions P0105 Ignition timing fixed at 5° BTDC Returned to normal condition P0110 Intake air temperature is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temperature is fixed at 80°(176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively VTA  0.1 V and  0.95 V P0135 P0141 The heater circuit in witch an abnormality is detected is turned off Ignition switch OFF P0325 Max. timing retardation Ignition switch OFF P0336 Fuel cut Returned to normal condition P1135 The heater circuit in which an abnormality is detected is turned off Ignition switch OFF P1300 P1310 Fuel cut IGF signal is detected for 2 consecutive ignitions 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA HAND–HELD TESTER only: By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See page DI–3). (2) Set the check mode (See page DI–3). (3) Perform a simulation test (See page IN–21). (4) Check the connector and terminal (See page IN–31). (5) Handle the connector (See page IN–31). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? NO Charge or replace battery. YES Author: Date: 243 DI–9 DIAGNOSTICS 2 – ENGINE (5S–FE) Is engine cranked? NO Proceed to page ST–2 and continue to troubleshoot. NO Go to step 7. YES 3 Does engine start? YES 4 Check air filter. PREPARATION: Remove the air filter. CHECK: Visually check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the filter with compressed air. First blow from inside thoroughly, then blow from outside of the filter. Outside Inside P00495 NG Repair or replace. OK Author: Date: 244 DI–10 DIAGNOSTICS 5 – ENGINE (5S–FE) Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the air conditioning. (d) Shift the transmission into the N position. (e) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3 on the vehicle. CHECK: Use the CURRENT DATA to check the idle speed. OK: Idle speed: 650 ∼ 750 rpm NG Proceed to problem symptoms table on page DI–28. OK Author: Date: 245 DI–11 DIAGNOSTICS 6 TE1 ENGINE (5S–FE) Check ignition timing. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Shift the transmission into the N position. (c) Keep the engine speed at idle. (d) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (e) Using a timing light, connect the tester to the No.1 high– tension cord. CHECK: Check the ignition timing. OK: Ignition timing: 10° BTDC at idle E1 SST DLC1 NG A07370 S05309 – A07664 Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–28. Author: Date: 246 DI–12 DIAGNOSTICS 7 – ENGINE (5S–FE) Check fuel pressure. Fuel Inlet Hose S05327 PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and push TOYOTA hand–held tester main switch ON. (d) Use the ACTIVE TEST mode to operate the fuel pump. (e) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (f) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector (See page SF–6). CHECK: Check for fuel pressure in the fuel inlet hose when it is pinched off. HINT: At this time, you will hear a fuel flowing noise. NG Proceed to page SF–6 and continue to troubleshoot. OK Author: Date: 247 DI–13 DIAGNOSTICS 8 – ENGINE (5S–FE) Check for spark. A00359 PREPARATION: (a) Disconnect the high–tension cord from the spark plug. (b) Remove the spark plug. (c) Install the spark plug to the high–tension cord. (d) Disconnect the injector connector. (e) Ground the spark plug. CHECK: Check if spark occurs while the engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 ∼ 10 seconds at a time. NG Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–28. Author: Date: 248 DI–14 DIAGNOSTICS – ENGINE (5S–FE) 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand–held tester display Measurement Item Normal Condition*1 FUEL SYS #1 Fuel System Bank 1 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 19.7 ∼ 50.4 % Racing without load (2,500rpm): 16.8 ∼ 47.4 % Engine Coolant Temp. Sensor Value After warming up: 80 ∼ 95°C (176 ∼ 203°F) COOLANT TEMP. SHORT FT #1 Short–term Fuel Trim Bank 1 0 ± 20 % LONG FT #1 Long–term Fuel Trim Bank 1 0 ± 20 % ENGINE SPD Engine Speed Idling: 650 ∼ 750 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No. 1 Idling: BTDC 0 ∼ 10° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. MAP Absolute Pressure inside Intake Manifold Idling: 20 ∼ 51 kPa Racing without load (2,500 rpm): 17 ∼ 48 kPa THROTTLE POS Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0%, 5 V → 100 % Throttle Fully Closed: 6 ∼ 16 % Throttle Fully Open: 64 ∼ 98 % O2S B1, S1 Voltage Output of Heated Oxygen Sensor Bank 1 Sensor 1 Idling: 0.1 ∼ 0.9 V (0.56 ∼ 0.76 V *2) O2FT B1, S1 Heated Oxygen Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) INTAKE AIR 0 ± 20 % Idling: 2.8 ∼ 3.8 V A/FS B1, S1 *3 Voltage Output of A/F Sensor A/FFT B1, S1 *3 A/F Sensor Fuel Trim (Same as SHORT FT #1) O2S B1, S2 Voltage Output of Heated Oxygen Sensor Bank 1 Sensor 2 0 ± 20 % Driving at 50 km/h (31 mph): 0.05 ∼ 0.95 V *1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. *2: Only for California Specification vehicles, when you use the OBD II scan tool (excluding TOYOTA hand– held tester). *3: Only for California Specification vehicles, when you use the TOYOTA hand–held tester. Author: Date: 249 DI–15 DIAGNOSTICS (b) – ENGINE (5S–FE) TOYOTA Enhanced Signals. TOYOTA hand–held tester display Measurement Item Normal Condition*1 MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 2.9 ∼ 5.1 ms Intake Air Control Valve Duty Ratio Opening ratio rotary solenoid type IAC valve Idling: 25 ∼ 62 % Starter Signal Cranking: ON CTP SIG Closed Throttle Position Signal Throttle fully closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SIG Park/Neutral Position Switch Signal P or N position: ON Electrical Load Signal Defogger S/W ON: ON Stop Light Switch Signal Stop light switch ON: ON Power Steering Oil Pressure Switch Signal Turn steering wheel: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON INJECTOR IAC DUTY RATIO STARTER SIG ELECTCL LOAD SIG STOP LIGHT SW PS OIL PRESS SW CYL#1, CYL#2, CYL#3, CYL#4 Abnormal revolution variation for each cylinder 0% IGNITION Total number of ignition for every 1,000 revolutions 0 ∼ 2,000 rpm EGR SYSTEM EGR system operating condition Idling: OFF FUEL PUMP Fuel Pump Signal Idling: ON A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON A/C MAG CLUTCH A/C Switch Signal A/C ON: ON EVAP (PURGE) VSV EVAP VSV Signal VSV operating: Avove 30 % VAPOR PRESS VSV Vapor Pressure VSV Signal VSV operating: ON Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 ∼ 1.2 V O2 LR B1, S1 *2 Heated Oxygen Sensor Lean Rich Bank 1 Sensor 1: Response time for oxygen sensor output to switch from lean to rich Idling after warming up: 0 ∼ 1,000 msec. O2 RL B1, S1 *2 Heated Oxygen Sensor Rich Lean Bank 1 Sensor 1: Response time for oxygen sensor output to switch from rich to lean Idling after warming up: 0 ∼ 1,000 msec. TOTAL FT B1 *1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. *2: Except California Specification vehicles. Author: Date: 250 DI–16 DIAGNOSTICS – ENGINE (5S–FE) DI00I–09 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ’’See Page ’’ for the respective ’’DTC No.’’ in the DTC chart. SAE Controlled: DTC No. (See Page) Detection Item Trouble Area MIL*1 Memory P0105 (DI–29) Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction  Open or short in manifold absolute pressure sensor circuit  Manifold absolute pressure sensor  ECM   P0106 (DI–33) Manifold Absolute Pressure Circuit Range/Performance Problem  Manifold absolute pressure sensor  Vacuum line   P0110 (DI–35) Intake Air Temp. Circuit Malfunction  Open or short in intake air temp. sensor circuit  Intake air temp. sensor (built into mass air flow meter)  ECM   P0115 (DI–41) Engine Coolant Temp. Circuit Malfunction  Open or short in engine coolant temp. sensor circuit  Engine coolant temp. sensor  ECM   P0116 (DI–47) Engine Coolant Temp. Circuit Range/Performance Problem  Engine coolant temp. sensor  Cooling system   P0120 (DI–49) Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction  Open or short in throttle position sensor circuit  Throttle position sensor  ECM   P0121 (DI–54) Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem  Throttle position sensor   *2 P0125 (DI–61) Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)  Open or short in heated oxygen sensor (bank 1 sensor 1) circuit  Heated oxygen sensor (bank 1 sensor 1)  ECM   *3 P0125 (DI–55) Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)  Open or short in A/F sensor circuit  A/F sensor  ECM   Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)  Heated oxygen sensor  Fuel trim malfunction   Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)  Heated oxygen sensor  Fuel trim malfunction   Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)  Open or short in heater circuit of heated oxygen sensor  Heated oxygen sensor heater  ECM   *2 P0130 (DI–66) *2 P0133 (DI–71) *2 P0135 (DI–75) *1: 


MIL lights up *2: Except California specification vehicles *3: Only for California specification vehicles Author: Date: 251 DI–17 DIAGNOSTICS DTC No. (See Page) *1: *2: *3: *4: – ENGINE (5S–FE) Detection Item Trouble Area MIL*1 Memory P0136 (DI–77) Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)  Heated oxygen sensor   P0141 (DI–75) Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)  Same as DTC P0135   *3 P0171 (DI–84) System too Lean (Fuel Trim) (Except California Spec.)  Air intake (hose loose)  Fuel line pressure  Injector blockage  Heated oxygen sensor (bank 1 sensor 1)  Manifold absolute pressure sensor  Engine coolant temp. sensor *1  *3 P0172 (DI–84) System too Rich (Fuel Trim) (Except California Spec.)  Fuel line pressure  Injector leak, blockage  Heated oxygen sensor (bank 1 sensor 1)  Manifold absolute pressure sensor  Engine coolant temp. sensor *1  *4 P0171 (DI–79) System too Lean (Fuel Trim) (Only for California Spec.)  Air intake (hose loose)  Fuel line pressure  Injector blockage  Manifold absolute pressure sensor  Engine coolant temp. sensor  A/F sensor *1  *4 P0172 (DI–79) System too Rich (Fuel Trim) (Only for California Spec.)  Fuel line pressure  Injector leak, blockage  Manifold absolute pressure sensor  Engine coolant temp. sensor  A/F sensor *1  P0300 (DI–89) Random/Multiple Cylinder Misfire Detected P0301 P0302 P0303 P0304 (DI–89) Misfire Detected – Cylinder 1 – Cylinder 2 – Cylinder 3 – Cylinder 4  Ignition system  Injector  Fuel line pressure  EGR  Compression C i pressure  Valve clearance not to specification  Valve timing  Manifold absolute pressure sensor  Engine coolant temp. sensor  Open or short engine wire  Connector connection  ECM *2  P0325 (DI–97) Knock Sensor 1 Circuit Malfunction  Open or short in knock sensor 1 circuit  Knock sensor 1 (looseness)  ECM *1  P0335 (DI–100) Crankshaft Position Sensor ”A” Circuit Malfunction  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Starter  ECM *1  MIL lights up MIL lights up or blinking Except California Specification vehicles Only for California Specification vehicles Author: Date: 252 DI–18 DIAGNOSTICS DTC No. (See Page) – ENGINE (5S–FE) MIL*1 Memory Camshaft Position Sensor Circuit Malfunction  Open or short in camshaft position sensor circuit  Camshaft position sensor  Distributor  Starter  ECM   P0401 (DI–105) Exhaust Gas Recirculation Flow Insufficient Detected  EGR valve stuck closed  Open or short in VSV circuit for EGR  Vacuum or EGR hose disconnected  Manifold absolute pressure sensor  EGR VSV open or close malfunction  ECM   P0402 (DI–113) Exhaust Gas Recirculation Flow Excessive Detected  EGR valve stuck open  Vacuum or EGR hose is connected to wrong post  Manifold absolute pressure sensor  ECM   *2 P0420 (DI–116) Catalyst System Efficiency Below Threshold (Except California Spec.)  Three–way catalytic converter  Open or short in heated oxygen sensor circuit  Heated oxygen sensor   *3 P0420 (DI–119) Catalyst System Efficiency Below Threshold (Only for California Spec.)  Three–way catalystic converter  Open short in heated oxygen sensor (bank 1 sensor 2) circuit  Heated oxygen sensor (bank 1 sensor 2)  Open or short in A/F sensor circuit  A/F sensor   P0440 (DI–122) Evaporative Emission Control System Malfunction  Vapor pressure sensor  Fuel tank cap incorrectly installed  Fuel tank cap cracked or damaged  Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in fig. 1)  Hose or tube cracked, holed, damaged or loose seal ((3) in fig. 1)  Fuel tank cracked, holed or damaged  Charcoal canister cracked, holed or damaged  Fuel tank over fill check valve cracked or damaged   P0441 (DI–129) Evaporative Emission Control System Incorrect Purge Flow   P0446 (DI–129) Evaporative Emission Control System Vent Control Malfunction   P0450 (DI–142) Evaporative Emission Control System Pressure Sensor Malfunction   P0451 (DI–142) Evaporative Emission Control System Pressure Sensor (Range/performance)   P0340 (DI–103) Detection Item Trouble Area  Open or short in VSV circuit for vapor pressure sensor  VSV for vapor pressure sensor  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  Open O or short h t in i VSV circuit i it for f EVAP  VSV for EVAP  Vacuum hose cracks, hole, blocked, damaged or disconnected ((1), (4), (5) holed (6) and (7) in fig. 1)  Charcoal canister cracked, holed or damaged  Fuel tank over fill check valve cracked or damaged  Open or short in vapor pressure sensor circuit  Vapor V pressure sensor  ECM *1: 


MIL lights up *2: Except California Specification vehicles *3: Only for California Specification vehicles Author: Date: 253 DI–19 DIAGNOSTICS DTC No. (See Page) P0500 (DI–145) P0505 (DI–148) Detection Item – ENGINE (5S–FE) Trouble Area MIL*1 Memory Vehicle Speed Sensor Malfunction  Combination meter  Open or short in No.1 vehicle speed sensor circuit  No.1 vehicle speed sensor  ECM   Idle Control System Malfunction  IAC valve is stuck or closed  Open or short in IAC valve circuit  Open or short in A/C switch circuit  Air intake (hose loose)  ECM   MIL*1 Memory *1: 


MIL lights up 2. MANUFACTURER CONTROLLED DTC No. (See Page) Detection Item *2 P1130 (DI–152) A/F Sensor Circuit Range/Performance Malfunction  Open or short in A/F sensor circuit  A/F sensor  ECM   *2 P1133 (DI–157) A/F Sensor Circuit Response Malfunction  A/F sensor   *2 P1135 (DI–161) A/F Sensor Heater Circuit Malfunction  Open or short in heater circuit of A/F sensor  A/F sensor heater  ECM   P1300 (DI–163) Igniter Circuit Malfunction (No.1)  Open or short in IGF or IGT circuit from igniter to ECM  Ignition coil (No.1)  ECM   P1310 (DI–163) Igniter Circuit Malfunction (No.2)  Open or short in IGF or IGT circuit from igniter to ECM  Ignition coil (No.2)  ECM   P1335 (DI–169) Crankshaft Position Sensor Circuit Malfunction (During engine running)  Open short in crankshaft position sensor circuit  Crankshaft position sensor  ECM –  *3 P1520 (DI–170) Stop Light Switch Signal Malfunction  Short in stop light switch signal circuit  Stop light switch  ECM   P1600 (DI–173) ECM BATT Malfunction  Open in back up power source circuit  ECM   *3 P1780 (DI–175) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM   Trouble Area *1: 


MIL lights up *2: Only for California Specification vehicles *3: Only for A/T models Author: Date: 254 DI–20 DIAGNOSTICS DTC No. (See Page) – Detection Item ENGINE (5S–FE) Trouble Area MIL*1 Memory *2 B2795 (DI–928) Unmatched key Code  Immobiliser system –  *2 B2796 (DI–929) No Communnication in Immobiliser system  Immobiliser system –  *2 B2797 (DI–932) Communication Malfunction No.1  Immobiliser system –  *2 B2798 (DI–935) Communication Malfunction No.2  Immobiliser system –  *1: –


MIL does not light up *2: Only for w/ engine immobiliser system models Author: Date: 255 DI–21 DIAGNOSTICS – ENGINE (5S–FE) DI1JS–03 PARTS LOCATION Manifold Absolute Throttle Position Sensor Pressure Sensor ECM Combination Meter Injector (Speedometer) Camshaft Position DLC3 Sensor Heated Oxygen DLC1 Sensor (Bank 1 Sensor 2) VSV for EGR Crankshaft Position Sensor Knock Sensor 1 A/F Sensor *2 Intake Air Temp. Sensor Heated Oxygen Sensor (Bank 1 Sensor 1) *1 Engine Coolant Temp. Sensor Park/Neutral Position Switch Ignition Coil (No.1, No.2) VSV for EVAP Idle Air Control Valve Vapor Pressure Sensor Charcoal Canister VSV for Vapor Pressure Sensor *1: Except California Specification vehicles *2: Only for California Specification vehicles A03431 A03430 A03537 Author: Date: 256 DI–22 DIAGNOSTICS – ENGINE (5S–FE) DI1JT–03 TERMINALS OF ECM Without engine immobiliser system ECM Terminals E7 E8 E9 D00032 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (E7 – 1) – E1 (E9 – 14) B – Y ↔ BR Always 9 ∼ 14 + B (E7 – 12) – E1 (E9 – 14) B – Y ↔ BR IG switch ON 9 ∼ 14 Y ↔ BR IG switch ON 4.5 ∼ 5.5 IG switch ON Throttle valve fully closed 0.3 ∼ 1.0 IG switch ON Throttle valve fully open 3.2 ∼ 4.9 IG switch ON 3.3 ∼ 3.9 Apply vacuum 26.7 kPa (200 mmHg, 7.9 in.Hg) 2.5 ∼ 3.1 VC (E8 – 1) – E2 (E8 – 9) VTA (E8 – 11) – E2 (E8 – 9) PIM (E8 – 2) – E2 (E8 – 9) LG ↔ BR B – Y ↔ BR THA (E8 – 3) – E2 (E8 – 9) Y – B ↔ BR Idling, Intake air temp. 20°C (68° F) 0.5 ∼ 3.4 THW (E8 – 4) – E2 (E8 – 9) G – B ↔ BR Idling, Engine coolant temp. 80°C (176°F) 0.2 ∼ 1.0 *1 GR ↔ BR Cranking 6.0 or more *2 B – O ↔ BR Cranking 6.0 or more STA (E7 – 11) – E1 (E9 – 14) 9 ∼ 14 IG switch ON #10 (E9 – 12) – E01 (E9 – 13) L ↔ BR Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON #20 (E9 – 11) – E01 (E9 – 13) R ↔ BR Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON #30 (E9 – 25) – E01 (E9 – 13) Y ↔ BR Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON #40 (E9 – 24) – E01 (E9 – 13) W ↔ BR IGT1 (E9 – 20) – E1 (E9 – 14) Idling Pulse generation (See page DI–89) B ↔ BR Idling Pulse generation (See page DI–163) IGT2 (E9 – 19) – E1 (E9 – 14) Y – R ↔ BR Idling Pulse generation (See page DI–163) IGF (E9 – 3) – E1 (E9 – 14) W – R ↔ BR 4.5 ∼ 5.5 IG switch ON, Disconnect ignition coil connector Pulse generation (See page DI–163) Idling *1: TMC made *2: TMMK made Author: Date: 257 DI–23 DIAGNOSTICS Symbols (Terminals No.) – ENGINE (5S–FE) Wiring Color Condition STD Voltage (V) G
(E9 – 5) – NE(E9 – 17) B–W↔L Idling Pulse generation (See page DI–100) NE
(E9 – 4) – NE(E9 – 17) B–R↔L Idling Pulse generation (See page DI–100) FC (E7 – 14) – E01 (E9 – 13) G – R ↔ BR IG switch ON 9 ∼ 14 EGR (E9 – 23) – E01(E9 – 13) P – B ↔ BR IG switch ON 0∼3 ISCC (E9 – 9) – E01 (E9 – 13) B – O ↔ BR IG switch ON Disconnect E9 connector of ECM 9∼4 ISCO (E9 –10) – E01(E9 – 13) W ↔ BR IG switch ON Disconnect E9 connector of ECM Below 3.0 *1 OX1 (E8 – 6) – E1 (E9 – 14) W ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–66) OX2 (E8 – 5) – E1 (E9 – 14) B ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation *1 1 HT1 (E9 – 8) – E1 (E9 – 14) L – Y ↔ BR HT2 (E9 – 21) – E1 (E9 – 14) P – B ↔ BR KNK (E8 – 13) – E1 (E9 – 14) W ↔ BR Idling Below 3.0 9 ∼ 14 IG switch ON Idling Below 3.0 9 ∼ 14 IG switch ON Pulse generation (See page DI–97) Idling IG switch ON Other shift position in P or N position 9 ∼ 14 IG switch ON Shift position in P or N position 0 ∼ 3.0 *3 3 NSW (E7 – 22) – E1 (E9 – 14) B – W ↔ BR SPD (E7 – 9) – E1 (E9 – 14) V – W ↔ BR IG switch ON Rotate driving wheel slowly TE1 (E8 – 15) – E1 (E9 – 14) L – W ↔ BR IG switch ON 9 ∼ 14 G – R ↔ BR Idling 9 ∼ 14 W (E7 – 5) – E1 (E9 – 14) EVP (E9 – 22) – E1 (E9 – 14) TPC (E8 – 8) – E1 (E9 – 14) PTNK (E8 – 7) – E2 (E8 – 9) Pulse generation (See page DI–145) IG switch ON Below 3.0 V – W ↔ BR IG switch ON 9 ∼ 14 V ↔ BR IG switch ON 9 ∼ 14 P ↔ BR IG switch ON, Disconnect vacuum hose from vapor pressure sensor 2.9 ∼ 3.7 Apply vacuum (less than 66.7 kPa (500 mmHg, 19.7 in.Hg)) Below 0.5 *2 AF
(E8 – 6) – E1 (E9 – 14) W ↔ BR Always (IG switch ON) 3.3 fixed*4 *2 AF (E8 – 14) – E1 (E9 – 14) O ↔ BR Always (IG switch ON) 3.0 fixed*4 *1: *2: *3: *4: Except California Specification vehicles Only for California Specification vehicles Only for A/T models The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Author: Date: 258 DI–24 DIAGNOSTICS Symbols (Terminals No.) – ENGINE (5S–FE) Wiring Color Condition STD Voltage (V) Idling *1 1 HTAF (E9 – 2) – E04 (E9 – 15) G ↔ BR LOCK IN (E9 – 18) – E1 (E9 – 14) W – L ↔ BR LOCK (E7 – 15) – E1(E9 – 14) R – W ↔ BR A/C SW (E7 – 10) – E1 (E9 – 14) R – B ↔ BR PRS (E7 – 13) – E1 (E9 – 14) G ↔ BR THR (E8 – 10) – E2 (E8 – 9) L – R ↔ BR MGC (E7 – 21) – E01(E9 – 14) L – Y ↔ BR 9 ∼ 14 IG switch ON * STP (E7 – 4) – E1 (E9 – 14) G – W ↔ BR ELS (E7 – 2) – E1 (E9 – 14) B – R ↔ BR PSSW (E8 – 12) – E1 (E9 – 14) B – L ↔ BR SIL (E7 – 16) – E1 (E9 – 14) Below 3.0 W ↔ BR Pulse generation (See page DI–190) A/C compressor is operating A/C indicator light lights up Below 4.0 A/C indicator light does not lights up Below 1.0 A/C switch ON 9 ∼ 14 A/C switch OFF Below 1.0 A/C pressure is normally Below 1.0 IG switch ON, A/C evaporator temp. 0°C (32°F) 2.2 ∼ 2.6 IG switch ON, A/C evaporator temp. 15°C (59°F) 1.4 ∼ 1.8 A/C magnetic clutch ON Below 1.0 9 ∼ 14 A/C magnetic clutch OFF 7.5 ∼ 14 IG switch ON, Brake pedal depressed IG switch ON, Brake pedal released Below 1.5 Defogger switch and taillight switch ON 7.5 ∼ 14 Defogger switch and taillight switch OFF Below 1.5 9 ∼ 14 IG switch ON At idling, Turn steering wheel to lock position Below 3.0 During transmission Pulse generation *: Only for A/T models *1: Only for California Specification vehicles Author: Date: 259 DI–25 DIAGNOSTICS – ENGINE (5S–FE) With engine immobiliser system ECM Terminals E8 E9 E10 E7 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 1110 9 8 7 6 5 4 3 2 1 262524 2322 2120191817 16 1514 16 151413 12 1110 9 12 11 10 9 8 7 22 21 201918 171615 1413 12 A02958 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (E7 – 2) – E1 (E9 – 24) B – Y ↔ BR Always 9 ∼ 14 + B (E7 – 12) – E1 (E9 – 24) B – Y ↔ BR IG switch ON 9 ∼ 14 Y ↔ BR IG switch ON 4.5 ∼ 5.5 IG switch ON Throttle valve fully closed 0.3 ∼ 1.0 IG switch ON Throttle valve fully open 3.2 ∼ 4.9 IG switch ON 3.3 ∼ 3.9 Apply vacuum 26.7 kPa (200 mmHg, 7.9 in.Hg) 2.5 ∼ 3.1 VC (E8 – 1) – E2 (E8 – 9) VTA (E8 – 10) – E2 (E8 – 9) PIM (E8 – 2) – E2 (E8 – 9) LG ↔ BR B – Y ↔ BR THA (E8 – 3) – E2 (E8 – 9) Y – B ↔ BR Idling, Intake air temp. 20°C (68° F) 0.5 ∼ 3.4 THW (E8 – 4) – E2 (E8 – 9) G – B ↔ BR Idling, Engine coolant temp. 80°C (176°F) 0.2 ∼ 1.0 *1 GR ↔ BR Cranking 6.0 or more *2 B – O ↔ BR Cranking 6.0 or more STA (E7 – 11) – E1 (E9 – 24) 9 ∼ 14 IG switch ON #10 (E9 – 12) – E01 (E9 – 13) L ↔ BR #20 (E9 – 11) – E01 (E9 – 13) R ↔ BR Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON #30 (E9 – 10) – E01 (E9 – 13) Y ↔ BR Pulse generation (See page DI–89) Idling 9 ∼ 14 IG switch ON #40 (E9 – 9) – E01 (E9 – 13) W ↔ BR IGT1 (E9 – 23) – E1 (E9 – 24) IGT2 (E9 – 22) – E1 (E9 – 24) Idling Pulse generation (See page DI–89) B ↔ BR Idling Pulse generation (See page DI–163) Y – R ↔ BR Idling Pulse generation (See page DI–163) 4.5 ∼ 5.5 IG switch ON, Disconnect ignition coil connector IGF (E9 – 17) – E1 (E9 – 24) W – R ↔ BR Pulse generation (See page DI–163) Idling *1: TMC made *2: TMMK made Author: Date: 260 DI–26 DIAGNOSTICS – ENGINE (5S–FE) Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) G
(E10 – 11) – NE(E10 – 6) B–W↔L Idling Pulse generation (See page DI–100) NE
(E10 – 12) – NE(E10 – 6) B–R↔L Idling Pulse generation (See page DI–100) FC (E7 – 14) – E01 (E9 – 13) G – R ↔ BR IG switch ON 9 ∼ 14 EGR (E8 – 15) – E01(E9 – 13) P – B ↔ BR IG switch ON 0∼3 ISCC (E9 – 6) – E01 (E9 – 13) B – O ↔ BR IG switch ON Disconnect E9 connector of ECM 9∼4 ISCO (E9 –7) – E01(E9 – 13) W ↔ BR IG switch ON Disconnect E9 connector of ECM Below 3.0 *1 OX1 (E8 – 5) – E1 (E9 – 24) W ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–66) OX2 (E8 – 13) – E1 (E9 – 24) B ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation *1 1 HT1 (E9 – 1) – E1 (E9 – 24) L – Y ↔ BR HT2 (E9 – 14) – E1 (E9 – 24) P – B ↔ BR KNK (E8 – 12) – E1 (E9 – 24) W ↔ BR Idling Below 3.0 9 ∼ 14 IG switch ON Idling Below 3.0 9 ∼ 14 IG switch ON Pulse generation (See page DI–97) Idling IG switch ON Other shift position in P or N position 9 ∼ 14 IG switch ON Shift position in P or N position 0 ∼ 3.0 *3 3 NSW (E7 – 22) – E1 (E9 – 24) B – W ↔ BR SPD (E7 – 8) – E1 (E9 – 24) V – W ↔ BR IG switch ON Rotate driving wheel slowly TE1 (E8 – 7) – E1 (E9 – 24) L – W ↔ BR IG switch ON 9 ∼ 14 G – R ↔ BR Idling 9 ∼ 14 W (E7 – 4) – E1 (E9 – 24) EVP (E9 – 3) – E1 (E9 – 24) TPC (E8 – 16) – E1 (E9 – 24) PTNK (E8 – 8) – E2 (E8 – 9) Pulse generation (See page DI–145) IG switch ON Below 3.0 V – W ↔ BR IG switch ON 9 ∼ 14 V ↔ BR IG switch ON 9 ∼ 14 P ↔ BR IG switch ON, Disconnect vacuum hose from vapor pressure sensor 2.9 ∼ 3.7 Apply vacuum (less than 66.7 kPa (500 mmHg, 19.7 in.Hg)) Below 0.5 *2 AF
(E8 – 6) – E1 (E9 – 24) W ↔ BR Always (IG switch ON) 3.3 fixed*4 *2 AF (E8 – 14) – E1 (E9 – 24) O ↔ BR Always (IG switch ON) 3.0 fixed*4 *1: *2: *3: *4: Except California Specification vehicles Only for California Specification vehicles Only for A/T models The ECM terminal voltage is fixed regardless of the output voltage from the sensor. Author: Date: 261 DI–27 DIAGNOSTICS Symbols (Terminals No.) – ENGINE (5S–FE) Wiring Color Condition STD Voltage (V) Idling *1 1 HTAF (E9 – 2) – E04 (E9 – 15) G ↔ BR LOCK IN (E9 – 19) – E1 (E9 – 24) W – L ↔ BR LOCK (E7 – 20) – E1 (E9 – 24) R – W ↔ BR A/C SW (E7 – 10) – E1 (E9 – 24) R – B ↔ BR PRS (E7 – 19) – E1 (E9 – 24) G ↔ BR THR (E8 – 11) – E2 (E8 – 9) L – R ↔ BR MGC (E7 – 21) – E01 (E9 – 13) L – Y ↔ BR G – W ↔ BR ELS (E7 – 13) – E1 (E9 – 24) B – R ↔ BR – E1 (E9 – 24) SIL (E7 – 6) – E1 (E9 – 24) 9 ∼ 14 IG switch ON * STP (E7 – 9) – E1 (E9 – 24) PSSW (E9 – 4) Below 3.0 B – L ↔ BR W ↔ BR TACH (E7 – 7) – E1 (E9 – 24) B – O ↔ BR KSW (E10 – 4) – E1 (E9 – 24) L – B ↔ BR RXCK (E10 – 3) – E1 (E9 – 24) Pulse generation (See page DI–190) A/C compressor is operating A/C indicator light lights up Below 4.0 A/C indicator light does not lights up Below 1.0 A/C switch ON 9 ∼ 14 A/C switch OFF Below 1.0 A/C pressure is normally Below 1.0 IG switch ON, A/C evaporator temp. 0°C (32°F) 2.2 ∼ 2.6 IG switch ON, A/C evaporator temp. 15°C (59°F) 1.4 ∼ 1.8 A/C magnetic clutch ON Below 1.0 9 ∼ 14 A/C magnetic clutch OFF 7.5 ∼ 14 IG switch ON, Brake pedal depressed IG switch ON, Brake pedal released Below 1.5 Defogger switch and taillight switch ON 7.5 ∼ 14 Defogger switch and taillight switch OFF Below 1.5 9 ∼ 14 IG switch ON At idling, Turn steering wheel to lock position Below 3.0 During transmission Pulse generation Idling Pulse generation At the time of inserting key Below 1.5 In the condition without key inserted Pulse generation R – L ↔ BR At the time of inserting key Pulse generation CODE (E10 – 8) – E1 (E9 – 24) G – W ↔ BR At the time of inserting key Pulse generation TXCT (E10 – 1) – E1 (E9 – 24) L – Y ↔ BR At the time of inserting key Pulse generation IMLD (E10 – 1) – E1 (E9 – 24) R – Y ↔ BR In the condition without key inserted Pulse generation MREL (E10 – 7) – E1 (E9 – 24) B – W ↔ BR IG switch ON 9 ∼ 14 IGSW (E7 – 1) – E1 (E9 – 24) B – R ↔ BR IG switch ON 9 ∼ 14 *: Only for A/T models *1: Only for California Specification vehicles Author: Date: 262 DI–28 DIAGNOSTICS – ENGINE (5S–FE) DI00L–03 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Engine does not crank (Does not start) 1. Starter 2. starter relay ST–2 ST–20 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI–179 DI–183 IN–31 No complete combustion (Does not start) 1. Fuel pump control circuit DI–183 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI–176 DI–183 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–176 DI–183 Hot engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–176 DI–183 High engine idle speed (Poor idling) 1. A/C switch circuit 2. ECM power source circuit AC–84 DI–179 Low engine idle speed (Poor idling) 1. A/C switch circuit 2. Fuel pump control circuit AC–84 DI–183 Rough idling (Poor idling) 1. Compression 2. Fuel pump control circuit EM–3 DI–183 Hunting (Poor idling) 1. ECM power source circuit 2. Fuel pump control circuit DI–179 DI–183 Hesitation/Poor acceleration (Poor driveability) 1. Fuel pump control circuit 2. A/T faulty DI–183 DI–405 Surging (Poor driveability) 1. Fuel pump control circuit DI–183 Soon after starting (Engine stall) 1. Fuel pump control circuit DI–183 During A/C operation (Engine stall) 1. A/C switch circuit 2. Engine control module (ECM) AC–84 IN–31 A/C switch indicatior blinking 1. A/C Compressor lock sensor circuit 2. A/C Evaporator temp. sensor circuit DI–190 DI–192 Unable to refuel/ Difficult to refuel 1. ORVR system EC–6 Author: Date: 263 DI–29 DIAGNOSTICS – ENGINE (5S–FE) DI00M–05 CIRCUIT INSPECTION DTC P0105 Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction CIRCUIT DESCRIPTION V Output Voltage (3.96) 3.6 2.4 1.2 150 450 20 60 mmHg 750 (840) kPa 100 (112) By a built–in sensor unit, the manifold absolute pressure sensor detects the intake manifold pressure as a voltage. The ECM then determines the basic injection duration and basic injection advance angle based on this voltage. Since the manifold absolute pressure sensor does not use the atmospheric pressure as a criterion, but senses the absolute pressure inside the intake manifold (the pressure in proportion to the present absolute vacuum 0), it is not influenced by fluctuations in the atmospheric pressure due to high altitude and other factors. This permits it to control the air–fuel ratio at the proper lever under all conditions. Manifold Absolute Pressure P01242 DTC No. P0105 DTC Detecting Condition Trouble Area Open or short in manifold absolute pressure sensor circuit
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM HINT: After confirming DTC P0105, use the OBD II scan tool or TOYOTA hand–held tester to confirm the manifold absolute pressure from the CURRENT DATA. Manifold Absolute Pressure (kPa) Approx. 0 130 or more Malfunction
PIM circuit short
VC circuit open or short
PIM circuit open
E2 circuit open Author: Date: 264 DI–30 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM Manifold Absolute Pressure Sensor ECM 3 Y 1 VC E8 2 B–Y 2 PIM E8 1 BR 9 E2 E8 5V E1 A00309 INSPECTION PROCEDURE HINT:

If DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem) and P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 265 DI–31 DIAGNOSTICS 1 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of manifold absolute pressure. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read value of the manifold absolute pressure on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as atmospheric pressure. OK Check for intermittent problems (See page DI–3). NG 2 Check voltage between terminals VC and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V ON w/o Immobiliser E2 (–) VC (+) w/ Immobiliser NG BE6653 P23721 A03008 E2 (–) Check and replace ECM (See page IN–31). VC (+) A03407 OK Author: Date: 266 DI–32 DIAGNOSTICS 3 – ENGINE (5S–FE) Check voltage between terminals PIM and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals PIM and E2 of the ECM connector. OK: Voltage: 3.3 – 3.9 V ON w/o Immobiliser PIM (+) E2 (+) OK Check and replace ECM (See page IN–31). w/ Immobiliser BE6653 P23722 A03009 PIM (+) E2 (+) A03408 NG 4 Check for open and short in harness and connector between manifold absolute pressure sensor and ECM. NG Repair or replace harness or connector. OK Replace manifold absolute pressure sensor (See page SF–52). Author: Date: 267 DI–33 DIAGNOSTICS – ENGINE (5S–FE) DI00N–04 DTC P0106 Manifold Absolute Pressure Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction) on page DI–29. DTC No. DTC Detecting Condition Trouble Area After engine is warmed up, conditions (a) and (b) continue with engine speed 400 ∼ 1,000 rpm (2 trip detection logic) (a) Throttle valve fully closed (b) Manifold absolute pressure sensor output > 3.0 V P0106 Condition (c) and (d) continue with engine speed 2,500 rpm or less (2 trip detection logic) (c) VTA > 1.85 (d) Manifold absolute pressure sensor output < 1.0 V
Manifold absolute pressure ressure sensor
Vacuum line WIRING DIAGRAM Refer to DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction) on page DI–29. INSPECTION PROCEDURE HINT:
If DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction) and P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem) are output simultaneously, manifold absolute pressure sensor circuit may be open. Perform troubleshooting of DTC P0105 first. If DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem), P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction) and P0120 (Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.

1 Are there any other codes (besides DTC P0106) being output? YES Go to relevant DTC chart. NO Author: Date: 268 DI–34 DIAGNOSTICS 2 – ENGINE (5S–FE) Check manifold absolute pressure sensor operation (See page SF–52). OK Check vacuum line between intake air chamber and manifold absolute pressure sensor. NG Replace manifold absolute pressure sensor. Author: Date: 269 DI–35 DIAGNOSTICS – ENGINE (5S–FE) DI00O–05 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION (fig.1) 30 20 10 Resistance kΩ 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 – 20 (– 4) 0 (32) 20 (68) 40 (104) 60 (140) 80 100 (176) (212) Temp.°C (F°) FI4741 DTC No. P0110 The intake air temp. sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature, the lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See fig.1). The air intake temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temp. sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0110, it operates the fail safe function in which the intake air temperature is assumed to be 20°C (68°F). DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM HINT: After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand–held tester to confirm the intake air temperature from the CURRENT DATA. Temperature Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit Author: Date: 270 DI–36 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM ECM Intake Air Temp. Sensor 2 Y–B 3 THA E8 1 BR 9 E8 5V R E2 E1 A00310 INSPECTION PROCEDURE HINT:

If DTCs P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem), P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction) and P0120 (Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 271 DI–37 DIAGNOSTICS 1 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of intake air temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual air intake temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates – 40°C (– 40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) .... Go to step 2. 140°C (284°F) or more .... Go to step 4. OK Check for intermittent problems (See page DI–3). 2 Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 2 3 1 9 E8 E8 THA E2 E1 A00391 PREPARATION: (a) Disconnect the intake air temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand– held tester. OK: Temp. value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace intake air temp. sensor. NG Author: Date: 272 DI–38 DIAGNOSTICS 3 – ENGINE (5S–FE) Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 3 E8 THA 9 E8 E2 E1 w/o Immobiliser THA PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Connect between terminals THA and E2 of the ECM connector. HINT: The intake air temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–31). (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more E2 w/ Immobiliser THA A03010 E2 A03409 OK Open in harness between terminals E2 or THA, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–31). Author: Date: 273 DI–39 DIAGNOSTICS 4 – ENGINE (5S–FE) Check for short in harness and ECM. ON Intake Air Temp. Sensor 2 1 ECM 5V 3 E8 9 E8 THA E2 E1 PREPARATION: (a) Disconnect the intake air temp. sensor connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) A00393 OK Replace intake air temp. sensor. NG Author: Date: 274 DI–40 DIAGNOSTICS 5 – ENGINE (5S–FE) Check for short in harness or ECM. ON ECM Intake Air Temp. Sensor 5V THA E2 E1 w/o Immobiliser PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Disconnect the E8 connector from the ECM. HINT: The intake air temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) E8 Connector w/ Immobiliser OK Repair or replace harness or connector. E8 Connector A03011 A03410 NG Check and replace ECM (See page IN–31). Author: Date: 275 DI–41 DIAGNOSTICS – ENGINE (5S–FE) DI00P–05 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temp. sensor changes the resistance value according to the engine coolant temp. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction shown on page DI–35. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. P0115 Detection Item Open or short in engine coolant temp. sensor circuit Trouble Area
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM HINT: After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand–held tester to confirm the engine coolant temp. from the CURRENT DATA. Temp. Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit Author: Date: 276 DI–42 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM ECM Engine Coolant Temp. Sensor 5V 2 G–B 4 THW E8 1 BR 9 E8 R E2 E1 A00310 INSPECTION PROCEDURE HINT:

If DTCs P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem), P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction) and P0120 (Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 277 DI–43 DIAGNOSTICS 1 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of engine coolant temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual engine coolant temperature HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (–40°F).
If there is open circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI–3). 2 Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 5V 2 1 4 E8 9 E8 THW E2 E1 A00395 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. NG Author: Date: 278 DI–44 DIAGNOSTICS 3 – ENGINE (5S–FE) Check for open in harness or ECM. ON Engine Coolant Temp. Sensor 2 ECM E8 1 5V 4 9 E8 THW E2 E1 w/o Immobiliser OK E2 THW PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Connect between terminals THW and E2 of the ECM connector. HINT: The engine coolant temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–31). (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more Open in harness between terminals E2 or THW, repair or replace harness. w/ Immobiliser THW A03012 E2 A03411 NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–31). Author: Date: 279 DI–45 DIAGNOSTICS 4 – ENGINE (5S–FE) Check for short in harness and ECM. ON Engine Coolant Temp. Sensor ECM 5V 4 E8 9 E8 THW E2 E1 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: – 40°C (– 40°F) A00397 OK Replace engine coolant temp. sensor. NG Author: Date: 280 DI–46 DIAGNOSTICS 5 – ENGINE (5S–FE) Check for short in harness or ECM. ON Engine Coolant Temp. Sensor 5V THW E2 E1 w/o Immobiliser PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Disconnect the E8 connector from the ECM. HINT: The engine coolant temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) E8 Connector w/ Immobiliser OK Repair or replace harness or connector. E8 Connector A03011 A03412 NG Check and replace ECM (See page IN–31). Author: Date: 281 DI–47 DIAGNOSTICS – ENGINE (5S–FE) DI00Q–05 DTC P0116 Engine Coolant Temp. Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 (Engine Coolant Temp. Circuit Malfunction) on page DI–41. DTC No. DTC Detecting Condition Trouble Area If THW < –7°C (19.4°F) or THA < –7°C (19.4°F) 20 min. or more after starting engine, engine coolant temp. sensor value is 30°C (86°F)*1 20°C (48°F)*2 or less (2 trip detection logic) If THW –7°C (19.4°F) and THA
–7°C (19.4°F) and 10°C (50°F) at engine start, 5 min. or more after starting engine, engine coolant temp. sensor value is 30°C (86°F)*1 20°C (48°F)*2 or less (2 trip detection logic) P0116 If THW
10°C (50°F) and THA
10°C (50°F) at engine start, 2 min. or more after starting engine, engine coolant temp. sensor value is 30°C (86°F)*1 20°C (48°F)*2 or less (2 trip detection logic)
Engine coolant temp. sensor
Cooling system When THW 35°C (95°F) and 60°C (140°F), THA
–6.7°C (19.9°F) when starting the engine, condition (a) and (b) continues: (a) Vehicle speed is changing (Not stable) (b) Water temperature change is lower than 3°C (37.4°F) from the water temperature since when sterting the engine (2 trip detection logic) *1: Except California Specification vehicles. *2: Only for California Specification vehicles. INSPECTION PROCEDURE HINT:
If DTCs P0115 (Engine Coolant Temp. Circuit Malfunction) and P0116 (Engine Coolant Temp. Circuit Range/Performance Problem) are output simultaneously, engine coolant temp. sensor circuit may be open. Perform troubleshooting of DTC P0115 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0116) being output? YES Go to relevant DTC chart. NO Author: Date: 282 DI–48 DIAGNOSTICS 2 – ENGINE (5S–FE) Check thermostat (See page CO–10). NG Replace thermostat. OK Replace engine coolant temp. sensor. Author: Date: 283 DI–49 DIAGNOSTICS – ENGINE (5S–FE) DI00R–05 DTC P0120 Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 ∼ 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 ∼ 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from this signal input from terminal VTA, and uses it as one of the conditions for deciding the air– fuel ratio correction, power increase correction and fuel–cut control etc. ECM VC VTA E2 P24296 DTC No. P0120 DTC Detecting Condition Trouble Area Condition (a) or (b) continues with more than 5 sec.: (a) VTA < 0.1 V (b) VTA > 4.9 V
Open or short in throttle position sensor circuit
Throttle position sensor
ECM HINT: After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand–held tester to confirm the throttle valve opening percentage. Throttle valve opening position expressed as percentage Trouble Area Throttle valve fully closed Throttle valve fully open 0% 0% VC line open VTA line open or short Approx. 100 % Approx. 100 % E2 line open Author: Date: 284 DI–50 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM Throttle Position Sensor ECM 1 Y 3 LG 1 VC E8 10 11 E8 E8 5V VTA (*1) (*2) 2 BR 9 E2 E8 *1: w/o Immobiliser *2: w/ Immobiliser A03595 INSPECTION PROCEDURE HINT:

If DTCs P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure /Barometric Pressure Circuit Range/Performance Problem), P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction) and P0120 (Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 285 DI–51 DIAGNOSTICS 1 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA hand–held tester, read the throttle valve opening percentage. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the throttle valve opening percentage. OK: FI7052 OK Throttle valve Throttle valve opening position expressed as percentage Fully open Approx. 70 % Fully closed Approx. 10 % Check for intermittent problems (See page DI–3). NG 2 Check voltage between terminal VC of throttle position sensor connector and body ground. PREPARATION: (a) Disconnect the throttle position sensor connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal VC of the throttle position connector and body ground. OK: Voltage: 4.5 ∼ 5.5 V ON VC (+) A00369 NG Go to step 5. OK Author: Date: 286 DI–52 DIAGNOSTICS 3 – ENGINE (5S–FE) Check throttle position sensor (See page SF–29). NG Replace throttle position sensor. OK 4 Check voltage between terminals VTA and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VTA and E2 of the ECM connector. OK: ON w/o Immobiliser VTA (+) E2 (–) Throttle valve Voltage Fully closed 0.3 ∼ 1.0 V Fully open 3.2 ∼ 4.9 V w/ Immobiliser A03013 VTA (+) E2 (–) A03413 NG Check for open and short in harness and connector between ECM and throttle position sensor (VTA or E2 line) (See page IN–31). OK Check and replace ECM (See page IN–31). Author: Date: 287 DI–53 DIAGNOSTICS 5 – ENGINE (5S–FE) Check voltage between terminals VC and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 ∼ 5.5 V ON w/o Immobiliser VC (+) E2 (–) w/ Immobiliser A03008 E2 (–) VC (+) A03414 NG Check and replace ECM (See page IN–31). OK Check for open in harness and connector between ECM and sensor (VC line) (See page IN–31). Author: Date: 288 DI–54 DIAGNOSTICS – ENGINE (5S–FE) DI00S–04 DTC P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 (Throttle/Pedal Position Sensor/Switch "A" Circuit Malfunction) on page DI–49. DTC No. P0121 Detection Item Trouble Area After vehicle speed has been exceeded 30 km/h (19 mph) even once, output value of throttle position sensor is out of applicable range while vehicle speed between 30 km/h (19 mph) and 0 km/h (0 mph) (2 trip detection logic)
Throttle position sensor INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0121) being output? YES Go to relevant DTC chart. NO Replace throttle position sensor. Author: Date: 289 DI–55 DIAGNOSTICS – ENGINE (5S–FE) DI1JU–03 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air–fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air– fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air–fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air–fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. *: The voltage value changes at the inside of the ECM only. Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode ECM Monitored A/F Sensor Voltage Atmosphere Heater Coating (Ceramic) (V) 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 12 13 14 15 16 17 18 19 Air–Fuel Ratio Cover Exhaust Gas A00477 DTC No. P0125 DTC Detecting Condition After engine is warmed up, A/F sensor output* does not change when conditions (a), (b), and (c) continue for at least 1.5 min.: *: Output value changes at inside of ECM only (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 ∼ 100 km/h (25 ∼ 62 mph) (c) Throttle valve is not fully closed Trouble Area
Fuel system
Injector
Ignition system
Gas leakage on exhaust system
Open or short in A/F sensor circuit
A/F sensor
ECM Author: Date: 290 DI–56 DIAGNOSTICS – ENGINE (5S–FE) HINT: After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of A/F sensor from the CURRENT DATA. The ECM controls the voltage of AF
and AF terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester.


WIRING DIAGRAM J27 2 5 J/C 2 3 6 1 7 W–R 2 MAIN FL II3 4 II2 II4 4 G (*3) *3: California *4: Except California 1 B 2 HTAF E9 13 5 OX2 E8 E8 E04 (*2) (*1) E1 B–W (*5) 14 AF O (*6) E8 3.0V (*3) 12 P–B 14 21 HT2 E9 E9 (*2) (*1) EC *5:TMC Made 6 1 II3 Heated Oxygen Sensor (Bank 1 BR Sensor 2) *1: w/o Immobiliser *2: w/ Immobiliser Battery 3 AF
3.3V BR FL 1 Block 1 F4 F6 B W–R 2L 4 B 5 1K 3 1K EB B–G 1 2A 5 1B 2 (*3) 6 E8 to Analog–Digital Converter A/F Sensor 7 1W 4 W–B 2F AM2 EFI EFI Relay L (*5) W(*6) IGN Instrument Panel J/B 1 3 ECM J27 2K 7 2 2J Engine Room R/B No.2 J27 B–R (*1) J/C B–W(*2) B–Y P–B J27 II3 E B–R B IG Switch B–Y B–Y B J19 J/C B (*3) B–Y B B E B–Y 9 B–Y *6:TMMK Made B–W(*2) E03 7 E10 MREL (*2) A03597 INSPECTION PROCEDURE HINT:

If the vehicle run out fuel, the air–fuel ratio is LEAN and DTC P0125 will be recorded. The MIL then comes on. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 291 DI–57 DIAGNOSTICS 1 – ENGINE (5S–FE) Are there any other codes (besides DTC P0125) being output? YES Go to relevant DTC chart. NO 2 Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AF
terminal of ECM is 3.3 V fixed and the A/F terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF
/AF) of ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (* 0.660 V)
Not remains at 3.8 3 8 V (* 0.76 0 76 V) or more
Not remains at 2.8 V (* 0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (* 0.76 V), it is normal.
If output voltage of the A/F sensor remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F the sensor circuit may be open.
If output voltage of A/F sensor remains at 3.8 V (* 0.76 V) or more, or 2.8 V (* 0.56 V) or less even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 10. NG Author: Date: 292 DI–58 DIAGNOSTICS 3 – ENGINE (5S–FE) Check for open and short in harness and connector between ECM and A/F sensor (See page IN–31). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (See page SF–59). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Replace or replace. OK 6 Check EGR system (See page EC–12). NG Repair EGR system. OK 7 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 293 DI–59 DIAGNOSTICS 8 – ENGINE (5S–FE) Check injector injection (See page SF–23). NG Replace injector. OK 9 Check gas leakage on exhaust system. NG Repair or replace. OK Replace A/F sensor. 10 Perform confirmation driving pattern (See page DI–152). Go 11 Is there DTC P0125 being output again? YES Check and replace ECM. NO Author: Date: 294 DI–60 DIAGNOSTICS 12 – ENGINE (5S–FE) Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P0125 is caused by running out of fuel. Author: Date: 295 DI–61 DIAGNOSTICS – ENGINE (5S–FE) DI00T–05 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The heated oxygen sensor has the characteristic where by its output voltage changes suddenly in the vicinity of the stoichiometric air–fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air–fuel ratio. When the air–fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the heated oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air–fuel ratio is RICHER than the stoichiometric air–fuel ratio the oxygen concentration in the exhaust gas is reduced and the heated oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the heated oxygen sensor whether the air–fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the heated oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air–fuel ratio control. The heated oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Ideal Air–Fuel Mixture Flange Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) Output Voltage Atmosphere Richer – Air Fuel Ratio – Leaner Cover Exhaust Gas P21242 FI7210 DTC No. P0125 A00027 DTC Detecting Condition After engine is warmed up, heated oxygen sensor (bank 1 sensor 1) output does not indicate RICH even once when conditions (a), (b) and (c) continue for at least 1.5 min.: (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 ∼ 100 km/h (25 ∼ 62 mph) (c) Throttle valve does not fully closed Trouble Area
Fuel system
Injector
Ignition system
Gas leakage on exhaust system
Open or short in heated oxygen sensor (bank 1 sensor 1) circuit
Heated oxygen sensor (bank 1 sensor 1)
ECM Author: Date: 296 DI–62 DIAGNOSTICS – ENGINE (5S–FE) HINT: After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of the heated oxygen sensor (bank 1 sensor 1) from the CURRENT DATA. If voltage output of the heated oxygen sensor (bank 1 sensor 1) is 0 V, heated oxygen sensor (bank 1 sensor 1) circuit may be open or short. B–Y WIRING DIAGRAM B–Y B–Y B J/C J27 J19 J/C 9 II3 B B–Y J27 (*3) B–Y ECM B–Y E E J27 J27 B B–Y B W B–R (*1) 1 2A EB 2L 4 B–R 5 1K 3 1K 2 6 1 7 (*2) (*1) 4 L–Y (*3) 1 8 HT1 E9 E9 (*2) B (*1) E03 13 5 OX2 E8 E8 (*2) (*1) E1 12 II2 BR FL MAIN 6 1 II3 3 Heated Oxygen Sensor 4 (Bank 1 Sensor 2) Battery 2 BR II3 BR FL 1 Block 1 F6 F4 B–G W–R 3 5 6 OX1 E8 E8 E1 1 B P–B AM2 4 W–B 2F W–R 2 EFI 5 5 1B IG Switch EFI Relay IGN Instrument Panel J/B 1 7 1W BR 2K 7 3 B B–W(*2) Engine Room R/B No.2 2 2J 2 Heated Oxygen Sensor (Bank 1 Sensor 1) (*3) *1: w/o Immobiliser *2: w/ Immobiliser *3: Except California (*3) P–B 14 21 HT2 E9 E9 (*2) EC B–W (*2) II4 (*1) E03 7 E10 MREL (*2) A03596 INSPECTION PROCEDURE HINT:

If the vehicle run out fuel, the air–fuel ratio is LEAN and DTC P0125 will be recorded. The MIL then comes on. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 297 DI–63 DIAGNOSTICS 1 – ENGINE (5S–FE) Are there any other codes (besides DTC P0125) being output? YES Go to relevant DTC chart. NO 2 Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of heated oxygen sensor (bank 1 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp. (above 75°C (169°F)). CHECK: Read voltage output of the heated oxygen sensor (bank 1 sensor 1) when the engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 times using the accelerator pedal. OK: Heated oxygen sensor (bank 1 sensor 1) output a RICH signal (0.45 V or more) at least once. OK Go to step 10. NG 3 Check for open and short in harness and connector between ECM and heated oxygen sensor (bank 1 sensor 1) (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 298 DI–64 DIAGNOSTICS 4 – ENGINE (5S–FE) Check whether misfire is occurred or not by monitoring DTC and data list. NG Perform troubleshooting for misfire (See page DI–163). OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–12). NG Repair EGR system. OK 7 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 8 Check injector injection (See page SF–23) NG Replace injector. OK Author: Date: 299 DI–65 DIAGNOSTICS 9 – ENGINE (5S–FE) Check gas leakage on exhaust system. NG Repair or replace. OK Replace oxygen sensor (bank 1 sensor 1). 10 Perform confirmation driving pattern (See page DI–152). Go 11 Is there DTC P0125 being output again? YES Check and replace ECM. NO 12 Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P0125 is caused by running out of fuel. Author: Date: 300 DI–66 DIAGNOSTICS – ENGINE (5S–FE) DI00V–05 DTC P0130 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) (Except California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. DTC No. DTC Detecting Condition P0130 Voltage output of heated oxygen sensor remains at 0.4 V or more, or 0.55 V or less, during idling after engine is warmed up (2 trip detection logic) Trouble Area
Heated oxygen sensor
Fuel trim malfunction HINT: Sensor 1 refers to the sensor closer to the engine body. The heated oxygen sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. Author: Date: 301 DI–67 DIAGNOSTICS – ENGINE (5S–FE) CONFIRMATION DRIVING PATTERN Vehicle speed 50 ∼ 65 km/h (31 ∼ 40 mph) Idling IG SW OFF (4) (5) (3) (1) (2) 1 ∼ 3 min. 1 min. Time A01666 (1) Connect the TOYOTA hand–held tester to the DLC3. (2) Switch the TOYOTA hand–held tester from normal mode to check mode (See page DI–3). (3) Start the engine and warm it up with all accessory switches OFF. (4) Drive the vehicle at 50 ∼ 65 km/h (31 ∼ 40 mph) for 1 ∼ 3 min. to warm up the heated oxygen sensor. (5) Let the engine idle for 1 min. (6) Perform steps (3) to (5) three times. HINT: If a malfunction exists, the MIL will light up during step (6). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (3) to (6), then perform steps (3) to (6) again. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0130) being output? YES Go to relevant DTC chart. NO Author: Date: 302 DI–68 DIAGNOSTICS 2 – ENGINE (5S–FE) Check the output voltage of heated oxygen sensor during idling. PREPARATION: Warm up the heated oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensor during idling. OK: Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK Go to step 8. NG 3 Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 303 DI–69 DIAGNOSTICS 4 – ENGINE (5S–FE) Check air induction system (See page SF–1). NG Repair or replace. OK 5 Check EGR system (See page EC–12). NG Repair EGR system. OK 6 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 7 Check injector injection (See page SF–23). NG Replace injector. OK Replace oxygen sensor (bank 1 sensor 1). Author: Date: 304 DI–70 DIAGNOSTICS 8 – ENGINE (5S–FE) Perform confirmation driving pattern (See page DI–152). Go 9 Is there DTC P0130 being output again? NO Check for intermittent problems (See page DI–3). YES Check and Replace ECM (See page IN–31). Author: Date: 305 DI–71 DIAGNOSTICS – ENGINE (5S–FE) DI4NF–01 DTC P0133 Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) (Ex. CA Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. DTC No. DTC Detecting Condition Trouble Area P0133 Response time for heated oxygen sensor’s voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after engine is warmed up (2 trip detection logic)
Heated oxygen sensor
Fuel trim malfunction HINT: Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scantool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0133) being output? YES Go to relevant DTC chart. NO Author: Date: 306 DI–72 DIAGNOSTICS 2 – ENGINE (5S–FE) Check output voltage of heated oxygen sensor during idling. PREPARATION: Warm up the heated oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensor during idling. OK: Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK Go to step 8. NG 3 Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 307 DI–73 DIAGNOSTICS 4 – ENGINE (5S–FE) Check air induction system (See page SF–1). NG Repair or replace. OK 5 Check EGR system (See page EC–12). NG Replace EGR system. OK 6 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 7 Check injector injection (See page SF–23). NG Replace injector. OK Replace oxygen sensor (bank 1 sensor 1). Author: Date: 308 DI–74 DIAGNOSTICS 8 – ENGINE (5S–FE) Perform confirmation driving pattern (See page DI–152). Go 9 Is there DTC P0133 being output again? NG Check for intermittent problems (See page DI–3). YES Check and replace ECM (See page IN–31). Author: Date: 309 DI–75 DIAGNOSTICS – ENGINE (5S–FE) DI00X–04 DTC P0135 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) (Ex. CA Spec.) DTC P0141 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. DTC No. DTC Detecting Condition P0135 P0141 When heater operates, heater current exceeds 2 A (2 trip detection logic) P0135 P0141 Heater current of 0.2 A or less when heater operates (2 trip detection logic) Trouble Area
Open or short in heater circuit of heated oxygen sensor
Heated H t d oxygen sensor heater h t
ECM HINT:

Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 310 DI–76 DIAGNOSTICS 1 – ENGINE (5S–FE) Check voltage between terminals HT1, HT2 of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals HT1, HT2 of the ECM connector and body ground. HINT:
Connect terminal HT1 to bank 1 sensor 1.
Connect terminal HT2 to bank 1 sensor 2. OK: Voltage: 9 ∼ 14 V ON w/o Immobiliser HT1 HT2 w/ Immobiliser HT1 OK Check and replace ECM (See page IN–31). HT2 A03014 A03415 NG 2 Check resistance of heated oxygen sensor heaters (See pages SF–61, SF–63). NG Replace heated oxygen sensor. OK Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor, and heated oxygen sensor and ECM. (See page IN–31). Author: Date: 311 DI–77 DIAGNOSTICS – ENGINE (5S–FE) DI00Y–08 DTC P0136 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. DTC No. P0136 DTC Detecting Condition Trouble Area Voltage output of heated oxygen sensor remains at 0.45*1/0.40*2 V or more, or 0.60*1/0.50*2 V or less when vehicle is driven at 40 km/h (25 mph) or more after engine is warmed up *1: for California Spec. *2: except California Spec. (2 trip detection logic).
Heated oxygen sensor HINT: Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–55. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0136) being output? YES Go to relevant DTC chart. NO Author: Date: 312 DI–78 DIAGNOSTICS 2 – ENGINE (5S–FE) Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK 3 Check output voltage of heated oxygen sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp. CHECK: Read voltage output of the heated oxygen sensor when the engine suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 min. using the accelerator pedal. OK: Heated oxygen sensor output voltage: Alternates from 0.45*1/0.40* 2 V or less to 0.60*1/0.50* 2 V or more. *1: for California Spec. *2: except California Spec. OK Check that each connector is properly connected. NG Replace heated oxygen sensor. Author: Date: 313 DI–79 DIAGNOSTICS – ENGINE (5S–FE) DI1JW–03 DTC P0171 System too Lean (Fuel Trim) (Only for California Spec.) DTC P0172 System too Rich (Fuel Trim) (Only for California Spec.) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the A/F sensor is approximately proportional to the existing air–fuel ratio, and ECM comparing it with the ideal theoretical value, the ECM reduces fuel volume immediately if the air–fuel ratio is rich and increases fuel volume if it is lean. Long–term fuel trim compensates the deviation from the central value of the short–term fuel trim stored up by each engine tolerance, and the deviation from the central value due to the passage of time and changes of using environment. If both the short–term fuel trim and long–term fuel trim exceed a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on rich side (2 trip detection logic)
Gas leakage on exhaust system
Air intake (loose hoses)
Fuel line pressure
Injector blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
A/F sensor When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on lean side (2 trip detection logic)
Gas leakage on exhaust system
Fuel line pressure
Injector leak, blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
A/F sensor HINT:




When the DTC P0171 is recorded, the actual air–fuel ratio is on the lean side. When DTC P0172 is recorded, the actual air–fuel ratio is on the rich side. If the vehicle runs out of fuel, the air–fuel ratio is lean and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ± 38 %, the system is functioning normally. The A/F sensor output voltage and the short–term fuel trim value can be read using the OBD II scan tool or TOYOTA hand–held tester. The ECM controls the voltage of AF
and AF terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. Author: Date: 314 DI–80 DIAGNOSTICS
– ENGINE (5S–FE) OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air¯fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check air induction system (See page SF–1). NG Repair or replace. OK 2 Check injector injection (See page SF–23). NG Replace injector. OK 3 Check manifold absolute pressure sensor and engine coolant temp. sensor (See pages SF–53 and SF–49). NG Repair or replace. OK 4 Check for spark and ignition (See page IG–1). NG Repair or replace. OK Author: Date: 315 DI–81 DIAGNOSTICS 5 – ENGINE (5S–FE) Check fuel pressure (See page SF–6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter. OK 6 Check gas leakage on exhaust system. NG Repair or replace. OK Check and replace ECM (See page IN–31). Author: Date: 316 DI–82 DIAGNOSTICS 7 – ENGINE (5S–FE) Check output voltage of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AF
terminal of ECM is 3.3 V fixed and AF terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF
/AF) of ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (* 0.660 V)
Not remains at 3 3.8 8 V (* 0 0.76 76 V) or more
Not remains at 2.8 V (* 0.56 V) or less *: When you use OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of A/F sensor is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of A/F sensor is above 3.8 V (* 0.76 V), it is normally.
If output voltage of A/F sensor remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensor circuit may be open.
If output voltage of A/F sensor remains at 3.8 V (* 0.76 V) or more, or 2.8 V (* 0.56 V) or less even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG Author: Date: 317 DI–83 DIAGNOSTICS 8 – ENGINE (5S–FE) Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI–152). Go 10 Is there DTC P0171 or P0172 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P0171 or P0172 is caused by running out of fuel. Author: Date: 318 DI–84 DIAGNOSTICS – ENGINE (5S–FE) DI4NG–01 DTC P0171 System too Lean (Fuel Trim) (Except California Spec.) DTC P0172 System too Rich (Fuel Trim) (Except California Spec.) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the heated oxygen sensor indicates whether the air–fuel ratio is RICH or LEAN compared to the ideal theoretical value, triggering a reduction in fuel volume if the air–fuel ratio is rich, and an increase in fuel volume if it is lean. Long–term fuel trim is overall fuel compensation carried out long–term to compensate for continual deviation of the short–term fuel trim from the central value due to individual engine differences, wear over time and changes in the usage environment. If both the short–term fuel trim and long–term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on RICH side (2 trip detection logic)
Gas leakage on exhaust system
Air intake (hose loose)
Fuel line pressure
Injector blockage
Heated oxygen sensor (bank 1 sensor 1)
Manifold absolute pressure sensor
Engine coolant temp. sensor When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Gas leakage on exhaust system
Fuel line pressure
Injector leak, blockage
Heated oxygen sensor (bank 1 sensor 1)
Manifold absolute pressure sensor
Engine coolant temp. sensor HINT:



When the DTC P0171 is recorded, the actual air–fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air–fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air–fuel ratio is LEAN and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ± 38 %, the system is functioning normally. The heated oxygen sensor (bank 1 sensor 1) output voltage and the short–term fuel trim value can be read using the OBD II scan tool or TOYOTA hand–held tester. Author: Date: 319 DI–85 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check air induction system (See page SF–1). NG Repair or replace. OK 2 Check injector injection (See page SF–23). NG Replace injector. OK 3 Check manifold absolute pressure sensor and engine coolant temp. sensor (See pages SF–53 and SF–49). NG Repair or replace. OK 4 Check for spark and ignition (See page IG–1). NG Repair or replace. OK Author: Date: 320 DI–86 DIAGNOSTICS 5 – ENGINE (5S–FE) Check fuel pressure (See page SF–6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter. OK 6 Check gas leakage on exhaust system. NG Repair or replace. OK Check and replace ECM (See page IN–31). Author: Date: 321 DI–87 DIAGNOSTICS 7 – ENGINE (5S–FE) Check the output voltage of heated oxygen sensor during idling. PREPARATION: Warm up the heated oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensor during idling. OK: Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK Go to step 9. NG 8 Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK Replace oxygen sensor. Author: Date: 322 DI–88 DIAGNOSTICS 9 – ENGINE (5S–FE) Perform confirmation driving pattern (See page DI–66). Go 10 Is there DTC P0171 or P0172 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P0171 or P0172 is caused by running out of fuel. Author: Date: 323 DI–89 DIAGNOSTICS – ENGINE (5S–FE) DI011–07 DTC P0300 Random/Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in the crankshaft rotation for each cylinder. The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring occurs. DTC No. P0300 P0301 P0302 P0303 P0304 DTC Detecting Condition Misfiring Mi fi i off random d cylinders li d is i detected d t t d during d i any particular ti l 200 or 1,000 revolutions For any particular 200 revolutions for engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) Trouble Area
Ignition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure ressure sensor
Engine coolant temp. sensor
Open or short in engine wire
Connector connection
ECM HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the misfires were detected and recorded at different times. Author: Date: 324 DI–90 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM Instrument Panel J/B B–R IG Switch 7 8 1C B–R B–R W–R 5 1K 5 1B Injector 2 B B B–R J21 J/C 2 B Battery W–R AM2 MAIN FL 1 R B–R 1 Y No. 3 2 1 W 12 #10 E9 BR Engine Room J/B No. 2 11 E9 BR #20 10 25 E9 E9 (*2) (*1) 9 E9 24 #40 E9 (*2) No. 4 F4 1 F6 1 L No. 2 4 2L FL Block 1 No. 1 B–R B B–G 2 B 12 II3 B–R 6 3 1K ECM #30 (*1) 13 E9 26 E9 E01 E02 1 2A B EC *1: w/o Immobiliser *2: w/ Immobiliser A03626 Author: Date: 325 DI–91 DIAGNOSTICS – ENGINE (5S–FE) CONFIRMATION DRIVING PATTERN (1) Connect the TOYOTA hand–held tester or OBD II scan tool. (2) Record DTC and the freeze frame data. (3) Use the TOYOTA hand–held tester to set to Check Mode. (See page DI–3) (4) Drive the vehicle several times with the engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the data list. If you have no TOYOTA hand–held tester, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. HINT: In order to memorize DTC of misfire, it is necessary to drive around MISFIRE RPM, MISFIRE LOAD in the data list for the following period of time. Engine Speed Time Idling 3 minutes 30 seconds or more 1000 rpm 3 minutes or more 2000 rpm 1 minutes 30 seconds or more 3000 rpm 1 minutes or more (5) Check whether there is misfire or not by monitoring DTC and the freeze frame data. After that, record them. (6) Turn the ignition switch OFF and wait at least 5 seconds. Author: Date: 326 DI–92 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT:
If is the case that DTC besides misfire is memorized simultaneously, first perform the troubleshooting for them. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame data records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the vehicle is brought to the workshop and the misfire is not occurred, misfire can be confirmed by reproducing the condition or freeze frame data. Also, after finishing the repair, confirm that there is no misfire. (See the confirmation driving pattern) When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is besides the range of ±20%, there is a possibility that the air–fuel ratio is inclining either to ”rich” (–20% or less) or ”lean” (+20% or more). When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility or misfire only during warming up. In the case that misfire cannot be reproduced, the reason may be because of the driving with lack or fuel, the use of improper fuel, a stain of ignition plug, and etc.




1 Check wire harness, connector and vacuum hose in engine room. CHECK: (a) Check the connection conditions of the wire harness and connector. (b) Check the disconnection, piping and break of the vacuum hose. NG Repair or replace, then confirm that there is no misfire (See the confirmation driving pattern). OK Author: Date: 327 DI–93 DIAGNOSTICS 2 – ENGINE (5S–FE) Check spark plug and spark of misfiring cylinder. A00434 PREPARATION: (a) Disconnect the high–tension cord from the spark plug. (b) Remove the spark plug. CHECK: (a) Check the plug type. (b) Check the electrode for carbon deposits. (c) Check the electrode gap. OK: (a) Platinum–tipped spark plugs with twin ground electrodes. Recommended spark plug: ND made: PK20TR11 NGK made: BKR6EKPB–11 (b) No large carbon deposit present. Not wet with gasoline or oil. (c) Electrode gap: 1.1 mm (0.043 in.) PREPARATION: (a) Install the spark plug to the high–tension code. (b) Disconnect the injector connector. (c) Ground the spark plug. CHECK: Check if spark occurs while the engine is being cracked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 ∼ 10 seconds at a time. OK: Spark jumps across electrode gap. NG Replace or check ignition system (See page IG–1). OK Author: Date: 328 DI–94 DIAGNOSTICS 3 – ENGINE (5S–FE) Check voltage of ECM terminal for injector of failed cylinder. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON w/o Immobiliser #10 (+) #20 (+) #30 (+) #40 (+) w/ Immobiliser #10 (+) #20 (+) #30 (+) #40 (+) A03015 A03416 Reference: INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM With the engine idling, measure between terminals #10 ∼ #40 and E01 of the ECM connector. HINT: The correct waveforms are shown. Injector Signal Waveform (Magnification) 10 V/ Division 10 V/ Division GND GND 100 msec./Division (Idling) Injection duration FI6588 FI6538 1 msec./Division (Idling) A00064 OK Go to step 4. NG Author: Date: 329 DI–95 DIAGNOSTICS 4 – ENGINE (5S–FE) Check resistance of injector of misfiring cylinder (See page SF–20). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN–31). 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter. OK 6 Check injector injection (See page SF–23). NG Replace injector. OK 7 Check EGR system (See page EC–12). NG Repair EGR system. OK Author: Date: 330 DI–96 DIAGNOSTICS 8 – ENGINE (5S–FE) Check manifold absolute pressure sensor and engine coolant temp. sensor (See pages SF–53 AND SF–49). NG Repair or replace. OK Check compression pressure, valve clearance and valve timing (See pages EM–3, EM–4 AND EM–23). Author: Date: 331 DI–97 DIAGNOSTICS – ENGINE (5S–FE) DI012–10 DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more (2 trip detection logic)
Open or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM HINT: If the ECM detects above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM ECM Knock Sensor 1 1 W 12 E8 13 KNK E8 (*2) (*1) E1 *1: w/o Immobiliser *2: w/ Immobiliser A03598 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 332 DI–98 DIAGNOSTICS 1 ENGINE (5S–FE) Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Disconnect the E8 connector from the ECM. CHECK: Measure resistance between terminal KNK of the ECM connector and body ground. OK: Resistance: 1 MΩ or higher LOCK w/o Immobiliser E8 Connector KNK OK w/ Immobiliser E8 Connector A03016 – Go to step 3. KNK A03417 NG 2 Check knock sensor 1 (See page SF–57). NG Replace knock sensor 1. OK 3 Check for open and short in harness and connector between ECM and knock sensor 1 (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 333 DI–99 DIAGNOSTICS 4 – ENGINE (5S–FE) Does malfunction disappear when good knock sensor 1 is installed? YES Replace knock sensor 1. NO Check and replace ECM (See page IN–31). Reference: INSPECTION USING OSCILLOSCOPE With the engine racing (4,000 rpm), measure between terminal KNK of the ECM connector and body ground. HINT: The correct waveforms are as shown. KNK Signal Waveform 0.5 V/ Division 0V 5 msec./Division 0.5 V/ Division 0V 100 sec./Division A00406 Spread the time on the horizontal axis, and confirm that period of the wave is 132 µsec. (Normal mode vibration frequency of knock sensor: 7.6 kHz) HINT: If normal mode vibration frequency is not 7.6 kHz the sensor is malfunctioning. Author: Date: 334 DI–100 DIAGNOSTICS – ENGINE (5S–FE) DI013–10 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consist of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals of every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle the engine speed by the NE signals. DTC No. DTC Detecting Condition Trouble Area No crankshaft position sensor signal to ECM during cranking (2 trip detection logic) P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit.
Crankshaft C k h ft position iti sensor
Starter
ECM WIRING DIAGRAM ECM Camshaft Position Sensor 1 11 5 G+ E10 E9 B–W (*2) 2 L 1 B–R B–R 12 4 NE+ E10 E9 (*2) 2 BR L (*1) (*1) 6 17 NE– E10 E9 (*2) (*1) E1 Crankshaft Position Sensor *1: w/o Immobiliser *2: w/ Immobiliser A03599 Author: Date: 335 DI–101 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT:
Perform troubleshooting of DTC 335 first. If notrouble is found, troubleshoot the following mechanical system. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Check resistance of crankshaft position sensor (See page IG–1). G G and NE Signal Waveforms 5 V/ Division Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check between terminals G and G–, NE and NE– of the ECM HINT: The correct waveforms are as shown. NE 20 msec./Division (Idling) 5 V/ Division G NE A01991 A01992 10 msec./Division (Idling) A02359 NG Replace crankshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 336 DI–102 DIAGNOSTICS 3 – ENGINE (5S–FE) Inspect sensor installation and teeth of crankshaft timing pulley (See pages IG–10 and EM–15). NG Tighten the sensor. Replace crankshaft timing pulley. OK Check and replace ECM (See page IN–31). Author: Date: 337 DI–103 DIAGNOSTICS – ENGINE (5S–FE) DI014–09 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G signal) consist of signal plate and pickup coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. DTC No. DTC Detecting Condition No camshaft position sensor signal to ECM during cranking (2 trip detection logic) P0340 No camshaft position sensor signal to ECM with engine speed 600 rpm or more Trouble Area
Open or short in camshaft position sensor circuit
Camshaft position sensor
Distributor Di t ib t
Starter
ECM WIRING DIAGRAM Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–100. Author: Date: 338 DI–104 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check resistance of camshaft position sensor (signal generator) (See page IG–1). Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–100. NG Replace camshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN–31). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and tooth of camshaft timing pulley (See pages IG–9 and EM–17). NG Tighten the sensor. Replace camshaft timing pulley. OK Check and replace ECM (See page IN–31). Author: Date: 339 DI–105 DIAGNOSTICS – ENGINE (5S–FE) DI015–05 DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected CIRCUIT DESCRIPTION ← The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. Throttle Body This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut–off). Under the following conditions, EGR is cut to maintain driveabilThrottle ity. Valve ECM
Before engine is warmed up. EGR Valve
During deceleration (throttle valve closed).
Light engine load (amount of intake air very small).
Engine idling. VSV
Engine speed over 4,400 rpm.
High engine load (amount of intake air very large). EGR Exhaust Gas Vacuum Modulator P25430 DTC No. P0401 DTC Detecting Condition After engine is warmed up, intake manifold absolute pressure is larger than value calculated by ECM while EGR system is ON (2 trip detection logic) Trouble Area
EGR valve stuck closed
Open or short in VSV circuit for EGR
Vacuum or EGR hose disconnected
Manifold absolute pressure sensor
VSV for EGR open or close malfunction
ECM Author: Date: 340 DI–106 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM ECM 9 II3 J19 J/C B−Y B B B−Y VSV for EGR 2 1 P−B B−Y B W−B From Battery 1 2A EFI 5 3 2 2J 4 2F 2 1 7 2K B−Y B−W (*2) 6 II4 (*1) 15 23 EGR E8 E9 (*2) (*1) E01 From Ignition SW B−W (*2) EFI Relay 7 E10 MREL (*2) Engine Room J/B No.2 EB *1: w/o Immobiliser *2: w/ Immobiliser A07551 Author: Date: 341 DI–107 DIAGNOSTICS – ENGINE (5S–FE) SYSTEM CHECK DRIVING PATTERN Vehicle Speed 60 ∼ 80 km/h (38 ∼ 50 mph) Idling IG SW OFF (6) (3) (2) (7) (4) (5) (1) Warm up 3 ∼ 5 min. 2 min. 3 ∼ 5 min. 2 min. Time P20769 (1) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (2) Start and warm up the engine with all accessories switched OFF. (3) Run the vehicle at 60 ∼ 80 km/h (38 ∼ 50 mph) for 3 min. or more. (4) Idle the engine for about 2 min. (5) Do steps (3) and (4) again. (6) Stop at safe place and turn the ignition switch OFF. (7) Do steps (2) to (5) again. (8) Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand–held tester. If COMPL is displayed and the MIL does not light up, the system is normal. If INCMPL is displayed and the MIL does not light up, run the vehicle again and check it. HINT: INCMPL is displayed when either condition (a) or (b) exists. (a) The system check is incomplete. (b) There is a malfunction in the system. If there is a malfunction in the system, the MIL will light up after steps (2) to (5) above are done. (2 trip detection logic) INSPECTION PROCEDURE HINT:


If DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance Problem) and P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) are output simultaneously, perform troubleshooting of DTC P0105 first. If DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) and P0402 (Exhaust Gas Recirculation Flow Excessive Detected) are output simultaneously, perform troubleshooting of DTC P0402 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 342 DI–108 DIAGNOSTICS – ENGINE (5S–FE) TOYOTA hand–held tester: 1 Check connection of the vacuum hose and EGR hose (See page EC–12). NG Repair or replace. OK 2 Check VSV for EGR. Air Air E G E Air Filter System: OFF G System: ON A00407 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check operation of the VSV when it is operated by the TOYOTA hand–held tester. OK: EGR system is OFF: Air from port E is flowing out through the air filter. EGR system is ON: Air from port E is flowing out port G. OK Go to step 4. NG 3 Check operation of the VSV for EGR (See page SF–43). NG Replace VSV for EGR. OK Check for open and short in harness and connector between engine room J/B No.2 and ECM (See page IN–31). Author: Date: 343 DI–109 DIAGNOSTICS 4 – ENGINE (5S–FE) Check EGR system (See page EC–12). NG Repair or replace. OK 5 Check EGR vacuum modulator (See page EC–12). NG Repair or replace. OK 6 Check EGR valve (See page EC–12). NG Repair or replace. OK 7 Check manifold absolute pressure sensor (See page SF–53). NG Repair or replace. OK Check and replace ECM (See page IN–31). Author: Date: 344 DI–110 DIAGNOSTICS – ENGINE (5S–FE) OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check connection of vacuum hose and EGR hose (See page EC–12). NG Repair or replace. OK 2 Check VSV for EGR. ON w/o Immobiliser E9 Connector EGR ON w/ Immobiliser OFF Air E8 Connector EGR Air OFF ON A03017 Air Filter VSV is ON Air OK E E G PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Disconnect the E9 connector (w/o immobilizer) or E8 connector (w/ immobilizer) the ECM. (c) Turn the ignition switch ON. CHECK: Check VSV function (1) Connect between terminal EGR of the ECM connector and body ground (ON). (2) Disconnect between terminal EGR of the ECM connector and body ground (ON). OK: (1) VSV is ON: Air from port E is flowing out through the air filter. (2) VSV is OFF: Air from port E is flowing out port G. Go to step 4. G VSV is OFF A03418 NG Author: Date: 345 DI–111 DIAGNOSTICS 3 – ENGINE (5S–FE) Check operation of VSV for EGR (See page SF–43). NG Replace VSV for EGR. OK Check for open and short in harness and connector between engine room J/B No.2 and ECM (See page IN–31). 4 Check EGR system (See page EC–12). NG Repair or replace. OK 5 Check EGR vacuum modulator (See page EC–12). NG Repair or replace. OK 6 Check EGR valve (See page EC–12). NG Repair or replace. OK Author: Date: 346 DI–112 DIAGNOSTICS 7 – ENGINE (5S–FE) Check manifold absolute pressure sensor (See page SF–53). NG Repair and replace. OK Check and replace ECM (See page IN–31). Author: Date: 347 DI–113 DIAGNOSTICS – ENGINE (5S–FE) DI016–04 DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected CIRCUIT DESCRIPTION Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on page DI–105. DTC No. P0402 DTC Detecting Condition Trouble Area After engine is warmed up, conditions (a) and (b) continue: (a) Intake manifold absolute pressure is larger than value calculated by ECM while EGR system is ON (b) Misfiring is detected during idling (2 trip detection logic)
EGR valve stuck open
Vacuum or EGR hose is connected to wrong post
Manifold absolute pressure sensor
ECM WIRING DIAGRAM Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on DI–105. SYSTEM CHECK DRIVING PATTEM Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on DI–105. INSPECTION PROCEDURE HINT:
If DTC P0105 (Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction), P0106 (Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance Problem) and P0402 (Exhaust Gas Recirculation Flow Excessive Detected) are output simultaneously, perform troubleshooting of DTC P0105 first. If DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) and P0402 (Exhaust Gas Recirculation Flow Excessive Detected) are output simultaneously, perform troubleshooting of DTC P0402 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.

1 Check connection of vacuum hose and EGR hose (See page EC–12). NG Repair or replace. OK Author: Date: 348 DI–114 DIAGNOSTICS 2 – ENGINE (5S–FE) Check EGR valve (See page EC–12). NG Repair or replace. OK 3 Check VSV for EGR*. *: If you have TOYOTA hand–held tester, see page DI–105, step 2. If you have no TOYOTA hand–held tester, see page DI–105, step 2. OK Go to step 4. NG 4 Check operation of VSV for EGR (See page SF–43). NG Replace VSV for EGR. OK Check for open and short in harness and connector between engine room J/B No.2 and ECM (See page IN–31). 5 Check EGR system (See page EC–12.) NG Repair or replace. OK Author: Date: 349 DI–115 DIAGNOSTICS 6 – ENGINE (5S–FE) Check EGR vacuum modulator (See page EC–12). NG Repair or replace. OK 7 Check manifold absolute pressure sensor (See page SF–53). NG Repair or replace. OK Check and replace ECM (See page IN–31). Author: Date: 350 DI–116 DIAGNOSTICS – ENGINE (5S–FE) DI1JX–03 DTC P0420 Catalyst System Efficiency Below Threshold (Except California Spec.) CIRCUIT DESCRIPTION The ECM compares the waveform of the heated oxygen sensor located before the catalyst with the waveform of the heated oxygen sensor located behind the catalyst to determine whether or not catalyst performance has deteriorated. Air–fuel ratio feedback compensation keeps the waveform of the heated oxygen sensor before the catalyst repeatedly changing back and forth from rich to lean. If the catalyst is functioning normally, the waveform of the heated oxygen sensor behind the catalyst switches back and forth between rich and lean much more slowly than the waveform of the heated oxygen sensor before the catalyst. But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated. Waveform of Heated Oxygen Sensor before Catalyst Normal Catalyst Waveform of Heated Oxygen Sensor behind Catalyst FI7081 DTC No. P0420 DTC Detecting Condition After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed range, waveforms of heated oxygen sensors (bank 1 sensor 1, 2) have same amplitude (2 trip detection logic) Trouble Area
Three–way catalytic converter
Open or short in heated oxygen sensor circuit
Heated oxygen sensor Author: Date: 351 DI–117 DIAGNOSTICS – ENGINE (5S–FE) CONFIRMATION ENGINE RACING PATTERN Engine Speed (c) 2,500 ∼ 3,000 rpm (b) Idling IG SW OFF (d) (a) 3 min. or so Warmed up Check Time FI7132 (a) (b) (c) (d) Connect the TOYOTA hand–held tester to the DLC3, or connect the probe of the oscilloscope between terminals OX1, OX2 and E1 of the ECM connector. Start engine and warm it up with all accessories switched OFF until water temp. is stable. Race the engine at 2,500 ∼ 3,000 rpm for about 3 min. After confirming that the waveforms of the heated oxygen sensor (bank 1 sensor 1 (OX1)), oscillate around 0.5 V during feedback to the ECM, check the waveform of the heated oxygen sensor (bank 1 sensor 2 (OX2)). OX Signal Waveform (Oscilloscope) 1.0 V HINT:

0V 200 msec. /Division If there is a malfunction in the system, the waveform of the heated oxygen sensor (bank 1 sensor 2 (OX2)) is almost the same as that of the heated oxygen sensor (bank 1 sensor 1 (OX1)) on the left. There are some cases where, even though a malfunction exists, the MIL may either light up or not light up. FI6514 Author: Date: 352 DI–118 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0420) being output? YES Go to relevant DTC chart. NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK 3 Check heated oxygen sensor (bank 1 sensor 1) (See page DI–66). NG Repair or replace. OK 4 Check heated oxygen sensor (bank 1 sensor 2) (See page DI–77). NG Repair or replace. OK Replace three–way catalytic converter. Author: Date: 353 DI–119 DIAGNOSTICS – ENGINE (5S–FE) DI1JY–03 DTC P0420 Catalyst System Efficiency Below Threshold (Only for California Spec.) CIRCUIT DESCRIPTION The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flutteringly between rich and lean, it indicates that catalyst performance has deteriorated. Waveform of A/F Sensor Normal Catalyst Waveform of Heated Oxygen Sensor behind Catalyst Abnormal Catalyst A00357 DTC No. DTC Detecting Condition P0420 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed range, waveform of heated oxygen sensor (bank 1 sensor 2) alternates flutteringly between rich and lean (2 trip detection logic) Trouble Area
Three–way catalytic converter
Open or short in heated oxygen sensor (bank 1 sensor 2) circuit
Heated oxygen sensor (bank 1 sensor 2)
Open or short in A/F sensor circuit
A/F sensor Author: Date: 354 DI–120 DIAGNOSTICS – ENGINE (5S–FE) CONFIRMATION ENGINE RACING PATTERN Engine Speed (c) (d) 3,000 rpm 2,000 rpm Idling IG SW OFF (b) (a) Time Warmed up 3 min. or so 2 sec. 2 sec. Check A00479 (a) (b) (c) (d) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. Start the engine and warm it up with all accessories switched OFF until water temp. is stable. Race the engine at 2,500 ∼ 3,000 rpm for about 3 min. When racing the engine at 3,000 rpm for 2 sec. and 2,000 rpm for 2 sec. alternately, check the waveform of the heated oxygen sensor (bank 1 sensor 2). INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0420) being output? YES Go to relevant DTC chart. NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK Author: Date: 355 DI–121 DIAGNOSTICS 3 – ENGINE (5S–FE) Check A/F sensor (See page DI–66). NG Repair or replace. OK 4 Check heated oxygen sensor (bank 1 sensor 2) (See page DI–77). NG Repair or replace. OK Replace three–way catalytic converter. Author: Date: 356 DI–122 DIAGNOSTICS – ENGINE (5S–FE) DI1JZ–04 DTC P0440 Evaporative Emission Control System Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0440 is recorded by the ECM when evaporative emissions leak from the components within the dotted line in fig. 1 below, or when the vapor pressure sensor malfunctions. ECM fig.1 Vapor Pressure Sensor (6) (7) VSV for EVAP (1) VSV for Vapor Pressure Sensor Fuel Tank Over Fill (2) Check Valve (8) (9) (4) (5) (3) Fuel Tank Charcoal Canister A06549 DTC No. P0440 DTC Detecting Condition Fuel tank pressure is atmospheric pressure after vehicle is driven for 20 min. (2 trip detection logic) Trouble Area
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in fig. 1)
Hose or tube cracked, holed, damaged or loose seal ((3) in fig. 1)
Fuel tank cracked, holed or damaged
Charcoal canister cracked, holed or damaged
Fuel tank over fill check valve cracked or damaged Author: Date: 357 DI–123 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM ECM Vapor Pressure Sensor 3 Y 2 P 1 E 6 ID1 1 J28 J27 5 II4 PTNK E2 V 3 22 E9 E9 (*2) (*1) 16 8 E8 E8 (*2) (*1) EVP TPC E01 E01 Engine Room J/B No.2 1 From Battery J27 2A 4 W–B J27 2 V 5V B–Y J/C B (*1) VC E1 VSV for Vapor Pressure Sensor B–Y B 1 ID1 2 (*2) 9 V–W 1 V 7 E8 E8 VSV for EVAP B 8 E8 BR B–Y B–Y J/C E 3 B–Y B E8 P II2 J19 J/C II3 10 8 II4 BR ID1 1 Y II4 P 2 BR 7 Y ID1 9 B–Y B–Y 5 ID1 2F EFI 5 3 2 1 2 2J 7 2K (*2) B–W 6 II4 (*2) B–W 7 E10 MREL (*2) EFI Relay B–R (*1) EB From Ignition SW *1: w/o Immobiliser *2: w/ Immobiliser A07552 INSPECTION PROCEDURE HINT:



If DTC P0441 (Evaporative Emission Control System Incorrect Purge Flow), P0446 (Evaporative Emission Control System Vent Control Malfunction), P0450 (Evaporative Emission Control System Pressure Sensor Malfunction) or P0451 is output after DTC P0440 (Evaporative Emission Control System Malfunction), first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Ask the customer whether, after the MIL came on, the customer found the fuel tank cap loose and tightened it. Also ask the customer whether the fuel tank cap was loose when refuelling. If the fuel tank cap was not loose, it was the cause of the DTC. If the fuel tank cap was not loose or if the customer was not sure if it was loose, troubleshoot according to the following procedure. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor. Author: Date: 358 DI–124 DIAGNOSTICS 1 – ENGINE (5S–FE) Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near the fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of the following parts.
Fuel tank
Charcoal canister
Fuel tank filler pipe
Hoses and tubes around fuel tank and charcoal canister A01653 NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed. NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC–6). NG Replace fuel tank cap. OK Author: Date: 359 DI–125 DIAGNOSTICS 5 – ENGINE (5S–FE) Check filler neck for damage. PREPARATION: Remove the fuel tank cap. CHECK: Visually check the filler neck for damage. NG Replace filler neck. OK 6 Check vacuum hoses between vapor pressure sensor and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole and damage. NG Repair or replace. OK 7 Check hose and tube between fuel tank and charcoal canister. CHECK: (a) Check for proper connection of the fuel tank and fuel evap pipe, fuel evap pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister. (b) Check the hose and tube for cracks, hole and damage. NG Repair or replace. OK Author: Date: 360 DI–126 DIAGNOSTICS 8 – ENGINE (5S–FE) Check charcoal canister (See page EC–6). NG Replace charcoal canister. OK 9 Check voltage between terminals VC and E2 of ECM connector. CHECK: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 ∼ 5.5 V ON w/o Immobiliser E2 (–) VC (+) NG Check and replace ECM (See page IN–31). w/ Immobiliser A03008 E2 (–) VC (+) A03419 OK Author: Date: 361 DI–127 DIAGNOSTICS 10 – ENGINE (5S–FE) Check voltage between terminals PTNK and E2 of ECM connector. ON w/o Immobiliser E2 (–) PTNK (+) w/ Immobiliser PTNK (+) E2 (–) (1) PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals PTNK and E2 of the ECM connector. (1) Disconnect the vacuum hose from the vapor pressure sensor. (2) Using the MITYVAC (Hand–Held Vacuum Pump), apply vacuum 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor. NOTICE: The vacuum applied to the vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg). OK: (1) Voltage: 2.9 ∼ 3.7 V (2) Voltage: 0.5 V or less (2) OK A03018 Go to step 12. Vacuum A03420 NG 11 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 362 DI–128 DIAGNOSTICS 12 – ENGINE (5S–FE) Check fuel tank and fuel tank over fill check valve for cracks and damage (See page EC–6). NG Replace fuel tank or fuel tank over fill check valve. OK It is likely that vehicle user did not properly close fuel tank cap. Please explain to customer how to properly install fuel tank cap. Author: Date: 363 DI–129 DIAGNOSTICS – ENGINE (5S–FE) DI019–10 DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC P0446 Evaporative Emission Control System Vent Control Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components within the dotted line in fig. 1 below, or when there is a malfunction in either the VSV for EVAP, the VSV for vapor pressure sensor, or in the vapor pressure sensor itself. ECM fig.1 Vapor Pressure Sensor (7) VSV for EVAP (6) (1) (4) VSV for Vapor Pressure Sensor (2) (5) Fuel Tank Over Fill Check Valve (8) (9) (3) Charcoal Canister Fuel Tank A06550 Author: Date: 364 DI–130 DIAGNOSTICS DTC No. – ENGINE (5S–FE) DTC Detecting Condition Trouble Area Pressure in the charcoal canister does not drop during purge control (2 trip detection logic) P0441 During purge cut–off, pressure in charcoal canister is very low compared with atmospheric pressure (2 trip detection logic) When VSV for vapor pressure sensor is OFF, ECM judges that there is no continuity between vapor pressure sensor and charcoal canister (2 trip detection logic) P0446 When VSV for vapor pressure sensor is ON, ECM judges that there is no continuity between vapor pressure sensor and fuel tank (2 trip detection logic)
Open or short in VSV circuit for vapor pressure sensor
VSV for vapor pressure sensor
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
Open or short in VSV circuit for EVAP
VSV for EVAP
Vacuum hose cracks, cracks hole, hole blocked, blocked damaged or disconnected ((1), (4), (5) holed (6) and (7) in fig. 1)
Charcoal canister cracked, holed or damaged
Fuel tank over fill check valve cracked or damaged After purge cut off operates, pressure in charcoal canister is maintained at atmospheric pressure (2 trip detection logic) WIRING DIAGRAM Refer to DTC P0440 (Evaporative Emission Control System Malfunction) on page DI–122. INSPECTION PROCEDURE TOYOTA hand–held tester: HINT:


If DTC P0441 (Evaporative Emission Control System Incorrect Purge Flow), P0446 (Evaporative Emission Control System Vent Control Malfunction), P0450 (Evaporative Emission Control System Pressure Sensor Malfunction) or P0451 is output after DTC P0440 (Evaporative Emission Control System Malfunction), first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor. Author: Date: 365 DI–131 DIAGNOSTICS 1 – ENGINE (5S–FE) Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 2 Check vacuum hoses (1), (4), (5), (6), (7), (8) and (9) on page DI–122). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 3 Check voltage between terminals VC and E2 of ECM connector (See page DI–122, step 9). NG Check and replace ECM (See page IN–31). OK 4 Check voltage between terminals PTNK and E2 of ECM connector (See page DI–122, step 10). OK Go to step 6. NG Author: Date: 366 DI–132 DIAGNOSTICS 5 – ENGINE (5S–FE) Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. 6 Check purge flow. VSV is ON PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (c) Disconnect the vacuum hose for the VSV for EVAP from the charcoal canister. (d) Start the engine. CHECK: When the VSV for EVAP is operated by the TOYOTA hand– held tester, check whether the disconnected hose applies suction to your finger. OK: VSV is ON: Disconnected hose applies suction to your finger. VSV is OFF: Disconnected hose applies no suction to your finger. To Throttle Body Suction VSV is OFF To Throttle Body No Suction A03278 A03279 OK Go to step 10. A03456 NG Author: Date: 367 DI–133 DIAGNOSTICS 7 – ENGINE (5S–FE) Check vacuum hose between intake manifold and VSV for EVAP, and VSV for EVAP and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 8 Check operation of VSV for EVAP (See page SF–45). OK Go to step 9. NG Replace VSV, charcoal canister and then clean the vacuum hose between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister. 9 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 368 DI–134 DIAGNOSTICS 10 – ENGINE (5S–FE) Check the VSV for vapor pressure sensor. ON E F VSV is ON E G F G VSV is OFF A00472 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check the VSV operation when it is operated by TOYOTA hand–held tester. OK: (1) VSV is ON: Air from port E is flowing out through port F. (2) VSV is OFF: Air from port E is flowing out through port G. OK Go to step 13. NG 11 Check operation of VSV for vapor pressure sensor (See page SF–47). OK Gp to step 12. NG Replace VSV charcoal canister, and then clean the vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and vapor pressure sensor. Author: Date: 369 DI–135 DIAGNOSTICS 12 – ENGINE (5S–FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 13 When VSV connector for vapor pressure sensor is disconnected and VSV for EVAP is ON, measure voltage between terminals PTNK and E2 of ECM connector. VSV Connector for Vapor Pressure Sensor w/o Immobiliser PTNK (+) PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Disconnect the VSV connector for the vapor pressure sensor. (d) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (e) Start the engine. CHECK: Measure voltage between terminals PTNK and E2 of the ECM connector using the TOYOTA hand–held tester when the VSV for the EVAP is ON. OK: Voltage: 2.0 V or less E2 (–) w/ Immobiliser OK A03280 A03018 PTNK (+) Go to step 15. E2 (–) A03421 NG Author: Date: 370 DI–136 DIAGNOSTICS 14 – ENGINE (5S–FE) Check vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and vapor pressure sensor and VSV for vapor pressure sensor. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 15 Engine Check the charcoal canister. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Remove the fuel tank cap. (d) Disconnect the VSV connector for the vapor pressure sensor. (e) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (f) Start the engine. (g) The VSV for the EVAP is ON by the TOYOTA hand–held tester and remains on for 5 sec. CHECK: Measure voltage between terminals PTNK and E2 of the ECM connector 5 sec. after switching the VSV for the EVAP from ON to OFF. OK: Voltage: 2.5 V or less Start Stop VSV for Vapor ON Pressure Sensor OFF ON VSV for EVAP OFF 5 sec. 5 sec. w/o Immobiliser PTNK (+) E2 (–) w/ Immobiliser NG A03018 PTNK (+) Replace charcoal canister. E2(–) A03422 OK Author: Date: 371 DI–137 DIAGNOSTICS 16 – ENGINE (5S–FE) Remove charcoal canister and check it (See page EC–5) NG Replace charcoal canister. OK 17 Check fuel tank over fill check valve (See page EC–6). NG Replace fuel tank over fill check valve or fuel tank. OK Check and replace ECM (See page IN–31). OBD II scan tool (excluding TOYOTA hand–held tester): HINT: If DTC P0441 (Evaporative Emission Control System Incorrect Purge Flow), P0446 (Evaporative Emission Control System Vent Control Malfunction) or P0450 (Evaporative Emission Control System Pressure Sensor Malfunction) is output after DTC P0440 (Evaporative Emission Control System Malfunction), first troubleshoot DTC P0441, P0446 or P0450. If no malfunction is detected, troubleshoot DTC P0440 next. 1 Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK Author: Date: 372 DI–138 DIAGNOSTICS 2 – ENGINE (5S–FE) Check vacuum hoses ((1), (4), (5), (6), (7), (8) and (9) on page DI–122). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 3 Check voltage between terminals VC and E2 of ECM connector (See page DI–122, step 9). NG Check and replace ECM (See page IN–31). OK 4 Check voltage between terminals PTNK and E2 of ECM connector (See page DI–122, step 10). OK Go to step 6. NG 5 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 373 DI–139 DIAGNOSTICS 6 – ENGINE (5S–FE) Check VSV for EVAP. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal EVP of the ECM connector and body ground (ON). (2) Disconnect between terminal EVP of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from port E is flowing out through port F. (2) VSV is OFF: Air does not flow from port E to port F. ON w/o Immobiliser EVP ON OFF w/ Immobiliser E EVP ON OFF OK E F A03019 Go to step 8. E F VSV is ON VSV is OFF A03423 NG 7 Check operator of VSV for EVAP (See page SF–45). NG Go to step 9. OK Replace VSV and clean vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister, and then check charcoal canister. Author: Date: 374 DI–140 DIAGNOSTICS 8 – ENGINE (5S–FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, and VSV for EVAP and ECM (See page IN–31) NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 9 Check VSV for vapor pressure sensor. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: (a) Connect between terminal TPC of the ECM connector and body ground (ON). (b) Disconnect between terminal TPC of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from port E is flowing out through port F. (2) VSV is OFF: Air from port E is flowing out through port G. ON w/o Immobiliser OFF TPC ON w/ Immobiliser OFF TPC ON E F E G VSV is ON A03020 F G VSV is OFF A03424 OK Check and replace charcoal canister (See page EC–6). NG Author: Date: 375 DI–141 DIAGNOSTICS 10 – ENGINE (5S–FE) Check operation of VSV for vapor pressure sensor (See page SF–47). NG Go to step 11. OK Replace VSV and clean vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and vapor pressure sensor, and then check the charcoal canister. 11 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 12 Check fuel tank over fill check valve (See page EC–6). NG Replace fuel tank over fill check valve or fuel tank. OK Check and replace charcoal canister (See page EC–6). Author: Date: 376 DI–142 DIAGNOSTICS – ENGINE (5S–FE) DI1K0–04 DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range/Performance CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 is recorded by the ECM when the vapor pressure sensor malfunction. ECM Vapor Pressure Sensor VSV for Vapor Pressure Sensor VSV for EVAP Fuel Tank Over Fill Check Valve Charcoal Canister Fuel Tank A06551 Author: Date: 377 DI–143 DIAGNOSTICS DTC No. – ENGINE (5S–FE) DTC Detecting Condition Trouble Area P0450 10 seconds or more after engine starting codition (a) or (b) continues for 7 seconds or more: (2 trip detection logic) (a) vapor pressure sensor value < –4 kpa (–30 mmHg, –1.0 in.Hg) (b) Vapor pressure sensor value
2.1 kpa (–15 mmHg, 0.4 in.Hg) P0451 Vapor pressure sensor output extremely changes under conditions of (a), (b) and (c): (2 trip detection logic) (a) Vehicle speed: 0 km/h (0 mph) (b) Engine speed: idling (c) VSV for vapor pressure sensor is ON
Open or short in vapor pressure sensor circuit
Vapor pressure sensor
ECM
Fuel F l tank t k over fill check h k valve l cracked k d or damaged. d d WIRING DIAGRAM Refer to DTC P0440 (Evaporative Emission Control System Malfunction) on page DI–122. INSPECTION PROCEDURE HINT:
If DTC P0441 (Evaporative Emission Control System Incorrect Purge Flow), P0446 (Evaporative Emission Control System Vent Control Malfunction), P0450 (Evaporative Emission Control System Pressure Sensor Malfunction) or P0451 is output after DTC P0440 (Evaporative Emission Control System Malfunction), first troubleshoot DTC P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor.

1 Check voltage between terminals VC and E2 of ECM connector (See page DI–122, step 9). NG Check and replace ECM (See page IN–31). OK Author: Date: 378 DI–144 DIAGNOSTICS 2 – ENGINE (5S–FE) Check voltage between terminals PTNK and E2 of ECM connector (See page DI–122, step 10 ). OK Check and replace ECM (See page IN–31). NG 3 Check for open and short in harness and connector between the vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 379 DI–145 DIAGNOSTICS – ENGINE (5S–FE) DI01B–10 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The No.1 vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pluse signals. 4–Pulse 4–Pulse No.1 Vehicle Speed Sensor Combination Meter ECM Transaxle No.1 Vehicle Speed Sensor A00414 DTC No. DTC Detecting Condition Trouble Area P0500 During vehicle is being driven, no vehicle speed sensor signal to ECM (2 trip detection logic)
Combination meter
Open or short in No.1 vehicle speed sensor circuit
No.1 vehicle speed sensor
ECM WIRING DIAGRAM ECM Combination Meter 14 C9 5V V–W 3 IG3 J15 J/C V–W V–W B B 8 E7 9 SPD E7 (*2) (*1) *1: w/o Immobiliser *2: w/ Immobiliser A03601 Author: Date: 380 DI–146 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. See combination meter troubleshooting (See page BE–2). OK Author: Date: 381 DI–147 DIAGNOSTICS 2 ENGINE (5S–FE) Check voltage between terminal SPD of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn the ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. ON w/o Immobiliser SP1 (+) w/ Immobiliser A03021 – 4.5 ∼ 5.5 V SP1 (+) 0 Turn the wheel A03425 NG AT7809 Check and repair harness and connector between combination meter and ECM. OK Check and replace ECM (See page IN–31). Author: Date: 382 DI–148 DIAGNOSTICS – ENGINE (5S–FE) DI01C–05 DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION Intake Air Chamber Throttle Valve From Air Cleaner Signal The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle–up and provide feedback for the target idling speed. ECM Valve To Cylinder IAC Valve P01559 DTC No. DTC Detecting Condition Trouble AreaTrouble Area
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C switch circuit
Air intake (hose loose)
ECM Idle speed continues to vary greatly from the target speed (2 trip detection logic) P0505 WIRING DIAGRAM ECM IAC Valve J19 J/C 9 II3 W B–Y 1 B–Y B 2 B B–Y B–O 3 7 E9 10 E9 (*2) (*1) 6 E9 9 E9 (*2) (*1) ISCO ISCC E01 E01 Engine Room J/B No.2 From Battery W–B B EB 1 2A EFI 5 3 2 2J 4 2F 2 1 7 2K B–W (*2) 6 II4 B–W (*2) 7 E10 MREL (*2) EFI Relay B–R (*1) From Ignition SW *1: w/o Immobiliser *2: w/ Immobiliser Author: Date: A07553 383 DI–149 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the air conditioning. (d) Shift the transmission into N or neutral position. (e) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3 on the vehicle. (f) Using SST, connect terminals TE1 and E1 of the DLC1. CHECK: Check the difference of engine speed between the ones less than 5 sec. and more than 5 sec. after connecting terminals TE1 and E1 of the DLC1. OK: Difference of engine speed: More than 100 rpm OK Go to step 6. NG Author: Date: 384 DI–150 DIAGNOSTICS 2 – ENGINE (5S–FE) Check voltage between terminals RSO, RSC of ECM connector and body ground. w/o Immobiliser A00416 E9 Connector RSO(+) PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Disconnect the E9 connector of the ECM. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminals RSO, RSC of the ECM connector and body ground, OK: Voltage: 9 ∼ 14 V RSC(+) w/ Immobiliser OK Go to step 4. E9 Connector RSO(+) RSC(+) A03022 A03426 NG 3 Check IAC valve (See page SF–35). NG Replace IAC valve. OK Check for open and short in harness and connector between engine room J/B No.2 and IAC valve, and IAC valve and ECM (See page IN–31). Author: Date: 385 DI–151 DIAGNOSTICS 4 – ENGINE (5S–FE) Check operation of IAC valve (See page SF–35). NG Repair or replace IAC valve. OK 5 Check blockage of IAC valve and passage to bypass throttle valve. NG Repair or replace IAC valve. OK Check and replace ECM (See page IN–31). 6 Check for A/C signal circuit (See page AC–84). NG Repair or replace. OK Check air induction system (See page SF–1). Author: Date: 386 DI–152 DIAGNOSTICS – ENGINE (5S–FE) DI01D–06 DTC P1130 A/F Sensor Circuit Range/Performance Malfunction (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–61. DTC No. DTC Detecting Condition Trouble Area Voltage output* of A/F sensor remains at 3.8 V or more, or 2.8 V or less, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at the inside of ECM only P1130 Voltage output* of A/F sensor does not change from 3.30 V, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at inside of ECM only
Open or short in A/F sensor circuit
A/F sensor
ECM Open or short in A/F sensor circuit (2 trip detection logic) HINT:



After confirming DTC P1130, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of A/F sensor (AFS B1 S1 / O2S B1 S1) from the CURRENT DATA. The A/F sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. The ECM controls the voltage of AF
and AF terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand−held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–61. Author: Date: 387 DI–153 DIAGNOSTICS – ENGINE (5S–FE) CONFIRMATION DRIVING PATTERN Vehicle Speed 60 ∼ 120 km/h (38 ∼ 75 mph) Idling IG SW OFF (4) (3) (1)(2) 3 ∼ 5 min. Time A00364 (1) (2) (3) (4) Connect the TOYOTA hand–held tester to the DLC3. Switch the TOYOTA hand–held tester from normal mode to check mode (See page DI–3). Start the engine and warm it up with all accessory switches OFF. Drive the vehicle at 60 ∼ 120 km/h (38 ∼ 75 mph) and engine speed at 1,600 ∼ 3,200 rpm for 3 ∼ 5 min. HINT: If a malfunction exists, the MIL will light up during step (4). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (3) and (4), then perform steps (3) and (4) again. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P1130) being output? YES Go to relevant DTC chart. NO Author: Date: 388 DI–154 DIAGNOSTICS 2 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AF
terminal of ECM is 3.3 V fixed and AF terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF
/AF) of ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (* 0.660 V)
Not remains at 3 3.8 8 V (* 0 0.76 76 V) or more
Not remains at 2.8 V (* 0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (* 0.76 V), it is normally.
If output voltage of the A/F sensor remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensor circuit may be open.
If output voltage of the A/F sensor remains at 3.8 V (* 0.76 V) or more, or 2.8 V (* 0.56 V) or less even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 389 DI–155 DIAGNOSTICS 4 – ENGINE (5S–FE) Check resistance of A/F sensor heater (See page SF–59). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–12). NG Repair EGR system. OK 7 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 390 DI–156 DIAGNOSTICS 8 – ENGINE (5S–FE) Check injector injection (See page SF–23). NG Replace injector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI–152). Go 10 Is there DTC P1130 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P0125 is caused by running out of fuel. Author: Date: 391 DI–157 DIAGNOSTICS – ENGINE (5S–FE) DI01E–06 DTC P1133 A/F Sensor Circuit Response Malfunction (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–61. DTC No. P1133 DTC Detecting Condition Trouble Area After engine is warmed up, and during vehicle driving at engine speed 1,600 rpm or more and vehicle speed 60 km/h (38 mph) or more, if response characteristic of A/F sensor becomes deteriorated (2 trip detection logic)
A/F sensor INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the, malfunction. 1 Are there any other codes (besides DTC P1133) being output? YES Go to relevant DTC chart. NO Author: Date: 392 DI–158 DIAGNOSTICS 2 – ENGINE (5S–FE) Connect OBD II scan tool or TOYOTA nand–held teter, and read value for voltage output of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AF
terminal of ECM is 3.3 V fixed and AF terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF
/AF) of ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (* 0.660 V)
Not remains at 3 3.8 8 V (* 0 0.76 76 V) or more
Not remains at 2.8 V (* 0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (* 0.76 V), it is normally.
If output voltage of the A/F sensor remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensor circuit may be open.
If output voltage of the A/F sensor remains at 3.8 V (* 0.76 V) or more, or 2.8 V (* 0.56 V) or less even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 393 DI–159 DIAGNOSTICS 4 – ENGINE (5S–FE) Check resistance of A/F sensor heater (See page SF–59). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–12). NG Repair EGR system. OK 7 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 394 DI–160 DIAGNOSTICS 8 – ENGINE (5S–FE) Check injector injection (See page SF–23). NG Replace injector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI–152). Go 10 Is there DTC P1133 being output again? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past? NO Check for intermittent problems. YES DTC P1133 is caused by running out of fuel. Author: Date: 395 DI–161 DIAGNOSTICS – ENGINE (5S–FE) DI01F–05 DTC P1135 A/F Sensor Heater Circuit Malfunction (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–61. DTC No. DTC Detecting Condition Trouble Area When heater operates, heater current exceeds 8 A (2 trip detection logic) P1135 Heater current of 0.25 A or less when heater operates (2 trip detection logic)
Open or short in heater circuit of A/F sensor
A/F sensor h heater t
ECM WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–61. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check voltage between terminal HTAF of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals HTAF of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON HTAF (+) A00430 OK Check and replace ECM (See page IN–31). NG Author: Date: 396 DI–162 DIAGNOSTICS 2 – ENGINE (5S–FE) Check resistance of A/F sensor heater (See page SF–59). NG Replace A/F sensor. OK Check and repair harness or connector between EFI main relay (Marking: EFI) and A/F sensor, and A/F sensor and ECM (See page IN–31). Author: Date: 397 DI–163 DIAGNOSTICS – ENGINE (5S–FE) DI01G–06 DTC P1300 Igniter Circuit Malfunction No.1 DTC P1310 Igniter Circuit Malfunction No.2 CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (°CA) before the desired ignition timing and outputs and ignition signal (IGT) 1 to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr2 turns on. When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal O. This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM. DTC No. DTC Detecting Condition Trouble Area P1300 No IGF signal to ECM for 4 consecutive IGT1 signals during engine running
Open or short in IGF or IGT circuit from igniter to ECM
Ignition coil No.1 (Igniter No.1)
ECM P1310 No IGF signal to ECM for 4 consecutive IGT2 signals during engine running
Open or short in IGF or IGT circuit from igniter to ECM
Ignition coil No.2 (Igniter No.2)
ECM HINT: Ignition coil No.1 is for cylinder No.1 and No.4, and ignition coil No.2 is for cylinder No.2 and No.3. Author: Date: 398 DI–164 DIAGNOSTICS – ENGINE (5S–FE) WIRING DIAGRAM ECM IG Switch 7 B–R 6 W–R 13 5 1K 1B B 2A 2L 4 Engine Room J/B No.2 B–G A J/C Battery A A BR EC (*2) IGT1 Tr1 (*1) 3 Igniter No.2 2 Tr2 Ignition Coil No.2 W–R 3 Y–R W–R BR 4 J19 23 20 E9 E9 Spark Plug 1 BR 1 F4 MAIN FL Tr2 5V W–R FL Block Igniter No.1 BR B–R 1 F6 4 B W–R B AM2 Ignition Coil No.1 B 2 B–R B 1 J25 J/C Instrument Panel J/B 1 B–R II3 5 Spark Plug 22 19 E9 E9 IGT2 17 3 E9 E9 IGF (*2) Tr1 (*1) *1: w/o Immobiliser *2: w/ Immobiliser A07122 INSPECTION PROCEDURE HINT:


If DTC P1300 is displayed, check ignition coil No.1 circuit. If DTC P1300 is displayed, check ignition coil No.2 circuit. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check for spark plug and spark of misifining cylinder (See page DI–89). NG Go to step 4. OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and ignition coils (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 399 DI–165 DIAGNOSTICS 3 – ENGINE (5S–FE) Disconnect ignition coil connectors, and check voltage between terminal IGF of ECM connector and body ground. PREPARATION: (a) Disconnect the ignition coil connector. (b) Remove the glove compartment (See page SF–64). (c) Turn the ignition switch ON. CHECK: Measure voltage between terminal IGF of the ECM connector and body ground. OK: Voltage: 4.5 ∼ 5.5 V ON w/o Immobiliser IGF (+) OK Replace ignition coil. w/ Immobiliser A00417 A03023 IGF (+) A03427 NG Check and replace ECM (See page IN–31). 4 Check for open and short in harness and connector in IGT1, 2 signal circuit between ECM and ignition coils (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 400 DI–166 DIAGNOSTICS 5 – ENGINE (5S–FE) Check voltage between terminals IGT1, 2 of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF–64). CHECK: Measure voltage between terminal IGT1, 2 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V START w/o Immobiliser IGT2 (+) IGT1 (+) w/ Immobiliser IGT2 (+) A03024 IGT1 (+) A03428 Reference: INSPECTION USING OSCILLOSCOPE During idling, check waveform between terminals IGT1, 2 and IGT Signal Waveform 2 V/ E1 of the ECM. Division HINT: IGT The correct waveforms are as shown. 0V IGF 0V 10 msec./Division (Idling) FI6680 NG Check and replace ECM (See page IN–31). NG Author: Date: 401 DI–167 DIAGNOSTICS 6 – ENGINE (5S–FE) Disconnect ignition coil connectors, and check voltage between terminals IGT1, 2 of ECM connector and body ground. PREPARATION: (a) Disconnect the ignition coil connectors. (b) Remove the glove compartment (See page SF–64). CHECK: Measure voltage between terminals IGT1, 2 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 5 V START w/o Immobiliser IGT2 (+) IGT1 (+) OK Replace ignition coil. w/ Immobiliser IGT2 (+) A03024 IGT1 (+) A03428 NG 7 Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil connector. CHECK: Measure voltage between terminal 1 of the ignition coil with the igniter connector and body ground when the ignition switch is turned to ON and STA position. OK: Voltage: 9 ∼ 14 V ON START 1 (+) BE6653 A01761 A01861 NG Repair ignition coil with igniter power source circuit. OK Author: Date: 402 DI–168 DIAGNOSTICS 8 – ENGINE (5S–FE) Check for open and short in harness and connector between ignition switch and ignition coils (See page IN–31). NG Repair or replace harness or connector. OK 9 Check ignition coil (See page IG–5). NG Replace ignition coil. OK 10 Check EFI main relay (Marking: EFI) (See page SF–40). NG Replace EFI main relay. OK Replace igniter. Author: Date: 403 DI–169 DIAGNOSTICS – ENGINE (5S–FE) DI1K1–02 DTC P1335 Crankshaft Position Sensor Circuit Malfunction (During engine running) CIRCUIT DESCRIPTION Refer to DTC P0335 (Crankshaft Position ”A” Circuit Malfunction) on page DI–100. DTC No. P1335 DTC Detecting Condition If conditions (a) through (c) are met: (a) NE
1,000 rpm (b) NE signal is not detected for over 50 m sec. (c) Not during cranking Trouble Area
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
ECM WIRING DIAGRAM Refer to DTC P0335 (Crankshaft Position ”A” Circuit Malfunction) on page DI–100. INSPECTION PROCEDURE Refer to DTC P0335 (Crankshaft Position ”A” Circuit Malfunction) on page DI–100. Author: Date: 404 DI–170 DIAGNOSTICS – ENGINE (5S–FE) DI01H–07 DTC P1520 Stop Light Switch Signal Malfunction (Only for A/T) CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut–off engine speed. (The fuel cut–off engine speed is reduced slightly when the vehicle is braking.) DTC No. DTC Detecting Condition Trouble Area Stop light switch does not turn off even once vehicle is driven (2 trip detection logic) P1520
Short in stop light switch signal circuit
Stop light switch
ECM WIRING DIAGRAM Instrument Panel J/B Stop Light Switch W G–W 2 1 5 1R Light Failure Sensor 1 F4 R B–R MAIN FL W–B FL Block ALT 1 F9 2 F9 A J27 C J28 G–W 9 4 E7 E7 (*2) (*1) STP Battery BL J40 J/C *1: w/o Immobiliser *2: w/ Immobiliser 7 1 2 1 A 2 High Mount Stop Light W–B A G–R 2 Stop Light (RH) 5 W–B 2 Stop Light (LH) 5 W–B Instrument Panel J/B 4 1B B–R G–W ECM 2 1S G–W STOP 7 1C 4 1R J27 J/C BP A03604 Author: Date: 405 DI–171 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check operation of stop light. PREPARATION: Check if the stop lights go on and off normally when the brake pedal is operated and released. NG Check and repair stop light circuit (See page BE–37). OK Author: Date: 406 DI–172 DIAGNOSTICS 2 – ENGINE (5S–FE) Check STP signal. ON Brake Pedal Depressed Brake Pedal Released ON When using TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. CHECK: Read the STP signal on the TOYOTA hand–held tester. OK: Brake pedal is depressed: STP ... ON Brake pedal is released: STP ... OFF w/o Immobiliser When not using TOYOTA hand–held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check voltage between terminal STP of the ECM connector and body ground. OK: STP (+) w/ Immobiliser Brake pedal Voltage Depressed 7.5 ∼ 14 V Released Below 1.5 V STP (+) A03025 A03429 OK Check for intermittent problems (See page DI–3). NG 3 Check harness and connector between ECM and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 407 DI–173 DIAGNOSTICS – ENGINE (5S–FE) DI01I–10 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air–fuel ratio adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area
Open in back up power source circuit
ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM Engine Room J/B No.2 B–G 1 F4 1 F6 B 1 2A EFI 8 2J B–Y FL Block MAIN FL 2 E7 1 E7 (*2) (*1) BATT *1: w/o Immobiliser *2: w/ Immobiliser Battery A03605 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 408 DI–174 DIAGNOSTICS 1 – ENGINE (5S–FE) Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF–64). CHECK: Measure voltage between terminal BATT of the ECM connector and body ground. OK: Voltage 9 ∼ 14 V LOCK w/o Immobiliser BATT (+) OK Check and replace ECM (See page IN–31). w/ Immobiliser BATT (+) A03026 A03448 NG 2 Check EFI fuse. PREPARATION: Remove the EFI fuse from the engine room J/B No.2. CHECK: Check continuity of the EFI fuse. OK: Continuity Engine Room J/B No.2 NG EFI Fuse A00356 Check for short in all harness and components connected to EFI fuse. OK Check and repair harness or connector between battery and EFI fuse, and EFI fuse and ECM (See page IN–31). Author: Date: 409 DI–175 DIAGNOSTICS – ENGINE (5S–FE) DI01J–05 DTC P1780 Park/Neutral Position Switch Malfunction (Only for A/T) CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery positive voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. DTC No. DTC Detecting Condition 2 or more switches are ON simultaneously for P, R, N, D, 2 and L positions (2 trip detection logic) P1780 When driving under conditions (a) and (b) for 30 sec. or more park/neutral position switch is ON (N position): (2 trip detection logic) (a) Vehicle speed: 80 km/h (50 mph) or more (b) Engine speed: 2,000 ∼ 5,000 rpm Trouble Area
Short Sh t in i park/neutral k/ t l position iti switch it h circuit i it
Park/neutral position switch
ECM HINT: After confirming DTC P1780, use the TOYOTA hand–held tester to confirm the PNP switch signal from the CURRENT DATA. WIRING DIAGRAM Refer to DTC P1780 on page DI–424. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Refer to DTC P1780 on DI–424. Author: Date: 410 DI–176 DIAGNOSTICS – ENGINE (5S–FE) DI01K–10 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after–start injection control. WIRING DIAGRAM Instrument Panel J/B IG Switch R 8 4 1K 3 1J STARTER 5 7 1K W–R J29 J/C B–W B (A/T) B–W B B 5 1B Park/Neutral Position Switch 10 5 6 II2 B–W GR 11 II2 (A/T) 1 B–O (A/T,*2) GR (A/T,*1) C J/C B J8 J7 GR (*1) B–O (*2) B–W (M/T) W–R ECM 2 (M/T) Clutch Start Switch GR (*1) B–O (*2) 11 STA E7 B J7 E1 GR (*1) B–O (*2) B B 1 2A 3 2B 11 2J MAIN FL 1 Block 1 F4 F6 AM2 4 2L 5 1 Engine Room J/B No. 2 ST Relay 3 2 W–B B–G 5 2D 9 2K A MAIN FL B–R 1 S1 1 S2 B–R J11 J/C Starter Battery *1: TMC Made *2: TMMK Made IG A03606 Author: Date: 411 DI–177 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table on page DI–28. TOYOTA hand–held tester: 1 Connect TOYOTA hand–held tester, and check STA signal. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand–held tester while the starter operates. OK: Ignition Switch Position ON START STA signal OFF ON OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–28). NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 412 DI–178 DIAGNOSTICS – ENGINE (5S–FE) OBD II scan tool (excluding TOYOTA hand–held tester): HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table on page DI–28. 1 Check voltage between terminal STA of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal STA of the ECM connector and body ground, during the engine cranking. OK: Voltage: 6 V or more START w/o Immobiliser STA (+) OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–28). w/ Immobiliser STA (+) A03027 A03449 NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 413 DI–179 DIAGNOSTICS – ENGINE (5S–FE) DI01L–05 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM ECM B–Y B J27 J/C B J28 12 +B E7 B–Y B–W (*1) B–R (*2) 2 4 2F W–B EB Instrument Panel J/B 3 1K 6 IG Switch 14 24 E9 E9 E1 (*2) (*1) 4 2L 7 B 7 E10 MREL W–R BR 1 2A 5 1B 5 1K AM2 5 EFI Relay B–Y (*1) IGN 1 6 II4 7 1W B–R 3 Engine Room J/B No.2 W–R 7 2K EFI 2 2J 1 F6 FL Block A 1 F4 J23 J/C A B–G Battery BR MAIN FL *1: w/ Immobiliser *2: w/o Immobiliser EC A07554 Author: Date: 414 DI–180 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE 1 Check voltage between terminals + B and E1 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals + B and E1 of the ECM connector. OK: Voltage: 9 ∼ 14 V ON w/o Immobiliser +B (+) E1 (–) w/ Immobiliser OK Proceed to next circuit inspection shown on Problem symptoms table (See page DI–28). +B (+) E1 (–) BE6653 A03028 A03709 NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN–31). NG Repair or replace harness or connector. OK 3 Check EFI main relay (Marking: EFI) (See page SF–40). NG Replace EFI main relay. OK Author: Date: 415 DI–181 DIAGNOSTICS 4 – ENGINE (5S–FE) Check EFI fuse (See page DI–173, step 2). NG Check for short in all harness and components connected to EFI fuse. OK 5 Check for open in harness and connector between EFI main relay (Marking: EFI) and battery, and EFI main relay and ECM (See page IN–31). NG Repair or replace harness or connector. OK 6 Check IGN fuse. PREPARATION: Remove the IGN fuse from the instrument panel J/B. CHECK: Check continuity of the IGN fuse. OK: Continuity IGN Fuse Instrument Panel J/B NG A00355 Check for short in all harness and components connected to IGN fuse. OK Author: Date: 416 DI–182 DIAGNOSTICS 7 – ENGINE (5S–FE) Check ignition switch (See page BE–14). NG Replace ignition switch. OK Check for open in harness and connector between IG switch and EFI main relay, and EFI main relay and body ground (See page IN–31). Author: Date: 417 DI–183 DIAGNOSTICS – ENGINE (5S–FE) DI01M–05 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil and also current flows to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EFI Relay EFI IG Switch IGN AM2 CIR OPN Relay Fuel Pump ECM Park/Neutral Position Switch (Clutch Start Switch) FC Tr ST STARTER ST Relay MAIN FL MAIN (STA Signal) STA (NE Signal) NE Starter Battery A00325 Author: Date: 418 7 IK1 B–R (*4) B–R B–W (*1) Engine Room J/B No.2 Instrument Panel J/B IG Switch 3 7 IGN 7 B–R 1K 1W 6 B–R (*4) B–W B 5 3 2 1 Park/Neutral Position Switch GR B–W (A/T) 6 5 Clutch Start Switch Date: B–W (M/T) B–R MAIN FL 1 5 2D 11 2J 1 B–R GR (*2) B–O (*3) 5 EB1 EB1 4 G–R 10 II2 GR (*2) B–O (*3) C J7 B *1: w/ Immobiliser *2: TMC Made *3: TMMK Made *4: w/o Immobiliser 7 E10 MREL (*1) 14 FC E7 J8 J/C E01 7 ID1 GR (*2) B–O (*3) 2 (M/T) 1 S1 4 1 S2 7 Fuel Pump 5 Starter Battery ECM W–B BL J40 J/C A ENGINE (5S–FE) II2 3 – 11 B 2 CIR OPN Relay L–B IG B 5 DIAGNOSTICS J29 J/C 1 L–B B–W B–G Author: A MAIN 9 2K W–B 1 1 ST Relay II4 L–B B 1 G–R B EFI 1 2A 3 2B B B EB 6 B–R (*1) 4 2L W–R W–B J11 J/C 2 EFI Relay AM2 1 1 F6 F4 FL Block 1 10 2C 4 W–B 2F B–W W–R 3 Engine Room R/B No.1 4 STARTER 3 1J 1K 5 5 1K 1B R 8 7 2K 5 DI–184 WIRING DIAGRAM B–R (*1) A07555 419 DI–185 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Connect TOYOTA hand–held tester, and check operation of fuel pump (See page DI–3). OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–28). NG 2 Check for ECM power source circuit (See page DI–179). NG Repair or replace. OK 3 Check circuit opening relay (Marking: CIR OPN) (See page SF–41). NG Replace circuit opening relay. OK Author: Date: 420 DI–186 DIAGNOSTICS 4 – ENGINE (5S–FE) Check voltage between terminal FC of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal FC of the ECM connector and body ground. OK: Voltage 9 ∼ 14 V ON w/o Immobiliser FC (+) w/ Immobiliser FC (+) A03029 A03450 OK Go to step 5. NG Check for open in harness and connector between EFI main relay, and circuit opening relay and circuit opening relay and ECM (See page IN–31). 5 Check fuel pump (See page SF–6). NG Repair or replace fuel pump. OK Author: Date: 421 DI–187 DIAGNOSTICS 6 – ENGINE (5S–FE) Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel pump, and fuel pump and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check operation of fuel pump. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: (a) Connect between terminal FC of the ECM connector and body ground. (b) Check for fuel pressure in the fuel inlet hose when it is pinched off. OK: There is pressure in fuel inlet hose. HINT: At this time, you will hear a fuel return flowing noise. ON w/o Immobiliser FC OFF w/ Immobiliser OFF ON FC ON OK Fuel Inlet Hose Proceed to next circuit inspection shown on problem symptoms table (See page DI–28). A03030 A03451 NG Author: Date: 422 DI–188 DIAGNOSTICS 2 – ENGINE (5S–FE) Check for ECM power source circuit (See page DI–179). NG Repair or replace. OK 3 Check circuit opening relay (Marking: CIR OPN) (See page SF–41). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground (See page DI–183, step 4). OK Go to step 5. NG Check for open in harness and connector between EFI main relay and circuit opening relay, and circuit opening relay and ECM (See page IN–31). 5 Check fuel pump (See page SF–6). NG Repair or replace fuel pump. OK Author: Date: 423 DI–189 DIAGNOSTICS 6 – ENGINE (5S–FE) Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel pump, and fuel pump and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 424 DI–190 DIAGNOSTICS – ENGINE (5S–FE) DI01N–04 A/C Compressor Lock Sencor Circuit CIRCUIT DESCRIPTION This sensor sends 1 pulse par engine revolution to the ECM. If the number ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the ECM turns the compressor off. And, the indicator flashes at about 1 second intervals. WIRING DIAGRAM ECM 9 W–L IK2 10 W–L W–L II3 1 A/C Compressor Lock Sensor 2 10 BR BR IK2 J8 J/C 6 BR B J23 J/C II3 B BR BR A A BR A EC 19 18 E9 E9 (*2) (*1) 24 14 E9 E9 (*2) (*1) LOCK IN E1 *1: w/o Immobiliser *2: w/ Immobiliser A03610 INSPECTION PROCEDURE 1 Check compressor. PREPARATION: (a) Check the compressor drive belt tension (See page AC–16). (b) Check if the compressor does not lock during operation with the engine started and blower switch and A/C switch ON. NG Adjust drive belt tension or repair compressor (See page AC–17). OK Author: Date: 425 DI–191 DIAGNOSTICS 2 – ENGINE (5S–FE) Check compressor lock sensor. 1 PREPARATION: Disconnect the compressor lock sensor connector. CHECK: Measure resistance between terminals 1 and 2 of the compressor lock sensor connector. OK: Resistance: 65 – 125 Ω at 20°C (68°F) 2 N15622 0.2 V/Div. Reference: Inspection using oscilloscope During cranking or idling, measure voltage between terminals LOCK IN Signal Waveform LOCK IN and E1 of the ECM. HINT: The correct waveform appears as shown in the illustration on the left. 0V NG 20 msec./Division (Idling) Replace compressor lock sensor (See page AC–40). N02774 OK 3 Check harness and connector between A/C compressor lock sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 426 DI–192 DIAGNOSTICS – ENGINE (5S–FE) DI01O–04 A/C Evaporator Temp. Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the ECM. WIRING DIAGRAM ECM 5V 1 L–W II2 L–R 1 11 10 E8 E8 (*2) (*1) THR A/C Evaporator Temp. Sensor 2 9 3 BR II2 BR E8 E2 *1: w/o Immobiliser *2: w/ Immobiliser A03611 Author: Date: 427 DI–193 DIAGNOSTICS – ENGINE (5S–FE) INSPECTION PROCEDURE 1 Check voltage between terminals THR and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–64). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals THR and E1 of the ECM connector at each temperature. OK: Voltage at 0°C (32 F): 2.2 – 2.6 V at 15°C (59°F): 1.4 – 1.8 V HINT: As the temperature increases, the voltage decreases. ON w/o Immobiliser E1 (–) THR (+) w/ Immobiliser OK BE3840 I00180 A03031 Check and replace ECM (See page IN–31). THR (+) E1 (–) A03452 NG 2 Check A/C evaporator temp. sensor. Thermometer Ice Ohmmeter Thermistor More than 10 cm (3.94 in.) AC0175 PREPARATION: Remove the A/C evaporator temp. sensor (See page AC–30). CHECK: Check resistance between terminals 1 and 2 of the A/C evaporator temp. sensor connector at each temperature. OK: Resistance at 0°C (32°F): 4.6 – 5.1 Ω at 15°C (59°F): 2.1 – 2.6 Ω HINT: As the temperature increases, the voltage decreases. NG Replace A/C evaporator temp. sensor. OK Author: Date: 428 DI–194 DIAGNOSTICS 3 – ENGINE (5S–FE) Check harness and connector between A/C evaporator temp. sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 429 DI–195 DIAGNOSTICS – ENGINE (1MZ–FE) ENGINE (1MZ–FE) DI078–08 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Vehicle Brought to Workshop Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. 1 Customer Problem Analysis P. DI–196 2 Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3 P. DI–197 If the display indicates a communication fault in the tool, inspect DLC3 P. DI–197 3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P. DI–197 4 Clear DTC and Freezed Frame Data P. DI–197 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI–197 7 Problem Symptom Confirmation If the engine does not start, perform steps 10 and 12 first Malfunction occurs. 9 10 DTC Check P. DI–197 Normal Malfunction code. 11 Basic Inspection P. DI–197 12 14 8 Malfunction does not occur. Symptom Simulation P. IN – 23 Problem Symptoms Table P. DI–221 Parts Inspection 15 DTC Chart P. DI–211 13 Circuit Inspection P. DI–222 Check for Intermittent Problems P. DI–197 Identification of Problem 16 Adjustment, Repair 17 Confirmation Test End Author: Date: 430 DI–196 DIAGNOSTICS – ENGINE (1MZ–FE) DI079–02 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Date Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Back fire Other No complete combustion High ( rpm) Low ( Muffler explosion (after–fire) rpm) Surging Others Dates Problem Occurred Constant Other Condition When Problem Occurs Problem Frequency Sometimes ( times per day/month) Weather Fine Cloudy Rainy Snowy Outdoor Temperature Hot Warm Cool Cold (approx. Place Highway Rough road Engine Temperature Engine Operation Cold Suburbs Other Warming up Inner city After warming up Starting Just after starting ( Constant speed Driving A/C switch ON/OFF Other Condition of MIL Normal Mode (Precheck) Once only Various/Other °F/ °C) Uphill Downhill Any temperature min.) Idling Acceleration Other Racing Deceleration Remains on Sometimes light up Does not light up Normal Malfunction code(s) (code Freezed frame data ( ) Malfunction code(s) (code Freezed frame data ( ) ) DTC Inspection Check Mode Normal Author: ) Date: 431 DI–197 DIAGNOSTICS – ENGINE (1MZ–FE) DI07A–06 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand– held tester, and read off various data output from the vehicle’s ECM.
FI0534 TOYOTA Hand–Held Tester A06134 OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the powertrain control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Codes (DTC) prescribed by SAE J2012 are recorded in the ECM memory (See page DI–211). If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off but the DTCs remain recorded in the ECM memory.
To check the DTC, connect the OBD II scan tool or TOYOTA hand–held tester to Data Link Connector 3 (DLC3) on the vehicle. The OBD II scan tool or TOYOTA hand–held tester also enables you to erase the DTC and check freezed frame data and various forms of engine data (For operating instructions, see the OBD II scan tool’s instruction book.). DTC include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI–211). Author: Date: 432 DI–198 DIAGNOSTICS – ENGINE (1MZ–FE)
The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTC use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily (TOYOTA hand–held tester only). (See page DI–197)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory. (1st trip) If the same malfunction is detected again during the second drive test, this second detection causes the MIL to light up. (2nd trip) (However, the IG switch must be turned OFF between the 1st trip and the 2nd trip.).
Freeze frame data: Freeze frame data records the engine condition when a misfire (DTCs P0300 ∼ P0306) or fuel trim malfunction (DTCs P0171, P0172) or other malfunction (first malfunction only), is detected. Because freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
Priorities for troubleshooting: If troubleshooting priorities for multiple DTC are given in the applicable DTC chart, these should be followed. If no instructions are given troubleshoot DTC according to the following priorities. (1) DTC other than fuel trim malfunction (DTCs P0171, P0172), EGR (DTCs P0401, P0402) and misfire (DTCs P0300 ∼ P0306). (2) Fuel trim malfunction (DTCs P0171, P0172) and EGR (DTCs P0401, P0402). (3) Misfire (DTCs P0300 ∼ P0306). Author: Date: 433 DI–199 DIAGNOSTICS (b) – ENGINE (1MZ–FE) Check the DLC3. The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141–2 format. DLC3 N09214 Terminal No. Connection / Voltage or Resistance Condition 7 Bus  Line / Pulse generation During transmission 4 Chassis Ground ↔ Body Ground /1 Ω or less Always 5 Signal Ground ↔ Body Ground /1 Ω or less Always 16 Battery Positive ↔ Body Ground /9 ∼ 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD II scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) S04159 INSPECT DIAGNOSIS (Normal Mode) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–46). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand–held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTC and freezed frame data recorded in normal mode. So before switching modes, always check the DTC and freezed frame data, and note them down. (1) Prepare the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester. Author: Date: 434 DI–200 DIAGNOSTICS (2) (3) (4) – ENGINE (1MZ–FE) Connect the OBD II scan tool or TOYOTA hand– held tester to DLC3 at the lower center of the instrument panel. Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester switch ON. Use the OBD II scan tool or TOYOTA hand–held tester to check the DTC and freezed frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book.). See page DI–197 to confirm the details of the DTC. (5) NOTICE:
When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand–held tester) to check the DTC, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, performe the following either action.
Turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM.
Check the 1st trip DTC using Mode 7 (Continuous Test Results) for SAE J1979. (c) Clear the DTC. The DTCs and freezed frame data will be erased by either action.
Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.)
Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased. 3. INSPECT DIAGNOSIS (Check Mode) HINT: TOYOTA hand–held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. Author: Date: 435 DI–201 DIAGNOSTICS (a) – Check the DTC. (1) Initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in ”P” or ”N” position
Air conditioning switched OFF (2) Turn ignition switch OFF. (3) Prepare the TOYOTA hand–held tester. (4) Connect the TOYOTA hand–held tester to the DLC3 at the lower center of the instrument panel. (5) Turn the ignition switch ON and push the TOYOTA hand–held tester switch ON. (6) Flashing ON OFF 0.13 Seconds FI3605 ENGINE (1MZ–FE) Switch the TOYOTA hand–held tester normal mode to check mode (Check that the MIL flashes.). NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the DTC and freezed frame data will be erased. (7) Start the engine (The MIL goes out after the engine start.). (8) Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTC and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode. So all DTC, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. Author: Date: 436 DI–202 DIAGNOSTICS – ENGINE (1MZ–FE) 4. FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. DTC No. Fail–Safe Operation Fail–Safe Deactivation Conditions P0100 Ignition timing fixed at 10° BTDC Returned to normal condition P0110 Intake air temperature is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temperature is fixed at 80°C (176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively (a) Vehicle speed: 0km/h (0mph) (b) VTA  0.1 V and  0.95 V P0135 P0141 P0155 The heater circuit in which an abnormality is detected is turned off Ignition switch OFF P0325 P0330 Max. timing retardation Ignition switch OFF P1300 Fuel cut IGF signal is detected for 6 consecutive ignition 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA HAND–HELD TESTER only: By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See page DI–197). (2) Set the check mode (See page DI–197). (3) Perform a simulation test (See page IN–21). (4) Check the connector and terminal (See page IN–31). (5) Handle the connector (See page IN–31). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped ? NO Charge or replace battery. YES Author: Date: 437 DI–203 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Is engine cranked? NO Proceed to page ST–18 and continue to troubleshoot. NO Go to step 7. YES 3 Does engine start? YES 4 Check air filter. PREPARATION: Remove the air filter. CHECK: Visually check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the filter with compressed air. First blow from inside thoroughly, then blow from outside of the filter. Outside Inside P00495 NG Repair or replace. OK Author: Date: 438 DI–204 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all accessories. (c) Switch off air conditioning. (d) Shift transmission into ”N” position. (e) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle speed. OK: Idle speed: 650 ∼ 750 rpm NG Proceed to problem symptoms table on page DI–221. OK 6 Check ignition timing. DLC1 TE1 E1 SST DLC1 P12915 P12952 PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all accessories. (c) Switch off air conditioning. (d) Shift transmission into ”N” position. (e) Keep the engine speed at idle. (f) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (g) Using a timing light, connect the tester to check wire. CHECK: Check ignition timing. OK: Ignition timing: 10° BTDC at idle A00209 NG Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–221. Author: Date: 439 DI–205 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check fuel pressure. P20186 PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (d) Use ACTIVE TEST mode to operate the fuel pump. (e) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector (See page SF–6). CHECK: Check that the pulsation damper screw rises up when the fuel pump operates. NG Proceed to page SF–6 and continue to troubleshoot. OK Author: Date: 440 DI–206 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check for spark. P23917 PREPARATION: (a) Remove the ignition coil or disconnect the high–tension cord from the spark plug. (b) Remove the spark plug. (c) Install the spark plug to the ignition coil or high–tension cord. (d) Disconnect the injector connector. (e) Hold the end about 12.5 mm (0.5 in.) from the ground. CHECK: Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 ∼ 10 seconds at a time. OK: Spark jumps across electrode gap. NG Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–221. Author: Date: 441 DI–207 DIAGNOSTICS – ENGINE (1MZ–FE) 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand–held tester display Measurement Item Normal Condition* FUEL SYS #1 Fuel System Bank 1 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warming up: CLOSED FUEL SYS #2 Fuel System Bank 2 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 13.1 ∼ 18.7% Racing without load (2,500rpm): 11.7 ∼ 17.3% Engine Coolant Temp. Sensor Value After warming up: 80 ∼ 95°C (176 ∼ 203°F) COOLANT TEMP. SHORT FT #1 Short–term Fuel Trim Bank 1 0 ± 20% LONG FT #1 Long–term Fuel Trim Bank 1 0 ± 20% SHORT FT #2 Short–term Fuel Trim Bank 2 0 ± 20% 0 ± 20% LONG FT #2 Long–term Fuel Trim Bank 2 ENGINE SPD Engine Speed Idling: 650 ∼ 750 rpm VEHICLE SPD Vehicle Speed Vehicle stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No. 1 Idling: BTDC 10 ∼ 25.0° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. Air Flow Rate Through Mass Air Flow Meter Idling: 3.3 ∼ 4.7 gm/sec. Racing without load (2,500 rpm): 10.4 ∼ 15.4 gm/sec. Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0%, 5 V → 100% Throttle valve fully closed: 7 ∼ 11% Throttle valve fully open: 65 ∼ 75% INTAKE AIR MAF THROTTLE POS *: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. Author: Date: 442 DI–208 DIAGNOSTICS TOYOTA hand–held tester display – ENGINE (1MZ–FE) Measurement Item Normal Condition*1 O2S B1, S1 Voltage Output of Oxygen Sensor Bank 1 Sensor 1 O2FT B1, S1 Oxygen Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) O2S B1, S2 Voltage Output of Oxygen Sensor Bank 1 Sensor 2 Driving 50 km/h (31 mph): 0.1 ∼ 0.9 V O2S B2, S1 Voltage Output of Oxygen Sensor Bank 2 Sensor 1 Idling: 0.1 ∼ 0.9 V (0.56 ∼ 0.76 V*2) O2FT B2, S1 Oxygen Sensor Fuel Trim Bank 2 Sensor 1 (Same as SHORT FT #2) A/FS B1, S1 *3 A/FS B2, S1 *3 Idling: 0.1 ∼ 0.9 V (0.56 ∼ 0.76 V*2) Voltage Output of A/F Sensor Bank 1 Sensor 1 Voltage Output of A/F Sensor Bank 2 Sensor 1 0 ± 20% 0 ± 20% Idling: 2.8 ∼ 3.8 V Idling: 2.8 ∼ 3.8 V A/FFT B1, S1 *3 A/F Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) O ± 20% A/FFT B2, S1 *3 A/F Sensor Fuel Trim Bank 2 Sensor 1 (Same as SHORT FT #1) O ± 20% *1: If no conditions are specifically stated for ”Idling”, it means the shift lever is shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. *2: Only for California Specification vehicles, when you use the OBD II scan tool (excluding TOYOTA hand– held tester). *3: Only for California Specification vehicles, when you use the TOYOTA hand–held tester. Author: Date: 443 DI–209 DIAGNOSTICS (b) – ENGINE (1MZ–FE) TOYOTA Enhanced Signals. TOYOTA hand–held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 1.6 ∼ 2.9 ms Intake Air Control Valve Duty Ratio Opening ratio rotary solenoid type IAC valve Idling: 27 ∼ 47 % Starter Signal Cranking: ON CTP SIG Closed Throttle Position Signal Throttle Fully Closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SW Park/Neutral Position Switch Signal P or N position: ON Electrical Load Signal Defogger switch ON: ON Stop Light Switch Signal Stop light switch ON: ON Power Steering Oil Pressure Switch Signal Turn steering wheel: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON INJECTOR IAC DUTY RATIO STARTER SIG ELCTRCL LOAD SIG STOP LIGHT SW PS OIL PRESS SW CYL#1 ∼ CYL#6 Abnormal revolution variation for each cylinder 0% IGNITION Total number of ignition for every 1,000 revolutions 0 ∼ 3,000 EGR Gas Temperature Sensor Value EGR not operating: Temperature between intake air temp. and engine coolant temp. Intake Air Control Valve VSV Signal VSV operating: ON EGR SYSTEM EGR system operating condition Idling: OFF A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON FUEL PUMP Fuel Pump Signal Idling: ON EVAP (PURGE) VSV EVAP VSV Signal VSV operating: Above 30% VAPOR PRESS VSV Vapor Pressure VSV Signal VSV operating: ON (TANK) EGRT GAS INTAKE CTRL VSV *: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. Author: Date: 444 DI–210 DIAGNOSTICS TOYOTA hand–held tester display – ENGINE (1MZ–FE) Measurement Item Normal Condition*1 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 ∼ 1.2 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 2 Idling: 0.8 ∼ 1.2 O2 LR B1, S1 *2 Oxygen Sensor Lean Rich Bank 2 Sensor 1 Response time for oxygen sensor output to switch from lean to rich Idling after warmed up: 0 ∼ 1,000 msec. O2 LR B2, S1 *2 Oxygen Sensor Lean Rich Bank 2 Sensor 1 Response time for oxygen sensor output to switch from lean to rich Idling after warmed up: 0 ∼ 1,000 msec. O2 RL B1, S1 *2 Oxygen Sensor Rich Lean Bank 1 Sensor 1 Response time for oxygen sensor output to switch from rich to lean Idling after warmed up: 0 ∼ 1,000 msec. O2 RL B2, S1 *2 Oxygen Sensor Rich Lean Bank 2 Sensor 1 Response time for oxygen sensor output to switch from rich to lean Idling after warmed up: 0 ∼ 1,000 msec. TOTAL FT B1 TOTAL FT B2 *1: If no conditions are specifically stated for ”Idling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. *2: Except California Specification vehicles. Author: Date: 445 DI–211 DIAGNOSTICS – ENGINE (1MZ–FE) DI07B–07 DIAGNOSTIC TROUBLE CODE CHART 1. SAE CONTROLLED HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ’’See page ’’ for the respective ’’DTC No.’’ in the DTC chart. DTC No. (See Page) Detection Item Trouble Area MIL*1 Memory P0100 (DI–222) Mass Air Flow Circuit Malfunction  Open or short in mass air flow meter circuit  Mass air flow meter  ECM   P0101 (DI–227) Mass Air Flow Circuit Range/Performance Problem  Mass air flow meter   P0110 (DI–228) Intake Air Temp. Circuit Malfunction  Open or short in intake air temp. sensor circuit  Intake air temp. sensor (built into mass air flow meter)  ECM   P0115 (DI–233) Engine Coolant Temp. Circuit Malfunction  Open or short in engine coolant temp. sensor circuit  Engine coolant temp. sensor  ECM   P0116 (DI–237) Engine Coolant Temp. Circuit Range/Performance Problem  Engine coolant temp. sensor  Cooling system   P0120 (DI–239) Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction  Open or short in throttle position sensor circuit  Throttle position sensor  ECM   P0121 (DI–243) Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem  Throttle position sensor   Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)  Fuel system  Injector  Ignition system  Gas leakage on exhaust system  Open or short in heated oxygen sensor circuit (bank 1, 2 sensor 1)  Heated oxygen sensor (bank 1, 2 sensor 1)  ECM   *3 P0125 (DI–249) Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)  Fuel system  Injector  Ignition system  Gas leakage on exhaust system  Open or short in A/F sensor circuit (bank 1, 2 sensor 1)  A/F sensor (bank 1, 2 sensor 1)  ECM   *2 P0130 (DI–255) Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1)  Heated oxygen sensor  Fuel trim malfunction   *2 P0125 (DI–244) *1: 


MIL lights up *2: Except California specification vehicles *3: Only for California specification vehicle Author: Date: 446 DI–212 DIAGNOSTICS DTC No. (See Page) ENGINE (1MZ–FE) Detection Item Trouble Area MIL Memory *2 P0133 (DI–259) Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1)  Heated oxygen sensor  Fuel trim malfunction   *2 P0135 (DI–263) Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)  Open or short in heater circuit of heated oxygen sensor  Heated oxygen sensor heater  ECM   P0136 (DI–265) Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)  Heated oxygen sensor   P0141 (DI–263) Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)  Same as DTC No. P0135 *1  *3 P0150 (DI–255) Heated Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 1)  Same as DTC No. P0130 *1  *3 P0153 (DI–259) Heated Oxygen Sensor Circuit Slow Response (Bank 2 Sensor 1)  Same as DTC No. P0133  Fuel trim malfunction *1  Heated Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 1)  Same as DTC No. P0135 *1  System too Lean (Fuel Trim) (Except California Spec.)  Air intake (hose loose)  Fuel line pressure  Injector blockage  Heated oxygen sensor (bank 1, 2 sensor 1) malfunction  Mass air flow meter  Engine coolant temp. sensor  Gas leakage on exhaust system *1  System too Rich (Fuel Trim) (Except California Spec.)  Fuel line pressure  Injector leak, blockage  Heated oxygen sensor (bank 1, 2 sensor 1) malfunction  Mass air flow meter  Engine coolant temp. sensor  Gas leakage on exhaust system *1  System too Lean (Fuel Trim) (Only for California Spec.)  Air intake (hose loose)  Fuel line pressure  Injector blockage  Mass air flow meter  Engine coolant temp. sensor  A/F sensor (bank 1, 2 sensor 1)  Gas leakage on exhaust system *1  System too rich (Fuel Trim) (Only for California Spec.)  Fuel line pressure  Injector leak, blockage  Heated oxygen sensor malfunction  Mass air flow meter  Engine coolant temp. sensor  A/F sensor (bank 1, 2 sensor 1)  Gas leakage on exhaust system *1  *3 P0155 (DI–263) *3 P0171 (DI–272) *3 P0172 (DI–272) *4 P0171 (DI–267) *4 P0172 (DI–267) *1: *2: *3: *4: – MIL lights up MIL light up or blinking Except California specification vehicles Only for California specification vehicle Author: Date: 447 DI–213 DIAGNOSTICS DTC No. (See Page) ENGINE (1MZ–FE) Trouble Area MIL Memory  Ignition system  Injector  Fuel line pressure  EGR  Compression pressure  Valve clearance not to specification  Valve timing  Mass air flow meter  Engine coolant temp. sensor  Open or short engine wire  Connector connection  ECM *2  P0300 (DI–276) Random/Multiple Cylinder Misfire Detected P0301 P0302 P0303 P0304 P0305 P0306 (DI–276) Misfire Detected – Cylinder 1 – Cylinder 2 – Cylinder 3 – Cylinder 4 – Cylinder 5 – Cylinder 6 P0325 (DI–283) Knock Sensor 1 Circuit Malfunction  Open or short in knock sensor 1 circuit  Knock sensor 1 (looseness)  ECM *1  P0330 (DI–283) Knock Sensor 2 Circuit Malfunction  Open or short in knock sensor 2 circuit  Knock sensor 2 (looseness)  ECM *1  P0335 (DI–287) Crankshaft Position Sensor ”A” Circuit Malfunction  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Starter  ECM *1  P0340 (DI–290) Camshaft Position Sensor Circuit Malfunction  Open or short in camshaft position sensor circuit  Camshaft position sensor  Starter  ECM *1  Exhaust Gas Recirculation Flow Insufficient Detected  EGR valve (stuck closed)  Open or short in EGR gas temp. sensor circuit  EGR gas temp. sensor  Open in VSV circuit for EGR  VSV for EGR  Vacuum control valve  Vacuum hose disconnected or blocked  ECM *1  P0402 (DI–302) Exhaust Gas Recirculation Flow Excessive Detected  EGR valve stuck open  VSV for EGR open malfunction  Short in VSV circuit for EGR  Open or short in EGR valve position sensor circuit  EGR valve position sensor  ECM *1  *3 P0420 (DI–305) Catalyst System Efficiency Below Threshold (Except California Spec.)  Three–way catalytic converter  Open or short in heated oxygen sensor circuit  Heated oxygen sensor *2  Catalyst System Efficiency Below Threshold (Only for California Spec.)  Three–way catalytic converter  Open or short in heated oxygen sensor (bank 1, sensor 2) circuit  Heated oxygen sensor (bank 1, sensor 2)  Open or short in A/F sensor (bank 1, 2 sensor 1) circuit  A/F sensor (bank 1, 2 sensor 1) *2  P0401 (DI–292) *4 P0420 (DI–308) *1: *2: *3: *4: Detection Item – MIL lights up MIL lights up on U.S.A and Canadian specification vehicles Except California specification vehicles Only for California specification vehicle Author: Date: 448 DI–214 DIAGNOSTICS DTC No. (See Page) Detection Item – ENGINE (1MZ–FE) Trouble Area MIL* Memory *1  Evaporative Emission Control System Malfunction  Vapor pressure sensor  Fuel tank cap incorrectly installed  Fuel tank cap cracked or damaged  Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in fig. 1)  Hose or tube cracked, holed, damaged or loose seal ((3) in fig. 1)  Fuel tank cracked, holed or damaged  Charcoal canister cracked, holed or damaged  Fuel tank over fill check valve cracked or damaged Evaporative Emission Control System Incorrect Purge Flow  Open or short in VSV circuit for EVAP  Open or short in VSV circuit for vapor pressure sensor  Open or short in vapor pressure sensor circuit  VSV for EVAP  VSV for vapor pressure sensor  Vapor pressure sensor  Vacuum hose cracks, holed blocked, damaged or disconnected ((1), (4), (5), (6) and (7) in fig.1)  Charcoal canister cracks, holed or damaged  Fuel tank over fill check valve cracked or damaged   P0446 (DI–318) Evaporative Emission Control System Vent Control Malfunction  Open or short in VSV circuit for EVAP  Open or short in VSV circuit for vapor pressure sensor  Open or short in vapor pressure sensor circuit  VSV for EVAP  VSV for vapor pressure sensor  Vapor pressure sensor  Vacuum hose cracks, holed blocked, damaged or disconnected ((1), (4), (5), (6) and (7) in fig.1)  Charcoal canister cracks, holed or damaged  Fuel tank over fill check valve cracked or damaged   P0450 (DI–331) Evaporative Emission Control System Pressure Sensor Malfunction  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  ECM   P0451 (DI–331) Evaporative Emission Control System Pressure Sensor Range/Performance  Open or short in vapor pressure sensor circuit  Vapor pressure sensor  ECM   P0500 (DI–333) Vehicle Speed Sensor Malfunction  Open or short in speed sensor circuit  Vehicle speed sensor  Combination meter  ECM   P0505 (DI–336) Idle Control System Malfunction  IAC valve is stuck or closed  Open or short in IAC valve circuit  Open or short in A/C signal circuit  Air intake (hose loose)   P0440 (DI–311) P0441 (DI–318) *: 


MIL lights up Author: Date: 449 DI–215 DIAGNOSTICS 2. – ENGINE (1MZ–FE) MANUFACTURER CONTROLLED DTC No. (See Page) Detection Item *2 P1130 (DI–340) A/F Sensor Circuit Range/Performance Malfunction (Bank 1 Sensor 1) *2 P1133 (DI–345) Trouble Area MIL*1 Memory  Open or short in A/F sensor circuit  A/F sensor (bank 1 sensor 2)  ECM   A/F Sensor Circuit Response Malfunction (Bank 1 Sensor 1)  A/F sensor (bank 1 sensor 2)   *2 P1135 (DI–349) A/F Sensor Heater Circuit Malfunction (Bank1 Sensor 1)  Open or short in A/F sensor (bank 1 sensor 2)  A/F sensor (bank 1 sensor 2) heater  ECM   *2 P1150 (DI–340) A/F Sensor Circuit Range/Performance Malfunction (Bank2 Sensor 1)  Same as DTC No. P1130   *2 P1153 (DI–345) A/F Sensor Circuit Response Malfunction (Bank 2 Sensor 1)  Same as DTC No. P1133   *2 P1155 (DI–349) A/F Sensor Heater Circuit Malfunction (Bank 2 Sensor 1)  Same as DTC No. P1135   P1300 (DI–351) Igniter Circuit Malfunction  Open or short in IGF or IGT circuit from igniter to ECM  Igniter  ECM   P1335 (DI–357) Crankshaft Position Sensor Circuit Malfunction (during engine running)  Open or short in crankshaft position sensor circuit  Crankshaft position sensor  Starter  ECM –  P1410 (DI–358) EGR Valve Position Sensor Circuit Malfunction  Open or short in EGR valve position sensor circuit  EGR valve position sensor  ECM   P1411 (DI–362) EGR Valve Position Sensor Circuit Range/Performance Problem  EGR valve position sensor   P1520 (DI–363) Stop Light Switch Signal Malfunction  Short in stop light switch signal circuit  Stop light switch  ECM   P1600 (DI–366) ECM BATT Malfunction  Open in back up power source circuit  ECM   P1780 (DI–368) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM   *1: 


MIL lights up, –


MIL does not light up *2: Only for California specification vehicles Author: Date: 450 DI–216 DIAGNOSTICS DTC No. (See Page) – Detection Item ENGINE (1MZ–FE) Trouble Area MIL* Memory B2795 (DI–928) Unmatched key Code  Immobiliser system –  B2796 (DI–929) No Communication in Immobiliser System  Immobiliser system –  B2797 (DI–932) Communication Malfunction No.1  Immobiliser system –  B2798 (DI–935) Communication Malfunction No.2  Immobiliser system –  *:–


MIL does not light up Author: Date: 451 DI–217 DIAGNOSTICS – ENGINE (1MZ–FE) DI07C–06 PARTS LOCATION Engine Coolant Temp. Sensor ECM VSV for ACIS Injector VSV for EGR EGR Valve Position Sensor VSV for EVAP Heated Oxygen Sensor (Bank 1 Sensor 2) DLC1 Knock Sensor 2 Crankshaft Position Sensor DLC3 Igniter Mass Air Flow Meter Camshaft Position Sensor IAC Valve Heated Oxygen Sensor *1 (Bank 2 Sensor 1) Park/Neutral Position Switch A/F Sensor*2 (Bank 2 Sensor 1) Heated Oxygen Sensor *1 (Bank 1 Sensor 1) A/F Sensor*2 (Bank 1 Sensor 1) EGR Gas Temp. Sensor Knock Sensor 1 Vapor Pressure Sensor Canister *1 : Except California Specification vehicles *2 : Only for California Specification vehicles A07469 Author: Date: 452 DI–218 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DP–01 TERMINALS OF ECM ECM Terminals E11 E10 E9 E8 E7 9 8 7 6 5 4 3 2 1 21201918171615141312 1110 313029 28 27 2625242322 76 5 4 3 2 1 1615141312 1110 9 8 242322 2120191817 6 5 4 3 2 1 121110 9 8 7 1716 151413 9 8 7 6 5 4 3 21 191817161514131211 10 282726252423 222120 7 6 5 4 3 2 1 151413121110 9 8 2221201918 1716 A02508 Symbols (Terminals No.) Wiring Color BATT (E7 – 1) – E1 (E10 – 17) B–Y ↔ BR Condition STD Voltage (V) Always 9 ∼ 14 +B (E7 – 16) – E1 (E10 – 17) R ↔ BR IG switch ON 9 ∼ 14 VC (E10 – 2) – E2 (E10 – 18) Y ↔ BR IG switch ON 4.5 ∼ 5.5 IG switch ON Throttle valve fully closed 0.3 ∼ 1.0 IG switch ON Throttle valve fully open 3.2 ∼ 4.9 P ↔ R–B Idling , A/C switch OFF 1.1 ∼ 1.5 THA (E10 – 22) – E2 (E10 – 18) L–Y ↔ BR Idling, Intake air temp. 20°C (68°F) 0.5 ∼ 3.4 THW (E10 –14) – E2 (E10 – 18) G–B ↔ BR Idling, Engine coolant temp. 80°C (176°F) 0.2 ∼ 1.0 STA (E7 – 7) – E1 (E10 – 17) GR ↔ BR Cranking VTA1 (E10 – 23) – E2 (E10 – 18) VG (E10 – 10) – E2G (E10 – 19) L ↔ BR 6.0 or more 9 ∼ 14 IG switch ON #10 (E10 – 5) – E01 (E11 – 21) L ↔ BR Pulse generation (See page DI–276) Idling 9 ∼ 14 IG switch ON #20 (E10 – 6) – E01 (E11 – 21) R ↔ BR Pulse generation (See page DI–276) Idling 9 ∼ 14 IG switch ON #30 (E11 – 1) – E01 (E11 – 21) Y ↔ BR Pulse generation (See page DI–276) Idling 9 ∼ 14 IG switch ON #40 (E11 – 2) – E01 (E11 – 21) W ↔ BR Pulse generation (See page DI–276) Idling 9 ∼ 14 IG switch ON #50 (E11 – 3) – E01 (E11 – 21) R–L ↔ BR Pulse generation (See page DI–276) Idling 9 ∼ 14 IG switch ON #60 (E11 – 4) – E01 (E11 – 21) IGT1 (E11 – 11) – E1 (E10– 17) IGT2 (E11 – 12) – E1 (E10 – 17) IGT3 (E11 – 13) – E1 (E10 – 17) G ↔ BR Idling Pulse generation (See page DI–276) GR ↔ BR Idling Pulse generation (See page DI–351) BR–Y ↔ BR Idling Pulse generation (See page DI–351) LG–B ↔ BR Idling Pulse generation (See page DI–351) Author: Date: 453 DI–219 DIAGNOSTICS Symbols (Terminals No.) Wiring Color IGF (E11 – 25) – E1 (E10 – 17) W–R ↔ BR THG (E10 – 13) G–Y ↔ BR – ENGINE (1MZ–FE) Condition STD Voltage (V) 4.5 ∼ 5.5 IG switch ON – E2 (E10 – 18) Pulse generation (See page DI–351) Idling 4.5 ∼ 5.5 IG switch ON G22+ (E11 – 10) – NE– (E10 – 24) B–W ↔ L Idling Pulse generation (See page DI–287) NE+ (E10 – 16) – NE– (E10 – 24) B–R ↔ L Idling Pulse generation (See page DI–287) Taillight switch ON 7.5 ∼ 14 Taillight switch OFF 0 ∼ 1.5 Defogger switch ON 7.5 ∼ 14 Defogger switch OFF 0 ∼ 1.5 Y–G ↔ BR IG switch ON 9 ∼ 14 ACIS (E11 – 17) – E01 (E11 – 21) R–Y ↔ BR IG switch ON 9 ∼ 14 G R ↔ BR G–R IG switch ON 9 ∼ 14 FC (E7 – 3) – E01 (E11 – 21) Idling 0 ∼ 3.0 ELS (E7 – 19) – E1 (E10 – 17) G O ↔ BR G–O ELS2 (E7 – 18) – E1 (E10 – 17) B Y ↔ BR B–Y EGR (E11 – 18) – E01 (E11 –21) EVP1 (E10 – 7) – E01 (E11 – 21) LG ↔ BR IG switch ON 9 ∼ 14 RSC (E11 – 15) – E01 (E11 – 21) Y–B ↔ BR IG switch ON Disconnect E11 of ECM connector 9 ∼ 14 RSO (E11 – 16) – E01 (E11 – 21) R–W ↔ BR IG switch ON Disconnect E11 of ECM connector 9 ∼ 14 *OXR1 (E10 – 11) – E1 (E10 – 17) W ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–305) *OXL1 (E10 – 12) – E1 (E10 – 17) B ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–305) OXS (E8 – 8) – E1 (E10 – 17) B ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up Pulse generation (See page DI–305) *HTL (E10– (E10 4) – E03 (E11 – 30) Y R ↔ BR Y–R *HTR HTR (E10 – 3) – E03 (E11 – 30) L B ↔ BR L–B HTS (E8 – 9) – E03 (E11 –30) 30) P G ↔ BR P–G 9 ∼ 14 Idling IG switch ON Below 3.0 9 ∼ 14 Idling IG switch ON Below 3.0 9 ∼ 14 Idling IG switch ON Below 3.0 KNKR (E11 – 27) – E1 (E10 – 17) W ↔ BR Idling Pulse generation (See page DI–283) KNKL (E11 – 28)– E1 (E10 – 17) W ↔ BR Idling Pulse generation (See page DI–283) NSW (E7 – 20) – E1 (E10 – 17) SPD (E8 – 22) – E1 (E10 – 17) B W ↔ BR B–W V–W ↔ BR IG switch ON Other shift position in ”P” ,”N” position 9 ∼ 14 IG switch ON Shift position in ”P” ,”N” position 0 ∼ 3.0 IG switch ON Rotate driving wheel slowly Pulse generation *: Only for except California specification vehicles Author: Date: 454 DI–220 DIAGNOSTICS Symbols (Terminals No.) – ENGINE (1MZ–FE) Wiring Color Condition STD Voltage (V) TC (E11 – 6) – E1 (E10 – 17) L–W ↔ BR IG switch ON 9 ∼ 14 W (E7 – 6) – E01 (E11 – 21) G–R ↔ BR IG switch ON Below 3.0 PS (E10 – 9) – E1 (E10 – 17) B–L ↔ BR IG switch ON 9 ∼ 14 A/C switch OFF Below 2.0 ACT (E8 – 13) – E1 (E10 – 17) LG B ↔ BR LG–B A/C (E8 – 25) – E1 (E10 – 17) B Y ↔ BR B–Y CF (E11 – 29) – E1 (E10 – 17) G W ↔ BR G–W TACH (E8– 27) – E1 (E10 – 17) B–O ↔ BR Idling W–R ↔ BR IG switch ON Disconnect the vacuum hose from the vapor pressure sensor TPC (E7 – 9) – E01 (E11 – 21) PTNK (E7 – 17) – E1 (E10 – 17) SIL (E7 – 11) – E1 (E10 – 17) STP (E7 – 15) – E1 (E10 – 17) L–R ↔ BR W ↔ BR G W ↔ BR G–W A/C switch ON at idling 9 ∼ 14 A/C switch ON at idling Below 2.0 A/C switch OFF 9 ∼ 14 Electric cooling fan is operating on high speed 9 ∼ 14 Electric cooling fan is operating on low speed or OFF 0∼2 Pulse generation 9 ∼ 14 IG switch ON 3.0 ∼ 3.6 IG switch ON Apply vacuum 2.0 kPa (15 mmHg, 0.6 in.Hg) 1.3 ∼ 2.1 During transmission Pulse generation IG switch ON Brake pedal depressed 7.5 ∼ 14 IG switch ON Brake pedal released Below 1.5 IG switch ON Apply vacuum (0 kPa, 0 mmHg, 0 in.Hg) to EGR valve 0.4 ∼ 1.6 IG switch ON Apply vacuum (17.3 kPa, 130 mmHg, 5.12 in.Hg) to EGR valve 3.2 ∼ 5.1 EGLS (E11 – 22) – E1 (E10 – 17) W G ↔ BR W–G *1 AFR+ (E10 – 11 – E1 (E10 – 17) BR ↔ BR IG switch ON 3.3* *1 AFR– (E10 – 20) – E1 (E10 – 17) B–R ↔ BR IG switch ON 3.0* *1 AFL+ (E10 – 12) – E1 (E10 – 17) B–W ↔ BR IG switch ON 3.3* *1 AFL– (E10 – 21) – E1 (E10 – 17) L ↔ BR IG switch ON 3.0* *1 HAFR (E10 – 3) – E04 (E10 – 1) B R ↔ BR B–R IG switch ON Below 3.0 *1 HAFL (E10 – 4) – E05 (E10 – 8) B W ↔ BR B–W KSW (E8 – 11) – E1 (E10 – 17) L B ↔ BR L–B RXCK (E9 – 5) – E1 (E10 – 17) R–L ↔ BR At time of inserting the key Pulse generation CODE (E9 – 4) – E1 (E10 – 17) G–W ↔ BR At time of inserting the key Pulse generation IGSW (E7 – 2) – E1 (E10 – 17) B–R ↔ BR IG switch ON 9 ∼ 14 TXCT (E9– 10) – E1 (E10 – 17) L–Y ↔ BR At time of inserting the key Pulse IMLD (E9 – 16) – E1 (E10 – 17) R–Y ↔ BR In condition without the key inserted Pulse MREL (E7 – 8) – E1 (E10 – 17) B–R ↔ BR IG switch ON 9 ∼ 14 Idling (warm up the engine) Pulse generation IG switch ON Below 3.0 Idling (warm up the engine) Pulse generation At time of inserting the key Below 1.5 4∼ 5 In condition without the key inserted *: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. *1: Only for California specification vehicles Author: Date: 455 DI–221 DIAGNOSTICS – ENGINE (1MZ–FE) DI07E–06 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Engine does not crank (Does not start) 1. Starter 2. Starter relay ST–18 ST–20 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI–369 DI–374 IN–31 No complete combustion (Does not start) 1. Fuel pump control circuit DI–374 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI–384 DI–374 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–384 DI–374 Hot engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–384 DI–374 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor Circuit) 2. ECM power source circuit AC–88 DI–369 Low engine idle speed (Poor idling) 1. A/C signal circuit (Compressor Circuit) 2. Fuel pump control circuit AC–88 DI–374 Rough idling (Poor idling) 1. Compression 2. Fuel pump control circuit EM–3 DI–374 Hunting (Poor idling) 1. ECM power source circuit 2. Fuel pump control circuit DI–369 DI–374 Hesitation/Poor acceleration (Poor driveability) 1. Fuel pump control circuit 2. A/T faulty DI–374 DI–453 Surging (Poor driveability) 1. Fuel pump control circuit DI–374 Soon after starting (Engine stall) 1. Fuel pump control circuit DI–374 During A/C operation (Engine stall) 1. A/C signal circuit (Compressor Circuit) 2. Engine control module (ECM) AC–88 IN–31 Unable to refuel/Difficult to refuel 1. ORVR system EC–6 Author: Date: 456 DI–222 DIAGNOSTICS – ENGINE (1MZ–FE) DI07F–06 CIRCUIT INSPECTION DTC P0100 Mass Air Flow Circuit Malfunction CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. B+ Thermistor Power Transistor Platinum Hot wire A B Output Voltage Platinum Hot Wire FI6929 S05741 A00435 DTC No. P0100 Thermistor DTC Detecting Condition Trouble Area Open or short in mass air flow meter circuit with more than 3 sec. engine speed 4,000 rpm or less
Open or short in mass air flow meter circuit
Mass air flow meter
ECM If the ECM detects DTC 0100 it operates the fail–safe function, keeping the ignition timing and injection volume constant and making it possible to drive the vehicle. HINT: After confirming DTC P0100, use the OBD II scan tool or TOYOTA hand–held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.) 0.0 271.0 or more Malfunction
Mass air flow meter power source circuit open
VG circuit open or short
E2G circuit open Author: Date: 457 DI–223 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM Engine Room J/B 1 F9 Fusible Link Block EFI 5 3 2 1 2 2J 7 2K R B–W F4 Battery B–Y W–B B–G 1 FL MAIN ECM 9 II3 EFI Relay B–Y 1 2A 5 2C B Junction Connector B B B–Y J28 J27 A Junction Connector A J36 A J20 Junction A Connector 4 10 VG E10 5 19 E2G R–B E10 3 P J35 B+ Mass Air Flow Meter EB B–W E2 8 MREL E7 A06156 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 458 DI–224 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of mass air flow rate. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. (c) Start the engine. CHECK: Read mass air flow rate on the OBD II scan tool or TOYOTA hand–held tester. RESULT: Mass air flow rate (gm/sec.) 2 Type II 0.0 271.0 or more Type I Go to step 2. Type II Go to step 5. Check voltage of mass air flow meter power source. PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal 4 of mass air flow meter connector and body ground. OK: Voltage: 9 ∼ 14 V ON BE6653 S05337 Type I 4 (+) A00436 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and mass air flow meter (See page IN–31). OK Author: Date: 459 DI–225 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check voltage between terminal VG of ECM connector and body ground. VG (+) A02017 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Start the engine. CHECK: Measure voltage between terminal VG of the ECM connector and body ground while engine is idling. OK: Voltage: 1.1 ∼ 1.5 V (P or N position and A/C switch OFF) OK Check and replace ECM (See page IN–31). NG 4 Check for open and short in harness and connector between mass air flow meter and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace mass air flow meter. Author: Date: 460 DI–226 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check continuity between terminal E2G of ECM and body ground. PREPARATION: Remove the glove compartment (See page SF–73). CHECK: Check continuity between terminal E2G of the ECM connector and body ground. OK: Continuity (1 Ω or less) E2G A02018 NG Check and replace ECM (See page IN–31). OK 6 Check for open in harness and connector between mass air flow meter and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace mass air flow meter. Author: Date: 461 DI–227 DIAGNOSTICS – ENGINE (1MZ–FE) DI07G–06 DTC P0101 Mass Air Flow Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0100 (Mass Air Flow Circuit Malfunction) on page DI–222. DTC No. P0101 DTC Detecting Condition Trouble Area Conditions (a), (b) and (c) continue 10 sec. or more with engine speed NE < 900: (2 trip detection logic) (a) Throttle valve fully closed (b) Mass air flow meter output  2.2 V (c) THW  70°C
Mass air flow meter Conditions (a) and (b) continue 10 sec. or more with engine speed 1,500 rpm or more: (2 trip detection logic) (a) VTA  0.63 V (b) Mass air flow meter output
1.06 V WIRING DIAGRAM Refer to DTC P0100 (Mass Air Flow Circuit Malfunction) on page DI–222. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0101) being output? NO Replace mass air flow meter. YES Go to relevant DTC chart. Author: Date: 462 DI–228 DIAGNOSTICS – ENGINE (1MZ–FE) DI07H–07 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See Fig. 1). The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0110, it operates the fail–safe function in which the intake air temperature is assumed to be 20°C (68°F). (fig. 1) 30 20 10 Resistance kΩ 5 Acceptable 3 2 1 0.5 0.3 0.2 0.1 – 20 (– 4) 0 32 20 68 40 104 60 140 80 176 100 212 Temp. °C (F°) Intake air temp. °C (°F) Resistance (kΩ) Voltage (V) –20 (–4) 16.0 4.3 0 (32) 5.9 3.4 20 (68) 2.5 2.4 40 (104) 1.1 1.4 60 (140) 0.6 0.9 80 (176) 0.3 0.5 100 (212) 0.1 0.2 FI4741 DTC No. P0110 DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area
Open or short in intake air temp. sensor circuit
Intake air temp. sensor (built into mass air flow meter)
ECM HINT: After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand–held tester to confirm the intake air temp. from ”CURRENT DATA”. Temp. Displayed Malfunction –40°C ( –40°F ) Open circuit 140°C ( 284°F ) or more Short circuit Author: Date: 463 DI–229 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM ECM Intake Air Temp. Sensor (Inside the Mass Air Flow Meter) 5V 1 L–Y 2 BR 22 E10 R THA 18 E10 E2 E1 FI6448 INSPECTION PROCEDURE HINT:

If DTCs P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) and P1410 (EGR Valve Position Sensor Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 464 DI–230 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of intake air temp. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual intake air temp. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (−40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand–held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI–197). 2 Check for open in harness or ECM. ON ECM Intake Air Temp. Sensor 1 E10 18 E10 2 5V 22 THA E2 A00210 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Connect sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace mass air flow meter. NG Author: Date: 465 DI–231 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open in harness or ECM. ON ECM Intake Air Temp. Sensor 22 E10 18 E10 THA 5V THA E2 E2 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Connect between terminals THA and E2 of ECM connector. HINT: Mass air flow meter connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–31). CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: 140°C (284°F) or more A02019 OK Open in harness between terminal E2 or THA, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM. 4 Check for short in harness and ECM. ON ECM Intake Air Temp. Sensor 5V 22 E10 18 THA E10 E2 PREPARATION: (a) Disconnect the mass air flow meter connector. (b) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: –40°C (–40°F) A00212 OK Replace mass air flow meter. NG Author: Date: 466 DI–232 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check for short in harness or ECM. ON ECM Intake Air Temp. Sensor 5V THA E2 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E10 connector of ECM. HINT: Mass air flow meter connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: – 40°C (– 40°F) OK E10 Repair or replace harness or connector. A02043 NG Check and replace ECM (See page IN–31). Author: Date: 467 DI–233 DIAGNOSTICS – ENGINE (1MZ–FE) DI07I–06 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temp. sensor changes the resistance value according to the engine coolant temp. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction shown on page DI–228. If the ECM detects the DTC P0115, it operates fail–safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. P0115 Detection Item Trouble Area Open or short in engine coolant temp. sensor circuit
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM HINT: After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand–held tester to confirm the engine coolant temp. from CURRENT DATA. Temperature Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit WIRING DIAGRAM ECM 5V Engine Coolant Temp. Sensor 2 G–B 1 BR 14 E10 18 E10 THW E2 E1 FI6448 INSPECTION PROCEDURE HINT:

If DTCs P0110 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttle/Pedal/Position Sensor/Switch ”A” Circuit Malfunction) and P1410 (EGR Valve Position Sensor Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 468 DI–234 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Connect OBD II scan tool or TOYOTA hand–held tester, and read value of engine coolant temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual engine coolant temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (–40°F).
If there is open circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI–197). 2 Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 2 E10 18 E10 1 5V 14 THW E2 A00214 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read temp. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. NG Author: Date: 469 DI–235 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 14 2 E10 18 E10 5V THW E2 1 THW E2 A02020 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Connect between terminals THW and E2 of the ECM connector. HINT: Engine coolant temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–31). (c) Turn the ignition switch ON. CHECK: Read temperature. value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK Open in harness between terminal E2 or THW, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM. 4 Check for short in harness and ECM. ON ECM Engine Coolant Temp. Sensor 5V 14 E10 18 E10 THW E2 PREPARATION: (a) Disconnect the engine coolant temp. sensor connector. (b) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) A00216 OK Replace engine coolant temp. sensor. NG Author: Date: 470 DI–236 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check for short in harness or ECM. ON ECM Engine Coolant Temp. Sensor 5V THW E2 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E10 connector of the ECM. HINT: Engine coolant temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) OK E10 Repair or replace harness or connector. A02043 NG Check and replace ECM (See page IN–31). Author: Date: 471 DI–237 DIAGNOSTICS – ENGINE (1MZ–FE) DI07J–06 DTC P0116 Engine Coolant Temp. Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 (Engine Coolant Temp. Circuit Malfunction) on page DI–233. DTC No. DTC Detecting Condition Trouble Area If THW –7°C (19.4°F), 20 min. or more after starting engine, engine coolant temp. sensor value is 20°C (68°F) or less (2 trip detection logic) If THW
–7°C (19.4°F) and 10°C (50°F), 5 min. or more after starting engine, engine coolant temp. sensor value is 20°C (68°F) or less (2 trip detection logic) P0116 If THW
10°C (50 °F), 2 min. or more after starting engine, engine coolant temp. sensor value is 30°C (86°F) (2 trip detection logic)
Engine coolant temp. temp sensor
Cooling system When THW
35°C (95°F) or more and less than 60°C (140°F), THA
– 6.7°C (19.9°F) or more, when starting engine , condition (a) and (b) continues: (a) Vehicle speed is changing (Not stable) (b) When starting engine, THW< 3°C (37.4°F) (2 trip detection logic) INSPECTION PROCEDURE HINT:
If DTCs P0115 (Engine Coolant Temp. Circuit Malfunction) and P0116 (Engine Coolant Temp. Circuit Range/Performance) are output simultaneously, engine coolant temp. sensor circuit may be open. Perform troubleshooting of DTC P0115 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0116) being output? YES Go to relevant DTC chart. NO Author: Date: 472 DI–238 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check thermostat (See page CO–9). NG Replace thermostat. OK Replace engine coolant temp. sensor. Author: Date: 473 DI–239 DIAGNOSTICS – ENGINE (1MZ–FE) DI07K–06 DTC P0120 Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 2.7 ∼ 5.2 V when the throttle valve is fully opened. the ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air–fuel ratio correction, power increase correction and fuel–cut control etc. ECM Throttle Position Sensor VC VTA1 E2 P24296 DTC No. P0120 DTC Detecting Condition Trouble Area
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Condition (a) or (b) continues: (a) VTA 0.1 V (b) VTA 4.9 V HINT: After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand–held tester to confirm the throttle valve opening percentage and closed throttle position switch condition. Throttle valve opening position expressed as percentage Trouble Area Throttle valve fully closed Throttle valve fully open 0% 0% VC line open VTA line open or short Approx. 100 % Approx. 100 % E2 line open WIRING DIAGRAM Throttle Position Sensor ECM 1 Y 2 E10 VC 3 L 23 VTA1 E10 2 BR 18 E2 E10 5V S05019 Author: Date: 474 DI–240 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT:
If DTCs P0110(Intake Air temp. Circuit Malfunction), P0115(Engine Coolant Temp. Circuit Malfunction), P0120(Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction) and P1410 are output simultaneously, E2 (Sensor Ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Connect OBD II scan tool or TOYOTA hand–held tester, and read throttle valve opening percentage. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the throttle valve opening percentage. OK: FI7052 OK Throttle valve Throttle valve opening position expressed as percentage Fully open Approx. 75 % Fully closed Approx. 10 % Check for intermittent problems (See page DI–197). NG Author: Date: 475 DI–241 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check voltage between terminal 1 of wire harness side connector and body ground. PREPARATION: (a) Disconnect the throttle position sensor connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal 1 of wire harness side connector and body ground. OK: Voltage: 4.5 ∼ 5.5 V ON 1 (+) BE6653 S05338 A00437 NG Go to step 5. OK 3 Check throttle position sensor. PREPARATION: Disconnect the throttle position sensor connector. CHECK: Measure voltage between terminals 1, 3 and 2 of throttle position sensor. OK: 1 2 3 S05339 NG Terminals Throttle valve Resistance 1 ∼ 2  2.5 ∼ 5.9 kΩ 3 ∼ 2 Fully closed 0.2 ∼ 6.3 kΩ 3 ∼ 2 Fully open 2.0 ∼ 10.2 kΩ Replace throttle position sensor. OK Author: Date: 476 DI–242 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check voltage between terminals VTA1 and E2 of ECM. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VTA1 and E2 of the ECM connector. OK: ON VTA1 (+) E2 (–) A02021 NG Throttle valve Voltage Fully closed 0.3 ∼ 1.0 V Fully open 2.7 ∼ 5.2 V Check for open and short in harness and connector between ECM and throttle position sensor (VTA line) (See page IN–31). OK Check and replace ECM (See page IN–31). 5 Check voltage between terminals VC and E2 of ECM. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 ∼ 5.5 V ON VC (+) E2 (–) A02022 NG Check and replace ECM (See page IN–31). OK Check for open in harness and connector between ECM and sensor (VC line) (See page IN–31). Author: Date: 477 DI–243 DIAGNOSTICS – ENGINE (1MZ–FE) DI07L–06 DTC P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 (Throttle/Pedal Position Sensor/Switch "A" Circuit Malfunction) on page DI–239. DTC No. P0121 DTC Detecting Condition Trouble Area After vehicle speed has been exceeded 30 km/h (19 mph) even once, output value of throttle position sensor is out of applicable range while vehicle speed between 30 km/h (19 mph) and 0 km/h (0 mph) (2 trip detection logic)
Throttle position sensor INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0121) being output? YES Go to relevant DTC chart. NO Replace throttle position sensor. Author: Date: 478 DI–244 DIAGNOSTICS – ENGINE (1MZ–FE) DI07M–08 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air–fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air–fuel ratio. When the air–fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: < 0.45 V). When the air–fuel ratio is RICHER than the stoichiometric air–fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45 V). The ECM judges by the electromotive force from the oxygen sensor whether the air–fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air–fuel ratio control. The heated oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Ideal Air–Fuel Mixture Flange Platinum Electrode Solid Electrolyte (Zirconia Element) Platium Electrode Output Voltage Atmosphere Heater Coating(Ceramic) Cover Richer Air Fuel Ratio Exhaust Gas P21242 FI7210 DTC No. P0125 Leaner A00027 DTC Detecting Condition After engine is warmed up, heated oxygen sensor (bank 1, 2 sensor 1) output does not indicate RICH ( 0.45 V ) even once when conditions (a), (b), (c) and (d) continue for at least 2 min.: (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40
SPD and 100 km/h (25
SPD and 62 mph) (c) Throttle valve does not fully closed (d) 140 sec. or more after starting engine Trouble Area
Fuel system
Injector
Ignition system
Gas leakage on exhaust system
Open or short in heated oxygen sensors (bank 1, 2 sensor 1) circuit
Heated oxygen sensors (bank 1, 2 sensor 1)
ECM Author: Date: 479 DI–245 DIAGNOSTICS – ENGINE (1MZ–FE) HINT: After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of the heated oxygen sensors (bank 1, 2 sensor 1) from CURRENT DATA. If voltage output of the heated oxygen sensors (bank 1, 2 sensor 1) is less than 0.1 V, heated oxygen sensors (bank 1, 2 sensor 1) circuit may be open or short. WIRING DIAGRAM ECM B+ Junction Connector A J36 B–W 3 EFI Relay 1 2 EFI Engine Room J/B 2J 2 2A 1 1 F4 B–G W–B Fusible Link Block FL MAIN Heated Oxygen Sensor Y–R 4 1 W 2 Heated Oxygen Sensor (Bank 1 Sensor 1) 1 3 BR B–Y Battery 12 E10 OXL1 4 E10 HTL1 11 E10 OXR1 30 E11 E03 E1 E03 L–B HTR B 8 E8 OXS E03 E1 1 4 A A BR BR 9 E8 P–B EB MREL 3 E10 3 2 Heated Oxygen Sensor (Bank 1 Sensor 2) 8 E7 E1 4 BR BR 1 F6 B (Bank 2 Sensor 1) B 5 2C 5 J27 D Junction Connector B–Y B–Y A A 2 3 BR 7 2K 9 II3 B–W B–Y B–Y Junction Connector B B B–Y J27 J28 C J35 HTS E03 ED EC A07444 INSPECTION PROCEDURE HINT:

If the vehicle run out fuel, the air–fuel ratio is LEAN and DTC P0125 will be recorded. The MIL then comes on. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 480 DI–246 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Are there any other codes (besides DTC P0125) being output ? YES Go to relevant DTC chart. NO 2 Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of heated oxygen sensors (bank 1, 2 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp.(above 75°C (169°F)). CHECK: Read voltage output of the heated oxygen sensors (bank 1,2 sensor 1) when engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 times using accelerator pedal. OK: Heated oxygen sensors (bank 1, 2 sensor 1) output a RICH signal (0.45 V or more) at least once. OK Go to step 10. NG 3 Check for open and short in harness and connector between ECM and heated oxygen sensors (bank 1, 2 sensor 1) (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 481 DI–247 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check whether misfire is occurred or not by monitoring DTC and data list. NG Perform troubleshooting for misfire (See page DI–351). OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–11). NG Replace EGR system. OK 7 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 8 Check injector injection (See page SF–25) NG Replace injector. OK Author: Date: 482 DI–248 DIAGNOSTICS 9 – ENGINE (1MZ–FE) Check gas leakage on exhaust system. NG Repair or replace. OK Replace heated oxygen sensors (bank 1, 2 sensor 1). 10 Perform confirmation driving pattern (See page DI–255). Go 11 Is there DTC P0125 being output again ? YES Check and replace ECM (See page IN–31). NO 12 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems (See page DI–197). NO DTC P0125 is caused by running out of fuel. Author: Date: 483 DI–249 DIAGNOSTICS – ENGINE (1MZ–FE) DI07M–09 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.) CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air–fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air–fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air–fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air–fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. *: The voltage value changes at the inside of the ECM only. Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater ECM Monitored A/F Sensor Voltage Atmosphere (V) 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 Coating (Ceramic) 12 13 14 15 16 17 18 19 Air–Fuel Ratio Cover Exhaust Gas A00477 DTC No. P0125 DTC Detecting Condition After engine is warmed up, A/F sensor output* does not change when conditions (a), (b) and (c) continue for at least 1.5 min. *: Output value changes at inside of ECM only. (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 ∼ 100 km/h (25 ∼ 62 mph) (c) Throttle valve does not fully closed (d) After starting engine
140 sec Trouble Area
Fuel system
Injector
Ignition system
Gas leakage on exhaust system
Open or short in A/F sensor circuit (bank 1, 2 sensor 1)
A/F sensors (bank 1, 2 sensor 1)
ECM Author: Date: 484 DI–250 DIAGNOSTICS – ENGINE (1MZ–FE) HINT:


After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of heated oxygen sensors (bank 1, 2 sensor 1) from CURRENT DATA. The ECM controls the voltage of AFR, AFL, AFR and AFL terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester. E03 HTS A BR EC J22 Junction Connector II1 B–G EB C J35 Junction Connector C J35 B 1 F4 5 3 EFI 1 F6 1 2A 5 2C 2 1 2 2J 7 2K EFI Relay W–B B–W Engine Room J/B B–W B–W B A J36 1 2 A 4 3 2 B–Y BR BR B P–B B–W 9 E8 OXS 8 E8 B–W 8 MREL E7 E1 B+ E05 4 E10 HAFL AFL– 3.0 V 4 3 2 1 A/F Sensor (Bank 1, Sensor 2) A/F Sensor (Bank 2, Sensor 1) E J27 B–Y B J27 Junction connector B B B B ES1 E04 to Analog–Digital Converter AFL+ 3.3 V HAFR *L *1B–W 12 E10 3 B–R E10 *B–W 21 *1L E10 20 AFR– E10 3.0 V *G *1B–R 1 B B 2 A/F Sensor (Bank 1, Sensor 1) 1 J24 Junction Connector 4 3 11 AFR+ E10 3.3 V *G *1BR ECM to Analog–Digital Converter WIRING DIAGRAM 1 A/F HTR 1 A/F HTR Relay L 2 1 2 5 3 *: TMC Made *: TMMK Made 2 Engine Room Battery W–B W FL 2 FL MAIN 2 2 1 Engine Room A07445 Author: Date: 485 DI–251 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0125) being output ? YES Go to relevant DTC chart. NO Author: Date: 486 DI–252 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Connect the OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of A/F sensors (bank 1, 2 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensors (bank 1, 2 sensor 1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of A/F sensors (bank 1, 2 sensor 1) on the screen of OBD II scan tool or TOYOTA hand– held tester, when you perform all the following conditions. HINT: The voltage of AFR,AFL terminal of ECM is 3.3 fixed and the AFR,AFL terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AFR,AFL/ AFR,AFL) of ECM. OK: Condition Engine idling E i idling Engine idli Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or move, and operate throttle valve open and close A/F Sensor Voltage value
Not N t remains i att 3.3. 3 3 V (*0.660 (*0 ( 0.660 660 V)
Not remains at 3 3.8 8 V (*0.76 (*0 76 V) or more
Not remains at 2.8 V (*0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of A/F sensors (bank 1, 2 sensor 1) is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of A/F sensors (bank 1, 2 sensor 1) is above 3.8 V (* 0.76 V), it is normal.
If output voltage of A/F sensors (bank 1, 2 sensor 1) remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensors (bank 1, 2 sensor 1) circuit may be open.
If output voltage of A/F sensor remains at 3.8 V (* 0.76 V) or more, or 2.8 V (* 0.56 V) or less even after performing all the above conditions, A/F sensors (bank 1, 2 sensor 1) circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 10. NG 3 Check for open and short in harness and connector between ECM and A/F sensors (bank1, 2 sensor1) (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 487 DI–253 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check resistance of A/F sensor heaters (bank1, 2 sensor1) (See page SF–68). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–11). NG Replace EGR system. OK 7 Check fuel pressure (See page SF–21). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 8 Check injector injection (See page SF–25). NG Replace injector. OK Author: Date: 488 DI–254 DIAGNOSTICS 9 – ENGINE (1MZ–FE) Check gas leakage on exhaust system. NG Repair or replace OK Replace A/F sensors (bank1, 2 sensor1). 10 Perform confirmation driving pattern (See page DI–340). Go 11 Is there DTC P0125 being output again ? YES Check and replace ECM (See page IN–31). NO 12 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems (See page DI–197). YES DTC P0125 is caused by running out of fuel. Author: Date: 489 DI–255 DIAGNOSTICS – ENGINE (1MZ–FE) DI07N–07 DTC P0130 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) (Except California Spec.) DTC P0150 Heated Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 1) (Except California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI–244. DTC No. DTC Detecting Condition Trouble Area P0130 P0150 Voltage output of heated oxygen sensor remains at 0.4 V or more, or 0.55 V or less, during idling after engine is warmed up (2 trip detection logic)
Heated oxygen sensor
Fuel trim malfunction HINT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closer to the engine body. The heated oxygen sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI–244. CONFIRMATION DRIVING PATTERN Vehicle speed 50 ∼ 65 km/h (31 ∼ 40 mph) Idling IG SW OFF (4) (3) (5) (1) (2) 1 ∼ 3 min. 1 min. Time A01666 (1) (2) (3) (4) (5) (6) Connect the TOYOTA hand–held tester to the DLC3. Switch the TOYOTA hand–held tester from normal mode to check mode (See page DI–197). Start the engine and warm it up with all accessory switches OFF. Drive the vehicle at 50 ∼ 65 km/h (31 ∼ 40 mph) for 1 ∼ 3 min. to warm up the heated oxygen sensor. Let the engine idle for 1 min. Perform steps (3) to (5) three times. Author: Date: 490 DI–256 DIAGNOSTICS – ENGINE (1MZ–FE) HINT: If a malfunction exists, the MIL will light up during step (6). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (3) to (6), then perform steps (3) to (6) again. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0130, P0150) being output ? YES Go to relevant DTC chart. NO 2 Check the output voltage of heated oxygen sensors (bank1, 2 sensor1) during idling. PREPARATION: Warm up the heated oxygen sensors (bank1, 2 sensor1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensors (bank1, 2 sensor1) during idling. OK: Heated oxygen sensors (bank1, 2 sensor1) output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK Go to step 8. NG Author: Date: 491 DI–257 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and heated oxygen sensors (bank1, 2 sensor1) (See page IN–31). NG Repair or replace harness or connector. OK 4 Check air induction system (See page SF–1). NG Repair or replace. OK 5 Check EGR system (See page EC–11). NG Replace EGR system. OK 6 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 492 DI–258 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check injector injection (See page SF–25). NG Replace injector. OK Replace heated oxygen sensors (bank1, 2 sensor1). 8 Perform confirmation driving pattern. Go 9 Are there DTC P0130 and/or P0150 being output again ? NO Check for intermittent problems (see page DI–197). YES Check and replace ECM (See page IN–31). Author: Date: 493 DI–259 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DQ–01 DTC P0133 Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) (Ex. CA Spec.) DTC P0153 Heated Oxygen Sensor Circuit Slow Response (Bank 2 Sensor 1) (Ex. CA Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI–244. DTC No. DTC Detecting Condition Trouble Area P0133 P0153 Response time for heated oxygen sensor’s voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after engine is warmed up (2 trip detection logic)
Heated oxygen sensor
Fuel trim malfunction HINT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0133, P0153) being output ? YES Go to relevant DTC chart. NO Author: Date: 494 DI–260 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check the output voltage of heated oxygen sensors (bank1, 2 sensor1) during idling. PREPARATION: Warm up the heated oxygen sensors (bank1, 2 sensor1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensors (bank1, 2 sensor1) during idling. OK: Heated oxygen sensors (bank1, 2 sensor1) output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). P18349 OK Go to step 8. NG 3 Check for open and short in harness and connector between ECM and heated oxygen sensors (bank1, 2 sensor1) (See page IN–31). NG Repair or replace harness or connector. OK 4 Check air induction system (See page SF–1). NG Repair or replace. OK Author: Date: 495 DI–261 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check EGR system (See page EC–11). NG Replace EGR system. OK 6 Check fuel pressure (See page SF–1). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 7 Check injector injection (See page SF–25). NG Replace injector. OK Replace heated oxygen sensors (bank1, 2 sensor1). 8 Perform confirmation driving pattern (See page DI–255). Go Author: Date: 496 DI–262 DIAGNOSTICS 9 – ENGINE (1MZ–FE) Are there DTC P0133 and/or P0153 being output again ? NO Check for intermittent problems (see page DI–197). YES Check and Replace ECM (See page IN–31). Author: Date: 497 DI–263 DIAGNOSTICS – ENGINE (1MZ–FE) DI07P–06 DTC P0135 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) (EX. CA Spec.) DTC P0141 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) DTC P0155 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) (EX. CA Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–244. DTC No. P0135 P0141 P0155 DTC Detecting Condition When heater operates, heater current exceeds 2.35 A (2 trip detection logic) Heater current of 0.2 A or less when heater operates (2 trip detection logic) Trouble Area
Open or short in heater circuit of heated oxygen sensor
Heated H t d oxygen sensor heater h t
ECM HINT:



Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Except California Spec.)) on page DI–244. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 498 DI–264 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Check voltage between terminals HTR, HTS, HTL of ECM connectors and body ground. ON HTL (+) HTR (+) HTS (+) A02023 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals HTR, HTS, HTL of the ECM connectors and body ground. HINT:
Connect terminal HTR to bank 1 sensor 1.
Connect terminal HTS to bank 1 sensor 2.
Connect terminal HTL to bank 2 sensor 1. OK: Voltage: 9 ∼ 14 V OK Check and replace ECM (See page IN–31). NG 2 Check resistance of heated oxygen sensor heater (See page SF–71). NG Replace heated oxygen sensor. OK Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor, and heated oxygen sensor and ECM (See page IN–31). Author: Date: 499 DI–265 DIAGNOSTICS – ENGINE (1MZ–FE) DI07Q–06 DTC P0136 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI–244. DTC No. DTC Detecting Condition Trouble Area P0136 Voltage output of heated oxygen sensor (bank 1 sensor 2) remains at 0.4 V or more or 0.6*1 0.5*2 V or less when vehicle is driven at 50 km/h (31 mph) or more after engine is warmed up *1: for California Spec. *2: except California Spec. (2 trip detection logic)
Heated oxygen sensor HINT: Bank 1 refers to the bank that includes cylinder No.1. Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI–244. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0136) being output ? YES Go to relevant DTC chart. NO 2 Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 500 DI–266 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check output voltage of heated oxygen sensor (bank 1 sensor 2). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp. CHECK: Read voltage output of heated oxygen sensor (bank 1 sensor 2) when engine suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 min. using accelerator pedal. OK: Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0.6*1/0.5* 2 V or more. *1: for California Spec. *2: except California Spec. OK Check that each connector is properly connected. NG Replace heated oxygen sensor (bank 1 sensor 2). Author: Date: 501 DI–267 DIAGNOSTICS – ENGINE (1MZ–FE) DI07R–05 DTC P0171 System too Lean (Fuel Trim) (Only for California Spec.) DTC P0172 System too Rich (Fuel Trim) (Only for California Spec.) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the A/F sensor is approximately proportional to the existing air–fuel ratio, and ECM comparing it with the ideal theoretical value, the ECM reduces fuel volume immediately if the air–fuel ratio is rich and increases fuel volume if it is lean. Long–term fuel trim compensates the deviation from the central value of the short–term fuel trim stored up by each engine tolerance, and the deviation from the central value due to the passage of time and changes of using environment. If both the short–term fuel trim and long–term fuel trim exceed a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When air fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on RICH side (2 trip detection logic)
Gas leakage on exhaust system
Air intake (hose loose)
Fuel line pressure
Injector blockage
Mass air flow meter
Engine coolant temp. sensor
A/F sensors (bank 1, 2 sensor 1) When air fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Gas leakage on exhaust system
Fuel line pressure
Injector leak, blockage
Mass air flow meter
Engine coolant temp. sensor
A/F sensors (bank 1, 2 sensor 1) Author: Date: 502 DI–268 DIAGNOSTICS – ENGINE (1MZ–FE) HINT:
When the DTC P0171 is recorded, the actual air–fuel ratio is on the lean side. When DTC P0172 is recorded, the actual air–fuel ratio is on the rich side. If the vehicle runs out of fuel, the air–fuel ratio is lean and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ± 35 % (80°C (176°F) or more), the system is functioning normally. The A/F sensors (bank 1, 2 sensor 1) output voltage and the short–term fuel trim value can be read using the OBD II scan tool or TOYOTA hand–held tester. The ECM controls the voltage of AFR
, AFL
, AFR and AFL terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensors (bank 1, 2 sensor 1) output voltage which is displayed on the TOYOTA hand–held tester.




INSPECTION PROCEDURE Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check air induction system (See page SF–1). NG Repair or replace. OK 2 Check injector injection (See page SF–25). NG Replace injector. OK 3 Check mass air flow meter and engine coolant temp. sensor (See pages SF–35 and SF–63). NG Repair or replace. OK Author: Date: 503 DI–269 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check for spark and ignition (See page IG–1). NG Repair or replace. OK 5 Check fuel pressure (See page SF–21). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page SF–1). OK 6 Check gas leakage on exhaust system. NG Repair or replace. OK Author: Date: 504 DI–270 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check the output voltage A/F sensors (bank1, 2 sensor1). PREPARATION: (a) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensors (bank1, 2 sensor1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage value of A/F sensors (bank1, 2 sensor1) on the screen of OBDII scan tool or TOYOTA hand– held tester when you perform all the following conditions. HINT: The voltage of AFR
, AFL
terminal of ECM is 3.3 fixed AFR, AFL terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensors (bank1, 2 sensor1) output voltage at the terminals (AFR
, AFL
/ AFR, AFL) of ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (*0.660 V)
Not remains at 3 3.8 8 V (*0 (*0.76 76 V) or more
Not remains at 2.8 V (*0.56 V) or less *: When you use the OBDII scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of A/F sensors (bank1, 2 sensor1) is below 2.8 V (*0.56 V), it is normal.
During fuel cut, there is case that the output voltage of A/F sensors (bank1, 2 sensor1) is above 3.8 V (*0.76 V), it is normal.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.30 V (*0.660 V) even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be open.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.8 V (*0.76 V) or more, or 2.8 V (*0.56 V) or less even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be short. *: When you use the OBDII scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG Author: Date: 505 DI–271 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and A/F sensors (bank1, 2 sensor1) (See page IN–31). NG Repair or replace harness or connector. OK Replace A/F sensors (bank1, 2 sensor1). 9 perform confirmation driving pattern (See page DI–340). Go 10 Is there DTC P0171 or P0172 being output again ? YES Check and replace ECM (See page IN–31). NO 11 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems (See page DI–197). YES DTC P0171 or P0172 is caused by running out of fuel. Author: Date: 506 DI–272 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DR–01 DTC P0171 System too Lean (Fuel Trim) (Except California Spec.) DTC P0172 System too Rich (Fuel Trim) (Except California Spec.) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the heated oxygen sensor indicates whether the air–fuel ratio is RICH or LEAN compared to the ideal theoretical value, triggering a reduction in fuel volume if the air–fuel ratio is rich, and an increase in fuel volume if it is lean. Long–term fuel trim is overall fuel compensation carried out long–term to compensate for continual deviation of the short–term fuel trim from the central value due to individual engine differences, wear over time and changes in the usage environment. If both the short–term fuel trim and long–term fuel trim are LEAN or RICH beyond a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When air fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on RICH side (2 trip detection logic)
Air intake (hose loose)
Fuel line pressure
Injector blockage
Heated oxygen sensors (bank 1, 2 sensor 1) malfunction
Mass air flow meter
Engine coolant temp. sensor
Gas leakage on exhaust system When air fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Fuel line pressure
Injector leak, blockage
Heated oxygen sensors (bank 1, 2 sensor 1) malfunction
Mass air flow meter
Engine coolant temp. sensor
Gas leakage on exhaust system HINT:


When DTC P0171 is recorded, the actual air–fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air–fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air–fuel ratio is LEAN and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ± 35 % (80°C (176°F) or more), the system is functioning normally. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 507 DI–273 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Check air induction system (See page SF–1). NG Repair or replace. OK 2 Check injector injection (See page SF–21). NG Replace injector. OK 3 Check mass air flow meter and engine coolant temp. sensor (See pages SF–35 and SF–63). NG Repair or replace. OK 4 Check for spark and ignition (See page IG–1). NG Repair or replace. OK 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, pressure regulator, fuel pipe line and filter. OK Author: Date: 508 DI–274 DIAGNOSTICS 6 – ENGINE (1MZ–FE) Check gas leakage on exhaust system. NG Repair or replace. OK 7 Check the output voltage of heated oxygen sensors (bank1, 2 sensor1) during idling. PREPARATION: Warm up the heated oxygen sensors (bank1, 2 sensor1) the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBDII scan tool or TOYOTA hand–held tester to read the output voltage of the heated oxygen sensors (bank1, 2 sensor1) during idling. OK: Heated oxygen sensors (bank1, 2 sensor1) output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the Following table). P18349 OK Go to step 9. NG Author: Date: 509 DI–275 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and heated oxygen sensors (bank1, 2 sensor1) (See page SF–71). NG Repair or replace harness or connector. OK Replace heated oxygen sensors (bank1, 2 sensor1). 9 Perform confirmation driving pattern (See page DI–255). Go 10 Is there DTC P0171 or P0172 being output again ? YES Check and replace ECM. NO 11 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems. YES DTC P0171 or P0172 is caused by running out of fuel. Author: Date: 510 DI–276 DIAGNOSTICS – ENGINE (1MZ–FE) DI07S–07 DTC P0300 Random/Multiple Cylinder Misfire Detected DTC P0301 Cylinder 1 Misfire Detected DTC P0302 Cylinder 2 Misfire Detected DTC P0303 Cylinder 3 Misfire Detected DTC P0304 Cylinder 4 Misfire Detected DTC P0305 Cylinder 5 Misfire Detected DTC P0306 Cylinder 6 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in the crankshaft rotation for each cylinder. The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. When the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring occurs. DTC No. P0300 P0301 P0302 P0303 P0304 P0305 P0306 DTC Detecting Condition Misfiring of random cylinders is detected during any particular 200 or 1,000 revolutions For any particular 200 revolutions for engine, misfiring is detected which can cause catalyst overheating (This causes MIL to blink) For any particular 1,000 revolutions of engine, misfiring is detected which causes a deterioration in emission (2 trip detection logic) Trouble Area
Ignition system
Injector
Fuel line pressure
EGR
Compression pressure
Valve clearance not to specification
Valve timing
Mass air flow meter
Engine coolant temp. sensor
Open or short in engine wire
Connector connection
ECM Author: Date: 511 DI–277 DIAGNOSTICS – ENGINE (1MZ–FE) HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is recorded, it indicates that the misfires were detected and recorded at different times. WIRING DIAGRAM Instrument Panel J/B 3 1K B–R 6 12 8 B–R 1C II3 J18 Junction Connector Injector 1 B–R 2 B–R L 5 E10 #10 1 R 6 #20 E10 1 Y 1 #30 E11 1 W 2 E11 #40 No. 1 B–R 2 Ignition Switch 7 ECM W–R 5 1K No. 2 5 1B W–R B–R 2 4 2L B–R 2 B–G Fusible Link Block 1 1 F6 F4 AM2 No. 3 Engine Room J/B N0.2 No. 4 1 R–L B–R 2 No. 5 B–R 2 1 2A 1 G No. 6 B FL MAIN Battery 3 #50 E11 4 #60 E11 BR 21 E01 E11 BR 31 E02 E11 EC A03319 CONFIRMATION DRIVING PATTERN (1) Connect the TOYOTA hand–held tester or OBD II scan tool. (2) Record DTC and the freeze frame data. (3) Use the TOYOTA hand–held tester to set to Check Mode. (See page DI–197) (4) Drive the vehicle several times with the engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in the freeze frame data or MISFIRE RPM, MISFIRE LOAD in the data list. If you have no TOYOTA hand–held tester, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. HINT: In order to memorize DTC of misfire, it is necessary to drive around MISFIRE RPM, MISFIRE LOAD in the data list for the following period of time. Engine Speed Time Idling 3 minutes 30 seconds or more 1000 rpm 3 minutes or more 2000 rpm 1 minute 30 seconds or more 3000 rpm 1 minute or more (5) Check whether there is misfire or not by monitoring DTC and the freeze frame data. After that, record them. (6) Turn ignition switch OFF and wait at least 5 seconds. Author: Date: 512 DI–278 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT:
If is the case that DTC besides misfire is memorized simultaneously, first perform the troubleshooting for them. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame data records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the vehicle is brought to the workshop and the misfire is not occurred, misfire can be confirmed by reproducing the condition or freeze frame data. Also, after finishing the repair, confirm that there is no misfire. (See the confirmation driving pattern) When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data is besides the range of ±20%, there is a possibility that the air–fuel ratio is inclining either to ”rich” (–20% or less) or ”lean” (+20% or more). When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibility or misfire only during warming up. In the case that misfire cannot be reproduced, the reason may be because of the driving with lack or fuel, the use of improper fuel, a stain of ignition plug, and etc.




1 Check wire harness, connector and vacuum hose in engine room. CHECK: (a) Check the connection conditions of wire harness and connector. (b) Check the disconnection, piping and break of vacuum hose. NG Repair or replace, then confirm that there is no misfire (See the confirmation driving pattern). OK Author: Date: 513 DI–279 DIAGNOSTICS 2 P25779 P23917 – ENGINE (1MZ–FE) Check spark plug and spark of misfiring cylinder. A00221 PREPARATION: (a) Remove the ignition coil (See page IG–7). (b) Remove the spark plug. CHECK: (a) Check spark plug type. (b) Check for carbon deposits on electrode. (c) Check electrode gap. OK: (a) Twin ground electrodes type. Recommended spark plug: ND PK20TR11 NGK BKR6EKPB–11 (b) No large carbon deposit present. Not wet with gasoline or oil. (c) Electrode gap: Standerd: 1.0 – 1.1 mm (0.03937 – 0.043 in.). Maximum: 1.3 mm (0.051 in.). PREPARATION: (a) Install the spark plug to the ignition coil, and connect the ignition coil the connector. (b) Disconnect injector connector. (c) Hold the end about 12.5 mm (0.5 in.) from the ground. CHECK: Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, don’t crank the engine for more than 5 ∼ 10 sec. at a time. OK: Spark jumps across electrode gap. NG Replace or check ignition system (See page IG–1). OK Author: Date: 514 DI–280 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check voltage of ECM terminal for injector of failed cylinder. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON (+) (+) (+) (+) (+) (+) #10 #20 #30 #40 #50 #60 A02024 Reference INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM With the engine idling, measure between terminals #10 ∼ #60 and E01 of ECM. HINT: The correct waveform is as shown. (Magnification) 10 V /Division 10 V /Division GND GND FI6588 FI6538 1 msec./Division (Idling) Injection duration 100 msec./Division (Idling) OK A00064 Go to step 5. NG Author: Date: 515 DI–281 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check resistance of injector of misfiring cylinder (See page SF–21). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN–31). 5 Check fuel pressure (See page SF–6). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK 6 Check injector injection (See page SF–25). NG Replace injector. OK 7 Check EGR system (See page EC–11). NG Replace EGR system. OK Author: Date: 516 DI–282 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check mass air flow meter and engine coolant temp. sensor (See pages SF–35, SF–63). NG Repair or replace. OK Check compression pressure, valve clearance and valve timing. Author: Date: 517 DI–283 DIAGNOSTICS – ENGINE (1MZ–FE) DI07T–06 DTC P0325 Knock Sensor 1 Circuit Malfunction DTC P0330 Knock Sensor 2 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensors are fitted one to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed between 2,000 rpm and 5,600 rpm.
Open or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM P0330 No knock sensor 2 signal to ECM with engine speed between 2,000 rpm and 5,600 rpm.
Open or short in knock sensor 2 circuit
Knock sensor 2 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fail–safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM ECM Knock Sensor 1 (On right bank) 1 W 1 EC1 W 27 KNKR E11 E1 Knock Sensor 2 (On left bank) 1 W 2 EC1 W 28 KNKL E11 E1 A03315 Author: Date: 518 DI–284 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT:
DTC P0325 is for the right bank knock sensor circuit. DTC P0330 is for the left bank knock sensor circuit. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Connect OBD II scan tool or TOYOTA hand–held tester, and check knock sensor circuit. ECM Knock Sensor 1 EC1 27 KNKR 1 1 E6 PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Disconnect the wire to wire connector EC1. (c) Connect the terminals of the disconnected EC1 male connector and EC1 female as follows. 28 KNKL 1 2 2 Male connector ↔ Female connector E6 Terminal 1 ↔ Terminal 2 Male Female Connector Connector Terminal 2 ↔ Terminal 1 (d) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. (e) After the engine is warmed up, perform quick racing to 4,000 rpm three times. CHECK: Check the DTC. RESULT: EC1 Type I DTC same as when vehicle brought in. P0325 → P0325 or P0330 → P0330 Type II DTC different to when vehicle brought in. P0325 → P0330 or P0330 → P0325 A00304 Author: Date: 519 DI–285 DIAGNOSTICS 0.5 V /Division – ENGINE (1MZ–FE) Reference INSPECTION USING OSCILLOSCOPE
With the engine racing (4,000 rpm), measure between terminals KNKR, KNKL of the ECM connector and body ground. HINT: The correct waveforms are as shown. KNK Signal Waveforms 0V 5 msec./Division 200 mV /Division
Spread the time on the horizontal axis, and confirm that period of the wave is 141 µsec. (Normal mode vibration frequency of knock sensor: 7.1 kHz) 0V FI6510 FI6607 100 µsec./Division HINT: If normal mode vibration frequency is not 7.1 kHz, the sensor is malfunctioning. A00113 Type II Go to step 3 . Type I 2 Check for open and short in harness and connector between EC1 connector and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 520 DI–286 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open and short in harness and connector between EC1 connector and knock sensor (See page IN–31). HINT:

If DTC P0325 has changed to P0330, check the knock sensor circuit on the right bank side. If DTC P0330 has changed to P0325, check the knock sensor circuit on the left bank side. NG Repair or replace harness or connector. OK Replace knock sensor. Author: Date: 521 DI–287 DIAGNOSTICS – ENGINE (1MZ–FE) DI07U–06 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G22 signals, and the actual crankshaft angle and the engine speed by the NE signals. DTC No. DTC Detecting Condition Trouble Area No crankshaft position sensor signal to ECM during cranking (2 trip detection logic) P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit
Crankshaft position osition sensor
Starter
ECM WIRING DIAGRAM ECM Camshaft Position Sensor 1 10 B–W E11 2 L 1 B–R B–R 2 BR L 16 E10 24 E10 G22+ NE+ NE– E2 Crankshaft Position Sensor P25474 INSPECTION PROCEDURE HINT:

Perform troubleshooting of DTC P0335 first. If no trouble is found, troubleshoot the following mechanical systems. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 522 DI–288 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Check resistance of crankshaft position sensor (See page IG–12). G22, NE Signal Waveforms 5V /Division G22 Reference INSPECTION USING OSCILLOSCOPE During cranking or idling, check between terminals G22+ and NE–, NE and NE– of the ECM connector. HINT: The correct waveforms are as shown. NE 20 msec./Division (Idling) 5V /Division G22 NE FI7059 FI7060 10 msec./Division (Idling) A00069 NG Replace crankshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 523 DI–289 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Inspect sensor installation and teeth of crankshaft timing pulley. NG Tighten the sensor. Replace crankshaft timing pulley. OK Check and replace ECM (See page IN–31). Author: Date: 524 DI–290 DIAGNOSTICS – ENGINE (1MZ–FE) DI07V–06 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G22 signal) consist of a signal plate and pickup coil. The G22 signal plate has one tooth, on its outer circumference and is mounted on the left bank camshafts. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G22 signal and the actual crankshaft angle and the engine speed by the NE signals. DTC No. DTC Detecting Condition Trouble Area No camshaft position sensor signal to ECM during cranking (2 trip detection logic) P0340 No camshaft position sensor signal to ECM with engine speed 600 rpm or more
Open or short in camshaft position sensor circuit
Camshaft position osition sensor
Starter
ECM WIRING DIAGRAM Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–287 . INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check resistance of camshaft position sensor (See page IG–1). Reference INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI–287. NG Replace camshaft position sensor. OK Author: Date: 525 DI–291 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN–31). NG Repair or replace harness or connector. OK 3 Inspect sensor installation and tooth of left bank camshaft timing pulley. NG Tighten the sensor. Replace left bank camshaft timing pulley. OK Check and replace ECM (See page IN–31). Author: Date: 526 DI–292 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DS–01 DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected (Ex CA Spec.) CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions. The lift amount of EGR valve is controlled by the vacuum which is regulated by the Duty–VSV operated by the ECM. The lift amount of EGR valve is detected by the EGR valve position sensor which is mounted on the EGR valve and it provides feedback to the ECM to control the lift amount of EGR valve in response to engine operating conditions. Under the following conditions, EGR is cut to maintain driveability.
Before the engine is warmed up
During deceleration (throttle valve closed)
Light engine load (amount of intake air very small)
Engine speed over 4,000 rpm
Engine idling ECM Vacuum Control Valve Throttle Valve Mass Air Flow Meter VSV for EGR Intake Air Chamber Engine Coolant Temp. Sensor EGR Valve Position Sensor EGR Gas Temp. Sensor EGR Valve Crankshaft Position Sensor DTC No. P0401 DTC Detecting Condition After engine is warmed up and run at 80 km/h (50 mph) for 3 to 5 min. EGR gas temperature sensor valve does not exceed 35°C (95°F) above ambient air temperature (2 trip detection logic) A00199 Trouble Area
EGR valve (stuck closed)
Open or short in EGR gas temp. sensor circuit
EGR gas temp. sensor
Open in VSV circuit for EGR
VSV for EGR
Vacuum control valve
Vacuum hose disconnected or blocked
ECM Author: Date: 527 DI–293 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM Engine Room J/B 1 2A From FL MAIN EFI 5 3 2 2J B–Y Junction Connector B B J27 J28 B–Y 9 II3 J20 Junction VSV Connector for EGR B–Y B–Y A A1 Y–G 2 2 EFI Relay 1 1 B–W 2 Y E10 22 3 W–G W–B C J35 Junction Connector C J35 2 E11 18 BR E10 5V EGLS E2 5V 13 2 G–Y 1 VC BR EGR Valve Position Sensor B–W E11 E01 7 2K 5 2C ECM 18 EGR E10 THG BR B+ EGR Gas Temp. Sensor B–W EB 8 MREL E7 A07446 SYSTEM CHECK DRIVING PATTERN Vehicle Speed (5) (3) 70 ∼ 90 km/h (43 ∼ 56 mph) IG SW OFF (4) (2) Idling (1) Time Warmed up 3 ∼ 5 min. 3 min. 3 ∼ 5 min. 2 min. S06906 Author: Date: 528 DI–294 DIAGNOSTICS – ENGINE (1MZ–FE) (1) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (2) Start and warm up the engine with all accessories switched OFF. (3) Run the vehicle at 70 ∼ 90 km/h (43 ∼ 56 mph) for 3 min. or more. (4) Idle the engine for about 2 min. (5) Do steps (3) and (4) again. (6) Stop at safe place and turn the ignition switch OFF. (7) Do step (2) to (5) again. (8) Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand–held tester. If COMPL is displayed and the MIL does not light up, the system is normal. If INCMPL is displayed and the MIL does not light up, run the vehicle steps (2) to (6) from some times and check it. HINT: INCMPL is displayed when either condition (a) or (b) exists. (a) The system check is incomplete. (b) There is a malfunction in the system. If there is a malfunction in the system, the MIL light up after step (7) above is done. (2trip detection logic) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. TOYOTA hand–held tester 1 Connect TOYOTA hand–held tester, and read value of EGR gas temperature. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Warm up the engine. CHECK: Read EGR gas temperature on TOYOTA hand–held tester during idling. OK: EGR gas temperature : 5°C (41°F) ∼ 150°C (302°F) (Not immediately after driving) HINT: If there is an open circuit, TOYOTA hand–held tester indicates 3.1°C (37.6°F). If there is an short circuit, TOYOTA hand–held tester indicates 159.3°C (318.7°F). OK Go to step 4. NG Author: Date: 529 DI–295 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check for open or short in harness or ECM. ON ECM EGR Gas Temp. Sensor 1 5V 13 E10 18 THG E10 E2 2 ON ECM EGR Gas Temp. Sensor 1 5V 13 E10 18 E10 2 THG E2 For open circuit PREPARATION: (a) Disconnect the EGR gas temp. sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read EGR gas temperature on the TOYOTA hand–held tester. OK: EGR gas temperature : 159.3°C (318.7°F) For short circuit PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: Read EGR gas temperature on the TOYOTA hand–held tester. OK: EGR gas temp. : 3.1°C (37.6°F) OK A00305 Confirm good connection at sensor. If OK, check and replace EGR gas temp. sensor. NG Author: Date: 530 DI–296 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open or short in harness or ECM. ON ECM EGR Gas Temp. Sensor 13 1 E0 5V THG 18 E107 E2 2 THG E2 For open circuit PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Connect between terminals THG and E2 of the ECM connectors. HINT: EGR gas temp. sensor connector is disconnected. Before checking, do a visual check and contact pressure check for the ECM connector (See page IN–31). CHECK: Read EGR gas temperature on the TOYOTA hand–held tester. OK: EGR gas temperature : 159.3°C (318.7°F) A02048 ON ECM EGR Gas Temp. Sensor 5V THG E2 For short circuit PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E10 connector of ECM. CHECK: Read EGR gas temperature on the TOYOTA hand–held tester. OK: EGR gas temperature: 3.1°C (37.6°F) E10 A02043 OK Repair or replace harness. NG Confirm connection at ECM. If OK, check and replace ECM. Author: Date: 531 DI–297 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check connection and blockage of vacuum hose (See page EC–2). NG Repair or replace vacuum hose. OK 5 Check VSV for EGR. ON VSV is ON VSV is OFF Air Air E E F BE6653 A02507 G F G A02839 PREPARATION: Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check operation VSV, when it is operated by the TOYOTA hand–held tester. OK: VSV is ON: Air from pipe E is flowing out through pipe F and G. VSV is OFF: Air from pipe E is flowing out through pipe G. OK Go to step 8. NG 6 Check operation of VSV for EGR (See page SF–56). NG Replace VSV for EGR. OK Check for open in harness and connector between engine room J/B and ECM. Author: Date: 532 DI–298 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check EGR system (See page EC–11). NG Repair or replace. OK 8 Check EGR valve. PREPARATION: (a) Disconnect the vacuum hose from EGR valve. (b) Start the engine. CHECK: Check whether the engine stall when apply vacuum to EGR valve. OK: Engine runs rough or stall. Vacuum EGR Valve S05410 NG Repair or replace EGR valve. OK 9 Check vacuum control valve (See page EC–11). NG Replace vacuum control valve. OK Check and replace ECM (See page IN–31). Author: Date: 533 DI–299 DIAGNOSTICS – ENGINE (1MZ–FE) OBDII scan tool (excluding TOYOTA hand–held tester) 1 Check resistance of EGR gas temp. sensor. EGR Gas Temp. Sensor Connector P23871 PREPARATION: Disconnect the EGR gas temp. sensor connector. CHECK: Measure resistance between terminals of the EGR gas temp. sensor connector. OK: Resistance: 2.5 kΩ ∼ 600 kΩ (Not immediately after driving) HINT: If there is open circuit, ohmmeter indicates 720 kΩ or more. If there is short circuit, ohmmeter indicates 200 Ω or less. NG Replace EGR gas temp. sensor. OK 2 Check for open and short in harness and connector between EGR gas temp. sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK 3 Check connection and blockage of vacuum hose (See page EC–2). NG Repair or replace vacuum hose. OK Author: Date: 534 DI–300 DIAGNOSTICS 4 ENGINE (1MZ–FE) Check VSV for EGR. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E11 connector of ECM. (c) Turn the ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal EGR of the ECM and body ground (VSV is ON). (2) Disconnect between terminal EGR of the ECM and body ground (VSV is OFF). OK: (1) VSV is ON: Air from pipe E flows out through pipe F. (2) VSV is OFF: Air from pipe E flows out through pipe G. ON E11 EGR ON OFF VSV is ON VSV is OFF Air Air E F – E G F G A02047 OK Go to step 7. NG 5 Check operation of VSV for EGR (See page SF–56). NG Replace VSV for EGR. OK Check for open in harness and connector between engine room J/B and ECM (See page IN–31). 6 Check EGR system (See page EC–11). NG Repair or replace. OK Author: Date: 535 DI–301 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check EGR valve. PREPARATION: (a) Disconnect the vacuum hose from EGR valve. (b) Start the engine. CHECK: Check whether the engine stall when apply vacuum to EGR valve. OK: Engine runs rough or stall. Vacuum EGR Valve S05410 NG Repair or replace EGR valve. OK 8 Check vacuum control valve (See page EC–11). NG Replace vacuum control valve. OK Check and replace ECM (See page IN–31). Author: Date: 536 DI–302 DIAGNOSTICS – ENGINE (1MZ–FE) DI07X–06 DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected (Ex CA Spec.) CIRCUIT DESCRIPTION Refer to DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on page DI–292. DTC No. P0402 DTC Detecting Condition Trouble Area When EGR cut–off, lift amount of EGR valve is 2.6 mm (0.1 in.) or more (2 trip detection logic)
EGR valve stuck open
VSV for EGR open malfunction
Short in VSV circuit for EGR
Open or short in EGR valve position sensor circuit
EGR valve position sensor
ECM See DTC P0401 (Exhaust Gas Recirculation Flow Insufficient Detected) on See page DI–292 for SYSTEM CHECK DRIVING PATTERN and WIRING DIAGRAM. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. TOYOTA hand–held tester 1 Check connection and blockage of vacuum hose. NG Repair or replace vacuum hose. OK 2 Check VSV for EGR (See page DI–292, step 5). OK Go to step 4. NG Author: Date: 537 DI–303 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check operation of VSV for EGR (See page SF–56). NG Replace VSV for EGR. OK Check for short in harness between VSV for EGR and ECM (See page IN–31). 4 Check EGR valve (See page EC–11). NG Repair or replace EGR valve. OK 5 Check EGR valve position sensor (See page DI–358). NG Repair or replace EGR valve position sensor or harness. OK Check and replace ECM (See page IN–31). OBDII scan tool (excluding TOYOTA hand–held tester) 1 Check connection and blockage of vacuum hose. NG Repair or replace vacuum hose. OK Author: Date: 538 DI–304 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check VSV for EGR (See page DI–292, step 5). OK Go to step 4. NG 3 Check operation of VSV for EGR (See page SF–56). NG Replace VSV for EGR. OK Check for short in harness between VSV for EGR and ECM (See page IN–31). 4 Check EGR valve (See page EC–11). NG Repair or replace EGR valve. OK 5 Check EGR valve position sensor (See page DI–358). NG Repair or replace EGR valve position sensor or harness. OK Check and replace ECM (See page IN–31). Author: Date: 539 DI–305 DIAGNOSTICS – ENGINE (1MZ–FE) DI07Y–06 DTC P0420 Catalyst System Efficiency Below Threshold (Except California Spec.) CIRCUIT DESCRIPTION The ECM compares the waveform of the oxygen sensor located before the catalyst with the waveform of the oxygen sensor located after the catalyst to determine whether or not catalyst performance has deteriorated. Air–fuel ratio feedback compensation keeps the waveform of the oxygen sensor before the catalyst repeatedly changing back and forth from rich to lean. If the catalyst is functioning normally, the waveform of the oxygen sensor after the catalyst switches back and forth between rich and lean much more slowly than the waveform of the oxygen sensor before the catalyst. But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated. Waveform of Oxygen Sensor before Catalyst Normal Catalyst Waveform of Oxygen Sensor after Catalyst FI7081 DTC No. DTC Detecting Condition Trouble Area P0420 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed range, waveforms of heated oxygen sensors (bank 1 sensor 1, 2) have the same amplitude (2 trip detection logic)
Three–way catalytic converter
Open or short in heated oxygen sensor circuit
Heated oxygen sensor CONFIRMATION ENGINE RACING PATTERN Engine Speed (c) 2,500 ∼ 3,000 rpm Idling IG SW OFF (d) (b) (a) Warmed up 3 min. or so Check Time FI7132 Author: Date: 540 DI–306 DIAGNOSTICS (a) – ENGINE (1MZ–FE) Connect the TOYOTA hand–held tester to the DLC3, or connect the probe of the oscilloscope between terminals OXR1, OXL1, OXS and E1 of the ECM connector. Start engine and warm it up with all accessories switched OFF until water temp. is stable. Race the engine at 2,500 ∼ 3,000 rpm for about 3 min. After confirming that the waveform of the heated oxygen sensor, bank 1, 2 sensor 1 (OXR1, OXL1), oscillate around 0.5 V during feedback to the ECM, check the waveform of the heated oxygen sensor, bank 1 sensor 2 (OXS). (b) (c) (d) OX Signal Waveform (Oscilloscope) 1V 0V 200 m sec./Division HINT: If there is a malfunction in the system, the waveform of the heated oxygen sensor, bank 1 sensor 2 (OXS), is almost the same as that of the heated oxygen sensor, bank 1, 2 sensor 1 (OXR1, OXL1), on the left. There are some cases where, even though a malfunction exists, the MIL may either light up or not light up. FI6514 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held theater or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0420) being output? YES Go to relevant DTC chart. NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK Author: Date: 541 DI–307 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check heated oxygen sensor (bank 1, sensor 1) (See page DI–255). NG Repair or replace. OK 4 Check heated oxygen sensors (bank 1, 2 sensor 2) (See page DI–265). NG Repair or replace. OK Replace three–way catalytic converter. Author: Date: 542 DI–308 DIAGNOSTICS – ENGINE (1MZ–FE) DI1K4–03 DTC P0420 Catalyst System Efficiency Below Threshold (Only for California Spec.) CIRCUIT DESCRIPTION The ECM observes the waveform of the heated oxygen sensor located behind the catalyst to determine whether the catalyst is performance has deteriorated. If the catalyst is functioning normally, the waveform of the heated oxygen sensor located behind the catalyst switches back and forth between rich and lean much more slowly. When the waveform of the heated oxygen sensor located behind the catalyst alternates flatteringly between rich and lean, it indicates that catalyst performance has deteriorated. Waveform of A/F Sensor Normal Catalyst Waveform of Heated Oxygen Sensor Behind Catalyst Abnormal Catalyst A01674 DTC No. DTC Detecting Condition P0420 After engine and catalyst are warmed up, and while vehicle is driven within set vehicle and engine speed range, waveform of heated oxygen sensor (bank 1 sensor 2) alternates flatteringly between rich and lean (2 trip detection logic) Trouble Area
Three–way catalytic converter
Open or short in heated oxygen sensor (bank 1 sensor 2) circuit
Heated oxygen sensor (bank 1 sensor 2)
Open or short in A/F sensors (bank 1, 2 sensor 1) circuit
A/F sensors (bank 1, 2 sensor 1) Author: Date: 543 DI–309 DIAGNOSTICS – ENGINE (1MZ–FE) CONFIRMATION ENGINE RACING PATTERN Engine Speed 3,000 rpm (c) (d) 2,000 rpm Idling IG SW OFF (b) (a) 3 min. or so Warmed up Time 2 sec. 2 sec. Check A00479 (a) (b) (c) (d) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. Start engine and warm it up with all accessories switched OFF until water temp. is stable. Race the engine at 2,500 ∼ 3,000 rpm for about 3 min. When racing the engine at 3,000 rpm for 2 sec. and 2,000 rpm for 2 sec. alternately, check the waveform of the heated oxygen sensor (bank 1 sensor 2). INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0420) being output ? YES Go to relevant DTC chart. NO 2 Check gas leakage on exhaust system. NG Repair or replace. OK Author: Date: 544 DI–310 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check A/F sensors (bank 1, 2 sensor 1) (See page DI–255). NG Repair or replace. OK 4 Check heated oxygen sensor (bank 1 sensor 2) (See page DI–265). NG Repair or replace. OK Replace three–way catalytic converter. Author: Date: 545 DI–311 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DT–01 DTC P0440 Evaporative Emission Control System Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0440 is recorded by the ECM when evaporative emissions leak from the components within the dotted line in fig. 1 below, or when the vapor pressure sensor malfunctions. fig. 1 ECM Vapor Pressure Sensor VSV for EVAP (6) (7) (1) VSV for Vapor Pressure Sensor Fuel Tank Over Fill (2) Check Valve (4) (5) (8) (9) (3) Charcoal Canister Fuel Tank A01652 DTC No. P0440 DTC Detecting Condition Fuel tank pressure is atmospheric pressure after vehicle is driven for 20 min. (2 trip detection logic) Trouble Area
Vapor pressure sensor
Fuel tank cap incorrectly installed
Fuel tank cap cracked or damaged
Vacuum hose cracked, holed, blocked, damaged or disconnected ((1) or (2) in fig. 1)
Hose or tube cracked, holed, damaged or loose seal ((3) in fig. 1)
Fuel tank cracked, holed or damaged
Charcoal canister cracked, holed or damaged
Fuel tank over fill check valve cracked or damaged Author: Date: 546 DI–312 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM ECM 5V Vapor Pressure Sensor 2 FL MAIN From 1 2A 5 2C 2 2 ID1 BR 3 II1 Y 1 IA1 L–R 1 Engine Rom J/B 5 3 EFI 5 ID1 Y 3 2 E10 Y L–R 4 II1 BR BR 17 E7 PTNK 18 E10 E2 J23 Junction Junction Connector Connector VSV for EVAP 2 B B–Y 9 7 B B–Y B–Y LG B–Y J27 2J J28 II3 E10 A A 1 2 E J28 7 2K B–W 1 EFI Relay VC E1 EVP1 E01 ID1 10 B–Y 1 VSV for Vapor Pressure Sensor W–B C J35 Junction Connector C J35 2 V 2 ID1 V 9 E7 TPC E01 B+ EB B–W 8 E7 MREL A07447 INSPECTION PROCEDURE



If DTCs P0441, P0446, P0450 or P0451 is output after DTC P0440, first troubleshoot DTCs P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Ask the customer whether, after the MIL came on, the customer found the fuel tank cap loose and tightened it. Also ask the customer whether the fuel tank cap was loose when refuelling. If the fuel tank cap was not loose, it was the cause of the DTC. If the fuel tank cap was not loose or if the customer was not sure if it was loose, troubleshoot according to the following procedure. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor. Author: Date: 547 DI–313 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Check whether hose close to fuel tank have been modified, and check whether there are signs of any accident near fuel tank or charcoal canister. CHECK: Check for cracks, deformation and loose connection of these parts:
Fuel tank
Charcoal canister
Fuel tank filler pipe
Hoses and tubes around fuel tank and charcoal canister A01653 NG Repair or replace. OK 2 Check that fuel tank cap is TOYOTA genuine parts. NG Replace to TOYOTA genuine parts. OK 3 Check that fuel tank cap is correctly installed. NG Correctly install fuel tank cap. OK 4 Check fuel tank cap (See page EC–6). NG Replace fuel tank cap. OK Author: Date: 548 DI–314 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check filler neck for damage. PREPARATION: Remove the fuel tank cap. CHECK: Visually inspect the filler neck for damage. NG Replace filler pipe. OK 6 Check vacuum hoses between vapor pressure sensor and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and charcoal canister (See page EC–3 , SF–62 and EC–6). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole and damage. NG Repair or replace. OK 7 Check hose and tube between fuel tank and charcoal canister. CHECK: (a) Check for proper connection of the fuel tank and fuel evap pipe (See page SF–1), fuel evap pipe and fuel tube under the floor, fuel tube under the floor and charcoal canister. (b) Check the hose and tube for cracks, hole and damage. NG Repair or replace. OK Author: Date: 549 DI–315 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check charcoal canister for cracks, hole and damage (See page EC–6). NG Replace charcoal canister. OK 9 Check voltage between terminals VC and E2 of ECM connector. CHECK: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 ∼ 5.5 V ON VC (+) E2 (–) A02022 NG Check and replace ECM (See page IN–31). OK Author: Date: 550 DI–316 DIAGNOSTICS 10 – ENGINE (1MZ–FE) Check voltage between terminals PTNK and E2 of ECM connectors. ON E2 (–) (1) PTNK (+) (2) Vacuum A02025 PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals PTNK and E2 of the ECM connectors. (1) Disconnect the vacuum hose from the vapor pressure sensor. (2) Using the MITYVAC (Hand–Held Vacuum Pump), apply a vacuum of 4.0 kPa (30 mmHg, 1.18 in.Hg) to the vapor pressure sensor. NOTICE: The vacuum applied to the vapor pressure sensor must be less than 66.7 kPa (500 mmHg, 19.7 in.Hg). OK: (1) Voltage: 2.9 ∼ 3.7 V (2) Voltage: 0.5 V or less OK Go to step 12. NG 11 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 551 DI–317 DIAGNOSTICS 12 – ENGINE (1MZ–FE) Check fuell tank and fuel tank over fill check valve for cracks and damage. (See page EC–2) NG Replace fuel tank or fuel tank over fill check valve. OK It is likely that vehicle user did not properly close fuel tank cap. Please explain to customer how to properly install fuel tank cap. Author: Date: 552 DI–318 DIAGNOSTICS – ENGINE (1MZ–FE) DI080–07 DTC P0441 Evaporative Emission Control System Incorrect Purge Flow DTC P0446 Evaporative Emission Control System Vent Control Malfunction CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components within the dotted line in fig. 1 below, or when there is a malfunction in either the VSV for EVAP, the VSV for vapor pressure sensor, or in the vapor pressure sensor itself. fig. 1 ECM Vapor Pressure Sensor (7) VSV for EVAP (1) (6) VSV for Vapor Pressure Sensor (4) (2) (5) Fuel Tank Over Fill Check Valve (9) (8) (3) Charcoal Canister Fuel Tank A01654 Author: Date: 553 DI–319 DIAGNOSTICS DTC No. – ENGINE (1MZ–FE) DTC Detecting Condition Trouble Area Pressure in charcoal canister does not drop during purge control (2 trip detection logic) P0441 During purge cut–off, pressure in charcoal canister is very low compared with atmospheric pressure (2 trip detection logic) When VSV for vapor pressure sensor is OFF, ECM judges that there is no continuity between vapor pressure sensor and charcoal canister (2 trip detection logic) P0446 When VSV for vapor pressure sensor is ON, ECM judges that there is no continuity between vapor pressure sensor and fuel tank (2 trip detection logic) After purge cut off operates, pressure in charcoal canister is maintained at atmospheric pressure (2 trip detection logic)
Open or short in VSV circuit for EVAP
Open or short in VSV circuit for vapor pressure sensor
Open or short in vapor pressure sensor circuit
VSV for EVAP
VSV for vapor pressure sensor or pressure ressure sensor
Va Vapor
Vacuum hose cracks, holed blocked, damaged or disconnected ((1), (4), (5),(6) and (7) in fig. 1)
Charcoal canister cracks, holed or damaged
Fuel F l tank t k over fill check h k valve l cracked k d or damaged d d WIRING DIAGRAM Refer to DTC P0440 (Evaporative Emission Control System Malfunction) on page DI–311 for the WIRING DIAGRAM. INSPECTION PROCEDURE HINT:
If DTCs P0441, P0446, P0450 or P0451 is output after DTC P0440, first troubleshoot DTCs P0441, P0446, P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor.

TOYOTA hand–held tester 1 Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK Author: Date: 554 DI–320 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check vacuum hoses (1), (4), (5), (6), (7) and (8) on page DI–311). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 3 Check voltage between terminals VC and E2 of ECM connector (See page DI–311, step 9). NG Check and replace ECM (See page IN–31). OK 4 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–311, step 10). OK Go to step 6. NG 5 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 555 DI–321 DIAGNOSTICS 6 ENGINE (1MZ–FE) Check purge flow. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. (c) Disconnect from the charcoal canister the vacuum hose to the VSV for EVAP. (d) Start the engine. CHECK: When the VSV for EVAP is operated by the TOYOTA hand–held tester, check whether the disconnected hose applies suction to your finger. OK: VSV is ON: Disconnected hose applies suction to your finger. VSV is OFF: Disconnected hose applies no suction to your finger. VSV is ON VSV is OFF S04610 S04609 – A00230 OK Go to step 10. NG 7 Check vacuum hoses between intake manifold and VSV for EVAP, and VSV for EVAP and charcoal canister. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK Author: Date: 556 DI–322 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check operation of VSV for EVAP (See page SF–58). OK Go to step 9. NG Replace VSV and charcoal canister, and then clean the vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister. 9 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP, VSV for EVAP and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 557 DI–323 DIAGNOSTICS 10 – ENGINE (1MZ–FE) Check VSV for vapor pressure sensor. ON VSV is ON VSV is OFF Air Air E E G G F F BE6653 S00558 S00557 A00474 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check the VSV operation when it is operated by TOYOTA hand–held tester. OK: VSV is ON: Air from pipe E is flowing out through pipe F. VSV is OFF: Air from pipe E is flowing out through pipe G. OK Go to step 13. NG 11 Check operation of VSV for vapor pressure sensor (See page SF–62). OK Go to step 12. NG Replace VSV and charcoal canister, and then clean the vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and vapor pressure sensor. Author: Date: 558 DI–324 DIAGNOSTICS 12 – ENGINE (1MZ–FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 13 When VSV connector for vapor pressure sensor is disconnected and VSV for EVAP is ON, measure voltage between terminals PTNK and E2 of ECM connectors. VSV Connector for Vapor Pressure Sensor PTNK (+) E2 (–) A07146 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Disconnect the VSV connector for vapor pressure sensor. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. (d) Start the engine. CHECK: Measure voltage between terminals PTNK and E2 of ECM connectors. Using the TOYOTA hand–held tester when VSV for EVAP is ON, . OK: Voltage: 2.0 V or less OK Go to step 15. NG Author: Date: 559 DI–325 DIAGNOSTICS 14 – ENGINE (1MZ–FE) Check vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and vapor pressure sensor and VSV for vapor pressure sensor. CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK 15 Engine Check charcoal canister. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Remove the fuel tank cap. (c) Disconnect the VSV connector for vapor pressure sensor. (d) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. (e) Start the engine. (f) VSV for EVAP is ON by the TOYOTA hand–held tester and remains on for 5 sec. CHECK: Measure voltage between terminals PTNK and E2 of ECM connectors 5 sec. after switching VSV for EVAP from ON to OFF. Start Stop VSV for ON Vapor Pressure Sensor OFF VSV for ON EVAP OFF 5 sec. Measure Voltage E2 (–) PTNK (+) OK: Voltage: 2.5 V or less NG Replace charcoal canister. A07147 OK Author: Date: 560 DI–326 DIAGNOSTICS 16 – ENGINE (1MZ–FE) Remove charcoal canister and check it (See page EC–6). NG Replace charcoal canister. OK 17 Check fuel tank over fill check valve (See page EC–2). NG Replace fuel tank over fill check valve or fuel tank. OK Check and replace ECM (See page IN–31). OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check VSV connector for EVAP, VSV connector for vapor pressure sensor and vapor pressure sensor connector for looseness and disconnection. NG Repair or connect VSV or sensor connector. OK 2 Check vacuum hoses (1), (4), (5), (6) (7) and (8) on Page DI–311). CHECK: (a) Check that the vacuum hose is connected correctly. (b) Check the vacuum hose for looseness and disconnection. (c) Check the vacuum hose for cracks, hole, damage and blockage. NG Repair or replace. OK Author: Date: 561 DI–327 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check voltage between terminals VC and E2 of ECM connector (See page DI–311, step 9). NG Check and replace ECM (See page IN–31). OK 4 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–311, step 10). OK Go to step 6. NG 5 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 562 DI–328 DIAGNOSTICS 6 – ENGINE (1MZ–FE) Check VSV for EVAP. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal EVA1 of the ECM connector and body ground (ON). (2) Disconnect between terminal EVP of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from pipe E is flowing out through pipe F. (2) VSV is OFF: Air does not flow from pipe E to pipe F. ON OFF ON EVA1 VSV is ON Air VSV is OFF Air E F E F A07148 OK Go to step 9. NG 7 Check operation of VSV for EVAP (See page SF–58). OK Go to step 9. NG Replace VSV and charcoal canister, and then clean the vacuum hoses between throttle body and VSV for EVAP, and VSV for EVAP and charcoal canister. Author: Date: 563 DI–329 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for EVAP and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 9 Check VSV for vapor pressure sensor. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Check VSV function. (1) Connect between terminal TPC of the ECM connector and body ground (ON). (2) Disconnect between terminal TPC of the ECM connector and body ground (OFF). OK: (1) VSV is ON: Air from pipe E is flowing out through pipe F. (2) VSV is OFF: Air from pipe E flows out through pipe G. ON TPC OFF ON VSV is ON Air E G F VSV is OFF Air E F G A07149 OK Check and replace charcoal canister (See page EC–6). NG Author: Date: 564 DI–330 DIAGNOSTICS 10 – ENGINE (1MZ–FE) Check operation of VSV for vapor pressure sensor (See page SF–62). OK Go to step 11. NG Replace VSV and clean the vacuum hoses between charcoal canister and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and vapor pressure sensor, and then check the charcoal canister. 11 Check for open and short in harness and connector between EFI main relay (Marking: EFI) and VSV for vapor pressure sensor, and VSV for vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). 12 Check the fuel tank over fill check valve (See page EC–6). NG Replace fuel tank over fill check valve or fuel tank. OK Check and replace charcoal canister (See page EC–6). Author: Date: 565 DI–331 DIAGNOSTICS – ENGINE (1MZ–FE) DI1K5–03 DTC P0450 Evaporative Emission Control System Pressure Sensor Malfunction DTC P0451 Evaporative Emission Control System Pressure Sensor Range/Performance CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or p0451 is recorded by the ECM when the vapor pressure sensor malfunction. ECM Vapor Pressure Sensor VSV for EVAP VSV for Vapor Pressure Sensor Fuel Tank Over Fill Check Valve Charcoal Canister Fuel Tank A01655 DTC No. DTC Detecting Condition P0450 10 seconds or more after engine starting condition (a) or (b) continues for 7 seconds or more: (2 trip detection logic) (a) Vapor Pressure Sensor Value < –3.5 kPa (–26 mmHg, –1.0 in.Hg) (b) Vapor Pressure Sensor Value
1.5 kPa (15 mmHg, 0.4 in.Hg) P451 Vapor pressure sensor output extremely changes under conditions of (a), (b) and (c): (2 trip detection logic) (a) Vehicle speed: 0 km/h (0 mph) (b) Engine speed: Idling (c) VSV for vapor pressure sensor is ON. Trouble Area
Open or short in vapor pressure sensor circuit
Vapor V pressure sensor
ECM Author: Date: 566 DI–332 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM Refer to DTC P0440 (Evaporative Emission Control Malfunction) on page DI–311. INSPECTION PROCEDURE HINT:
If DTCs P0441, P0446, P0450 or P0451 is output after DTC P0440, first troubleshoot DTCs P0441, P0446 ,P0450 or P0451. If no malfunction is detected, troubleshoot DTC P0440 next. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. When the ENGINE RUN TIME in the freeze frame data is less than 200 seconds, carefully check the VSV for EVAP, charcoal canister and vapor pressure sensor.

1 Check voltage between terminals VC and E2 of ECM connector (See page DI–311, step 9). NG Check and replace ECM (See page IN–31). OK 2 Check voltage between terminals PTNK and E2 of ECM connectors (See page DI–311, step 10). OK Check and replace ECM (See page IN–31). NG 3 Check for open and short in harness and connector between vapor pressure sensor and ECM (See page IN–31). NG Repair or replace harness or connector. OK Replace vapor pressure sensor. Author: Date: 567 DI–333 DIAGNOSTICS – ENGINE (1MZ–FE) DI082–06 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4–Pulse 4–Pulse Vehicle Speed Sensor Combination Meter ECM Transaxle Vehicle Speed Sensor Q00515 Q00514 A00223 DTC No. P0500 DTC Detecting Condition Trouble Area No vehicle speed sensor signal to ECM under conditions (a) and (b): (2 trip detection logic) (a) Park/neutral position switch is OFF (b) Vehicle is being driven
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM WIRING DIAGRAM ECM Combination Meter 14 C9 V–W 3 IG3 J15 Junction Connector V–W 5V V–W B B 22 SPD E8 A03316 Author: Date: 568 DI–334 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedmeter display is normal. NG Check speedmeter circuit. OK 2 Check for short in harness and connector between terminal SPD of ECM and body ground (See page IN–31). E8 SPD PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E8 connector of ECM. CHECK: Check continuity between terminal SPD of ECM and body ground. OK: No continuity (1 MΩ or higher) A02030 NG Repair or replace harness or connector. OK Author: Date: 569 DI–335 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check voltage between terminal SPD of ECM connector and body ground. ON E8 SPD (+) PREPARATION: (a) Turn the ignition switch ON. (b) Disconnect the E8 connector of ECM. CHECK: Measure voltage between terminal SPD of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V A02029 NG Check for open in harness and connector between junction connector (J15) and ECM (See page IN–31). OK 4 Check for open in harness and connector between junction connector (J14) and combination meter (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 570 DI–336 DIAGNOSTICS – ENGINE (1MZ–FE) DI083–06 DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle–up and provide feedback for the target idling speed. Intake Air Chamber Throttle Valve From Air Cleaner Signal ECM IAC Valve Valve To Cylinders P01559 DTC No. P0505 DTC Detecting Condition Trouble Area
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in A/C signal circuit
Air intake (hose loose)
ECM Idle speed continues to vary greatly from target speed (2 trip detection logic) WIRING DIAGRAM B–Y ECM J16 IAC Valve 16 Junction RSO R–W E11 Connector 1 B–Y E01 A2 15 RSC Y–B A E11 3 E01 9 II3 From Battery FL MAIN B–G Fusible Link 1 Block 1 F4 Engine Room J/B 1 F6 B 2A W–B 5 2C EFI 5 3 1 2 EFI Relay 2 2J 7 2K B B–Y B J28 B B–Y Junction J27 Connector A C B–W B–W 8 J36 J35 E7 Junction Connector B+ MREL EC A07448 Author: Date: 571 DI–337 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check engine idle speed. PREPARATION: (a) Warm up engine to normal operating temperature. (b) Switch off all accessories. (c) Switch off air conditioning. (d) Shift transmission into ”N” or neutral position. (e) Connect the OBD II scan tool or TOYOTA hand–held tester to DLC3 on the vehicle. (f) Using SST, connect terminals TE1 and E1 of the DLC3. CHECK: Check the difference of engine speed between the ones less than 5 sec. and more than 5 sec. after connecting terminals TE1 and E1 of the DLC1. OK: Difference of engine speed: More than 100 rpm OK Go to step 6. NG Author: Date: 572 DI–338 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check voltage between terminals RSO, RSC of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the E11 connector of ECM. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminals RSO, RSC of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON E11 RSO (+) OK RSC (+) Go to step 4. A02031 NG 3 Check IAC valve (See page SF–46). NG Replace IAC valve. OK Check for open and short in harness and connector between engine room J/B and IAC valve, IAC valve and ECM (See page IN–31). 4 Check operation of IAC valve (See page SF–42). NG Repair or replace IAC valve. OK Author: Date: 573 DI–339 DIAGNOSTICS 5 – ENGINE (1MZ–FE) Check the blockage of IAC valve and the passage to bypass the throttle valve. NG Repair or replace IAC valve. OK Check and replace ECM (See page IN–31). 6 Check for A/C signal circuit (See page AC–88). NG Repair or replace. OK Check air induction system (See page SF–1). Author: Date: 574 DI–340 DIAGNOSTICS – ENGINE (1MZ–FE) DI1K6–03 DTC P1130 A/F Sensor Circuit Range/Performance Malfunction (Only for California Spec.) DTC P1150 A/F Sensor Circuit Range/Performance Malfunction (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Temp. for Closed Loop Fuel Control (Only for California Spec.)) on Page DI–249. DTC No. DTC Detecting Condition Trouble Area Voltage output* of A/F sensor remains at 3.8 V or more, or 2.8 V or less, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at inside of ECM only. P1130 P1150 Voltage output* of A/F sensor does not change from 3.30 V, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at inside of ECM only.
Open or short in A/F sensor (bank 1, 2 sensor 1) circuit
A/F sensor (bank 1, 2 sensor 1)
ECM Open or short in A/F sensor circuit (2 trip detection logic) HINT:



After confirming DTC P1130 or P01150, use the OBD II scan tool or TOYOTA hand–held tester to confirm voltage output of A/F sensor (AFS B1 S1/O2S B1 S1) from ”CURRENT DATA”. The A/F sensor’s output voltage and the short–term fuel value can be read using the OBD II scan tool or TOYOTA hand–held tester. The ECM controls the voltage of AFR/AFL
and AFR/AFL terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–249. Author: Date: 575 DI–341 DIAGNOSTICS – ENGINE (1MZ–FE) CONFIRMATION DRIVING PATTERN Vehicle Speed 60 ∼ 120 km/h (38 ∼ 75 mph) Idling IG SW OFF (4) (3) (1)(2) 3 ∼ 5 min. Time A00364 (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Switch the TOYOTA hand–held tester from normal mode to check mode (See page DI–197). (c) Start the engine and warm it up with all accessory switches OFF. (d) Drive the vehicle at 60 ∼ 120 km/h (38 ∼ 75 mph) and engine speed at 1,600 ∼ 3,200 rpm for 3 ∼ 5 min. HINT: If a malfunction exists, the MIL will light up during step (4). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (3) and (4), then perform steps (3) and (4) again. INSPECTION PROCEDURE HINT:


If DTC P1130 is displayed, check Bank 1 Sensor 1 circuit. If DTC P1150 is displayed, check Bank 2 Sensor 1 circuit. Read frame freeze data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P1130, P1150) being output? YES Go to relevant DTC chart. NO Author: Date: 576 DI–342 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Connect the OBDII scan tool or TOYOTA hand–held tester and read value for voltage output of A/F sensors (bank1, 2 sensor1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensors (bank1, 2 sensor1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage of A/F sensors (bank 1, 2 sensor 1) on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AFR
and AFL
terminals of ECM is fixed at 3.3 V and the voltage of AFR and AFL terminals is fixed at 3.0 V. Therefore, it is impossible to check the A/F sensors (bank1, 2 sensor1) output voltage at the terminals (AFR
, AFL
/AFR, AFL) of ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close.
Not remains at 3.30 V (*0.660 V)
Not remains at 3.8 3 8 V (*0.76 (*0 76 V) or more
Not remains at 2.8 V (*0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of A/F sensors (bank1, 2 sensor1) is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of A/F sensors (bank1, 2 sensor1) is above 3.8 V (* 0.76 V), it is normal.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be open.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.8 V (* 0.76V) or more, or 2.8 V (*0.56 V) or less even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG Author: Date: 577 DI–343 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and A/F sensors (bank 1, 2 sensor 1) (See page IN–31). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (See page SF–68). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–11). NG Replace EGR system. OK 7 Check fuel pressure (See page SF–21). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 578 DI–344 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check injector injection (See page SF–25). NG Replace injector. OK Replace A/F sensors (bank1, 2 sensor1). 9 Perform confirmation driving pattern. Go 10 Are there DTC P1130 and/or P1150 being output again ? YES Check and replace ECM (See page IN–31.). NO 11 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems (See page DI–197). YES DTC P1130 and /or P1150 is caused by running out of fuel. Author: Date: 579 DI–345 DIAGNOSTICS – ENGINE (1MZ–FE) DI1K7–03 DTC P1133 A/F Sensor Circuit Response Malfunction (Bank 1 Sensor 1) (Only for California Spec.) DTC P1153 A/F Sensor Circuit Response Malfunction (Bank 2 Sensor 1) (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–249. DTC No. P1133 P1155 DTC Detecting Condition Trouble Area After engine is warmed up and during vehicle driving at engine speed 1,400 rpm or more and vehicle speed 60 km/h (38 mph) or more, if response characteristic of A/F sensor becomes deteriorated (2 trip detection logic)
A/F sensors (bank 1, 2 sensor 1) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P1133, P1153) being output? YES Go to relevant DTC chart. NO Author: Date: 580 DI–346 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Connect the OBDII scan tool or TOYOTA hand–held tester and read value for voltage output of A/F sensors (bank1, 2 sensor1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensors (bank1, 2 sensor1) with the engine at 2,500 rpm for approx. 90 sec. CHECK: Read voltage of A/F sensors (bank 1, 2 sensor 1) on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of AFR
and AFL
terminals of ECM is fixed at 3.3 V and the voltage of AFR and AFL terminals is fixed at 3.0 V. Therefore, it is impossible to check the A/F sensors (bank1, 2 sensor1) output voltage at the terminals (AFR
, AFL
/AFR, AFL) of ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close.
Not remains at 3.30 V (*0.660 V)
Not remains at 3.8 3 8 V (*0.76 (*0 76 V) or more
Not remains at 2.8 V (*0.56 V) or less *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of A/F sensors (bank1, 2 sensor1) is below 2.8 V (* 0.56 V), it is normal.
During fuel cut, there is a case that the output voltage of A/F sensors (bank1, 2 sensor1) is above 3.8 V (* 0.76 V), it is normal.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.30 V (* 0.660 V) even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be open.
If output voltage of A/F sensors (bank1, 2 sensor1) remains at 3.8 V (* 0.76V) or more, or 2.8 V (*0.56 V) or less even after performing all the above conditions, A/F sensors (bank1, 2 sensor1) circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG Author: Date: 581 DI–347 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open and short in harness and connector between ECM and A/F sensors (bank 1, 2 sensor 1) (See page IN–31). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (See page SF–68). NG Replace A/F sensor. OK 5 Check air induction system (See page SF–1). NG Repair or replace. OK 6 Check EGR system (See page EC–11). NG Replace EGR system. OK 7 Check fuel pressure (See page SF–21). NG Check and repair fuel pump, fuel pipe line and filter (See page SF–1). OK Author: Date: 582 DI–348 DIAGNOSTICS 8 – ENGINE (1MZ–FE) Check injector injection (See page SF–25). NG Replace injector. OK Replace A/F sensors (bank1, 2 sensor1). 9 Perform confirmation driving pattern (See page DI–197). Go 10 Are there DTC P1133 and/or P1153 being output again ? YES Check and replace ECM (See page IN–31). NO 11 Did vehicle runs out of fuel in the past ? NO Check for intermittent problems (See page DI–197). YES DTC P1133 and /or P1153 is caused by running out of fuel. Author: Date: 583 DI–349 DIAGNOSTICS – ENGINE (1MZ–FE) DI1K8–04 DTC P1135 A/F Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) (Only for California Spec.) DTC P1155 A/F Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) (Only for California Spec.) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–249. DTC No. P1135 P1155 DTC Detecting Condition Trouble Area When heater operates, heater current exceeds 8 A (2 trip detection logic) Heater current of 0.25 A or less when heater operates (2 trip detection logic)
Open or in heater circuit of A/F sensors (bank 1, 2 sensor 1)
A/F sensors (bank 1, 2 sensor 1) heater
ECM WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control (Only for California Spec.)) on page DI–249. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check voltage between terminal HAFR, HAFL of ECM connector and body ground. PREPARATION: (a) Remove glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals HAFR, HAFL of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V HAFL (+) HAFR (+) A02509 OK Check and replace ECM (See page IN–31). NG Author: Date: 584 DI–350 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check resistance of A/F sensor heaters (bank 1, 2 sensor 1) (See page SF–68). NG Replace A/F sensors (bank 1, 2 sensor 1). OK Check and repair harness or connector between EFI main relay (Marking: EFI) and A/F sensors (bank 1, 2 sensor 1), and A/F sensors (bank 1, 2 sensor 1) and ECM (See page IN–31). Author: Date: 585 DI–351 DIAGNOSTICS – ENGINE (1MZ–FE) DI084–06 DTC P1300 Igniter Circuit Malfunction CIRCUIT DESCRIPTION A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces high–voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor. The DIS is a 2–cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one ignition coil. In the 2–cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end of the secondary winding. High voltage generated in the secondary winding is applied directly to the spark plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground electrode. The ECM determines ignition timing and outputs the ignition signals (IGT) for each cylinder. Based on IGT signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail–safe measure to the ECM. Ignition Coil Spark Plug From Battery Camshaft Position Sensor G IGT1 IGC1 No.2 Cylinder No.1 Cylinder IGT2 Crankshaft Position Sensor NE IGC2 No.4 Cylinder ECM No.3 Cylinder IGT3 IGC3 No.6 Cylinder Various Sensor IGF No.5 Cylinder TAC GND To Tachometer S00251 DTC No. P1300 DTC Detecting Condition Condition (a) is repeated 3 times consecutively during 6 consecutively IGT signals while engine is running (a) IGF signal is not input to ECM for 2 or more ignitions Trouble Area
Open or short in IGF or IGT circuit from igniter to ECM
Igniter
ECM Author: Date: 586 DI–352 DIAGNOSTICS – ENGINE (1MZ–FE) WIRING DIAGRAM Ignition Switch W–R 5 1K 5 1B 3 B–R 1K 7 6 8 1C B–R A 1 B–R 2 Y ECM B–R A A A A 5V 9 10 GR 7 1 BR–Y No.2 1 B–R 2L AM2 1 12 B–R II3 Ignition Coil 1 B–R Spark Plug Instrument 2 G Panel J/B No.1 W–R 4 J18 Junction Connector Instrument Panel J/B Engine Room J/B 2 L 6 2 LG–B No.3 5 2A B 1 F6 Fusible Link Block F4 1 W–R 4 BR ED 11 IGT1 E11 12 IGT2 E11 13 E11 IGT3 25 IGF E11 3 Igniter B–G FL MAIN Battery S05723 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check spark plug and spark of misfiring cylinder (See page DI–276). NG Go to step 4. OK Author: Date: 587 DI–353 DIAGNOSTICS 2 – ENGINE (1MZ–FE) Check for open and short in harness and connector in IGF signal circuit between ECM and igniter (See page IN–31). NG Repair or replace harness or connector. OK 3 Disconnect igniter connector and check voltage between terminal IGF of ECM connector and body ground. ON IGF (+) A02033 PREPARATION: (a) Disconnect the igniter connector. (b) Remove the glove compartment (See page SF–73). (c) Turn the ignition switch ON. CHECK: Measure voltage between terminal IGF of the ECM connector and body ground. OK: Voltage: 4.5 ∼ 5.5 V OK Replace igniter. NG Check and replace ECM (See page IN–31). 4 Check for open and short in harness and connector in IGT 1 ∼ 3 signal circuits between ECM and igniter (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 588 DI–354 DIAGNOSTICS – ENGINE (1MZ–FE) Check voltage between terminals IGT 1 ∼ 3 of ECM connector and body ground. 5 PREPARATION: Remove the glove compartment (See page SF–73). CHECK: Measure voltage between terminals IGT 1 ∼ 3 of the ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V START (+) (+) (+) IGT3 IGT2 IGT1 A02034 IGT1 ∼ IGT3 and IGF Signal Waveform VOLT 5 0 5 IGT1 0 5 0 IGT2 5 0 IGF Reference INSPECTION USING OSCILLOSCOPE During idling, check waveform between terminals IGT 1 ∼ 3, IGF and E1 of ECM. HINT: The correct waveforms are as shown. IGT3 20 msec./Division (Idling) P20870 NG Check and replace ECM (See page IN–31). OK 6 Disconnect igniter connector and check voltage between terminals IGT 1 ∼ 3 of ECM connector and body ground. PREPARATION: (a) Disconnect the igniter connector. (b) Remove the glove compartment (See page SF–73). CHECK: Measure voltage between terminals IGT 1 ∼ 3 of the ECM connector and body ground when engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V START (+) (+) (+) IGT 3 IGT2 IGT1 A02034 NG Check and replace ECM (See page IN–31). OK Author: Date: 589 DI–355 DIAGNOSTICS 7 – ENGINE (1MZ–FE) Check voltage between terminal 9 of igniter connector and body ground. ON PREPARATION: Disconnect the igniter connector. CHECK: Measure voltage between terminal 9 of igniter connector and body ground when ignition switch is turned to ”ON” and ”START” position. OK: Voltage: 9 ∼ 14 V START 9 (+) BE6653 P24329 A00124 NG Check and repair igniter power source circuit (See page IG–1). OK 8 Check for open and short in harness and connector between ignition switch and ignition coil, and ignition coil and igniter (See page IN–31). NG Repair or replace harness or connector. OK 9 Check ignition coil (See page IG–1). NG Replace ignition coil. OK Author: Date: 590 DI–356 DIAGNOSTICS 10 – ENGINE (1MZ–FE) Check EFI main relay (Marking: EFI) (See page SF–53). NG Replace EFI main relay (Marking: EFI). OK Replace igniter. Author: Date: 591 DI–357 DIAGNOSTICS – ENGINE (1MZ–FE) DI085–06 DTC P1335 Crankshaft Position Sensor Circuit Malfunction (during engine running) CIRCUIT DESCRIPTION Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–287. DTC No. P1335 DTC Detecting Condition No crankshaft position sensor signal to ECM with engine speed 1,000 rpm or more Trouble Area
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM WIRING DIAGRAM Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–287. INSPECTION PROCEDURE Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Refer to DTC P0335 (Crankshaft Position Sensor ”A” Circuit Malfunction) on page DI–287. Author: Date: 592 DI–358 DIAGNOSTICS – ENGINE (1MZ–FE) DI086–06 DTC P1410 EGR Valve Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION The EGR valve position sensor is mounted on the EGR valve and detects the lift amount of EGR valve. The lift amount of EGR valve which is detected by the EGR valve position sensor provides feedback to the ECM to control the lift amount of EGR valve in response to engine operating conditions. Output Voltage 5V 0V Close ← Valve Opening → Open S06113 DTC No. P1410 DTC Detecting Condition Trouble Area
Open or short in EGR valve position sensor circuit
EGR valve position sensor
ECM Open or short in EGR valve position sensor circuit (2 trip detection logic) WIRING DIAGRAM EGR Valve Position Sensor ECM 5V 1 Y 3 W–G 2 BR 2 E10 VC 22 E11 EGLS 18 E2 E10 S05464 Author: Date: 593 DI–359 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT:
If DTCs ”P0110” (Intake Air Temp. Circuit Malfunction), ”P0115” (Engine Coolant Temp. Circuit Malfunction), ”P0120” (Throttle/Pedal Position/Switch ”A” Circuit Malfunction), ”P1410” (EGR Valve Position Sensor Circuit Malfunction) are output simultaneously, E2 (Sensor Ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction.
1 Check voltage between terminal VC of wire harness side connector and body ground. ON 1 (+) BE6653 S05694 A00379 PREPARATION: (a) Disconnect the vacuum hose from EGR valve. (b) Disconnect the EGR valve position sensor connector. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminal 1 of wire harness side connector and body ground. OK: Voltage: 4.5 ∼ 5.5 V NG Go to step 4. OK 2 Check EGR valve position sensor. PREPARATION: Disconnect the EGR valve position sensor connector. CHECK: Measure resistance between terminals 1 (VC) and 2 (E2) of EGR valve position sensor. OK: Resistance: 1.5 ∼ 4.3 kΩ 1 2 S05742 NG Replace EGR valve position sensor. OK Author: Date: 594 DI–360 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check voltage between terminals EGLS and E2 of ECM connectors. ON EGLS (+) E2 (–) A02036 PREPARATION: (a) Disconnect the vacuum hose from EGR valve. (b) Connect the hand–held vacuum pump to EGR valve. (c) Remove the glove compartment (See page SF–73). (d) Turn the ignition switch ON. CHECK: Measure voltage between terminals EGLS and E2 of the ECM connectors. OK: Condition NG V lt Voltage EGR valve Vacuum Fully closed 0 kPa (0 mmHg, 0 in.Hg) 0.4 ∼ 1.6 V Fully open 17.3 kPa (130 mmHg, 5.12 in.Hg) 3.2 ∼ 5.1 V Check for open and short in harness and connector between ECM and EGR valve position sensor (EGLS or E2 line). OK Check and replace ECM (See page IN–31). Author: Date: 595 DI–361 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check voltage between terminals VC and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 ∼ 5.5 V ON VC (+) E2 (–) A02022 NG Check IN–31). and replace ECM (See page OK Check for open and short in harness and connector between ECM and EGR valve position sensor (VC line). Author: Date: 596 DI–362 DIAGNOSTICS – ENGINE (1MZ–FE) DI087–06 DTC P1411 EGR Valve Position Sensor Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P1410 (EGR Valve Position Sensor Circuit Malfunction) on page DI–358. DTC No. P1411 DTC Detecting Condition Trouble Area Conditions (a) and (b) continue for 500 msec. or more: (2 trip detection logic) (a) Engine Coolant Temp. < 5°C (41°F) (b) EGLS
1.65 V or EGLS < 0.35 V
EGR valve position sensor INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P1411) being output? YES Go to relevant DTC chart. NO Replace EGR valve position sensor. Author: Date: 597 DI–363 DIAGNOSTICS – ENGINE (1MZ–FE) DI088–06 DTC P1520 Stop Light Switch Signal Malfunction (Only for A/T) CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut–off engine speed (The fuel cut–off engine speed is reduced slightly when the vehicle is braking.). DTC No. DTC Detecting Condition Trouble Area P1520 Stop light switch does not turn off when repeating the driving at 30 km or more 10 times or more after depressing brake (2 trip detection logic)
Short in stop light switch signal circuit
Stop light switch
ECM WIRING DIAGRAM ECM Junction Instrument Panel J/B Connector Stop Light Switch Instrument Panel J/B 7 A 5 B–R 4 C G–W 15 STOP G–W 4 W STP G–W 1R 1R 1B 1C J27 E7 J28 1 2 ALT F9 1 Fusible Link Block 1S G–W 2 1 E1 7 F4 B–G FL MAIN 2 Light Failure Sensor To Stop Light Battery A07449 Author: Date: 598 DI–364 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. 1 Check operation of stop light. CHECK: Check if the stop lights go on and off normally when the brake pedal is operated and released. NG Check and repair stop light circuit. OK 2 Check STP signal. ON Brake Pedal Depressed Brake Pedal Released ON STP (+) When using TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. CHECK: Read the STP signal on the TOYOTA hand–held tester. OK: Brake pedal is depressed: STP ...... ON Brake pedal is released: STP ...... OFF When not using TOYOTA hand–held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check voltage between terminal STP of the ECM connector and body ground. OK: A02037 OK Brake pedal Voltage Depressed 7.5 ∼ 14 V Released Below 1.5 V Check for intermittent problems (See page DI–197). NG Author: Date: 599 DI–365 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check harness and connector between ECM and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 600 DI–366 DIAGNOSTICS – ENGINE (1MZ–FE) DI089–06 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air–fuel ratio adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area
Open in back up power source circuit
ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM Fusible Link Block B–G 1 F4 Engine Room J/B No.2 1 F6 1 B 2A EFI 1 8 2J B–Y E7 BATT FL MAIN Battery S05470 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because free frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 601 DI–367 DIAGNOSTICS 1 – ENGINE (1MZ–FE) Check voltage between terminal BATT of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF–73). CHECK: Measure voltage between terminal BATT of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V LOCK BATT (+) A02038 OK Check and replace ECM (See page IN–31). NG 2 Check EFI fuse. PREPARATION: Remove the EFI fuse from the engine room J/B. CHECK: Check continuity of EFI fuse. OK: Continuity Engine Room J/B NG EFI Fuse S04162 Check for short in all harness and components connected to EFI fuse. OK Check and repair harness or connector between battery and EFI fuse, and EFI fuse and ECM (See page IN–31). Author: Date: 602 DI–368 DIAGNOSTICS – ENGINE (1MZ–FE) DI08A–06 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. DTC No. DTC Detecting Condition 2 or more switches are ON simultaneously for ”N”, ”2”, ”L” and ”R” positions (2 trip detection logic) P1780 When driving under conditions (a) and (b) for 30 sec. or more the park/neutral position switch is ON (N position): (2 trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500
NE and 2,500 rpm Trouble Area
Short Sh t in i park/neutral k/ t l position iti switch it h circuit i it
Park/neutral position switch
ECM HINT: After confirming DTC P1780, use the TOYOTA hand–held tester to confirm the PNP switch signal from ”CURRENT DATA”. WIRING DIAGRAM Refer to DTC P1780 on page DI–479. INSPECTION PROCEDURE Refer to DTC P1780 (Park/Neutral Position Switch Malfunction) on page DI–479. HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc. at the time of the malfunction. Author: Date: 603 DI–369 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DU–01 ECM Power Source Circuit CIRCUIT INSPECTION When the ignition switch is turned on, battery positive voltage is applied to terminal IGSW of the ECM and the EFI main relay (Marking: EFI) control circuit in the ECM sends a signal to terminal MREL of the ECM switching on the EFI main relay. This signal causes current to flow to the coil, closing the contacts of the EFI, main relay and supplying power to terminals +B of the ECM. If the ignition switch is turned off, the ECM continues to switch on the EFI main relay for a maximum of 2 seconds for the initial setting of the IAC valve. WIRING DIAGRAM ECM 6 B–Y 7 W–R 5 1K 5 1B 2 E7 B–R Junction Connector B B J27 J28 B–Y IGSW 16 +B E7 W–R B+ B–W 4 2L 2 2J 7 2K 3 AM2 C C J35 J35 B–W 8 MREL E7 Junction Connector 1 EFI Relay Engine Room J/B 5 2 EFI Fusible Link FL Block 1 MAIN B–G 1 F4 F6 Battery 1 2A B 4 2F W–B Ignition Switch B–R Instrument Panel J/B 3 7 IGN 1K 1W EB J22 Junction Connector BR BR A A 17 E10 E1 EC A07450 Author: Date: 604 DI–370 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE 1 Check voltage between terminals +B and E1 or ECM connectors. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals +B and E1 of the ECM connectors. OK: Voltage: 9 ∼ 14 V +B (+) E1 (–) A02382 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–221). NG 2 Check for open in harness and connector between terminals E1 of ECM and body ground (See page IN–31). NG Repair or replace harness or connector. OK 3 Check voltage between terminal IGSW of ECM and body ground. PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal IGSW of ECM connectors and body ground. OK: Voltage: 9 ∼ 14 V IGSW (+) A02951 OK Go to step 6. NG Author: Date: 605 DI–371 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check EFI fuse. PREPARATION: Remove IGN fuse from instrument panel J/B. CHECK: Check continuity of IGN fuse. OK: Continuity IGN Fuse NG Check for short in all the harness and components connected to IGN fuse (See attached wiring diagram). Instrument Panel J/B S04164 OK 5 Check ignition switch (See page BE–13). NG Replace ignition switch. OK Check and repair harness and connector between battery and ignition switch, and ignition switch and ECM. Author: Date: 606 DI–372 DIAGNOSTICS 6 – ENGINE (1MZ–FE) Check voltage between terminal MREL of ECM and body ground. PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal MREL of the ECM connectors and body ground. OK: Voltage: 9 ∼ 14 V MREL (+) A02952 NG Check and replace ECM (See page DI–197). OK 7 Check EFI No.1 fuse of engine room J/B. NG Check for short in all the harness and components connected to EFI No.1 fuse (See attached wiring diagram). OK 8 Check EFI main relay (Marking: EFI) (See page SF–53). NG Replace EFI main relay (Marking: EFI). OK Author: Date: 607 DI–373 DIAGNOSTICS 9 – ENGINE (1MZ–FE) Check for open and short in harness and connector between terminal MREL of ECM and body ground (See page IN–31). NG Repair or harness or connector. OK Check and repair harness or connector between EFI No.1 fuse and battery (See page IN–31). Author: Date: 608 DI–374 DIAGNOSTICS – ENGINE (1MZ–FE) DI4DV–01 Fuel Pump Control Circuit CIRCUIT DESCRIPTION In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil and also current flows to terminal STA of ECM (STA signal). When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit opening relay, the relay switches on, power is supplied to the fuel pump and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EFI Main Relay Circuit Opening Relay EFI Fuel Pump ECM FC Tr MREL IG Switch IGN IGSW AM2 STARTER Park/ Neutral Position Switch MAIN (STA Signal) STA (NE Signal) Battery NE Starter Relay Starter A07151 Author: Date: 609 B–W AM2 5 3 1 2 B 10 B–R 2C 4 W–B 2F 5 11 2J 2 B 5 G–R EB1 G–R 3 FC E7 2 E01 – J11 Junction Connector A Pump 1 S2 5 W–B B–R 1K A ENGINE (1MZ–FE) 1W A 3 W–B 4 W–B 7 ID1 L–B AM2 7 Fuel *1GR (M/T)*B–O 6 7 II2 (A/T) GR R W–R IG2 Park/ Nutral Position Switch 10 B–R IGN 5 2 ST2 (A/T) Switch II2 EB1 B–R 11 B–W STARTER Start (A/T) B–W (M/T) B–W 1 10 7 1K1 L–B B Clutch 8 Battery B 3 1J 4 1K B J7 C J8 J26 Junction Connector B 5 1K 1 B–R Junction Connector *1GR (A/T) *B–O W–B Date: Instrument Panel J/B B–G Author: FL MAIN B–W 5 1B 1 L–B ST Relay *1GR *B–O 1 F6 Fusible Link 1 F4 Block 1 1 5 B–R 2D 9 W–B 2K 3 1 3 1 DIAGNOSTICS 5 MAIN 4 2L MREL CIR OPN Relay EFI Relay 3 2B 8 E7 B–W Engine Room R/B 7 2K EFI 1 2A B+ Junction Connector C J35 J35 WIRING DIAGRAM *: TMMK made *1: TMC made ECM Starter J40 EB Junction Connector BL IG DI–375 A07451 610 DI–376 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE TOYOTA hand–held tester 1 Connect TOYOTA hand–held tester and check operation of fuel pump. ON BE6653 P20186 A00244 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (c) Use ACTIVE TEST mode to operate the fuel pump. CHECK: Check that pulsation damper screw rises up when fuel pump is on by TOYOTA hand–held tester. OK: The pulsation damper screw rises up. OK Check for starter signal circuit ( See page DI–384). NG 2 Check for ECM power source circuit (See page DI–369). NG Repair or replace. OK 3 Check circuit opening relay (See page SF–54). NG Replace circuit opening relay. OK Author: Date: 611 DI–377 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check voltage between terminal FC of ECM and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn ignition switch ON. CHECK: Measure voltage between terminal FC of ECM and body ground. OK: Voltage 9 – 14 V ON FC (+) A02064 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay, circuit opening relay and ECM. OK 5 Check fuel pump (See page SF–6). NG Repair or replace fuel pump. OK 6 Check for open in harness and connector between circuit opening relay and fuel pump, and fuel pump and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 612 DI–378 DIAGNOSTICS – ENGINE (1MZ–FE) OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check operation of fuel pump. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: (a) Connect between terminal FC of the ECM connector and body ground. (b) Check that pulsation damper screw rises up when connect between terminal FC of the ECM and body ground. OK: The pulsation damper screw rises up. ON FC OK Check for starter signal circuit ( See page DI–384). A02042 NG 2 Check for ECM power source circuit (See page DI–369). NG Repair or replace. OK 3 Check circuit opening relay (See page SF–54). NG Replace circuit opening relay. OK Author: Date: 613 DI–379 DIAGNOSTICS 4 – ENGINE (1MZ–FE) Check voltage between terminal FC of ECM and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn ignition switch ON. CHECK: Measure voltage between terminal FC of ECM and body ground. OK: Voltage 9 – 14 V ON FC (+) A02064 NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay, circuit opening relay and ECM. OK 5 Check fuel pump (See page SF–6). NG Repair or replace fuel pump. OK 6 Check for open in harness and connector between circuit opening relay and fuel pump, and fuel pump and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 614 DI–380 DIAGNOSTICS – ENGINE (1MZ–FE) DI08E–06 IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the IACV (Intake Air Control Valve) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 3,700 rpm or less and the throttle valve opening angle is 60° or more, the ECM turns the VSV ON and closes the IACV. At all other times, the VSV is OFF, so the IACV is open. IACV closed (VSV: ON) 1 3 5 Throttle valve opening angle IACV Throttle Valve 2 4 30° 6 3,700 rpm Engine speed FI7011 FI6570 A00306 WIRING DIAGRAM ECM B+ Engine Room J/B W–B 4 2F 2 2J 7 2K 1 EFI 3 5 B–W 1 2A 8 E7 MREL From Battery EFI Relay B–Y EB 2 Junction Connector C C B–W J36 J35 B J27 B J28 Junction Connector B–Y 9 II3 B–Y A VSV for ACIS A B–Y R–Y 2 1 17 E11 J20 Junction Connector ACIS E01 A07452 Author: Date: 615 DI–381 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE TOYOTA hand–held tester 1 Connect TOYOTA hand–held tester and check operation of VSV for ACIS. ON VSV is ON VSV is OFF Air Air E E F F Air Filter BE6653 FI7073 FI7074 Air Filter A00307 PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (d) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check operation of VSV when VSV is operated by the TOYOTA hand–held tester. OK: VSV is ON: Air from pipe E is flowing out through pipe F. VSV is OFF: Air from pipe E is flowing out through the air filter. OK Check for vacuum tank (See page SF–51). NG 2 Check VSV for ACIS (See page SF–60). NG Replace VSV for ACIS. OK Author: Date: 616 DI–382 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check VSV for ACIS (See page SF–60). NG Replace VSV for ACIS. OK 2 Check voltage between terminal ACIS of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal ACIS of the ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON ACIS (+) A02041 NG Check for open and short in harness and connector between EFI main relay (Marking: EFI) and ECM (See page IN–31). OK Author: Date: 617 DI–383 DIAGNOSTICS 3 – ENGINE (1MZ–FE) Check for vacuum tank (See page SF–60). NG Repair or replace. OK Check and replace ECM (See page IN–31). Author: Date: 618 DI–384 DIAGNOSTICS – ENGINE (1MZ–FE) DI08B–06 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after–start injection control. WIRING DIAGRAM *GR *B–O(M/T) B–W(A/T) B J7 11 2J 1 MAIN 1 2 ECM 5 2D 9 2K B B 1 S2 Starter B–W(A/T) J11 A Junction Connector A J16 Junction Connector B–W W–B STARTER 3 1J Instrument Panel J/B W–B Sarter Relay 5 B–W(A/T) 11 II2 B B–R W–B 1 *1B–O *GR *1B–O *GR B J7 Junction Park/Neutral Connector Position Switch 2 B–W(M/T) Clutch Start Switch 6 C J8 10 II2 GR 3 2B B From Battery Engine Room J/B 3 5 *1GR *B–O 7 STA E7 4 1K IG E1 From Ignition Switch *: TMMK made *1: TMC made A07453 Author: Date: 619 DI–385 DIAGNOSTICS – ENGINE (1MZ–FE) INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table on page DI–221. TOYOTA hand–held tester 1 Connect TOYOTA hand–held tester, and check STA signal. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. CHECK: Read STA signal on the TOYOTA hand–held tester while starter operates. OK: Ignition switch position ON START STA signal OFF ON OK Proceed to next circuit inspection shown on problem symptom table (See page DI–221). NG 2 Check for open in harness and connector between ECM and starter relay (See page IN–31). NG Repair or replace or connector. OK Check and replace ECM (See page IN–31). Author: Date: 620 DI–386 DIAGNOSTICS – ENGINE (1MZ–FE) OBD II scan tool (excluding TOYOTA hand–held tester) 1 Check voltage between terminal STA of ECM connector and body ground. PREPARATION: Remove the glove compartment (See page SF–73). CHECK: Measure voltage between terminal STA of the ECM connector and body ground during engine cranking. OK: Voltage: 6 V or more ON STA (+) A07152 OK Proceed to next circuit inspection shown on problem symptom table (See page DI–221). NG 2 Check for open in harness and connector between ECM and starter relay (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–31). Author: Date: 621 DI–387 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE (A140E) DI02U–02 HOW TO PROCEED WITH TROUBLESHOOTING Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI–388 2 Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool / TOYOTA hand–held tester, inspect DLC3 P. DI–389 3 Check DTC and Freeze Frame Data (Precheck) Record or Print DTC and Freeze Frame Data P. DI–389 4 Clear DTC and Freeze Frame Data P. DI–389 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI–389 Symptom does not occur 8 7 Problem Symptom Confirmation Symptom Simulation P. IN–21 Symptom occurs 9 DTC Check P. DI–389 10 DTC Chart P. DI–401 OK Code 11 OK Mechanical System Test P. DI–389 NG 12 OK Manual Shifting Test P. DI–389 NG NG Problem Symptoms Table– P. DI–405 13 Chapter 1 (Electronic) P. DI–405 NG 14 Preliminary Check NG P. DI–389 Circuit Inspection Chapter 2 (On–Vehicle) P. DI–405 OK OK Chapter 3 (Off–Vehicle) P. DI–405 NG NG
O/D Cancel Signal Check
O/D Main Switch & O/D OFF Indicator Light Circuit Check 15 Parts Inspection P. DI–428 to DI–431 Identification of Problem 16 Repair 17 Confirmation Test Author: End Date: 622 DI–388 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI02V–02 CUSTOMER PROBLEM ANALYSIS CHECK Transaxle Control System Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / Date Problem Occurred How Often Problem Occurs ? / km mile Odometer Reading /  Continuous /  Intermittent (  Vehicle does not move (  Any position  No up–shift (  1st → 2nd  No down–shift (  O/D → 3rd times a day)  Particular position )  2nd → 3rd  3rd → 2nd  3rd → O/D )  2nd → 1st )  Lock–up malfunction Symptoms  Shift point too high or too low  Harsh engagement (  N → D  Lock–up  Any drive position )  Slip or shudder  No kick–down  Others Check Item Malfunction Indicator Lamp  Normal  Remains ON 1st Time  Normal code  Malfunction code (Code ) 2nd Time  Normal code  Malfunction code (Code ) DTC Check Author: Date: 623 DI–389 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI02W–02 PRE–CHECK 1. (a) FI0534 TOYOTA hand–held tester DLC3 S05335 DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect an OBD II scan tool complying with SAE J1987 or TOYOTA hand–held tester to the vehicle, and read off various data output from the vehicle’s ECM. OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (See page DI–16). If the malfunction only occurs in 3 trips, the MIL goes off but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect an OBD II scan tool or TOYOTA hand–held tester to DLC3 on the vehicle. The OBD II scan tool or TOYOTA hand–held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as the codes prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits. (See DTC chart on page DI–401) Author: Date: 624 DI–390 DIAGNOSTICS –

(b) AUTOMATIC TRANSAXLE (A140E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and for a malfunction that is only detected once or momentarily. (TOYOTA hand–held tester) (See page DI–401) *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the 2nd test drive, this 2nd detection causes the MIL to light up. Inspect the DLC3. The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. DLC3 N09214 Tester connection Condition Specified condition 2 (Bus
Line) – 5 (Signal ground) During communication 4 (Chassis Ground) – Body Always 1 Ω or less 5 (Signal Ground) – Body Always 1 Ω or less 16 (B+) – Body Always 9 – 14 V Pulse generation HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of OBD II scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. Author: Date: 625 DI–391 DIAGNOSTICS 2. (a) FI0534 TOYOTA hand–held tester DLC3 S05335 – AUTOMATIC TRANSAXLE (A140E) INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–47). (2) When the engine is started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: (TOYOTA hand–held tester only): When the diagnostic system is switched from normal mode to check mode, it erases all DTCs and freeze frame data recorded in normal mode. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare an OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester. (2) Connect the OBD II scan tool or TOYOTA hand– held tester to DLC3 at the lower portion of the instrument panel. (3) Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand–held tester switch ON. (4) Use the OBD II scan tool or TOYOTA hand–held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). (5) See page DI–401 to confirm the details of the DTCs. NOTICE: When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand–held tester) to check the DTCs, use normal mode. For codes on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptoms have been simulated the 1st time. Then repeat the simulation process again. When the program has DTCs, the DTCs are recorded in the ECM. Author: Date: 626 DI–392 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) 3. INSPECT DIAGNOSIS (CHECK MODE) HINT: TOYOTA hand–held tester only: Compared to the Normal mode, the Check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. (a) Check the DTC. (1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in P position
Air conditioning switched off (2) Turn the ignition switch OFF. (3) Prepare a TOYOTA hand–held tester. TOYOTA hand–held tester (4) (5) DLC3 S05335 (6) 0.13 sec. Connect the TOYOTA hand–held tester to DLC3 at the lower side of the instrument panel. Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. (7) 0.13 sec. ON (8) OFF BR3904 Switch the TOYOTA hand–held tester from Normal mode to Check mode (Check that the MIL flashes). Start the engine (MIL goes out after the engine starts). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTCs and freeze frame data, etc. HINT: Take care not to turn the ignition switch OFF, as turning it off the diagnosis system switches from Check mode to Normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. Author: Date: 627 DI–393 DIAGNOSTICS (b) – AUTOMATIC TRANSAXLE (A140E) Clearance the DTC. The following actions will erase the DTC and freeze frame data. Operating an OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) 4. ROAD TEST NOTICE: Perform the test at normal operating ATF temperature 50 – 80 °C (122 – 176 °F). (a) D position test Shift into the D position and fully depress the accelerator pedal and and check the following points: (1) Check up–shift operation. 1 → 2, 2 → 3 and 3 → O/D up–shifts take place, at the shift point shown in the automatic shift schedule (See page SS–54). HINT:
O/D Gear Up–shift Prohibition Control (1. Coolant temp. is 50 °C (122 °C) or less. 2. If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed.)
O/D Gear Lock–up Prohibition Control (1. Brake pedal is depressed. 2. Coolant temp. is 50 °C (122 °C) or less.) (2) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up–shifts. (3) Check for abnormal noises and vibration. Run at the D position lock–up or O/D gear and check for abnormal noises and vibration. HINT: The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential or torque converter clutch, etc. (4) Check kick–down operation. While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick–down vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick–downs conform to those indicated on the automatic shift schedule (See page SS–54). (5) Check abnormal shock and slip at kick–down. (6) Check the lock–up mechanism.
Drive in D position, O/D gear, at a steady speed (lock–up ON) of about 75 km/h (47 mph).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. If there is a big jump in engine speed, there is no lock–up. (b) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check up–shift operation. Check to see that the 1 → 2 up–shift takes place and that the shift point conforms to the automatic shift schedule (See page SS–54). HINT: There is no O/D up–shift and lock–up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. Author: Date: 628 DI–394 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) (3) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down–shift. (c) L position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (d) R position test Shift into the R position and fully depress the accelerator pedal and check for slipping. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (e) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. Q00519 5. BASIC INSPECTION (a) Check the fluid level. HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70 – 80 °C (158 – 176 °F)
Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (1) OK if hot Add if hot AT3417 Park the vehicle on a level surface and set the parking brake. (2) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (3) Pull out the dipstick and wipe it clean. (4) Push it back fully into the pipe. (5) Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) NOTICE: Do not overfill. (b) Check the fluid condition. If the level is not within the hot range. Author: Date: 629 DI–395 DIAGNOSTICS (c) – AUTOMATIC TRANSAXLE (A140E) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. Q00061 (3) With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) Capacity: 2.5 liters (2.6 US qts, 2.1 Imp. qts) (4) Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. AT8562 (5) OK if hot (6) Add if hot AT3417 With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. Check the fluid level is at the normal operating temperature, 70 – 80 °C (158 – 176 °F), and add as necessary. NOTICE: Do not overfill. (d) Check the fluid leaks. Check for leaks in the transaxle. If there are leaks, it is necessary to repair or replace O–rings, gasket, oil seals, plugs or other parts. (e) Inspect and adjust the throttle cable. (1) Check that the accelerator pedal is fully released. (2) Check that the inner cable is not slack. (3) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 – 1 mm (0 – 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. 0 ∼ 1 mm (0 ∼ 0.04 in.) AT4252 Author: Date: 630 DI–396 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) (f) Q00199 Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator is aligned with the correct position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (1) Loosen the nut on the shift lever. (2) Push the control shaft fully rearward. (3) P R N Q01561 Neutral Basic line Groove AT4478 Return the control shaft lever 2 notches to N position. (4) Set the shift lever to N position. (5) While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (6) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. (g) Inspect and adjust the park/neutral position. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedures. (1) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (2) Align the groove and neutral basic line. (3) Hold the switch in position and tighten the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) For continuity inspection of the park/neutral position switch, see page DI–424. (h) Check the idle speed. Idle speed : 750 ± 50 rpm (In N position and air conditioner OFF) Author: Date: 631 DI–397 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) 6. (a) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Do not continuously run this test for longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (3) Fully apply the parking brake. (4) Keep your left foot depressing firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 2,450 ± 150 rpm (7) Do the same test in R position. Stall speed: 2,450 ± 150 rpm Evaluation: Problem Possible cause (a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one–way clutch is operating properly
HINT: If more than 600 rpm below the specified value, the torque converter clutch could be faulty. (b) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No.2 one–way clutch not operating properly
O/D clutch slipping (c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st & reverse brake slipping
O/D clutch slipping (d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one–way clutch not operating properly Author: Date: 632 DI–398 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) (b) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, and 1st & reverse brake. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value. (1) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (2) Fully apply the parking brake. (3) Start the engine and check idle speed. Idle speed : 750 ± 50 rpm (In N position and air conditioner OFF) (4) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D Less than 1.2 seconds (5) In the same manner, measure the time lag for N → R. Time lag: N → R Less than 1.5 seconds Evaluation (If N → D time or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one–way clutch not operating N → R time lag is longer
Line pressure too low
Direct clutch worn
1st & reverse brake worn
O/D one–way clutch not operating properly Author: Date: 633 DI–399 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) 7. HYDRAULIC TEST Measure the line pressure. NOTICE:
Do the test at normal operation fluid temperature 50 – 80 °C (122 – 176 °F).
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) Warm up the ATF. (2) Remove the test plug on the transaxle case front left side and connect SST. (See page AX–17 for the location to connect SST) SST 09992–00095 (09992–00231, 09992–00271) (3) Fully apply the parking brake and chock the 4 wheels. (4) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (5) Start the engine and check idling speed. (6) Keep your left foot pressing firmly on the brake pedal and shift into D position. (7) Measure the line pressure when the engine is idling. (8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (9) In the same manner, do the test in R position. Specified line pressure: Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling 362 – 422 (3.7 – 4.3, 53 – 61) 618 – 794 (6.3 – 8.1, 90 – 115) Stall 735 – 862 (7.5 – 8.8, 107 – 125) 1,373 – 1,608 (14.0 – 16.4, 199 – 233) If the measured pressure is not up to the specified value, recheck the throttle cable adjustment and retest. Evaluation Problem Possible cause If the measured values at all positions are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective If the measured values at all positions are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective If pressure is low in the D position only
D position circuit fluid leakage
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st & reverse brake defective Author: Date: 634 DI–400 DIAGNOSTICS Q00200 – AUTOMATIC TRANSAXLE (A140E) 8. MANUAL SHIFTING TEST HINT: By this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. (a) Disconnect the solenoid wire. (b) Inspect the manual driving operation. Check that the shift and gear positions correspond to the table below. While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. Shift Position Gear Position D O/D 2 3rd L 1st R Reverse P Pawl Lock HINT: If the L, 2 and D gear positions are difficult to distinguish, do the above test. If any abnormality is found in the above test, the problem is in the transaxle itself. (c) Connect the solenoid wire. (d) Clear out the DTC (See page DI–389). Author: Date: 635 DI–401 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI02X–02 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given. * :
...MIL light up DTC No. (See Page) Detection Item Trouble Area MIL * Memory P0500 (DI–408) Vehicle Speed Sensor Malfunction (No.1 Vehicle Speed Sensor)  Open or short in No.1 vehicle speed sensor circuit  No.1 vehicle speed sensor  Combination meter  ECM  Automatic transaxle (clutch, brake or gear etc.)
 P0750 (DI–411) Shift Solenoid A Malfunction (Shift Solenoid Valve No.1)  Shift solenoid valve No.1 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0753 (DI–413) Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No.1)  Open or short in shift solenoid valve No.1 circuit  Shift solenoid valve No.1  ECM
 P0755 (DI–411) Shift Solenoid B Malfunction (Shift Solenoid Valve No.2)  Shift solenoid valve No.2 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0758 (DI–413) Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No.2)  Open or short in shift solenoid valve No.2 circuit  Shift solenoid valve No.2  ECM
 P0770 (DI–417) Shift Solenoid E Malfunction (Shift Solenoid Valve SL)  Shift solenoid valve SL is stuck open or closed  Valve body is blocked up or stuck  Lock–up clutch  Automatic transaxle (clutch, brake or gear etc.)
 P0773 (DI–419) Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL)  Open or short in shift solenoid valve SL circuit  Shift solenoid valve SL  ECM
 P1520 (DI–170) Stop Light Switch Signal Malfunction  Open or short in stop light switch circuit  Stop light switch  ECM
 P1780 (DI–424) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM
 Author: Date: 636 DI–402 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI02Y–02 PARTS LOCATION O/D Main Switch O/D OFF Indicator Light ECM Vehicle Speed Sensor Shift Solenoid Valve SL DLC3 Stop Light Switch Shift Solenoid Valve No.2 Park/Neutral Position Switch Shift Solenoid Valve No.1 D00938 Author: Date: 637 DI–403 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI1IZ–01 TERMINALS OF ECM w/ Engine Immobiliser System ECM Terminals E9 E8 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9 E10 E7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12 FI6526 Symbols (Terminals No.) S1 ↔ E1 (E9–8 (E9 8 ↔ E9 E9–24) 24) S2 ↔ E1 (E9 (E9–21 21 ↔ E9 E9–24) 24) SL ↔ E1 (E9–20 (E9 20 ↔ E9–24) E9 24) Wiring Color V ↔ BR L–B L B ↔ BR P ↔ BR OD1 ↔ E1 (E7–18 ↔ E9–24) Y–B ↔ BR OD2 ↔ E1 (E7–5 (E7 5 ↔ E9–24) E9 24) G O ↔ BR G–O L ↔ E1 (E7–15 (E7 15 ↔ E9–24) E9 24) Y ↔ BR 2 ↔ E1 (E7–16 (E7 16 ↔ E9–24) E9 24) *1L L–W W ↔ BR *2O ↔ BR R ↔ E1 (E7 (E7–17 17 – E9 E9–24) 24) R B ↔ BR R–B NSW ↔ E1 (E7–22 (E7 22 ↔ E9–24) E9 24) *1: *2: B W ↔ BR B–W Condition STD Voltage (V) IG ON 9 ∼ 14 1st or 2nd gear 9 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 1st or 2nd gear 9 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock–up position 9 ∼ 14 IG ON 9 ∼ 14 O/D main switch ON 9 ∼ 14 O/D main switch OFF Below 1 9 ∼ 14 IG ON and Shift lever L position IG ON and Shift lever other than L position Below 1 9 ∼ 14 IG ON and Shift lever 2 position IG ON and Shift lever other than 2 position Below 1 9 ∼ 14 IG ON and Shift lever R position IG ON and Shift lever other than R position Below 1 9 ∼ 14 IG ON and Shift lever P or N position IG ON and Shift lever other than P or N position Below 1 TMC made TMMK made Author: Date: 638 DI–404 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) w/o Engine Immobiliser System ECM Terminals E9 Symbols (Terminals No.) S1 ↔ E1 (E9–7 (E9 7 ↔ E9 E9–14) 14) S2 ↔ E1 (E9–6 (E9 6 ↔ E9 E9–14) 14) SL ↔ E1 (E9–1 (E9 1 ↔ E9–14) E9 14) E8 Wiring Color V ↔ BR L–B L B ↔ BR P ↔ BR OD1 ↔ E1 (E7–20 ↔ E9–14) Y–B ↔ BR OD2 ↔ E1 (E7–7 (E7 7 ↔ E9–14) E9 14) G O ↔ BR G–O L ↔ E1 (E7–19 (E7 19 ↔ E9–14) E9 14) Y ↔ BR 2 ↔ E1 (E7–18 (E7 18 ↔ E9–14) E9 14) *1L L–W W ↔ BR *2O ↔ BR R ↔ E1 (E7 (E7–17 17 – E9 E9–14) 14) R B ↔ BR R–B NSW ↔ E1 (E7–22 (E7 22 ↔ E9–14) E9 14) B W ↔ BR B–W E7 Condition STD Voltage (V) IG ON 9 ∼ 14 1st or 2nd gear 9 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 1st or 2nd gear 9 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock–up position 9 ∼ 14 IG ON 9 ∼ 14 O/D main switch ON 9 ∼ 14 O/D main switch OFF Below 1 9 ∼ 14 IG ON and Shift lever L position IG ON and Shift lever other than L position Below 1 9 ∼ 14 IG ON and Shift lever 2 position IG ON and Shift lever other than 2 position Below 1 9 ∼ 14 IG ON and Shift lever R position IG ON and Shift lever other than R position Below 1 9 ∼ 14 IG ON and Shift lever P or N position IG ON and Shift lever other than P or N position Below 1 *1: TMC made *2: TMMK made Author: Date: 639 DI–405 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI030–02 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On–vehicle Repair Matrix Chart Chapter 3: Off–vehicle repair Matrix Chart  If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check.  If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart Symptom Suspect Area See page No up–shift (A particular gear, from 1st to 3rd gear, is not up–shifted) 1. ECM IN–31 No up–shift (3rd → O/D) 1. O/D main switch & O/D OFF indicator light circuit 2. O/D cancel signal circuit 3. ECM DI–431 DI–428 IN–31 No down–shift (O/D → 3rd) 1. ECM IN–31 No down–shift (A particular gear, from 3rd to 1st gear, is not down–shifted) 1. ECM IN–31 No lock–up or No lock–up off 1. Stop light switch circuit 2. ECM DI–423 IN–31 Shift point too high or too low 1. ECM IN–31 Up–shift to O/D from 3rd while O/D main switch is OFF 1. O/D main switch & O/D OFF indicator light circuit 2. ECM DI–431 IN–31 Up–shift to O/D from 3rd while engine is cold 1. ECM IN–31 Poor acceleration 1. ECM IN–31 No kick–down 1. ECM IN–31 Engine stalls when starting off or stopping 1. ECM IN–31 Author: Date: 640 DI–406 DIAGNOSTICS 2. – AUTOMATIC TRANSAXLE (A140E) Chapter 2: On–Vehicle Repair (
: A140E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM385U) Symptom Suspect Area See page Vehicle does not move in any forward positions and reverse position 1. Manual valve 2. Throttle valve 3. Primary regulator valve 4. Off–vehicle repair matrix chart


– Vehicle does not move in R position 1. Off–vehicle repair matrix chart – No up–shift (1st → 2nd) 1. 1–2 shift valve 2. Off–vehicle repair matrix chart
– No up–shift (2nd → 3rd) 1. 2–3 shift valve 2. Off–vehicle repair matrix chart
– No up–shift (3rd → O/D) 1. 3–4 shift valve 2. Off–vehicle repair matrix chart
– No down–shift (O/D → 3rd) 1. 3–4 shift valve
No down–shift (3rd → 2nd) 1. 2–3 shift valve
No down–shift (2nd → 1st) 1. 1–2 shift valve
No lock–up or No lock–up off 1. Lock–up relay valve 2. Off–vehicle repair matrix chart
– Harsh engagement (N → D) 1. C1 accumulator 2. Off–vehicle repair matrix chart
– Harsh engagement (N → R) 1. C2 accumulator 2. Off–vehicle repair matrix chart
– Harsh engagement (N → L) 1. Low coast modulator valve
Harsh engagement (Lock–up) 1. Lock–up relay valve 2. Off–vehicle repair matrix chart
– Harsh engagement (1st → 2nd → 3rd → O/D) 1. Throttle modulator valve 2. Cut back valve 3. Throttle valve


Harsh engagement (2nd → 3rd) 1. C2 accumulator
Harsh engagement (3rd → O/D) 1. B0 accumulator
Harsh engagement (O/D → 3rd) 1. C0 accumulator 2. B0 accumulator

Slip or shudder (Forward and reverse) 1. Throttle valve 2. Oil strainer 3. Off–vehicle repair matrix chart

– No engine braking (1st: L position) 1. Low coast modulator valve 2. Off–vehicle repair matrix chart
– No engine braking (2nd: 2 position) 1. 2nd coast modulator valve 2. Off–vehicle repair matrix chart
– No kick–down 1. 1–2 shift valve 2. 2–3 shift valve 3. 3–4 shift valve


Author: Date: 641 DI–407 DIAGNOSTICS 3. – AUTOMATIC TRANSAXLE (A140E) Chapter 3: Off–Vehicle Repair (
: A140E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM385U) Symptom Suspect Area See page Vehicle does not move in any forward positions and reverse position 1. Front and rear planetary gear 2. O/D planetary gear 3. O/D one–way clutch (F0) 4. O/D direct clutch (C0) 5. O/D brake (B0) 6. Forward clutch (C1)





Vehicle does not move in R position 1. Front and rear planetary gear unit 2. Direct clutch (C2) 3. O/D direct clutch (C0) 4. 1st & reverse brake (B3)



No up–shift (1st → 2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

No up–shift (2nd → 3rd) 1. Direct clutch (C2)
No up–shift (3rd → O/D) 1. O/D brake (B0)
No lock–up or No lock–up off 1. Torque converter clutch Harsh engagement (N → D) 1. Forward clutch (C1) 2. O/D one–way clutch (F0) 3. No. 2 one–way clutch (F2)


Harsh engagement (N → R) 1. Direct clutch (C2) 2. 1st & reverse brake (B3)

Harsh engagement (Lock–up) 1. Torque converter clutch AX–26 Slip or shudder (Forward position: After warm–up) 1. Torque converter clutch 2. O/D direct clutch (C0) 3. Forward clutch (C1) 4. O/D one–way clutch (F0) AX–26


Slip or shudder (R position) 1. Direct clutch (C2) 2. 1st & reverse brake (B3) 3. O/D direct clutch (C0)


Slip or shudder (1st) 1. No. 2 one–way clutch (F2)
Slip or shudder (2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

Slip or shudder (3rd) 1. Direct clutch (C2)
Slip or shudder (O/D) 1. O/D brake (B0)
No engine braking (1st ∼ 3rd: D position) 1. 2nd brake (B2)
No engine braking (1st: L position) 1. 1st & reverse brake (B3)
No engine braking (2nd: 2 position) 1. 2nd coast brake (B1)
Poor acceleration (All positions) 1. Torque converter clutch 2. O/D planetary gear Poor acceleration (O/D) 1. O/D direct clutch (C0) 2. O/D planetary gear Large shift shock or engine stalls when starting off or stopping 1. Torque converter clutch Author: AX–26 AX–26


AX–26 Date: 642 DI–408 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI1J0–01 CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular wave form by the wave form shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pluse signals. 4–Pulse 4–Pulse Vehicle Speed Sensor Combination Meter ECM Transaxle Vehicle Speed Sensor A00414 DTC No. DTC Detecting Condition P0500 During vehicle is being driven, no vehicle speed sensor signal to ECM (2 trip detection logic) Clutch or brake slips or gear is broken Trouble Area
Combination meter
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
ECM
Automatic transaxle (clutch, brake or gear etc.) WIRING DIAGRAM See page DI–145. Author: Date: 643 DI–409 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) INSPECTION PROCEDURE 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. See combination meter troubleshooting (See page BE–47). OK 2 Check voltage between terminal SPD of ECM connector and body ground. PREPARATION: (a) Remove glove compartment (See page BO–75). (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. ON w/ Engine Immobiliser System SPD (–) (+) w/o Engine Immobiliser System 4.5 ∼ 5.5 V SPD (–) (+) 0 A03021 Turn the wheel D02238 NG AT7809 Check and repair harness and connector between combination meter and ECM (See page IN–31). OK Author: Date: 644 DI–410 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A140E) Check the ECM (See page IN–31). NG Replace the ECM. OK Check and repair the transaxle (clutch, brake or gear etc.). Author: Date: 645 DI–411 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI032–02 DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift Solenoid Valve No.1/No.2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor and crankshaft position sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0750 P0755 DTC Detecting Condition Trouble Area During normal driving, the gear required by the ECM does not match the actual gear (2 trip detection logic)
Shift solenoid valve No.1/No.2 is stuck open or closed
Valve body is blocked up or stuck
Automatic transaxle (clutch, brake or gear etc.) Check the shift solenoid valve No.1 when DTC P0750 is output and check the shift solenoid valve No.2 when DTC P0755 is output. INSPECTION PROCEDURE 1 Check shift solenoid valve No.1 or No.2 operation. Q07741 PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) By applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. NG Replace the shift solenoid valve No.1 or No.2. OK Author: Date: 646 DI–412 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A140E) Check the valve body (See page DI–405). NG Repair or replace the valve body. OK Repair or replace the transaxle. Author: Date: 647 DI–413 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI033–02 DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No.1/No.2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be performed electronically and must be done manually. Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops sending current to the short circuited solenoid). SHIFT SOLENOID NO.1 MALFUNCTIONING NORMAL Position D 2 L Solenoid valve No.1 No.2 ON OFF ON Gear 1st Solenoid valve No.1 No.2 ON X ON 2nd X OFF ON 3rd X OFF OFF O/D X SHIFT SOLENOID NO.2 MALFUNCTIONING Gear BOTH SOLENOIDS MALFUNCTIONING Gear when shift selector is manually operated 3rd Solenoid valve No.1 No.2 X ON 1st O/D 3rd OFF X O/D O/D ON 3rd OFF X O/D O/D OFF O/D OFF X O/D O/D 3rd ON X 1st 3rd 3rd OFF X 3rd 3rd ON Gear ON OFF 1st X ON ON ON 2nd X ON OFF ON 3rd X ON 3rd OFF X 3rd 3rd ON OFF 1st X OFF 1st ON X 1st 1st ON ON 2nd X ON 2nd ON X 1st 1st X: Malfunctions Check the shift solenoid valve No.1 when DTC P0753 is output and check the shift solenoid valve No.2 when DTC P0758 is output. DTC No. DTC Detecting Condition P0753 P0758 The ECM checks for an open or short circuit in the shift solenoid valves No.1 and No.2 circuit when it changes gear position. The ECM records DTC P0753 or P0758 if condition (a) or (b) is detected once, but it does not light up MIL. After 1 sec. ECM detects condition (a) or (b) in a trip again, it causes the MIL to light up. Trouble Area
Open or short in shift solenoid valve No.1/No.2 circuit
Shift solenoid valve No.1/No.2
ECM (a) When the solenoid is energized, the solenoid resistance is 8 Ω or less and is counted. (b) When the solenoid is not energized, the solenoid resistance is 100 kΩ or more and is counted. Author: Date: 648 DI–414 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) WIRING DIAGRAM ECM Transaxle Shift Solenoid Valve No.1 3 W E4 Shift Solenoid Valve No.2 *1: w/ Engine Immobiliser System *2: w/o Engine Immobiliser System 1 B E4 *2 *1 B+ 7 8 S1 E9 E9 V J25 Junction Connector L–B L–B A A A *2 *1 B+ 6 21 S2 E9 E9 Cruise Control ECU D01807 INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground. PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal S1 or S2 of ECM and body ground. OK: Resistance: 11 ∼ 15 Ω w/ Engine Immobiliser System S2 S1 w/o Engine Immobiliser System S1 S2 Q10102 D00102 D00990 OK Check and replace the ECM. NG Author: Date: 649 DI–415 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A140E) Check harness and connector between ECM and automatic transaxle solenoid connector. PREPARATION: Disconnect the solenoid connector from the automatic transaxle. CHECK: Check the harness and connector between terminal S1 or S2 of ECM and terminal S1 or S2 of solenoid connector. OK: There is no open and no short circuit. w/ Engine Immobiliser System S1 S2 S2 S1 w/o Engine Immobiliser System S1 S1 S2 S2 D00958 D00104 D00991 NG Repair or replace the harness or connector. OK Author: Date: 650 DI–416 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A140E) Check shift solenoid valve No.1 or No.2. PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the solenoid connector. (d) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Measure resistance between solenoid connector and body ground. (b) Connect the positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 ∼ 15 Ω (b) The solenoid makes an operating noise. Q07744 NG Replace the shift solenoid valve. OK Repair or replace the solenoid wire. Author: Date: 651 DI–417 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI034–02 DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION Drain Line Pressure Drain Q07745 The ECM uses the signals from the Throttle position sensor, Air–flow meter and Crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the ECM compares the engagement condition of the lock–up clutch with the lock–up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body, torque converter clutch or automatic transaxle (clutch, brake or gear etc.). DTC No. DTC Detecting Condition Trouble Area P0770
Lock–up does not occur when driving in the lock–up range (normal driving at 80 km/h [50 mph]), or lock–up remains ON in the lock–up OFF range. (2 trip detection logic)
When lock–up is ON, clutch or brake slips or gear is broken.
Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock–up clutch
Automatic transaxle (clutch, brake or gear etc.) INSPECTION PROCEDURE 1 Check solenoid valve SL operation. Q07746 PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve SL. CHECK: (a) By applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. NG Replace the solenoid valve SL. OK Author: Date: 652 DI–418 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A140E) Check valve body (See page DI–405). NG Repair or replace the valve body. OK 3 Check the torque converter clutch (See page AX–26). NG Replace the torque converter clutch. OK Repair or replace the transaxle. Author: Date: 653 DI–419 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI035–02 DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. Fail safe function If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. P0773 DTC Detecting Condition Trouble Area Either (a) or (b) is detected for 1 time.(2 trip detection logic) (a) Solenoid resistance is 8 Ω or less short circuit when solenoid is energized. (b) Solenoid resistance is 100 kΩ or more open circuit when solenoid is not energized.
Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM WIRING DIAGRAM Transaxle ECM B+ Shift Solenoid Valve SL 1 E3 *1 : w/ Engine Immobiliser System *2 : w/o Engine Immobiliser System *1 P *2 20 1 E9 E9 SL D01808 Author: Date: 654 DI–420 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM and body ground. PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal SL of ECM and body ground. OK: Resistance: 11 ∼ 15 Ω w/ Engine Immobiliser System SL w/o Engine Immobiliser System SL Q10099 Q07747 D00992 OK Check and replace the ECM. NG Author: Date: 655 DI–421 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A140E) Check harness and connector between ECM and automatic transaxle solenoid connector. w/ Engine Immobiliser System 1 SL 2 SL PREPARATION: Disconnect the solenoid connector from the transaxle. CHECK: Check the harness and connector between terminal SL of ECM and terminal SL of solenoid connector. OK: There is no open or short circuit. w/o Engine Immobiliser System SL SL D00937 Q07748 D00993 NG Repair or replace the harness or connector. OK Author: Date: 656 DI–422 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A140E) Check shift solenoid valve SL. Q07749 PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the shift solenoid valve SL connector. (d) Remove the shift solenoid valve SL. CHECK: (a) Measure resistance between terminal SL of shift solenoid valve and solenoid body. (b) Connect positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 ∼ 15 Ω (b) The shift solenoid valve SL makes operation noise. NG Replace the shift solenoid valve SL. OK Check and replace or repair the solenoid wire. Author: Date: 657 DI–423 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI036–02 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock–up condition, when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to ECM. Then the ECM cancels operation of the lock–up clutch while braking is in progress. DTC No. P1520 DTC Detecting Condition No stop light switch signal to ECM during driving. (2 trip detection logic) Trouble Area
Open or short in stop light switch circuit
Stop light switch
ECM WIRING DIAGRAM See page DI–170. INSPECTION PROCEDURE See page DI–170. Author: Date: 658 DI–424 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI037–02 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. DTC No. P1780 DTC Detection Condition When driving under conditions (a) and (b) for 30 seconds or more, the park/neutral position switch is ON (N position). (2 trip detection logic) (a) Vehicle speed: 80 km/h (50 mph) or more (b) Engine speed: 2,000 ∼ 5,000 rpm Trouble Area
Short in park/neutral position switch circuit
Park/neutral position switch
ECM Author: Date: 659 DI–425 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) WIRING DIAGRAM Combination Meter ECM 8 R R–B C8 11 C8 6 C8 2 L *3 *4 13 O IG13 16 Y 1V Junction 5 II2 Y E 3 P1 L–W 8 P1 R–L 6 II2 R–B Junction Y 3 II3 D D *4 O C C J27 A J27 J28 R–B 2 II2 F 18 E7 *3 L – W L *1 *2 D Connector *3 L – W *4 O R–B *1 19 15 E7 E7 Y E E J29 2 P1 R–L 5 *2 Connector 4 P1 A 1H 10 J29 Park/Neutral Position Switch A L–W O Y IG13 J21 Junction Connector Instrument Panel J/B R–B 16 E7 2 17 E7 R B+ J27, J28 R–L 6 5 Junction Connector 11 II2 B–W B J29 Junction B Connector GR R–L F J28 Junction Connector B–R 1 1B AM1 2 1K Ignition Switch 4 2 I16 I16 W B–Y 22 E7 B–W B B–W NSW B–W 1 1K GAUGE 1 1J B–R 1 F9 2 F9 ALT 1 F4 1 F6 B–G FL B MAIN Battery Instrument Panel J/B 5 1K 5 1B Instrument Panel J/B 7 I16 W–R 8 I16 AM2 1 2A STARTER 3 1J Engine Room J/B No.2 B 3 2B Engine Room J/B No.2 J7 J8 Junction Connector *5 C B 10 GR J8 J7 II2 *6 B–O 4 1K Instrument Panel J/B W – R Instrument Panel J/B 4 2L R 11 2J MAIN 5 ST Relay 3 1 2 5 2D 9 2K Starter J11 Junction Connector A *5 GR IK *6 B–O *1: w/ Engine Immobiliser System *4: TMMK Made *2: w/o Engine Immobiliser System *5: TMC Made w/o Traction Control *3: TMC Made *6: Except TMC Made w/o Traction Control Author: Date: D01820 660 DI–426 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) INSPECTION PROCEDURE 1 Read PNP, REVERSE, 2ND and LOW signals. When using TOYOTA hand–held tester: PREPARATION: (a) Remove the DLC3 cover. (b) Connect a TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. CHECK: Shift the shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2ND and LOW signals on the TOYOTA hand–held tester. OK: ON w/ Engine Immobiliser System L (–) (+) R (–) BE3840 Q08479 D00043 (+) NSW L 2 D00994 Signal 2 2ND OFF → ON L LOW OFF → ON R REVERSE OFF → ON P, N PNP OFF → ON When not using TOYOTA hand–held tester: PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminals NSW, 2, L and R of ECM and body ground when the shift lever is shifted in the following positions. OK: NSW R 2 w/o Engine Immobiliser System Shift position Position NSW–Body ground R–Body ground 2–Body ground L–Body ground P, N 0V 0V 0V 0V 0V 0V 0V 0V R 9 ∼ 14 V* D 9 ∼ 14 V 0V 2 9 ∼ 14 V 0V L 9 ∼ 14 V 0V 9 ∼ 14 V* 9 ∼ 14 V 0V 0V 9 ∼ 14 V HINT: The voltage will drop slightly due to lighting up of the back up light. OK Proceed to next circuit inspection shown on matrix chart (See page DI–405). NG Author: Date: 661 DI–427 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A140E) Check park/neutral position switch. PREPARATION: (a) Jack up the vehicle. (b) Remove the park/neutral position switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift Position Terminal No. to continuity Terminal No. to continuity P 4–7 5–6 R 4–8 – N 4 – 10 5–6 D 4–9 – 2 2–4 – L 2–3 – Q07657 OK: There is continuity. NG Replace the park/neutral position switch. OK 3 Check harness and connector between battery and park/neutral position switch, park/neutral position switch and ECM (See page IN–31). NG Repair or replace the harness and connector. OK Check and replace the ECM. Author: Date: 662 DI–428 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI038–02 O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising overdrive may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. WIRING DIAGRAM ECM Cruise Control ECU B+ OD *1 *2 14 C15 *2 Y–B *1 20 18 OD1 E7 E7 : w/ Engine Immobiliser System : w/o Engine Immobiliser System D01809 Author: Date: 663 DI–429 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) INSPECTION PROCEDURE 1 Check voltage between terminal OD1 of ECM and body ground. PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal OD1 of ECM and body ground. OK: Voltage: 9 ∼ 14 V ON w/ Engine Immobiliser System OD1 (+) (–) w/o Engine Immobiliser System OD1 BE3840 Q07658 D00103 D00995 OK Proceed to next circuit inspection shown on matrix chart (See page DI–405). NG 2 Check voltage between terminal OD of cruise control ECU harness side connector and body ground. PREPARATION: (a) Disconnect the cruise control ECU connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. OK: Voltage: 9 ∼ 14 V ON (–) BE3840 I00143 (+) OD D00057 OK Check and replace the cruise control ECU. NG Author: Date: 664 DI–430 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A140E) Check harness and connector between cruise control ECU and ECM. NG Repair or replace the harness or connector. OK Check and replace the ECM. Author: Date: 665 DI–431 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) DI1J1–01 O/D Main Switch & O/D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. In O/D main switch in OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. WIRING DIAGRAM Instrument Panel J/B 2 1 AM1 1K 1B 1 2 W Ignition Switch 2 4 I16 I16 AM1 IG1 ECM Instrument Panel J/B 2 GAUGE 1D 1 1K B+ B–Y *1 G–O B–R *2 5 7 E7 E7 OD2 R–L J4 Junction Connector D B–R O/D OFF 11 IG3 Indicator Light (Combination Meter) G–O 7 12 C J6 R–L G – OC Junction C8 C8 D C Connector G–O 2 O2 1 F9 FUSIBLE LINK BLOCK 2 F9 O/D Main Switch ALT 1 F4 (*3) FL MAIN B–G 4 O2 W–B A J5 Junction Connector A W–B Battery IF *1 *2 *3 : w/ Engine Immobiliser System : w/o Engine Immobiliser System : O/D Main Switch Contacts go open with switch pushed in Contacts go closed with switch pushed once again D01810 Author: Date: 666 DI–432 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) INSPECTION PROCEDURE O/D OFF indicator light does not light up 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity at each terminal 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Specified condition ON No continuity OFF Continuity Replace the O/D main switch. OK 2 Check and replace combination meter (See page BE–47). NG Replace the combination meter. OK Author: Date: 667 DI–433 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A140E) Check OVRDRIVE CUT SW2 signal. When using TOYOTA hand–held tester: PREPARATION: (a) Remove the DLC3 cover. (b) Connect TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. CHECK: Read the OVRDRIVE CUT SW2 signal on the TOYOTA hand– held tester. OK: O/D main switch condition OVRDRIVE CUT SW2 signal O/D ON (Pushed in) OFF O/D OFF (Pushed once again) ON When not using TOYOTA hand–held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check voltage between terminal OD2 of ECM and body ground. OK: ON w/ Engine Immobiliser System OD2 (–) O/D main switch condition Voltage O/D ON (Pushed in) 9 ∼ 14 O/D OFF (Pushed once again) Below 1.5 V (+) w/o Engine Immobiliser System OD2 BE3840 Q07661 Q07754 D01716 OK Check and replace the ECM (See page IN–31). NG Author: Date: 668 DI–434 DIAGNOSTICS 4 – AUTOMATIC TRANSAXLE (A140E) Check harness and connector between O/D OFF indicator light and ECM (See page IN–31). NG Repair or replace the harness or connector. OK Check and replace the ECM (See page IN–31). Author: Date: 669 DI–435 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A140E) O/D OFF indicator light remains ON 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity at each terminal 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Specified condition ON No continuity OFF Continuity Replace the O/D main switch. OK 2 Check harness and connector between O/D OFF indicator light and O/D main switch, O/D OFF indicator light and ECM (See page IN–31). NG Repair or replace the harness or connector. OK Check and replace the ECM (See page IN–31). Author: Date: 670 DI–436 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) AUTOMATIC TRANSAXLE (A541E) DI02C–02 HOW TO PROCEED WITH TROUBLESHOOTING Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI–437 2 Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool / TOYOTA hand–held tester, inspect DLC3 P. DI–438 3 Check DTC and Freezes Frame Data (Pre–check) Record or Print DTC and Freezed Frame Data P. DI–438 4 Clear DTC and Freezed Frame Data P. DI–449 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI–438 symptom does not occur 8 7 Problem Symptom Confirmation Symptom Simulation P. IN–21 symptom occur 9 DTC Check P. DI–438 10 DTC Chart P. DI–449 OK Code 11 OK Mechanical System Test P. DI–438 NG 12 13 OK Manual Shifting Test P. DI–438 NG NG Matrix Chart of Problem Symptoms – P. DI–453 Chapter 1 (Electronic) P. DI–453 NG 14 Preliminary Check NG P. DI–438 Chapter 2 (On–Vehicle) P. DI–453 OK NG 16 Repair Chapter 3 (Off–Vehicle) P. DI–453 NG 15 Parts Inspection
Main Throttle Signal Check Circuit
Stop Light Signal Check Inspection P. DI–484 to DI–487 Identification of Problem OK 17 Confirmation Test Author: End Date: 671 DI–437 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02D–01 CUSTOMER PROBLEM ANALYSIS CHECK Transaxle Control System Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / Date Problem Occurred How Often Does Problem Occur? / km mile Odometer Reading /  Continuous /  Intermittent (  Vehicle does not move (  Any position  No up–shift (  1st → 2nd  No down–shift (  O/D → 3rd times a day)  Particular position )  2nd → 3rd  3rd → 2nd  3rd → O/D )  2nd → 1st )  Lock–up malfunction Symptoms  Shift point too high or too low  Harsh engagement (  N → D  Lock–up  Any drive position )  Slip or shudder  No kick–down  Others Check Item Malfunction Indicator Lamp  Normal  Remains ON DTC Check 1st Time  Normal code  Malfunction code (Code ) 2nd Time  Normal code  Malfunction code (Code ) Author: Date: 672 DI–438 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02E–02 PRE–CHECK 1. (a) FI0534 TOYOTA hand–held tester DLC3 S05335 DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle an OBD II scan tool complying with SAE J1987 or TOYOTA hand– held tester, and read off various data output from the vehicle’s ECM. OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory. (See page DI–211) If the malfunction only occurs in 3 trips, the MIL goes off but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect an OBD II scan tool or TOYOTA hand–held tester to DLC3 on the vehicle. The OBD II scan tool or TOYOTA hand–held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI–449). Author: Date: 673 DI–439 DIAGNOSTICS –

(b) AUTOMATIC TRANSAXLE (A541E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and for a malfunction that is only detected once or momentarily. (TOYOTA hand–held tester) (See page DI–438) *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the 2nd test drive, this 2nd detection causes the MIL to light up. Inspect the DLC3. The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141–2 format. N09214 Tester connection Condition Specified condition 7 (Bus
Line) – 5 (Signal ground) During communication 4 (Chassis Ground) – Body Always 1 Ω or less 5 (Signal Ground) – Body Always 1 Ω or less 16 (B+) – Body Always 9 – 14 V Pulse generation HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of OBD II scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. (2) If communication is still not possible when the tool is connected connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. Author: Date: 674 DI–440 DIAGNOSTICS 2. (a) FI0534 TOYOTA hand–held tester HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–2). (2) When the engine is started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand–held tester only: When the diagnostic system is switched from normal mode to check mode, it erases all DTCs and freeze frame data recorded in normal mode. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare an OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester. (2) (4) S05335 AUTOMATIC TRANSAXLE (A541E) INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. (3) DLC3 – Connect the OBD II scan tool or TOYOTA hand– held tester to DLC3 at the lower of the instrument panel. Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand–held tester switch ON. Use the OBD II scan tool or TOYOTA hand–held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). See page DI–449 to confirm the details of the DTCs. (5) NOTICE: When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand–held tester) to check the DTCs, use normal mode. For codes on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptoms have been simulated the 1st time. Them repeat the simulation process again. When the program has DTCs are recorded in the ECM. Author: Date: 675 DI–441 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) 3. INSPECT DIAGNOSIS (CHECK MODE) HINT: TOYOTA hand–held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. (a) Check the DTC. (1) Check the initial conditions.
Battery positive voltage 11 V or more.
Throttle valve fully closed.
Transaxle in P position.
Air conditioning switched off. (2) Turn the ignition switch OFF. (3) Prepare a TOYOTA hand–held tester. TOYOTA hand–held tester (4) (5) DLC3 S05335 (6) 0.13 sec. Connect the TOYOTA hand–held tester to DLC3 at the lower of the instrument panel. Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. (7) 0.13 sec. ON (8) OFF BR3904 Switch the TOYOTA hand–held tester from Normal mode to Check mode (Check that the MIL flashes). Start the engine (MIL goes out after the engine starts). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc.. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTCs and freeze frame data, etc.. HINT: Take care not to turn the ignition switch OFF, as turning it off switches the diagnosis system from Check mode to Normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. Author: Date: 676 DI–442 DIAGNOSTICS (b) – AUTOMATIC TRANSAXLE (A541E) Clearance the DTC. The following actions will erase the DTC and freezed frame data. Operating an OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) 4. ROAD TEST NOTICE: Perform the test at normal operating ATF temperature 50 – 80 °C (122 – 176 °F). (a) D POSITION TEST Shift into the D position and fully depress the accelerator pedal and and check the following points: (1) Check up–shift operation. 1 → 2, 2 → 3 and 3 → O/D up–shift takes place, at the shift point shown in the automatic shift schedule (See page SS–56). HINT:
O/D Gear Up–shift Prohibition Control (1. Coolant temp. is 60 °C (140 °F) or less. 2. If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed.)
O/D Gear Lock–up Prohibition Control (1. Brake pedal is depressed. 2. Coolant temp. is 60 °C (140 °F) or less.) (2) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up–shifts. (3) Check for abnormal noises and vibration. Run at the D position lock–up or O/D gear and check for abnormal noises and vibration. HINT: The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential torque converter clutch, etc.. (4) Check kick–down operation. While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick–down vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick–downs conform to those indicated on the automatic shift schedule (See page SS–56). (5) Check abnormal shock and slip at kick–down. (6) Check the lock–up mechanism.
Drive in D position, O/D gear, at a steady speed (lock–up ON) of about 60 km/h (37 mph).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. If there is a big jump in engine speed, there is no lock–up. (b) 2 POSITION TEST Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check up–shift operation. Check to see that the 1 → 2 up–shift takes place and that the shift point conforms to the automatic shift schedule (See page SS–56). HINT: There is no O/D up–shift and lock–up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down–shift. Author: Date: 677 DI–443 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) (c) L POSITION TEST Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (d) R POSITION TEST Shift into the R position and fully depress the accelerator pedal and check for slipping. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (e) P POSITION TEST Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. Q00519 5. BASIC INSPECTION (a) Check the fluid level. HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70 – 80 °C (158 – 176 °F)
Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (1) OK if hot Add if hot AT3417 Park the vehicle on a level surface and set the parking brake. (2) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (3) Pull out the dipstick and wipe it clean. (4) Push it back fully into the pipe. (5) Pull it out and check that the fluid level is in the HOT range. If the level is at the low side, add new fluid. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) NOTICE: Do not overfill. (b) Check the fluid condition. If the level is at the low side, add new fluid. Author: Date: 678 DI–444 DIAGNOSTICS (c) – AUTOMATIC TRANSAXLE (A541E) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. AT4657 (3) With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) Capacity: 3.9 liters (4.1 US qts, 3.4 Imp. qts) (4) Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. AT8562 (5) OK if hot (6) Add if hot AT3417 0 ∼ 1 mm (0 ∼ 0.04 in.) With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. Check the fluid level at the normal operating temperature, 70 – 80 °C (158 – 176 °F), and add as necessary. NOTICE: Do not overfill. (d) Check the fluid leaks. Check for leaks in the transaxle. If there are leaks, it is necessary to repair or replace O–rings, gasket, oil seals, plugs or other parts. (e) Inspect and adjust the throttle cable. (1) Check that the accelerator pedal is fully released. (2) Check that the inner cable is not slack. (3) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 – 1 mm (0 – 0.04 in.) If the distance is not the standard, adjust the cable by the adjusting nuts. AT4252 Author: Date: 679 DI–445 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) (f) Q00199 Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator is not aligned with the correct position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (1) Loosen the nut on the shift lever. (2) Push the control shaft fully rearward. (3) Q04604 Neutral Basic Line Bolt Groove Bolt Q04700 Return the control shaft lever 2 notches to N position. (4) Set the shift lever to N position. (5) While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (6) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. (g) Inspect and adjust the park/neutral position. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedures. (1) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (2) Align the groove and neutral basic line. (3) Hold in position and tighten the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) For continuity inspection of the park/neutral position switch, see page DI–479. (h) Check the idle speed. Idle speed: 700 ± 50 rpm (In N position and air conditioner OFF) 6. (a) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Do not continuously run this test longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (3) Fully apply the parking brake. (4) Keep your left foot pressed firmly on the brake pedal. (5) Start the engine. Author: Date: 680 DI–446 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 2,600 ± 150 rpm (7) Do the same test in R position. Stall speed: 2,600 ± 150 rpm Evaluation: Problem Possible cause (a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one–way clutch is operating properly HINT: If more than 600 rpm below the specified value, the torque converter could be faulty. (b) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No.2 one–way clutch not operating properly
O/D clutch slipping (c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st and reverse brake slipping
O/D clutch slipping (d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one–way clutch not operating properly (b) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, and 1st and reverse brake. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value. (1) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (2) Fully apply the parking brake. (3) Start the engine and check idle speed. Idle speed: 700 ± 50 rpm (In N position and air conditioner OFF) (4) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. In the same manner, measure the time lag for N → R. Time lag: N → D Less than 1.2 seconds N → R Less than 1.5 seconds Evaluation (If N → D time or N → R time lag is longer than specified): Problem Possible cause N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one–way clutch not operating N → R time lag is longer
Line pressure too low
Direct clutch worn
1st and reverse brake worn
O/D one–way clutch not operating properly Author: Date: 681 DI–447 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) 7. HYDRAULIC TEST Measure the line pressure NOTICE:
Do the test at normal operation fluid temperature 50 – 80 °C (122 – 176 °F).
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) Warm up the ATF. (2) Remove the test plug on the transaxle case front left side and connect SST. (See page AX–21 for the location to connect SST) SST 09992–00095 (09992–00231, 09992–00271) (3) Fully apply the parking brake and chock the 4 wheels. (4) Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. (5) Start the engine and check idling speed. (6) Keep your left foot pressed firmly on the brake pedal and shift into D position. (7) Measure the line pressure when the engine is idling. (8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (9) In the same manner, do the test in R position. Specified line pressure: Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling 401 – 461 (4.1 – 4.7, 58 – 66) 804 – 882 (8.2 – 9.0, 117 – 128) Stall 1,138 – 1,236 (11.6 – 12.6, 165 – 179) 1,716 – 1,854 (17.5 – 18.9, 249 – 269) If the measured pressure is not up to specified value, recheck the throttle cable adjustment and retest. Evaluation Problem Possible cause If the measured values at all position are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective If the measured values at all position are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective If pressure is low in the D position only
D position circuit fluid leakage
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st and reverse brake defective Author: Date: 682 DI–448 DIAGNOSTICS Q00224 – AUTOMATIC TRANSAXLE (A541E) 8. MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. (a) Disconnect the solenoid wire. (b) Inspect the manual driving operation. Check that the shift and gear positions correspond with the table below. While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. Shift Position Gear Position D O/D 2 O/D L 1st R Reverse P Pawl Lock HINT: If the L, 2 and D position gear positions are difficult to positions are difficult to distinguish, do the following read test. If any abnormality is found in the above test, the problem is in the transaxle itself. (c) Connect the solenoid wire. (d) Cancel out the DTC (See page DI–438). Author: Date: 683 DI–449 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02F–02 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given. * : –...MIL does not light /
...MIL light up DTC No. (See Page) Detection Item Trouble Area MIL * Memory P0500 (DI–456) Vehicle Speed Sensor Malfunction (No.1 Vehicle Speed Sensor)  Open or short in No.1 vehicle speed sensor circuit  No.1 vehicle speed sensor  Combination meter  ECM  Automatic transaxle (clutch, brake or gear etc.)
 P0750 (DI–460) Shift Solenoid A Malfunction (Shift Solenoid Valve No.1)  Shift solenoid valve No.1 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0753 (DI–462) Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No.1)  Open or short in shift solenoid valve No.1 circuit  Shift solenoid valve No.1  ECM
 P0755 (DI–460) Shift Solenoid B Malfunction (Shift Solenoid Valve No.2)  Shift solenoid valve No.2 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0758 (DI–462) Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No.2)  Open or short in shift solenoid valve No.2 circuit  Shift solenoid valve No.2  ECM
 P0770 (DI–466) Shift Solenoid E Malfunction (Shift Solenoid Valve SL)  Shift solenoid valve SL is stuck open or closed  Valve body is blocked up or stuck  Lock–up clutch  Automatic transaxle (clutch, brake or gear etc.)
 P0773 (DI–468) Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL)  Open or short in shift solenoid valve SL circuit  Shift solenoid valve SL  ECM
 P1520 (DI–472) Stop Light Switch Signal Malfunction  Open or short in stop light switch circuit  Stop light switch  ECM
 P1705 (DI–473) NC2 Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor)  Open or short in direct clutch speed sensor circuit  Direct clutch speed sensor  ECM
 P1765 (DI–476) Linear Solenoid for Accumulator Pressure Control Circuit Malfunction (Shift Solenoid Valve SLN)  Open or short in shift solenoid valve SLN circuit  Shift solenoid valve SLN  ECM
 P1780 (DI–479) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM
 Author: Date: 684 DI–450 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02G–02 PARTS LOCATION Throttle Position Sensor Cruise Control ECU O/D Main Switch ECM O/D OFF Indicator LIght DLC3 Engine Coolant Temp. Sensor Crankshaft Position Sensor DLC2 Stop Light Switch Direct Clutch Speed Sensor Vehicle Speed Sensor Shift Solenoid Valve SL Park/Neutral Position Switch Shift Solenoid Valve SLN Shift Solenoid Valve No.1, No2 Q07932 Author: Date: 685 DI–451 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI1KA–01 TERMINALS OF ECM Except California, w/ Engine Immobilizer and / or TRAC: ECM Terminals E10 E9 E8 E7 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 8 7 6 5 4 3 2 1 16 15 14 13 12 11 26 25 24 23 22 2120 19 18 17 3433 3231 30 2928 27 11 10 9 8 7 7 17 16 15 14 13 12 22 2120 19 18 6 5 11 10 9 8 16 15 14 13 12 13 12 11 10 9 21 2019 18 1716 15 14 28 27 26 25 24 23 22 FI6810 Symbols (Terminals No.) S1 ↔ E1 (E10–11 (E10 11 ↔ E8 E8–16) 16) S2 ↔ E1 (E10 (E10–17 17 ↔ E8 E8–16) 16) SL ↔ E1 (E10–27 (E10 27 ↔ E8 E8–16) 16) NC2+ ↔ NC2– (E9–9 ↔ E9–4) SLN+ ↔ SLN– (E10–2 ↔ E 8–2) OD1 ↔ E1 (E7–7 ↔ E8–16) OD2 ↔ E1 (E7–6 (E7 6 ↔ E8–16) E8 16) Wiring Color V ↔ BR L–B L B ↔ BR P L ↔ BR P–L R↔G Condition IG ON 10 ∼ 14 1st or 2nd gear 10 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 1st or 2nd gear 10 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock–up position 10 ∼ 14 IG ON Y–B ↔ BR IG ON L ↔ E1 (E7–1 (E7 1 ↔ E8–16) E8 16) Y ↔ BR 2 ↔ E1 (E7–10 (E7 10 ↔ E8–16) E8 16) *1, 1, *3 3L L–W W ↔ BR *2, *4 O ↔ BR R ↔ E1 (E7–15 (E7 15 ↔ E8–16) E8 16) R B ↔ BR R–B NSW ↔ E1 (E10–14 ↔ E8–16) B W ↔ BR B–W Pulse signal is output Below 1 ↔ 4 ∼ 5 Engine is running W–L ↔ B–Y G O ↔ BR G–O STD Voltage (V) 10 ∼ 14 5∼6 O/D main switch ON 10 ∼ 14 O/D main switch OFF Below 1 IG ON and Shift lever L position 10 ∼ 14 IG ON and Shift lever other than L position Below 1 IG ON and Shift lever 2 position 10 ∼ 14 IG ON and Shift lever other than 2 position Below 1 IG ON and Shift lever R position 10 ∼ 14 IG ON and Shift lever other than R position Below 1 IG ON and Shift lever P or N position 10 ∼ 14 IG ON and Shift lever other than P or N position Below 1 *1: w/ Engine immobilizer system *2: w/o Engine immobilizer system *3 TMC made ex. USA w/ TRAC *4: TMMK made, TMC made USA w/ TRAC Author: Date: 686 DI–452 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) California, w/ Engine Immobilizer and / or TRAC: ECM Terminals E11 E10 E9 E8 E7 D01054 Symbols (Terminals No.) S1 ↔ E1 (E11–7 (E11 7 ↔ E10 E10–17) 17) S2 ↔ E1 (E11–8 (E11 8 ↔ E10 E10–17) 17) SL ↔ E1 (E11–9 (E11 9 ↔ E10 E10–17) 17) Wiring Color V ↔ BR L–B L B ↔ BR P L ↔ BR P–L Condition STD Voltage (V) IG ON 10 ∼ 14 1st or 2nd gear 10 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 1st or 2nd gear 10 ∼ 14 3rd or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock–up position 10 ∼ 14 ↔ (E11–14 ↔ E11–26) R↔G SLN+ ↔ SLN– (E11–20 ↔ E11–19) W–L ↔ B–Y IG ON 10 ∼ 14 OD1 ↔ E1 (E8–24 ↔ E10–17) Y–B ↔ BR IG ON 5∼6 OD2 ↔ E1 (E8–10 (E8 10 ↔ E10–17) E10 17) G O ↔ BR G–O NC2+ NC2– L ↔ E1 (E8–12 (E8 12 ↔ E10–17) E10 17) Y ↔ BR 2 ↔ E1 (E8–3 (E8 3 ↔ E10–17) E10 17) *1, 1, *3 3L L–W W ↔ BR *2, *4 O ↔ BR R ↔ E1 (E8–2 (E8 2 ↔ E10–17) E10 17) R B ↔ BR R–B NSW ↔ E1 (E8–20 ↔ E10–17) B W ↔ BR B–W Pulse signal is output Below 1 ↔ 4 ∼ 5 Engine is running O/D main switch ON 10 ∼ 14 O/D main switch OFF Below 1 IG ON and Shift lever L position 10 ∼ 14 IG ON and Shift lever other than L position Below 1 IG ON and Shift lever 2 position 10 ∼ 14 IG ON and Shift lever other than 2 position Below 1 IG ON and Shift lever R position 10 ∼ 14 IG ON and Shift lever other than R position Below 1 IG ON and Shift lever P or N position 10 ∼ 14 IG ON and Shift lever other than P or N position Below 1 *1: w/ Engine immobilizer system *2: w/o Engine immobilizer system *3 TMC made ex. USA w/ TRAC *4: TMMK made, TMC made USA w/ TRAC Author: Date: 687 DI–453 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02I–02 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On–vehicle Repair Matrix Chart Chapter 3: Off–vehicle repair Matrix Chart  If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check.  If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and replace the ECM. 1. Chapter 1: Electronic Circuit Matrix Chart Symptom Suspect Area See page No up–shift (1st → 2nd) ECM No up–shift (2nd → 3rd) ECM IN–31 No up–shift (3rd → O/D) 1. O/D main switch circuit 2. O/D cancel signal circuit 3. ECM DI–487 DI–484 IN–31 No down–shift (O/D → 3rd) ECM IN–31 No down–shift (3rd → 2nd) ECM IN–31 No down–shift (2nd → 1st) ECM IN–31 No lock–up or No lock–up off ECM IN–31 Shift point too high or too low ECM IN–31 Up–shift to 2nd while in L position ECM IN–31 Up–shift to 3rd while in L position ECM IN–31 Up–shift to O/D from 3rd 1. O/D main switch circuit 2. ECM DI–487 IN–31 Up–shift to O/D from 3rd while engine is cold ECM IN–31 Harsh engagement (N → D) ECM IN–31 Harsh engagement (Lock–up) ECM IN–31 Harsh engagement (Any driving position) ECM IN–31 Poor acceleration ECM IN–31 Large shift shock or engine stalls when starting off or stopping ECM IN–31 IN–31 Author: Date: 688 DI–454 DIAGNOSTICS 2. – AUTOMATIC TRANSAXLE (A541E) Chapter 2: On–Vehicle Repair (
: A541E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM530U) Symptom Suspect Area See page Vehicle does not move in any forward position and reverse position 1. Manual valve 2. Throttle valve 3. Primary regulator valve 4. Off–vehicle repair matrix chart


DI–453 Vehicle does not move in R position Off–vehicle repair matrix chart DI–453 No up–shift (1st → 2nd) 1. 1–2 shift valve 2. Off–vehicle repair matrix chart
DI–453 No up–shift (2nd → 3rd) 1. 2–3 shift valve 2. Off–vehicle repair matrix chart
DI–453 No up–shift (3rd → O/D) 1. 3–4 shift valve 2. Off–vehicle repair matrix chart
DI–453 No down–shift (O/D → 3rd) 3–4 shift valve
No down–shift (3rd → 2nd) 2–3 shift valve
No down–shift (2nd → 1st) 1–2 shift valve
No lock–up or No lock–up off 1. Lock–up relay valve 2. Off–vehicle repair matrix chart
DI–453 Harsh engagement (N → D) 1. C1 accumulator 2. Off–vehicle repair matrix chart
DI–453 Harsh engagement (N → R) 1. C2 accumulator 2. No.1 accumulator control valve 3. Off–vehicle repair matrix chart

DI–453 Harsh engagement (N → L) Low coast modulator valve Harsh engagement (Lock–up) 1. Lock–up relay valve 2. Off–vehicle repair matrix chart Harsh engagement (1st → 2nd → 3rd → O/D) 1. Throttle modulator valve 2. Cut back valve 3. Throttle valve


Harsh engagement (2nd → 3rd) C2 accumulator
Harsh engagement (3rd → O/D) B0 accumulator
Harsh engagement (O/D → 3rd) 1. C0 accumulator 2. B0 accumulator

Slip or shudder (Forward and reverse) 1. Throttle valve 2. Oil strainer 3. Off–vehicle repair matrix chart

DI–453 No engine braking (1st: L position) 1. Low coast modulator valve 2. Off–vehicle repair matrix chart
DI–453 No engine braking (2nd: 2 position) 1. 2nd coast modulator valve 2. Off–vehicle repair matrix chart
DI–453 No kick–down 1. 1–2 shift valve 2. 2–3 shift valve 3. 3–4 shift valve

DI–453


Author: Date: 689 DI–455 DIAGNOSTICS 3. – AUTOMATIC TRANSAXLE (A541E) Chapter 3: Off–Vehicle Repair (
: A541E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM530U) Symptom Suspect Area See page Vehicle does not move in any forward position and reverse position 1. Front and rear planetary gear 2. O/D planetary gear 3. O/D one–way clutch (F0) 4. O/D direct clutch (C0) 5. Forward clutch (C1) 6. O/D brake (B0)





Vehicle does not move in R position 1. Front and rear planetary gear unit 2. Direct clutch (C2) 3. O/D direct clutch (C0) 4. 1st and reverse brake (B3)



No up–shift (1st → 2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

No up–shift (2nd → 3rd) Direct clutch (C2)
No up–shift (3rd → O/D) O/D brake (B0)
No lock–up or No lock–up off Torque converter clutch
Harsh engagement (N → D) 1. Forward clutch (C1) 2. O/D one–way clutch (F0) 3. No. 2 one–way clutch (F2)


Harsh engagement (N → R) 1. Direct clutch (C2) 2. 1st and reverse brake (B3)

Harsh engagement (Lock–up) Torque converter clutch
Slip or shudder (Forward position: After warm–up) 1. Torque converter clutch 2. O/D direct clutch (C0) 3. Forward clutch (C1) 4. O/D one–way clutch (F0)



Slip or shudder (R position) 1. Direct clutch (C2) 2. 1st and reverse brake (B3) 3. O/D direct clutch (C0)


Slip or shudder (1st) No. 2 one–way clutch (F2)
Slip or shudder (2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

Slip or shudder (3rd) Direct clutch (C2)
Slip or shudder (O/D) O/D brake (B0)
No engine braking (1st ∼ 3rd: D position) 2nd brake (B2)
No engine braking (1st: L position) 1st and reverse brake (B3)
No engine braking (2nd: 2 position) 2nd coast brake (B1)
Poor acceleration (All position) 1. Torque converter clutch 2. O/D planetary gear

Poor acceleration (O/D) 1. O/D direct clutch (C0) 2. O/D planetary gear

Large shift shock or engine stalls when starting off or stopping Torque converter clutch
Author: Date: 690 DI–456 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI1KB–01 CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4–Pulse 4–Pulse Vehicle Speed Sensor Combination Meter ECM Transaxle Vehicle Speed Sensor Q00515 Q00514 A00223 DTC No. P0500 DTC Detecting Condition No vehicle speed sensor signal to ECM under conditions (a) and (b) (2 trip detection logic) (a) Park/neutral position switch is OFF (b) Vehicle is being driven Clutch or brake slips or gear is broken Trouble Area
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Combination meter
ECM
Automatic A t ti ttransaxle l ((clutch, l t h b brake k or gear etc.) t ) WIRING DIAGRAM See page DI–333. Author: Date: 691 DI–457 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. OK 2 Check for short in harness and connector between terminal SPD of ECM and body ground. Except California, w/ Engine Immobilizer and / or TRAC: SPD PREPARATION: (a) Remove the glove compartment (See page SF–73). (b) Disconnect the connector from ECM. CHECK: Check continuity between terminal SPD of ECM and body ground. OK: No continuity (1 M Ω or higher) California, w/ Engine Immobilizer and / or TRAC: SPD P23875 A02373 A02155 NG Repair or replace harness or connector. OK Author: Date: 692 DI–458 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A541E) Check voltage between terminal SPD of ECM connector and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground. OK: Voltage: 9 ∼ 14 V ON Except California, w/ Engine Immobilizer and / or TRAC: SPD (+) (–) California, w/ Engine Immobilizer and / or TRAC: (–) (+) SPD BE6653 P23876 D01908 D02281 NG Check for open in harness and connector between junction connector (J15) and ECM (See page IN–31). OK 4 Check for open in harness and connector between junction connector (J15) and combination meter (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 693 DI–459 DIAGNOSTICS 5 – AUTOMATIC TRANSAXLE (A541E) Check ECM (See page IN–31). NG Replace ECM. OK Check and repair the transaxle (clutch, brake or gear etc.). Author: Date: 694 DI–460 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02K–02 DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift Solenoid Valve No.1/No.2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor and direct clutch speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.) DTC No. P0750 P0755 DTC Detecting Condition Trouble Area During normal driving, the gear required by the ECM does not match the actual gear (2 trip detection logic)
Shift solenoid valve No.1/No.2 is stuck open or closed
Valve body is blocked up or stuck
Automatic transaxle (clutch, brake or gear etc.) Check the shift solenoid valve No.1 when DTC P0750 is output and check the shift solenoid valve No.2 when DTC P0755 is output. INSPECTION PROCEDURE 1 Check shift solenoid valve No.1 or No.2 operation. PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the valve opens. Q07781 NG Replace the shift solenoid valve No.1 or No.2. OK Author: Date: 695 DI–461 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) Check the valve body (See page DI–453 ). NG Repair or replace the valve body. OK Repair the transaxle. Author: Date: 696 DI–462 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02L–02 DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No.1/No.2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be performed electronically and must be done manually. Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops sending current to the short circuited solenoid). SHIFT SOLENOID NO.1 MALFUNCTIONING NORMAL Position D 2 L Solenoid valve No.1 No.2 ON OFF ON Gear 1st Solenoid valve No.1 No.2 ON X ON 2nd X OFF ON 3rd X OFF OFF O/D X Gear SHIFT SOLENOID NO.2 MALFUNCTIONING Solenoid valve No.1 No.2 X ON Gear BOTH SOLENOIDS MALFUNCTIONING Gear when shift selector is manually operated 1st O/D 3rd OFF X O/D O/D ON 3rd OFF X O/D O/D OFF O/D OFF X O/D O/D 3rd ON X 1st O/D 3rd OFF X O/D O/D ON 3rd ON OFF 1st X ON ON ON 2nd X ON OFF ON 3rd X ON 3rd OFF X O/D O/D ON OFF 1st X OFF 1st ON X 1st 1st ON ON 2nd X ON 2nd ON X 1st 1st X: Malfunctions Check the shift solenoid valve No.1 when DTC P0753 is output and check the shift solenoid valve No.2 when DTC P0758 is output. DTC No. DTC Detecting Condition P0753 P0758 The ECM checks for an open or short circuit in the shift solenoid valves No.1 and No.2 circuit when it changes. The ECM records DTC P0753 or P0758 if condition (a) or (b) is detected once, but it does not light up MIL. After ECM detects condition (a) or (b) continuously 8 times or more in a trip and the MIL light up. (a) When the solenoid is energized, the solenoid resistance is 8 Ω or less and is counted. (b) When the solenoid is not energized, the solenoid resistance is 100 kΩ or more and is counted. Trouble Area
Open or short in shift solenoid valve No.1/No.2 circuit
Shift solenoid valve No.1/No.2
ECM Author: Date: 697 DI–463 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) WIRING DIAGRAM Transaxle ECM Shift Solenoid Valve No.1 W Shift Solenoid Valve No.2 B B+ 3 E3 *2 *1 7 11 E11 E10 S1 V B+ 6 E3 L–B J/C J26 A A L–B *2 *1 8 17 S2 E11 E10 A Cruise Control ECU *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC D01092 INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground. Except California, w/ Engine Immobilizer and / or TRAC: S1 PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal S1 or S2 of ECM and body ground. OK: Resistance: 11 ∼ 15 Ω S2 California, w/ Engine Immobilizer and / or TRAC: S2 Q07642 D00833 S1 D01909 Author: Date: 698 DI–464 DIAGNOSTICS OK – AUTOMATIC TRANSAXLE (A541E) Check and replace the ECM. NG 2 Check harness and connector between ECM and automatic transaxle solenoid connector. Except California, w/ Engine Immobilizer and / or TRAC: S1 S2 S2 PREPARATION: Disconnect the solenoid connector from the automatic transaxle. CHECK: Check the harness and connector between terminal S1 or S2 of ECM and terminal S1 or S2 of solenoid connector. OK: There is no open and no short circuit. S1 California, w/ Engine Immobilizer and / or TRAC: S2 S1 S1 S2 Q07935 D00832 Q02283 D01910 NG Repair or replace the harness or connector. OK Author: Date: 699 DI–465 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A541E) Check shift solenoid valve No.1 or No.2. PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the solenoid connector. (d) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Measure resistance between solenoid connector and body ground. (b) Connect the positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 ∼ 15 Ω (b) The solenoid makes an operating noise. D00048 NG Replace the solenoid valve. OK Repair or replace the solenoid wire. Author: Date: 700 DI–466 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02M–02 DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION Controlled Pressure Line Pressure Controlled Pressure Drain Q04874 The ECM uses the signals from the throttle position sensor, air– flow meter and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the ECM compares the engagement condition of the lock–up clutch with the lock–up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body, torque converter clutch or automatic transaxle (clutch, brake or gear etc.). DTC No. DTC Detecting Condition Trouble Area P0770
Lock–up does not occur when driving in the lock–up range (normal driving at 80 km/h [50 mph]), or lock–up remains ON in the lock–up OFF range. (2 trip detection logic)
When lock–up is ON, clutch or brake slips or gear is broken.
Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock–up clutch
Automatic transaxle (clutch, brake or gear etc.) INSPECTION PROCEDURE 1 Check solenoid valve SL operation. PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve SL. CHECK: (a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens. Q08040 NG Replace the solenoid valve SL. OK Author: Date: 701 DI–467 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A541E) Check valve body (See page DI–453). NG Repair or replace the valve body. OK Check the torque converter clutch (See page AX–21). NG Replace the torque converter clutch. OK Repair the transaxle. Author: Date: 702 DI–468 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02N–02 DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. Fail safe function If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. P0773 DTC Detecting Condition Trouble Area Either (a) or (b) are detected for 1 time. (2 trip detection logic) (a) Solenoid resistance is 8 Ω or less short circuit when solenoid is energized. (b) Solenoid resistance is 100 kΩ or more open circuit when solenoid is not energized.
Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM WIRING DIAGRAM Transaxle ECM Shift Solenoid Valve SL B+ Y 2 E3 *2 *1 9 27 SL E11 E10 P–L *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC Author: D01093 Date: 703 DI–469 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM and body ground. Except California, w/ Engine Immobilizer and / or TRAC: PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal SL of ECM and body ground. OK: Resistance: 8 ∼ 100,000 Ω SL California, w/ Engine Immobilizer and / or TRAC: SL Q07648 D00839 D01911 OK Check and replace the ECM. NG Author: Date: 704 DI–470 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A541E) Check harness and connector between ECM and automatic transaxle solenoid connector (See page IN–31). Except California, w/ Engine Immobilizer and / or TRAC: SL PREPARATION: Disconnect the solenoid connector from the transaxle. CHECK: Check the harness and connector between terminal SL of ECM and terminal SL of solenoid connector. OK: There is no open or short circuit. SL California, w/ Engine Immobilizer and / or TRAC: SL SL Q07938 D00840 D01912 NG Repair or replace the harness or connector. OK Author: Date: 705 DI–471 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE (A541E) Check shift solenoid valve SL. D00049 PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the shift solenoid valve SL connector. (d) Remove the shift solenoid valve SL. CHECK: (a) Measure resistance between terminal SL of shift solenoid valve and solenoid body. (b) Connect positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 ∼ 15 Ω (b) The shift solenoid valve SL makes operation noise. NG Replace the shift solenoid valve SL. OK Check and replace or repair the solenoid wire. Author: Date: 706 DI–472 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02O–02 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock–up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signals to ECM. Then the ECM cancels operation of the lock–up clutch while braking is in progress. DTC No. P1520 DTC Detecting Condition No stop light switch signal to ECM during driving. (2 trip detection logic) Trouble Area
Open or short in stop light switch circuit
Stop light switch
ECM WIRING DIAGRAM See page DI–363. INSPECTION PROCEDURE See page DI–363. Author: Date: 707 DI–473 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02P–02 DTC P1705 NC2 Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the direct clutch drum. By comparing the direct clutch speed signal and the vehicle speed sensor signal, the ECM detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting. NC2 Revolution Sensor Q04869 DTC No. P1705 DTC Detecting Condition The ECM detects conditions (a), (b), (c), (d), (e) and (f) continuity for 4 sec or more. (2 trip detection logic) (a) Vehicle speed : 32 km/h (20 mph) or more (b) 3rd or 4th gear (c) NC2 < 300 rpm (d) Park/neutral position switch: OFF (e) Solenoid valves and vehicle speed sensor are normal (f) L position: OFF Trouble Area
Open or short in direct clutch speed sensor circuit
Direct clutch speed sensor
ECM WIRING DIAGRAM ECM R *2 *1 14 9 NC2+ E11 E9 2 V3 Direct Clutch Speed Sensor 4∼6V 1 V3 G *2 *1 26 4 NC2– E11 E9 *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC Author: D01094 Date: 708 DI–474 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE Check resistance between terminals NC2+ and NC2– of ECM. 1 Except California, w/ Engine Immobilizer and / or TRAC: NC2+ PREPARATION: Disconnect the connector from ECM. CHECK: Check resistance between terminals NC2+ and NC2– of ECM. OK: Resistance: 560 ∼ 680 Ω NC2– California, w/ Engine Immobilizer and / or TRAC: NC2+ NC2– Q07936 D00834 D01913 OK Check and replace the ECM. NG Author: Date: 709 DI–475 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A541E) Check No.2 vehicle speed sensor. Magnet PREPARATION: Remove the Direct clutch speed sensor from transaxle. CHECK: (a) Measure resistance between terminals 1 and 2 of speed sensor. (b) Check voltage between terminals 1 and 2 of the speed sensor when a magnet is put close to the front end of the speed sensor then taken away quickly. OK: (a) Resistance: 560 ∼ 680 Ω (b) Voltage is generated intermittently. HINT: The voltage generated is extremely low. Q08218 NG Replace the Direct clutch speed sensor. OK Check and repair the harness and connector between ECM and Direct clutch speed sensor (See page IN–31). Author: Date: 710 DI–476 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02Q–02 DTC P1765 Linear Solenoid for Accumulator Pressure Control Circuit Malfunction (Shift Solenoid Valve SLN) CIRCUIT DESCRIPTION High Accumulator Control Pressure The shift solenoid valve SLN controls the hydraulic pressure acting on the accumulator control valve when gears are shifted and performs smooth gear shifting. The ECM determines optimum operating pressure according to the signals from the throttle position sensor, vehicle speed sensor and direct clutch speed sensor and controls the volume of current flow to the solenoid valve. The amount of current to the solenoid is controlled by the (*) duty ratio of ECM output signals, causing a momentary change to the hydraulic pressure acting on the clutches during gear shifting. When the duty ratio is high, the hydraulic pressure acting on the clutches is low. 0 Electric Current (A) 1 AT5608 (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity, then D00060 DTC No. DTC Detecting Condition After the engine is warmed up, the current flow to the shift solenoid valve SLN for 1 sec or more under condition (a) or (b): (a) Engine speed: 500 rpm or more (b) Park/neutral position switch: ON (P or N position) P1765 Trouble Area
Open or short in shift solenoid valve SLN circuit
Shift solenoid valve SLN
ECM Reference Waveform between terminals SLN+ and SLN– when engine is idling. Waveform between terminals SLN+ and SLN– when during shift change. 5 V/div. 5 V/div. GND GND 1 msec./div. 1 msec./div. D00062 Author: Date: 711 DI–477 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) WIRING DIAGRAM ECM W–L 1 E3 R *2 *1 20 3 SLN+ E11 E10 Shift Solenoid Valve SLN L 4 E3 B–Y *2 *1 19 2 SLN– E11 E9 *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC D01095 INSPECTION PROCEDURE 1 Check shift solenoid valve SLN. 2 2 1 PREPARATION: Disconnect the shift solenoid valve SLN connector. CHECK: (a) Measure resistance between terminals 1 and 2 of solenoid connector. (b) Connect positive
lead with an 8 ∼10 W bulb to terminal 1 of solenoid connector and negative  lead to terminal 2, then check the movement of the valve. OK: (a) Resistance: 5.1 ∼ 5.5 Ω (b) 1 When battery positive voltage is applied. Valve move in direction in illustration. (on the left) When battery positive voltage is cut off. Valve move in direction in illustration. (on the right) D00050 Author: Date: 712 DI–478 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) Reference PREPARATION: Connect positive
lead of the variable power supply to terminal 1 of solenoid connector and negative  lead to terminal 2. CHECK: (a) Check the movement of the valve when the voltage is gradually increased. (A current greater than 1A should not be supplied.) (b) Check the movement of the valve when the voltage is cut off. OK: (a) As the voltage is increased, the valve should move direction. slowly in the direction. (b) The valve should return in the (+) 1 2 (–) D00051 NG Replace the shift solenoid valve SLN. OK 2 Check harness and connector between battery and shift solenoid valve SLN, shift solenoid valve SLN and ECM (See page IN–31). NG Repair or replace the harness or connector. OK Check and replace the ECM. Author: Date: 713 DI–479 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI1KC–01 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. DTC No. P1780 DTC Detection Condition When driving under conditions (a) and (b) for 30 seconds or more, the park/neutral position switch is ON (N position). (2 trip detection logic) (a) Vehicle speed: 70 km/h (44 mph) or more (b) Engine speed: 1,500 ∼ 2,500 rpm Trouble Area
Short in park/neutral position switch circuit
Park/neutral position switch
ECM Author: Date: 714 DI–480 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) WIRING DIAGRAM Except California, w/ Engine Immobilizer and / or TRAC: Instrument Panel J/B Combination Meter R 8 C8 2 11 C8 O 13 IJ1 L 6 C8 Y 16 IG3 ECM 5 1V 10 1H R–B L–W E 10 2 E7 E J/C J29 2L R–L A L Y Park/Neutral Position Switch 4 5 LL Y E Y P1 II2 2 C P1 1 E7 Y R–B D 3 6 L–W P1 II2 L–W L–W (*1, *3) O (*2, *4) D 15 R E7 D C C J27 A J28 J27 J/C J29 8 RL P1 J/C J24 3 R–B II3 R–B A 6 P1 R–L B+ J/C 5 P1 GR R–B B–W B–W B J/C J26 B B–W 11 II2 J/C J28 2 II2 R–L F J28 B F J28 14 NSW E10 J/C J29 B B B–W 10 II2 R–L 1 1B B–R AM1 1 2 W GR (*4) B–O (*5) B–R B–R 1 F9 2 1K F9 2 5 1B 5 1K 1 F4 4 2L F6 1 B–G FL Main 1 2A Battery B J7 C J8 GR (*4) B–O (*5) 4 1K R Starter 3 1J Engine Room J/B No.2 3 2B B B Fusible Link Block 1 1J B–W 7 AM2 ST2 8 I16 I16 AM2 GAUGE W–R W–R ALT Ignition Switch 2 4 1 I16 I16 B–Y 1K AM1 IG1 MAIN 1 5 5 B–R 2D Starter 2 9 2K 2 ST Relay 11 2J 3 1 J/C J11 A W–B J/C Left Kick IG Panel *1: w/ Engine Immobilizer System *2: w/o Engine Immobilizer System *3: TMC Made Ex. USA w/ TRAC *4: TMMK Made, TMC Made USA w/ TRAC D01897 Author: Date: 715 DI–481 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) California, w/ Engine Immobilizer and / or TRAC: Combination Meter R 8 C8 2 11 C8 O 13 IJ1 L 6 C8 Y 16 IG3 10 1H R–B ECM 5 1V Y L–W Park/Neutral Position Switch 4 5 Y LL Y E P1 II2 3 2 E8 E E J/C J29 2 C P1 2L 3 L–W P1 R–L 6 II2 L–W D 3 R–B II3 8 RL P1 J/C J24 D C J27 R–B A 6 P1 11 B B–W II2 5 B–W B P1 R–L 2 II2 R–L C J27 R–B A J28 B+ J/C B–W B B–W B 20 NSW E8 B J/C J29 J/C J26 GR L–W (*1, *3) O (*2, *4) 2 R E8 R–B D J/C J29 A 12 L E8 Y F J28 J/C J28 F J28 10 II2 R–L B–R AM1 1 2 2 1K B–R F9 2 5 1B Ignition Switch 2 4 I16 I16 AM1 IG1 ALT F6 1 Fusible Link Block Battery AM2 C J8 MAIN 1 F J7 GR (*4) B–O (*5) 4 1K R 3 1J Starter Engine Room J/B No.2 3 2B B 1 1J B–W 1 2A B GAUGE Instrument Panel J/B 7 AM2 ST2 8 I16 I16 4 2L 1 B–Y 1K 5 W–R 1K W–R 1 F4 B–G FL Main Instrument Panel J/B W GR (*4) B–O (*5) B–R 1 F9 1 1B 11 2J 5 3 5 B–R 2D Starter 2 9 2K 2 ST Relay 1 J/C J11 A W–B J/C *1: w/ Engine Immobilizer System *2: w/o Engine Immobilizer System *3: TMC Made Ex. USA w/ TRAC *4: TMMK Made, TMC Made USA w/ TRAC Left Kick Panel IG D01898 Author: Date: 716 DI–482 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE 1 Read PNP, REVERSE, 2ND and LOW signals. When using TOYOTA hand–held tester. PREPARATION: (a) Remove the DLC3 cover. (b) Connect a TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. CHECK: Shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2ND and LOW signals on the TOYOTA hand–held tester. OK: ON Except California, w/ Engine Immobilizer and / or TRAC: NSW L 2 L NSW BE3840 D00052 D00836 D01914 Signal 2 2ND OFF → ON L LOW OFF → ON R REVERSE OFF → ON P, N NSW OFF → ON When not using TOYOTA hand–held tester. PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminals NSW, 2, L and R of ECM and body ground when the shift lever is shifted to the following positions. OK: R California, w/ Engine Immobilizer and / or TRAC: R 2 Shift position Position NSW–Body ground R–Body ground 2–Body ground L–Body ground P, N 0V 0V 0V 0V 0V 0V 0V 0V R 9 ∼ 14 V* D 9 ∼ 14 V 0V 2 9 ∼ 14 V 0V L 9 ∼ 14 V 0V 9 ∼ 14 V* 9 ∼ 14 V 0V 0V 9 ∼ 14 V HINT: *: The voltage will drop slightly due to lighting up of the back up light. Author: Date: 717 DI–483 DIAGNOSTICS OK – AUTOMATIC TRANSAXLE (A541E) Proceed to next circuit inspection shown on matrix chart (See page DI–453). NG 2 Check park/neutral position switch. PREPARATION: (a) Jack up the vehicle. (b) Remove the park/neutral position switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift Position Q07657 Terminal No. to continuity P 2–7 5–6 R 2–8 – N 2–9 5–6 D 2 – 10 – 2 2–3 – L 2–4 – OK: There is continuity. NG Replace the park/neutral position switch. OK 3 Check harness and connector between battery and park/neutral position switch, park/neutral position switch and ECM (See page IN–31). NG Repair or replace the harness and connector. OK Check and replace the ECM. Author: Date: 718 DI–484 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI02S–02 O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising overdrive may be prohibited temporarily under some condition. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. WIRING DIAGRAM ECM Cruise Control ECU B+ 14 OD C15 Y–B *2 *1 24 7 OD1 E10 E7 *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC Author: D01899 Date: 719 DI–485 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE 1 Check voltage between terminal OD1 of ECM and body ground. ON Except California, w/ Engine Immobilizer and / or TRAC: (–) PREPARATION: Turn the ignition switch ON. CHECK: Measure voltage between terminal OD1 of ECM and body ground. OK: Voltage: 10 ∼ 14 V OD1 (+) California, w/ Engine Immobilizer and / or TRAC: (–) BE3840 Q07659 D00053 D00835 (+) OD1 D01915 OK Proceed to next circuit inspection shown on matrix chart (See page DI–453). NG Author: Date: 720 DI–486 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE (A541E) Check voltage between terminal OD of cruise control ECU harness side connector and body ground. PREPARATION: (a) Disconnect the cruise control ECU connector. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. OK: Voltage: 10 ∼ 14 V ON O/D (–) (+) AB0119 N19917 I00742 OK Check and replace the cruise control ECU. NG 3 Check harness and connector between cruise control ECU and ECM. NG Repair or replace the harness or connector. OK Check and replace the ECM. Author: Date: 721 DI–487 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) DI1KD–01 O/D Main Switch & O/D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. In O/D main switch at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. WIRING DIAGRAM ECM R–L O/D Indicator Light J/C J6 7 12 G–O G–O C10 C8 C C C D J/C J4 G–O D Instrument Panel J/B 1 2 GAUGE 1D 1K R–L Instrument Panel J/B 1 2 AM1 1B 1K 1 2 2 O2 *2 *1 10 6 G–O OD2 E8 E7 11 IG3 O/D Main Switch 4 O2 B–Y W Ignition Switch 4 2 I16 I16 AM1 IG1 B–R B–R 1 F9 B+ Fusible Link Block W–B 1 F4 B–G ALT B–R 2 F9 FL Main A J/C J5 A W–B Battery IF Left Kick Panel *1: Except California, w/ Engine Immobilizer and / or TRAC *2: California, w/ Engine Immobilizer and / or TRAC D01900 Author: Date: 722 DI–488 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) INSPECTION PROCEDURE O/D OFF indicator light does not light up 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between terminals 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Resistance ON ∞ Ω (open) OFF 0 Ω (continuity) Replace the O/D main switch. OK 2 Check and replace the combination meter (See page BE–2). Replace the combination meter. NG OK 3 Check OVRDRIVE CUT SW2 signal. When using TOYOTA hand–held tester PREPARATION: (a) Connect a TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and TOYOTA hand–held tester main switch ON. CHECK: Read the OVRDRIVE CUT SW2 signal on the TOYOTA hand– held tester. OK: O/D main switch condition OVRDRIVE CUT SW2 signal Pushed in OFF Pushed out ON Author: Date: 723 DI–489 DIAGNOSTICS ON Except California, w/ Engine Immobilizer and / or TRAC: (–) – AUTOMATIC TRANSAXLE (A541E) When not using TOYOTA hand–held tester PREPARATION: Turn the ignition switch ON. CHECK: Check voltage between terminal OD2 of ECM and body ground. OK: OD2 O/D main switch Voltage OFF Below 1 V ON 10 ∼ 14 V (+) California, w/ Engine Immobilizer and / or TRAC: (–) (+) OD2 BE3840 Q07662 D00837 D01916 NG Check and replace the ECM. NG 4 Check harness and connector between O/D OFF indicator light and ECM (See page IN–31). NG Repair or replace the harness or connector. OK Check and replace the ECM. Author: Date: 724 DI–490 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A541E) O/D OFF indicator light remains on 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between terminals 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Resistance ON ∞ Ω (open) OFF 0 Ω (continuity) Replace the O/D main switch. OK 2 Check harness and connector between O/D OFF indicator light and O/D main switch, O/D OFF indicator light and ECM (See page IN–31). NG Repair or replace the harness or connector. OK Check and replace the ECM. Author: Date: 725 DI–491 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03A–02 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI–492 2 Check and Clear DTC (Precheck) P. DI–493 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN–21 7 Problem Symptoms Table P. DI–501 Symptom occurs 5 Normal code DTC Check P. DI–493 Malfunction code 6 8 DTC Chart P. DI–497 Circuit Inspection 9 Sensor Check Check for Fluid Leakage P. DI–536 P. DI–502 ∼ DI–534 Identification of Problem 10 11 Repair Confirmation Test End Step 2, 5, 8, 9, 11: Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. Author: Date: 726 DI–492 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03B–02 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. Symptoms ABS does not operate efficiently. ABS Warning Light Abnormal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check Author: Date: 727 DI–493 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03C–03 PRE–CHECK 1. (a) F00047 Short Pin DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page DI–529). (b) Check the DTC. (1) Disconnect the short pin from DLC1. DLC1 F00006 DLC2 Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (3) Turn the ignition switch ON. (4) Read the DTC from the ABS warning light on the combination meter. (2) DLC1 E1 Tc Tc S−17−1 HINT:
E1 Iei−23−1−A F00041 If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI–532 or DI–529).
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (5) Codes are explained in the code table on page DI–497. (6) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. Normal Code 2 sec. 0.25 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 Author: Date: 728 DI–494 DIAGNOSTICS TOYOTA Hand–held Tester – ANTI–LOCK BRAKE SYSTEM (DENSO Made) (c) Using TOYOTA hand–held tester, check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC2. (2) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. (d) Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1 and remove the short pin from DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 5 seconds. DLC2 H07517 BR3890 (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC2 or DLC1. SST 09843 – 18020 (6) Connect the short pin to DLC1. Short Pin DLC1 F00006 TOYOTA Hand–held Tester ECU TOYOTA Break–out–box N09348 (e) Using TOYOTA break–out–box and TOYOTA hand–held tester, measure the ECU terminal values. (1) Hook up the TOYOTA hand–held tester and TOYOTA break–out–box to the vehicle. (2) Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester/TOYOTA break– out–box operator’s manual for further details. Author: Date: 729 DI–495 DIAGNOSTICS 2. (a) DLC1 E1 – SPEED SENSOR SIGNAL Check the speed sensor signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and E1 of DLC1. SST 09843 – 18020 (3) Start the engine. Tc Ts F02201 (4) 0.13 sec. ANTI–LOCK BRAKE SYSTEM (DENSO Made) 0.13 sec. ON OFF BR3904 Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI–529). (5) Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. (6) Stop the vehicle. (7) Using SST, connect terminals Tc and E1 of DLC1. SST 09843 – 18020 (8) Read the number of blinks of the ABS warning light. HINT:
See the list of DTC shown on the next page.
If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st. Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 4 sec. 2.5 sec. 0.5 sec. Repeat BR3893 (9) After doing the check, disconnect the SST from terminals Ts and E1, Tc and E1 of DLC1, and turn ignition switch OFF. SST 09843 – 18020 Author: Date: 730 DI–496 DIAGNOSTICS TOYOTA Hand–held Tester (b) DLC2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Using TOYOTA hand–held tester, check the DTC. (1) Do step 1. ∼ 6. on the previous page. (2) Hook up the TOYOTA hand–held tester to the DLC2. (3) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. H07517 DTC of speed sensor check function: Code No. Diagnosis Trouble Area 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor 73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor 75 Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor 76 Abnormal change in output voltage of left front speed sensor
Left front speed sensor rotor 77 Abnormal change in output voltage of right rear speed sensor
Right rear speed sensor rotor 78 Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor Author: Date: 731 DI–497 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03D–03 DIAGNOSTIC TROUBLE CODE CHART HINT:


Using SST 09843 –18020, connect the terminals Tc and E1, and remove the short pin. If any abnormality is not found when inspection parts, inspect the ECU. If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item Trouble Area 11 (DI–502) Open circuit in ABS solenoid relay circuit 12 (DI–502) Short circuit in ABS solenoid relay circuit 13 (DI–507) Open circuit in ABS motor relay circuit 14 (DI–507) Short circuit in ABS motor relay circuit 21 (DI–511) Open or short circuit in 2–position solenoid circuit for right front wheel
ABS actuator
SFRR or SFRH circuit 22 (DI–511) Open or short circuit in 2–position solenoid circuit for left front wheel
ABS actuator
SFLR or SFLH circuit 23 (DI–511) Open or short circuit in 2–position solenoid circuit for right rear wheel
ABS actuator
SRRR or SRRH circuit 24 (DI–511) Open or short circuit in 2–position solenoid circuit for left rear wheel
ABS actuator
SRLR or SRLH circuit 31 (DI–514) Right front wheel speed sensor signal malfunction 32 (DI–514) Left front wheel speed sensor signal malfunction 33 (DI–514) Right rear wheel speed sensor signal malfunction
ABS solenoid relay
ABS solenoid relay circuit
ABS motor relay
ABS motor relay circuit
Right front, left front, right rear and left rear speed sensor
Each E h speed d sensor circuit i it
Speed sensor rotor 34 (DI–514) Left rear wheel speed sensor signal malfunction 33, 34 (DI–519) Rear speed sensor rotor faulty
Rear axle hub
Right rear, left rear speed sensor
Rear speed sensor circuit 41 (DI–520) Power source voltage down
Battery
Charging system
Power source circuit 49 (DI–523) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit 51 (DI–525) Pump motor is locked
ABS pump motor Malfunction in ECU
ECU
Battery Always ON (DI–527) Author: Date: 732 DI–498 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03E–03 PARTS LOCATION Sensor Rotor ABS Warning Light ABS ECU DLC 1 Front Speed Sensor ABS Actuator DLC 2 ABS Solenoid Relay ABS Motor Relay Rear Speed Sensor Front Speed Sensor Stop Light Switch Sensor Rotor F01172 Author: Date: 733 DI–499 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI1JL–02 TERMINALS OF ECU A18 A19 3 2 1 13 12 11 10 9 8 7 12 11 10 9 8 7 26 25 24 23 22 21 20 19 18 17 16 15 14 6 5 4 6 5 4 3 2 1 F07155 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG1 (A19 – 13) – GND (A19 – 12, 25) B–R ↔ W–B IG switch ON 10 – 14 R+ (A19 – 26) – SR (A18 – 7) GR–R ↔ GR IG switch ON, ABS warning light OFF 9 – 14 R+ (A19 – 26) – MR (A18 – 1) GR–R ↔ GR–L SFRR (A19 – 1) – GND (A19 – 12, 25) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFRH (A19 – 2) – GND (A19 – 12, 25) R–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLR (A18 – 6) – GND (A19 – 12, 25) W–L ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLH (A18 – 5) – GND (A19 – 12, 25) L–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRR (A18 – 12) – GND (A19 – 12, 25) R–G ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRH (A18 – 11) – GND (A19 – 12, 25) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLR (A19 – 14) – GND (A19 – 12, 25) LG–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLH (A19 – 15) – GND (A19 – 12, 25) G–Y ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 WA (A19 – 11) – GND (A19 – 12, 25) G B ↔ W–B G–B W B IG switch ON, ABS warning light ON Below 2.0 IG switch ON Below 1.0 IG switch ON, ABS warning light OFF 10 – 14 Stop light switch OFF Below 1.5 Stop light switch ON 8 – 14 IG switch ON, ABS warning light OFF 10 – 14 STP (A19 – 5) – GND (A19 – 12, 25) G W ↔ W–B G–W W B D/G (A19 – 24) – GND (A19 – 12, 25) R–L ↔ W–B Tc (A19 – 8) – GND (A19 – 12, 25) LG–R ↔ W–B IG switch ON 8 – 14 Ts (A19 – 21) – GND (A19 – 12, 25) R–Y ↔ W–B IG switch ON 8 – 14 FR+ (A18 – 3) – FR– (A18 – 9) W↔B IG switch ON, slowly turn right front wheel AC generation FL+ (A18 – 8) – FL– (A18 – 2) R↔G IG switch ON, slowly turn left front wheel AC generation RR+ (A19 – 10) – RR– (A19 – 23) W↔B IG switch ON, slowly turn right rear wheel AC generation Author: Date: 734 DI–500 DIAGNOSTICS RL+ (A19 – 22) – RL– (A19 – 9) R↔G MT (A18 – 10) – GND (A18 – 12, 25) R–W ↔ W–B – ANTI–LOCK BRAKE SYSTEM (DENSO Made) IG switch ON, slowly turn left rear wheel AC generation IG switch ON Below 1.5 Author: Date: 735 DI–501 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03G–04 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptom Suspect Area See page ABS does not operate Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS ECU. 13.Check the DTC reconfirming that the normal code is output. 14.IG power source circuit. 15.Speed sensor circuit. 16.Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page DI–536). ABS does not operate efficiently Only when 1. το 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page DI–536). ABS warning light abnormal 1. ABS warning light circuit 2. ABS ECU DI–529 DI–527 DTC check cannot be done Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit 2. Tc terminal circuit DI–529 DI–532 Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS ECU DI–534 DI–527 Author: Date: DI–493 DI–520 DI–514 BR–50 DI–493 DI–514 DI–523 BR–50 736 DI–502 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03H–03 CIRCUIT INSPECTION DTC 11, 12 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition 11 Condition 1. or 2. continues for 0.2 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and when the solenoid relay is ON.*1 2. With solenoid relay ON driving, when IG1 terminal of ABS ECU is less than 9.5 V.*1 12 Immediately after IG switch has been turned ON, when the solenoid relay is OFF.*2 Trouble Area
ABS solenoid relay
ABS solenoid relay circuit
ECU *1 Solenoid relay contact OFF condition: All of solenoid terminal voltage is half of IG1 terminal voltage or less than. *2 Solenoid relay contact ON condition: All of solenoid terminal voltage is half of IG 1 terminal voltage or more. Fail safe function: If trouble occurs in the ABS solenoid relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. Author: Date: 737 DI–503 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) WIRING DIAGRAM 1 IK1 GR–R ABS Solenoid Relay 3 6 4 ABS ECU 26 A19 R+ GR–R Engine Room R/B No.3 GR 3 7 A18 SR DLC1 ABS Actuator 5 3 3 1 3 2 3 ABS 1 2 3 W–L B–G Fusible Link Block 1 F4 1 F5 ALT B–G FL Main W–B 4 A4 1 A5 R–B 11 IK2 R–B 2 A19 SFRH 5 A5 W–R 12 IK2 W–R 1 A19 SFRR 3 A5 L–B 5 A18 SFLH 7 A5 W–L 6 A18 SFLR 4 A5 W–R 11 A18 SRRH 8 A5 R–G 12 A18 SRRR 2 A5 G–Y 13 IK2 G–Y 15 A19 SRLH 6 A5 LG–B 5 IK2 LG–B 14 A19 SRLR Battery EA F07147 Author: Date: 738 DI–504 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS solenoid relay). (+) PREPARATION: Remove ABS solenoid relay from Engine Room R/B No. 3. CHECK: Measure the voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS solenoid relay). OK: Voltage: 10 – 14 V (–) Engine Room R/B No. 3 123 45 6 F00048 NG Check and repair harness or connector. OK 2 Check continuity between terminal 3 of ABS solenoid relay and terminal SRLR, SRLH, SRRR, SRRH, SFLR, SFLH, SFRR or SFRH of ABS ECU. ABS Solenoid Relay 3 A4 4 A5 ABS Actuator CHECK: Check continuity between terminal 3 of Engine Room R/B No.3 (for ABS solenoid relay) and terminal SRLR, SRLH, SRRR, SRRH, SFLR, SRLH, SFRR or SFRH of ABS ECU. OK: Continuity HINT: Resistance of each solenoid coil SRLR, SRRR, SFLR, SFRR: 4.3 Ω SRLH, SRRH, SFLH, SFRH: 8.8 Ω 1234 5678 4321 8765 A18 ECU SFRH SFRR SFLH SFLR SRLR SRLH SRRH SRRR F07153 NG Repair or replace harness or ABS actuator. OK Author: Date: 739 DI–505 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check ABS solenoid relay. 3 2 6 CHECK: Check continuity between each terminal of ABS solenoid relay. OK: 1 5 4 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Open 3 2 1 CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: Continuity Continuity 6 5 4 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Continuity 3 2 1 Open (–) (+) 6 5 4 F00042 NG Replace ABS solenoid relay. OK Author: Date: 740 DI–506 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check for open and short circuit in harness and connector between ABS solenoid relay and ABS ECU (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 741 DI–507 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03I–03 DTC 13, 14 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor. DTC No. DTC Detecting Condition 13 Condition 1. or 2. continues for 0.2 sec. or more: 1. ABS ECU terminal IG1 voltage is 9.5 V to 18.5 V, and when motor relay is ON in the midst of initial check or in operation of ABS control.*1 2. Motor relay is ON driving in the midst of initial check or in operation of ABS control, ABS ECU terminal IG1 voltage becomes 9.5 V or less.*2 14 Condition below continues for 4 sec. or more: When the motor relay is OFF, there is open circuit in MT terminal of ABS ECU. Trouble Area
ABS motor relay
ABS motor relay circuit
ECU *1 Relay contact OFF condition: MT terminal voltage is below 3.6 V. *2 Relay contact ON condition: MT terminal voltage is 3.6 V or above. Fail safe function: If trouble occurs in the ABS motor relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. Author: Date: 742 DI–508 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) WIRING DIAGRAM ABS ECU ABS Motor Relay B–G F5 1 ABS 3 3 1 3 2 4 3 GR–R 1 IK1 GR–R GR–L 3 26 A19 R+ 1 A18 MR Fusible Link Block ALT Engine Room R/B No.3 F4 1 ABS Actuator 3 A4 B–G R–W 10 A18 MT 2 A4 W–R FL Main 1 A4 W–B Battery EA F07146 Author: Date: 743 DI–509 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check voltage between terminal 1 of Engine Room R/B No. 3 (for ABS motor relay) and body ground. (–) PREPARATION: Remove ABS motor relay from Engine Room R/B No. 3. CHECK: Measure voltage between terminal 1 of Engine Room R/B No. 3 (for ABS motor relay) and body ground. OK: Voltage: 10 – 14 V (+) 1 Engine Room R/B No. 3 2 3 4 F00049 NG Check and repair harness or connector. OK 2 Check continuity between terminal 2 of ABS motor relay and terminal MT of ABS ECU. 2 ABS Motor Relay 2 A4 2 CHECK: Check continuity between terminal 2 of Engine Room R/B No.3 (for ABS motor relay) and terminal MT of ABS ECU. OK: Continuity HINT: There is a resistance of 4 ∼ 6 Ω between terminals A4 – 2 and A4 – 3 of ABS actuator. A4 ABS Actuator 3 3 A18 ECU MT F07154 NG Repair or replace harness or ABS actuator. OK Author: Date: 744 DI–510 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check ABS motor relay. 2 1 4 3 CHECK: Check continuity between each terminal of ABS motor relay. OK: Terminals 3 and 4 Continuity (Reference value 62 Ω) Terminals 1 and 2 Open Open 2 Continuity 1 4 CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals of ABS motor relay. 3 Continuity 2 OK: 1 Terminals 1 and 2 (–) 4 Continuity 3 (+) F00044 NG Replace ABS motor relay. OK 4 Check for open and short circuit in harness and connector between ABS motor relay and ABS ECU (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 745 DI–511 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03J–03 DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area 21 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SFRR or SFRH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SFRR or SFRH circuit 22 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SFLR or SFLH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SFLR or SFLH circuit 23 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SRRR or SRRH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SRRR or SRRH circuit 24 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SRLR or SRLH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SRLR or SRLH circuit *1 Solenoid relay contact ON condition: All of solenoid terminal voltage is half of IG1 terminal voltage or less than. Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. Author: Date: 746 DI–512 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) WIRING DIAGRAM 1 IK1 GR–R ABS Solenoid Relay 3 6 4 ABS ECU 26 A19 R+ GR–R Engine Room R/B No.3 GR 3 7 A18 SR DLC1 ABS Actuator 5 3 3 1 3 2 3 ABS 1 2 3 W–L B–G Fusible Link Block 1 F4 1 F5 ALT B–G FL Main W–B 4 A4 1 A5 R–B 11 IK2 R–B 2 A19 SFRH 5 A5 W–R 12 IK2 W–R 1 A19 SFRR 3 A5 L–B 5 A18 SFLH 7 A5 W–L 6 A18 SFLR 4 A5 W–R 11 A18 SRRH 8 A5 R–G 12 A18 SRRR 2 A5 G–Y 13 IK2 G–Y 15 A19 SRLH 6 A5 LG–B 5 IK2 LG–B 14 A19 SRLR Battery EA F07147 Author: Date: 747 DI–513 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check ABS actuator solenoid. 4 3 8 7 A4 2 1 A5 6 5 4 W00714 PREPARATION: Disconnect the 2 connectors from ABS actuator. CHECK: Check continuity between terminals A4 – 4 and A5 – 1, 2, 3, 4, 5, 6, 7, 8 of ABS actuator connector. OK: Continuity HINT: Resistance of each solenoid coil is 1.2 Ω. NG Replace ABS actuator. OK 2 Check for open and short circuit in harness and connector between ABS ECU and actuator (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 748 DI–514 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI1JM–02 DTC Speed Sensor Circuit 31, 32, 33, 34 CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 –V F00010 DTC No. DTC Detecting Condition 31, 32, 33, 34 Detection of any of conditions from 1. through 4.: 1. Vehicle speed is at 10 km/h (6 mph) or more and the speed sensor signal circuit is open or short circuit continues for 15 sec. or more. 2. Momentary interruption of the speed sensor signal occurs 7 times or more. 3. Vehicle speed is at 20 km/h (12mph) or more and interference on the speed sensor signal continues for 5 sec. or more. 4. Open circuit condition of the speed sensor signal circuit continues for 0.5 sec. or more. Trouble Area
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Speed sensor rotor HINT:



DTC DTC DTC DTC No. No. No. No. 31 is for the right front speed sensor. 32 is for the left front speed sensor. 33 is for the right rear speed sensor. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. Author: Date: 749 DI–515 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) WIRING DIAGRAM ABS ECU W 3 A18 FR+ B 9 A18 FR– 2 Right Front Speed Sensor 1 R 1 IK2 R 8 A18 FL+ G 6 IK2 G 2 A18 FL– W 2 IL1 W 10 A19 RR+ B 1 IL1 B 23 A19 RR– R 3 ID1 R 22 A19 RL+ G 9 ID1 G 9 A19 RL– 2 Left Front Speed Sensor 1 1 Right Rear Speed Sensor 2 1 Left Rear Speed Sensor 2 F00116 Author: Date: 750 DI–516 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check speed sensor. 1 2 R14205 1 2 R14213 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 – 2.5 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 1.2 – 2.3 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–493). OK Author: Date: 751 DI–517 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check for open and short circuit in harness and connector between each speed sensor and ECU (See page IN–31). NG Repair or replace harness or connector. OK 3 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. OK NG BR3795 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–493). OK 4 Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the ABS ECU. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ABS ECU. CHECK: Drive the vehicle with about 30 km/h (19 mph), and check the signal waveform. W04200 OK Check and replace ABS ECU. NG Author: Date: 752 DI–518 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check sensor rotor and sensor tip. R00948 R00947 Front: PREPARATION: Remove the front drive shaft (See page SA–17 or SA–26). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR–68). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. Rear: PREPARATION: Remove the axle hub (See page SA–52). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See page BR–71). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI–493). OK Check and replace ABS ECU. Author: Date: 753 DI–519 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03L–03 DTC 33, 34 Rear Speed Sensor Rotor Faulty CIRCUIT DESCRIPTION DTC No. 33, 34 DTC Detecting Condition Trouble Area The condition that the both rear side wheels’ speed is lower than the front wheels’ speed at 20 km/h (12 mph) or more for 20 sec. or more when the IG switch turns ON and OFF , which is repeated in a sequence more than 8 times.
Rear axle hub
Right rear, left rear speed sensor
Rear speed sensor circuit INSPECTION PROCEDURE 1 Check rear axle hub (See page SA–9). NG Replace rear axle hub. OK 2 Check rear speed sensor (See page DI–514). NG Replace rear speed sensor. OK 3 Check for open and short circuit in harness and connector between rear speed sensor and ECU (See page IN–31). NG Repair or replace harness and connector. OK Check and replace ABS ECU. Author: Date: 754 DI–520 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03M–03 DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition 41 Condition 1. or 2. is detected: 1. Vehicle speed is at 3 km/h (1.9 mph) or more and ECU terminal IG1 voltage is 9.5 V or less , which continues for 10 sec. or more. 2. When IG1 terminal voltage is less than 9.5 V, there is open circuit in the motor relay or in the solenoid relay, or the solenoid circuit malfunction. Trouble Area
Battery
Charging system
Power source circuit Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM Ignition Switch B–Y 2 AM1 IG1 4 1 1K 9 1J ABS ECU J/C J12 Instrument Panel J/B B–R B–R C ECU–IG C 13 A19 IG1 W 2 1K Instrument Panel J/B 1 1B AM1 1 F4 B–G FL Block B–R 1 F9 W–B 12 A19 GND1 W–B 25 A19 GND2 ALT A FL MAIN Battery J11 Junction Connector IG Instrument Panel Brace LH F07156 Author: Date: 755 DI–521 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove ECU–IG fuse from Instrument Panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity ECU–IG Instrument Panel J/B NG Check for short circuit in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). NG Check and repair the charging system 5S–FE engine: (See page CH–1) 1MZ–FE engIne: (See page CH–1). F00073 OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK Author: Date: 756 DI–522 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check voltage between terminals IG1 and GND of ABS ECU connector. PREPARATION: Remove ABS ECU with connectors still connected. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals IG1 and GND of ABS ECU connector. OK: Voltage: 10 – 14 V ON (–) (+) IG1 GND GND F07151 OK Check and replace ABS ECU. NG 4 Check continuity between terminals GND of ABS ECU connector and body ground. LOCK F07152 GND (+) (–) GND F07216 PREPARATION: Disconnect the connector from the ABS ECU. CHECK: Measure resistance between terminal GND of ABS ECU connector and body ground. OK: Resistance: 1 Ω or less NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between ABS ECU and ECU–IG fuse (See page IN–31). Author: Date: 757 DI–523 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03N–03 DTC 49 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. 49 DTC Detecting Condition Trouble Area ABS ECU terminal IG1 voltage is 9.5 V to 18.5 V and ABS is in non–operation, the open circuit of the stop light switch circuit continues for 0.3 sec. or more.
Stop light switch
Stop light switch circuit WIRING DIAGRAM ABS ECU J/C G–W Instrument Panel J/B Stop Light 1R 5 Switch 4 2 G–W 1R 1S 2 1 W J27 A J28 C 7 1 F4 STOP FL Block 1 4 1B 1 F9 G–W G–W R Instrument Panel J/B 7 1C 5 A19 STP G–R 2 Light Failure Sensor G–R G–R 2 R11 B–R ALT B–G MAIN 2 R9 H10 2 High Right Mounted Stop Stop Light 5 R11 H10 1 5 R9 Light W–B W–B A W–B W–B J/C W–B A J40 W–B Battery Left Stop Light BL Under the BP Back Panel Left Center Center Pillar F00124 INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. NG Repair stop light circuit (See page BE–37). OK Author: Date: 758 DI–524 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check voltage between terminal STP of ABS ECU and body ground. STP (+) (–) PREPARATION: Remove ABS ECU with connectors still connected. CHECK: Measure voltage between terminal STP of ABS ECU and body ground when brake pedal is depressed. OK: Voltage: 8 – 14 V F07150 OK Check and replace ABS ECU. NG 3 Check for open circuit in harness and connector between ABS ECU and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–501). Author: Date: 759 DI–525 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI4KW–01 DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition 51 Trouble Area
ABS pump motor ABS actuator pump motor is not operating normally. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM ABS ECU ABS Motor Relay B–G F5 1 ABS 3 3 1 3 2 4 3 GR–R 1 IK1 GR–R GR–L 3 26 A19 R+ 1 A18 MR Fusible Link Block ALT Engine Room R/B No.3 F4 1 ABS Actuator 3 A4 B–G R–W 10 A18 MT 2 A4 W–R FL Main 1 A4 W–B Battery EA F07146 Author: Date: 760 DI–526 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) INSPECTION PROCEDURE 1 Check operation of ABS & TRAC pump motor. A4 1 2 (–) (+) F03291 PREPARATION: Disconnect the ABS actuator connector. CHECK: Connect positive
lead to terminal A4–2 and negative  lead to terminal A4 – 1 of the ABS actuator connector, check that the pump motor is operates. OK: The running sound of the pump motor should be heard. OK Check for open circuit in harness and connector between ABS motor relay, ABS actuator and ABS ECU (See page IN–31). NG Replace ABS actuator. Author: Date: 761 DI–527 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03P–04 DTC Always ON ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. Always ON DTC Detecting Condition ABS ECU internal malfunction is detected. Trouble Area
ECU
Battery Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI–493. YES Repair circuit indicated by the code output. YES Check ABS solenoid relay. Check for short circuit in harness and connector between ABS solenoid relay and DLC1 (See page IN–31). YES Check for open or short circuit in harness and connector between ECU–IG fuse and ABS ECU (See page IN–31). NO 2 Is normal code displayed? NO 3 Is ABS warning light go off? NO Author: Date: 762 DI–528 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check battery positive voltage. CHECK: Check the battery positive voltage. OK: 10 – 14 V NG Check and repair the charging system 5S–FE engine: (See page CH–1) 1MZ–FE engine: (See page CH–1). OK 5 Check ABS warning light. PREPARATION: (a) Disconnect the connector from the ABS ECU. (b) Turn the ignition switch ON. CHECK: Check the ABS warning light goes off. OK Check and replace ABS ECU. NG Check for short circuit in harness and connector between ABS warning light, DLC1, DLC2, and ABS ECU (See page IN–31). Author: Date: 763 DI–529 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03Q–03 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Engine Room R/B No. 3 Instrument Panel J/B 2 1D ABS Solenoid Relay 1 Battery 6 2 4 5 GAUGE R–L 3 D ABS ECU J/C J4 3 3 R–L 8 IK2 R–L D R–L 3 3 4 II3 C10 7 ABS Warning R–L Light 23 C10 4 Short DLC1 ABS ECU Pin R–L 22 12 IG3 G–B 3 W–L 4 A4 ABS Actuator W–B ABS ECU 5 II3 EA G–B G–B C C J/C J29 G–B 11 A19 WA C F07217 INSPECTION PROCEDURE Troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 1 Check ABS warning light. See combination meter troubleshooting on page BE–2. NG Repair bulb or combination meter assembly. OK Author: Date: 764 DI–530 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check ABS solenoid relay. 3 2 1 6 5 4 PREPARATION: Remove ABS solenoid relay from Engine Room R/B No. 3. CHECK: Check continuity between each terminal of ABS solenoid relay. OK: Open 3 2 1 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Continuity Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: 65 4 Continuity 3 2 1 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Open (–) 6 5 4 CHECK: Connect the
test lead to terminal 5 and the  lead to terminal 3. Check continuity between the terminals. OK: Continuity If there is no continuity, connect the  test lead to terminal 5 and the
lead to terminal 3. Recheck continuity between terminals. (+) Continuity (–) 3 2 1 (+) 65 4 F00043 NG Replace ABS solenoid relay. OK Check for open circuit in harness and connector between DLC1, ABS solenoid relay and body ground (See page IN–31). Author: Date: 765 DI–531 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Is DTC output? Check DTC on page DI–493. YES Repair circuit indicated by the code output. NO 4 Does ABS warning light go off if short pin is removed? NO Check for short circuit in harness and connector between ABS warning light, DLC1 and ABS ECU (See page IN–31). YES 5 Check ABS solenoid relay (See step 2). NG Replace ABS solenoid relay. OK Check for short circuit in harness and connector between DLC1 and ABS solenoid relay (See page IN–31). Author: Date: 766 DI–532 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03R–03 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM 6 II3 BR DLC1 A J/C BR A A BR B J/C C J8 J7 BR 3 E1 Tc J/C J3 DLC2 BR 3 LG–R 11 E1 11 II3 LG–R Tc B 4 ABS ECU LG–R 8 A19 Tc B B LG–R J22: (1MZ–FE) J23: (5S–FE) EC F00113 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC1. DLC2 CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Tc and E1 of DLC2 or DLC1. OK: Voltage: 10 – 14 V DLC1 E1 Tc E1 Tc F02607 F00445 F02612 OK If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. NG Author: Date: 767 DI–533 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check for open and short circuit in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS ECU. Author: Date: 768 DI–534 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03S–03 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM ABS ECU DLC1 BR 3 E1 Ts R–Y 16 8 II3 R–Y 8 A19 Ts A J22: (1MZ–FE) J23: (5S–FE) J/C BR A EC F00172 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 – 14 V ON E1 Ts AB0119 S08096 DLC1 F00446 OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. NG Author: Date: 769 DI–535 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (DENSO Made) Check for open and short circuit in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS ECU. Author: Date: 770 DI–536 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (DENSO Made) DI03T–03 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F00071 Author: Date: 771 DI–537 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) ANTI–LOCK BRAKE SYSTEM (BOSCH Made) HOW TO PROCEED WITH TROUBLESHOOTING DI051–04 Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI–538 2 Check and Clear DTC (Precheck) P. DI–539 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN–21 7 Problem Symptoms Table P. DI–545 Symptom occurs 5 Normal code DTC Check P. DI–539 Malfunction code 6 8 DTC Chart P. DI–542 Circuit Inspection 9 Sensor Check Check for Fluid Leakage P. DI–571 P. DI–546 ∼ DI–569 Identification of Problem 10 11 Repair Confirmation Test Step 2, 5, 9, 11: End Diagnostic steps permitting the use of the TOYOTA hand–held tester. Author: Date: 772 DI–538 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI03U–04 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. Symptoms ABS does not operate intermittently. ABS Warning Light Abnormal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check Author: Date: 773 DI–539 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI03V–04 PRE–CHECK 1. (a) F00047 DLC2 Tc Tc S−17−1 Check the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Read the DTC from the ABS warning light on the combination meter. HINT: E1 Iei−23−1−A HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page DI–565). (b) DLC1 E1 DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the ABS warning light goes on for 2 seconds. F00041 Normal Code 0.25 sec. 0.5 sec. 0.25 sec. ON OFF
If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI–567 or DI–565).
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page DI–542. (5) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 F00103 TOYOTA Hand–held Tester (c) Using TOYOTA hand–held tester, check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC2. (2) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. DLC2 H07517 Author: Date: 774 DI–540 DIAGNOSTICS (d) BR3890 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 3 seconds. (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC2 or DLC1. SST 09843 – 18020 HINT: Cancellation cannot be done by removing the battery cable or ECU–B fuse. 2. (a) DLC1 E1 Ts 0.13 sec. Tc SPEED SENSOR SIGNAL Check the speed sensor signal. (1) When the ignition switch is turned ON, check that the ABS warning light goes on for 2 seconds. (2) Turn the ignition switch OFF. (3) Using SST, connect terminals Ts and E1 of DLC1. SST 09843 – 18020 (4) Start the engine. F02201 0.12 sec. ON OFF BR3904 (5) Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI–565). (6) Drive vehicle straight forward. HINT: Drive vehicle at 45 – 55 km/h (28 – 34 mph) for several seconds. If the brake is applied during the check, the check routine must be started again. (7) Stop the vehicle. (8) Turn the ignition switch OFF. (9) Disconnect the SST from terminals Ts and E1 and, connect the SST to terminals Tc and E1 of DLC1. SST 09843 – 18020 (10) Turn the ignition switch ON. (11) Read the number of blinks of the ABS warning light. Author: Date: 775 DI–541 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) HINT:


See the list of DTC shown at the bottom of this page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st. Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 4 sec. 2.5 sec. 0.5 sec. Repeat BR3893 (12) After doing the check, disconnect the SST from terminals Tc and E1 of DLC1, and turn ignition switch OFF. SST 09843 – 18020 TOYOTA Hand–held Tester (b) DLC2 Using TOYOTA hand–held tester, check the DTC. (1) Do step 1. ∼ 6. on the previous page. (2) Hook up the TOYOTA hand–held tester to the DLC2. (3) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. H07517 DTC of speed sensor check function: Code No. Diagnosis Trouble Area 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor 73 Low output voltage of right rear speed sensor Right rear speed sensor Sensor installation Right rear speed sensor rotor 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor 75 Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor 76 Abnormal change in output voltage of left front speed sensor
Left front speed sensor rotor 77 Abnormal change in output voltage of right rear speed sensor
Right rear speed sensor rotor 78 Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor Author: Date: 776 DI–542 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI03W–11 DIAGNOSTIC TROUBLE CODE CHART HINT:

Using SST 09843 –18020, connect the terminals Tc and E1. If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item Trouble Area ABS solenoid valve relay faulty
ABS solenoid valve relay
Valve supply voltage
ECU 13 (DI–548) ABS pump motor faulty
ABS motor relay
Pump motor voltage
Pump motor lead disconnected
ECU 21 (DI–550) Right front solenoid valves faulty
ABS actuator (right front inlet or outlet solenoid valve) 22 (DI–550) Left front solenoid valves faulty
ABS actuator (left front inlet or outlet solenoid valve) 23 (DI–550) Right rear solenoid valves faulty
ABS actuator (right rear inlet or outlet solenoid valve) 24 (DI–550) Left rear solenoid valves faulty
ABS actuator (left rear inlet or outlet solenoid valve) 31 (DI–552) Right front wheel speed sensor signal malfunction 32 (DI–552) Left front wheel speed sensor signal malfunction 33 (DI–552) Right rear wheel speed sensor signal malfunction 11 (DI–546) 34 (DI–552)
Right front, left front, right rear and left rear speed sensor
Each speed s eed sensor circuit
Sensor installation
ECU Left rear wheel speed sensor signal malfunction 35 (DI–552) Open circuit in right front wheel speed sensor circuit 36 (DI–552) Open circuit in left front wheel speed sensor circuit 37 (DI–557) Speed sensor rotor is wrong number of teeth on one of the 4 wheels 38 (DI–552) Open circuit in right rear wheel speed sensor circuit 39 (DI–552) Open circuit in left rear wheel speed sensor circuit
Right front, left front speed sensor
Each E h speed d sensor circuit i it
ECU
Speed sensor
Sensor rotor
ECU
Right rear, left rear speed sensor
Each E h speed d sensor circuit i it
ECU 41 (DI–558) Low battery positive voltage
Battery
Charging system regulator
Power source circuit
ECU 58 (DI–561) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit
ECU 62 (DI–563) Malfunction in ECU
ECU Author: Date: 777 DI–543 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI03X–05 PARTS LOCATION Sensor Rotor ABS Warning Light Front Speed Sensor ABS Actuator (w/ ECU, Relay) DLC1 Rear Speed Sensor DLC2 Sensor Rotor Stop Light Switch Front Speed Sensor F01175 Author: Date: 778 DI–544 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI1JN–03 TERMINALS OF ECU A6 1 2 4 3 5 6 7 8 20 16 17 10 9 21 12 11 22 23 13 24 14 25 15 26 19 18 F00050 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) +B (A6 – 17, 18) – GND (A6 – 16, 19) L ↔ W–B IG1 (A6 – 15) – GND (A6 – 16, 19) B–R ↔ W–B WA (A6 – 21) – GND (A6 – 16, 26) R L ↔ W–B R–L W B STP (A6 – 14) – GND (A6 – 16, 19) G W ↔ W–B G–W W B Tc (A6 – 12) – GND (A6 – 16, 19) LG–R ↔ W–B IG switch ON 5.7 – 8.1 Ts (A6 – 11) – GND (A6 – 16, 19) R–Y ↔ W–B IG switch ON 5.7 – 8.1 FR+ (A6 – 5) – FR– (A6 – 4) W↔B IG switch ON, slowly turn right front wheel AC generation FL+ (A6 – 7) – FL– (A6 – 6) R↔G IG switch ON, slowly turn left front wheel AC generation RR+ (A6 – 3) – RR– (A6 – 1) P↔L IG switch ON, slowly turn right rear wheel AC generation RL+ (A6 – 9) RL– (A6 – 8) Y ↔ BR IG switch ON, slowly turn left rear wheel AC generation Always 10 – 14 IG switch ON 10 – 14 IG switch ON, ABS warning light ON Below 2.6 IG switch ON, ABS warning light OFF 10 – 14 Stop light switch OFF Below 1.5 Stop light switch ON 5 – 14 Author: Date: 779 DI–545 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI03Z–10 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptom ABS does not operate ABS does not operate intermittently Suspect Area See page Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Power source circuit 3. Speed sensor circuit 4. Check the hydraulic circuit for leakage. Only when 1. το 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the hydraulic circuit for leakage. DI–539 DI–558 DI–552 DI–571 DI–539 DI–552 DI–561 DI–571 ABS warning light abnormal 1. ABS warning light circuit 2. ABS ECU DI–565 DI–563 DTC check cannot be done Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit 2. Tc terminal circuit DI–565 DI–567 Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS ECU DI–569 DI–563 Author: Date: 780 DI–546 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI040–08 CIRCUIT INSPECTION DTC 11 ABS Solenoid Valve Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition Detection of any conditions from 1. through 3.: 1. 3 or more solenoid valves are shown faulty in response and simultaneously valve supply voltage is detected faulty. 2. Solenoid valve relay will not be switched OFF. 3. Valve relay is frozen in spite of its high valve relay supply voltage. 11 Trouble Area
ABS solenoid valve relay
Valve supply voltage
ECU Fail safe function: If trouble occurs in the ABS solenoid valve relay circuit, the ECU cuts off current to the ABS solenoid valve relay and prohibits ABS control. WIRING DIAGRAM L L 3 ABS 18 A6 +B 2 1 A6 17 +B Actuator Assembly Engine Room R/B No.3 3 B–G 1 F5 Valve Relay ECU ALT 1 F4 B–G FL Block GND1 19 A6 W–B Motor Relay MAIN W–B Battery EA GND2 16 A6 W–B F03949 Author: Date: 781 DI–547 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) INSPECTION PROCEDURE 1 Check voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator connector. PREPARATION: Disconnect the ABS actuator connector. CHECK: Measure the voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator harness side connector. OK: Voltage: 10 – 14 V LOCK A6 (–) 17 19 18 16 (+) F00064 NG Check and replace fuses. Check and repair harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 782 DI–548 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI041–08 DTC 13 Pump Motor Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor. DTC No. DTC Detecting Condition 13 Detection of any conditions from (1) through (3): 1. After actuation of the motor relay, pump motor voltage will not be supplied within 0.4 sec. 2. Pump motor voltage is at a high level, motor relay will not actuate for 2.5 sec. or more. 3. Pump motor voltage keeps low level for longer than 0.4 sec. and the pump repeats activating for 7 sec. 3 times maximally. since the last activation, the pump motor has been gone dead because of short circuit. Trouble Area
ABS motor relay
Pump motor voltage
Pump motor lead disconnected
ECU Fail safe function: If trouble occurs in the ABS motor relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM L L 3 ABS 18 A6 +B 2 1 A6 17 +B Actuator Assembly Engine Room R/B No.3 3 B–G 1 F5 Valve Relay ECU ALT 1 F4 B–G FL Block GND1 19 A6 W–B Motor Relay MAIN W–B Battery EA GND2 16 A6 W–B F03949 Author: Date: 783 DI–549 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) INSPECTION PROCEDURE 1 Check voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator connector. PREPARATION: Disconnect the ABS actuator connector. CHECK: Measure the voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator harness side connector. OK: Voltage: 10 – 14 V LOCK A6 (–) 19 18 17 16 (+) F00064 NG Check and replace fuses. Check and repair harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 784 DI–550 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI042–08 DTC 21, 22, 23, 24 ABS Solenoid Valve Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition 21, 22, 23, 24 Solenoid valve signal does not match to the check result. Trouble Area
Each solenoid valve Fail safe function: If trouble occurs in the actuator solenoid valve circuit, the ECU cuts off current to the ABS solenoid valve relay and prohibits ABS control. WIRING DIAGRAM L L 3 ABS 18 A6 +B 2 1 A6 17 +B Actuator Assembly Engine Room R/B No.3 3 B–G 1 F5 Valve Relay ECU ALT 1 F4 B–G FL Block GND1 19 A6 W–B Motor Relay MAIN W–B Battery EA GND2 16 A6 W–B F03949 Author: Date: 785 DI–551 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) INSPECTION PROCEDURE 1 Check the DTC once more. PREPARATION: (a) Clear the DTC (See page DI–539). (b) Turn the ignition switch OFF. CHECK: Turn the ignition switch ON, and check if the same DTC is stored in the memory. NO No problem. YES Replace ABS ECU. Author: Date: 786 DI–552 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI043–04 DTC 31, 32, 33, 34, 35, 36, 38, 39 Speed Sensor Circuit CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 –V F00010 DTC No. DTC Detecting Condition Trouble Area 31, 32, 33, 34 Detection of any of conditions from 1. through 3.: 1. Vehicle speed is more than 40 km/h (25 mph), pulses are not input for 0.01 sec. 2. After the initial start or restart and when the vehicle speed has reached 12 km/h (7 mph), the wheel with 0 km/h (0 mph) of wheel speed is detected. 3. After the initial start or restart and when the vehicle speed has reached 70 km/h (44 mph), front wheel with 0 km/h (0 mph) of wheel speed is detected.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Sensor installation
ECU 35, 36, 38, 39 Detecting abnormality in the resistance value of each speed sensor.
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
ECU HINT:



DTC No. 31 and 35 are for the right front speed sensor. DTC No. 32 and 36 are for the left front speed sensor. DTC No. 33 and 38 are for the right rear speed sensor. DTC No. 34 and 39 are for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid valve relay and prohibits ABS control. Author: Date: 787 DI–553 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) WIRING DIAGRAM ECU W 5 A6 FR+ B 4 A6 FR– 2 Right Front Speed Sensor 1 R 1 IK2 R 7 A6 FL+ G 6 IK2 G 6 A6 FL– P 2 IL1 P L 1 IL1 L Y 3 ID1 Y BR 9 ID1 BR 2 Left Front Speed Sensor 1 1 Right Rear Speed Sensor 2 1 Left Rear Speed Sensor 2 2 IK3 P 3 A6 RR+ L 1 A6 RR– 3 IK3 Y 9 A6 RL+ 9 IK3 BR 8 A6 RL– 6 IK3 F00086 Author: Date: 788 DI–554 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) INSPECTION PROCEDURE 1 Check speed sensor. 1 2 R14205 1 2 R14213 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 – 2.5 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 1.2 – 2.3 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–539). OK Author: Date: 789 DI–555 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check for open and short circuit in harness and connector between each speed sensor and ECU (See page IN–31). NG Repair or replace harness or connector. OK 3 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. OK NG BR3795 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–539). OK 4 Check sensor rotor and sensor tip. R00948 Front: PREPARATION: Remove the front drive shaft (See page SA–17 or SA–26). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR–68). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. Author: Date: 790 DI–556 DIAGNOSTICS R00947 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Rear: PREPARATION: Remove the axle hub (See page SA–52). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See page BR–70). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI–539). OK Check and replace ABS ECU. Author: Date: 791 DI–557 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI044–04 DTC 37 Speed Sensor Rotor Faulty CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 37 Detection of any of conditions from 1. through 3.: 1. Occurrence of differential to some degree in the wheel speed between the front and rear wheels of either left or right side of the vehicle and the front left and right wheels. (Detection of differential in mini tire size, spinning wheel and decelerating wheel.) 2. Continuous ABS control for 60 sec. or more. 3. Interference on 1 or more wheels for 20 sec. with the brake pedal depressed, or for 5 sec. when the brake pedal is not depressed.
Speed sensor
Sensor rotor
ECU INSPECTION PROCEDURE 1 Check sensor rotor (See page DI–552). NG Replace sensor rotor. OK 2 Check speed sensor (See page DI–552). NG Replace speed sensor. OK 3 Check for open and short circuit in harness and connector between speed sensor and ECU (See page IN–31). NG Repair or replace harness and connector. OK Check and replace ABS ECU. Author: Date: 792 DI–558 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI045–08 DTC 41 Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition 41 Vehicle speed at about 6 km/h (4 mph), low battery voltage is less than 9.4 V at the time of non–operation of ABS control or less than 8.8 V at the time of operation of ABS control, and high battery voltage is more than 17.4 V. Trouble Area
Battery
Charging system
Power source circuit
ECU Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid valve relay and prohibits ABS control. WIRING DIAGRAM L B–R L 3 ABS 18 A6 +B 2 1 17 A6 +B IG1 A6 15 5 IK3 J/C B–R B–R C C J12 Actuator Assembly 1J 9 Engine Room R/B No.3 ECU–IG 3 B–G 1 F5 Instrument Panel J/B Valve Relay ECU ALT 1 F4 B–G FL Block GND1 Motor Relay 19 A6 W–B MAIN W–B Battery EA GND2 16 A6 W–B F03950 Author: Date: 793 DI–559 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove ECU–IG fuse from Instrument Panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity ECU–IG Instrument Panel J/B F00073 NG Check for short circuit in all the harness and components connected to ECU–IG fuse (See the attached wiring diagram.) NG Check and repair the charging system 5S–FE engine: (See page CH–1) 1MZ–FE engine: (See page CH–1). OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK Author: Date: 794 DI–560 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check voltage between terminals IG1 and GND of ABS actuator connector. PREPARATION: Disconnect ABS actuator connector. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals IG1 and GND of ABS actuator harness side connector. OK: Voltage: 10 – 14 V ON IG1 GND (+) (–) F00067 OK Check and replace ABS ECU. NG 4 Check continuity between terminals GND of ABS actuator connector and body ground. CHECK: Measure resistance between terminal GND of ABS actuator harness side connector and body ground. OK: Resistance: 1 Ω or less LOCK (–) (+) GND F00068 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between ABS ECU and ECU–IG (See page IN–31). Author: Date: 795 DI–561 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI046–09 DTC 58 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area
Stop light switch
Stop light switch circuit
ECU Stop light switch circuit is open, and stop light switch voltage is in the level between 65 % or more and less than 93 % of the battery voltage. 49 WIRING DIAGRAM ECU J/C G–W Instrument Panel J/B 5 1R Stop Light Switch 4 G–W 1R 2 1 W J28 C J27 A 2 1S 1 G–W IK3 G–W STP G–W 7 R Instrument Panel J/B 7 1C STOP 14 A6 Light Failure Sensor 1 4 1B G–R 2 G–R G–R 1 F4 FL Block ALT 1 F9 B–R B–G High H10 2 Mounted Stop H10 1 Light W–B A J/C J40 MAIN Battery A 2 2 Right R11 Left R9 Stop Stop Light R11 5 Light R9 5 W–B W–B W–B W–B W–B BL BP F00125 INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. NG Repair stop light circuit (See page BE–36). OK Author: Date: 796 DI–562 DIAGNOSTICS 2 (–) – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check voltage between terminal STP of ABS actuator and body ground. PREPARATION: Disconnect ABS actuator connector. CHECK: Measure voltage between terminal STP of ABS actuator harness side connector and body ground when brake pedal is depressed. OK: Voltage: 8 – 14 V (+) STP F00069 OK Check and replace ABS ECU. NG 3 Check for open circuit in harness and connector between ABS ECU and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–545). Author: Date: 797 DI–563 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI047–06 DTC 62 ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. 62 DTC Detecting Condition Trouble Area ABS ECU continuously detects the proper operation of ABS.
Battery
ECU Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid valve relay and prohibits ABS control. INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI–539. YES Repair circuit indicated by the code output. YES Check for short circuit in harness and connector between DLC1 or DLC2 and ABS ECU (See page IN–31). NO 2 Is normal code displayed? NO 3 Does ABS warning light go off? YES Check for open and short circuit in harness and connector of Tc circuit between ECU and DLC2 or DLC1. NO Author: Date: 798 DI–564 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check voltage between terminals IG1 and GND of ABS actuator connector. PREPARATION: Disconnect ABS actuator connector. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals IG1 and GND of ABS actuator harness side connector. OK: Voltage: 10 – 14 V ON IG1 (+) (–) GND F00067 NG Check for open and short circuit in harness and connector between ECU–IG fuse and ABS actuator (See page IN–31). OK 5 Check connection of ABS actuator connector. CHECK: Check the connection of the ABS actuator connector and check the ABS warning light goes off. OK Repair or replace harness or connector. NG Check and replace ABS ECU. Author: Date: 799 DI–565 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI048–08 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects any trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM J/C D R–L ABS Warning Light 7 R–L C10 D ECU J/C J29 4 R–L 12 C10 IG3 R–L C R–L C J4 10 21 R–L IK3 A6 WA C R–L 14 ABS 2 1D Instrument Panel J/B DLC2 GAUGE F00096 INSPECTION PROCEDURE Troubleshoot in accordance with the chart below for each trouble symptom ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 2 1 Check ABS warning light. See combination meter troubleshooting on page BE–2. NG Repair bulb or combination meter assembly. OK Check for open circuit in harness and connector between GAUGE fuse, DLC2 and ABS ECU (See page IN–31). Author: Date: 800 DI–566 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Is DTC output? Check DTC on page DI–539. YES Repair circuit indicated by the code output. NO Check for short circuit in harness and connector between ABS warning light, DLC1, DLC2, and ECU (See page IN–31). Author: Date: 801 DI–567 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI049–08 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM ECU 6 BR II3 BR B J8 J/C C J7 DLC2 BR 3 E1 Tc LG–R 4 B J/C J3 LG–R B 12 12 LG–R IK2 A6 Tc B A J/C A BR A DLC1 BR 3 E1 Tc P–B (1MZ–FE) LG–R (5S–FE) 11 11 II3 LG–R J22: (1MZ–FE) J23: (5S–FE) EC F00120 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC1. DLC2 CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Tc and E1 of DLC2 or DLC1. OK: Voltage: 10 – 14 V DLC1 E1 Tc E1 Tc F02607 F00445 F02612 OK If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. NG Author: Date: 802 DI–568 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check for open and short circuit in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS ECU. Author: Date: 803 DI–569 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI04A–08 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM ECU BR DLC1 B–Y (1MZ–FE) LG (5S–FE) 8 E1 Ts II3 3 16 R–Y 5 IK2 R–Y 11 A6 Ts A J/C A J22: (1MZ–FE) J23: (5S–FE) BR EC F00095 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 – 14 V ON E1 AB0119 S08096 Ts DLC1 F00446 OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. NG Author: Date: 804 DI–570 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) Check for open and short circuit in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS ECU. Author: Date: 805 DI–571 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM (BOSCH Made) DI04B–10 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F00072 Author: Date: 806 DI–572 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM ABS & TRACTION CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING DI04C–02 Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop 1 2 Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. Customer Problem Analysis P. DI–573 Check and Clear DTC (Precheck) P. DI–574 Symptom does not occur 3 Symptom Simulation P. IN–21 4 Problem Symptom Confirmation Symptom occurs 5 Normal code DTC Check P. DI–574 Malfunction code 6 8 7 DTC Chart P. DI–578 Circuit Inspection 9 Sensor Check P.DI–584 ∼ DI–620 Problem Symptoms Table P. DI–583 Check for Fluid Leakage P.DI–623 Identification of Problem 10 11 Repair Confirmation Test End Step 2, 5, 8, 9, 11: Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. Author: Date: 807 DI–573 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04D–02 CUSTOMER PROBLEM ANALYSIS CHECK ABS & TRAC Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. ABS does not operate efficiently. TRAC does not operate. (Wheels spin when starting rapidly.) Symptoms Check Item ABS Warning Light Abnormal Remains ON Does not Light Up TRAC OFF Indicator Light Abnormal Remains ON Blinks SLIP Indicator Light Abnormal Remains ON Does not Light Up Malfunction Indicator Light Normal Malfunction Code (Code ) 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) Does not Light Up DTC Check Author: Date: 808 DI–574 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04E–04 PRE–CHECK 1. (a) F00075 DLC2 E1 Tc Tc S−17−1 E1 Iei−23−1−A F00041 Normal Code 2 sec. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit, TRAC OFF indicator light circuit and SLIP indicator light circuit (See page DI–612, DI–617, DI–620). (b) DLC1 0.25 sec. 0.25 sec. ON OFF DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the ABS warning light, TRAC OFF indicator light and SLIP indicator light go on for 3 seconds. Check the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Read the DTC from the ABS warning light and TRAC OFF indicator light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit, TRAC OFF indicator light circuit (See page DI–621 or DI–612, DI–617). As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (4) Codes are explained in the code table on page DI–578. (5) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 Code 21 R01346 Author: Date: 809 DI–575 DIAGNOSTICS TOYOTA Hand–held Tester – ABS & TRACTION CONTROL SYSTEM (c) Using TOYOTA hand–held tester, check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC2. (2) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. (d) Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 5 seconds. (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC2 or DLC1. SST 09843 – 18020 (e) Using TOYOTA break–out–box and TOYOTA hand–held tester, measure the ECU terminal values. (1) Hook up the TOYOTA hand–held tester and TOYOTA break–out–box to the vehicle. (2) Read the ECU input/output values by following the prompts on the tester screen. DLC2 H07517 BR3890 TOYOTA Hand–held Tester ECU TOYOTA Break–out–box N09348 HINT: TOYOTA hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester/TOYOTA break– out–box operator’s manual for further details. Author: Date: 810 DI–576 DIAGNOSTICS 2. (a) E1 Ts DLC1 ABS & TRACTION CONTROL SYSTEM SPEED SENSOR SIGNAL Check the speed sensor signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and E1 of DLC1. SST 09843 – 18020 (3) Start the engine. Tc F02201 (4) 0.13 sec. – 0.13 sec. ON OFF BR3904 Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI–612). (5) Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. (6) Stop the vehicle. (7) Using SST, connect terminals Tc and E1 of DLC1. SST 09843 – 18020 (8) Read the number of blinks of the ABS warning light. HINT:
See the list of DTC shown on the next page.
If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st.
If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 4 sec. 2.5 sec. 0.5 sec. Repeat BR3893 (9) After doing the check, disconnect the SST from terminals Ts and E1, Tc and E1 of DLC1, and turn ignition switch OFF. SST 09843 – 18020 Author: Date: 811 DI–577 DIAGNOSTICS TOYOTA Hand–held Tester (b) DLC2 – ABS & TRACTION CONTROL SYSTEM Using TOYOTA hand–held tester, check the DTC. (1) Do step 1. ∼ 6. on the previous page. (2) Hook up the TOYOTA hand–held tester to the DLC2. (3) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. H07517 DTC of speed sensor check function: Code No. Diagnosis Trouble Area 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor 73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor 75 Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor 76 Abnormal change in output voltage of left front speed sensor
Left front speed sensor rotor 77 Abnormal change in output voltage of right rear speed sensor
Right rear speed sensor rotor 78 Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor Author: Date: 812 DI–578 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04F–04 DIAGNOSTIC TROUBLE CODE CHART HINT:

Using SST 09843 –18020, connect the terminals Tc and E1. If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item Trouble Area 11 (DI–584) Open circuit in ABS & TRAC solenoid relay circuit 12 (DI–584) Short circuit in ABS & TRAC solenoid relay circuit 13 (DI–587) Open circuit in ABS & TRAC motor relay circuit 14 (DI–587) Short circuit in ABS & TRAC motor relay circuit 21 (DI–590) Open or short circuit in right front solenoid circuit
ABS & TRAC actuator
SFRR or SFRH circuit
ECU 22 (DI–590) Open or short circuit in left front solenoid circuit
ABS & TRAC actuator
SFLR or SFLH circuit
ECU 23 (DI–590) Open or short circuit in right rear solenoid circuit
ABS & TRAC actuator
SRRR or SRRH circuit
ECU 24 (DI–590) Open or short circuit in left rear solenoid circuit
ABS & TRAC actuator
SRLR or SRLH circuit
ECU 25 (DI–590) Open or short circuit in SMC1 circuit
ABS & TRAC actuator
SMC1 circuit
ECU 26 (DI–590) Open or short circuit in SMC2 circuit
ABS & TRAC actuator
SMC2 circuit
ECU 27 (DI–590) Open or short circuit in SRC1 circuit
ABS & TRAC actuator
SRC1 circuit
ECU 28 (DI–590) Open or short circuit in SRC2 circuit
ABS & TRAC actuator
SRC2 circuit
ECU 31 (DI–593) Right front wheel speed sensor signal malfunction 32 (DI–593) Left front wheel speed sensor signal malfunction 33 (DI–593) Right rear wheel speed sensor signal malfunction 34 (DI–593) Left rear wheel speed sensor signal malfunction 41 (DI–598) Low battery positive voltage or abnormally high battery positive voltage
ABS & TRAC solenoid relay
ABS & TRAC solenoid l id relay l circuit i it
ECU
ABS & TRAC motor relay
ABS & TRAC motor t relay l circuit i it
ECU
Right front, left front, right rear and left rear speed sensor
Each speed s eed sensor circuit
Speed sensor rotor
ECU
Battery
Charging system
Power source circuit
ECU Author: Date: 813 DI–579 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM 43* (DI–601) Malfunction in ABS control system
ABS control system 44* (DI–602) Open or short circuit in NE signal circuit
NEO circuit
ECM
ECU 49 (DI–604) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit
ECU 51 (DI–606) Pump motor is locked
ABS pump motor 53* (DI–608) Malfunction in ECM communication circuit
TRC+ or TRC – circuit
EFI+ or EFI– circuit
ECM
ECU 61* (DI–609) Malfunction in engine control system
Engine control system Malfunction in ECU
ECU Always ON (DI–610) *: TRAC OFF indicator light blinking Author: Date: 814 DI–580 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04G–04 PARTS LOCATION SLIP Indicator Light TRAC OFF Indicator Light ABS Warning Light Sensor Rotor ABS & TRAC ECU TRAC OFF Switch DLC1 Front Speed Sensor ABS & TRAC Actuator ABS & TRAC Solenoid Relay DLC2 ABS & TRAC Motor Relay Sensor Rotor Front Speed Sensor Rear Speed Sensor Stop Light Switch F01177 Author: Date: 815 DI–581 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI1JO–03 TERMINALS OF ECU A15 13 12 11 10 9 8 7 A16 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 8 7 6 5 4 A17 3 2 1 16 15 14 13 12 11 10 9 3 2 1 12 11 10 9 8 7 6 5 4 R05698 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG1 (A16 – 8) – GND (A15 – 15, A17 – 9, 10) B–R ↔ W–B IG switch ON 10 – 14 R+ (A15 – 1) – SR (A15 – 11) GR–R ↔ GR IG switch ON, ABS warning light OFF 9 – 14 R+ (A15 – 1) – MR (A15 – 24) GR–R ↔ GR–L SFRR (A15 – 26) – GND (A15 – 15, A17 – 9, 10) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFRH (A15 – 13) – GND (A15 – 15, A17 – 9, 10) R–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLR (A17 – 1) – GND (A15 – 15, A17 – 9, 10) W–L ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLH (A17 – 2) – GND (A15 – 15, A17 – 9, 10) L–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRR (A17 – 7) – GND (A15 – 15, A17 – 9, 10) R–G ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRH (A17 – 8) – GND (A15 – 15, A17 – 9, 10) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLR (A15 – 12) – GND (A15 – 15, A17 – 9, 10) LG–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLH (A15 – 25) – GND (A15 – 15, A17 – 9, 10) G–Y ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 AST (A15 – 10) – GND (A15 – 15, A17 – 9, 10) R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 WA (A16 – 4) – GND (A15 – 15, A17 – 9, 10) G B ↔ W–B G–B W B IG switch ON, ABS warning light ON Below 2.0 IG switch ON, ABS warning light OFF 10 – 14 STP (A16 – 16) – GND (A15 – 15, A17 – 9, 10) G W ↔ W–B G–W W B D/G (A15 – 22) – GND (A15 – 15, A17 – 9, 10) R–L ↔ W–B Tc (A15 – 9) – GND (A15 – 15, A17 – 9, 10) IG switch ON Below 1.0 Stop light switch OFF Below 1.5 Stop light switch ON 8 – 14 IG switch ON, ABS warning light ON 10 – 14 LG–R ↔ W–B IG switch ON 8 – 14 Ts (A15 – 23) – GND (A15 – 15, A17 – 9, 10) R–Y ↔ W–B IG switch ON 8 – 14 FR+ (A15 – 17) – FR– (A15 – 18) W↔B IG switch ON, slowly turn right front wheel AC generation FL+ (A15 – 5) – FL– (A15 – 4) R↔G IG switch ON, slowly turn left front wheel AC generation RR+ (A16 – 9) – RR– (A16 – 10) W↔B IG switch ON, slowly turn right rear wheel AC generation RL+ (A16 – 2) – RL– (A16 – 1) R↔G IG switch ON, slowly turn left rear wheel AC generation Author: Date: 816 DI–582 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM MT (A15 – 14) – GND (A15 – 15, A17 – 9, 10) R–W ↔ W–B IG switch ON SRC1 (A17 – 5) – GND (A15 – 15, A17 – 9, 10) B–R ↔ W–B IG switch ON, TRAC OFF indicator light OFF 10 – 14 SRC2 (A17 – 6) – GND (A15 – 15, A17 – 9, 10) B–Y ↔ W–B IG switch ON, TRAC OFF indicator light OFF 10 – 14 SMC1 (A17 – 12) – GND (A15 – 15, A17 – 9, 10) Y–R ↔ W–B IG switch ON, TRAC OFF indicator light OFF 10 – 14 SMC2 (A17 – 6) – GND (A15 – 15, A17 – 9, 10) Y–B ↔ W–B IG switch ON, TRAC OFF indicator light OFF 10 – 14 NEO (A16 – 15) – GND (A15 – 15, A17 – 9, 10) BR–W ↔ W–B EFI+ (A16 – 6) – GND (A15 – 15, A17 – 9, 10) Below 1.5 Idling Pulse generation W ↔ W–B IG switch ON Pulse generation EFI– (A16 – 14) – GND (A15 – 15, A17 – 9, 10) B ↔ W–B IG switch ON Pulse generation TRC+ (A16 – 13) – GND (A15 – 15, A17 – 9, 10) G ↔ W–B TRAC control active Pulse generation TRC– (A16 – 5) – GND (A15 – 15, A17 – 9, 10) L ↔ W–B TRAC control active Pulse generation IND (A16 – 3) – GND (A15 – 15, A17 – 9, 10) LG ↔ W–B W B WT (A16 – 12) – GND (A15 – 15, A17 – 9, 10) L↔W W–B B CSW (A16 – 11) – GND (A15 – 15, A17 – 9, 10) LG ↔ W–B W B IG switch ON, SLIP indicator light ON Below 2.0 IG switch ON, SLIP indicator light OFF 10 – 14 IG switch ON, TRAC OFF indicator light ON Below 2.0 IG switch ON, TRAC OFF indicator light OFF 10 – 14 IG switch ON, TRAC cut switch pushed in Below 2.0 IG switch ON, TRAC cut switch released 8 – 14 Author: Date: 817 DI–583 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04I–04 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptom Suspect Area See page ABS does not operate. Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS & TRAC ECU. 1. Check the DTC reconfirming that the normal code is output. 2. IG power source circuit 3. Speed sensor circuit 4. Check the ABS & TRAC actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page DI–623). ABS does not operate efficiently. Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS & TRAC ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Speed sensor circuit. 3. Stop light switch circuit. 4. Check the ABS & TRAC actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page DI–623). ABS warning light abnormal. 1. ABS warning light circuit 2. ABS & TRAC ECU DI–612 DI–610 DTC check cannot be done. Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS & TRAC ECU. 1. ABS warning light circuit 2. TRAC OFF indicator light circuit 3. Tc terminal circuit DI–612 DI–617 DI–621 Speed sensor signal check cannot be done. 1. Ts terminal circuit 2. ABS & TRAC ECU DI–615 DI–610 TRAC does not operate. Only when inspection circuits for each problem symptom are all normal and the problem is still occurring, replace the ABS & TRAC ECU. 1. Check the DTC, reconfirming that the normal code is output. 2. IG power source circuit 3. Check the hydraulic circuit for leakage 4. Speed sensor circuit DI–574 DI–598 DI–593 BR–61 DI–574 DI–593 DI–604 BR–61 DI–574 DI–598 DI–623 DI–593 SLIP indicator light abnormal. SLIP indicator light circuit DI–620 TRAC OFF indicator light abnormal. Only when inspection circuits for each problem symptom are all normal and the problem is still occurring, replace the ABS & TRAC ECU. 1. TRAC OFF indicator light circuit 2. TRAC cut switch circuit DI–617 DI–617 Author: Date: 818 DI–584 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04J–04 CIRCUIT INSPECTION DTC 11, 12 ABS & TRAC Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS & TRAC solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition Trouble Area 11 Condition 1. to 3. are detected: 1. Malfunction of solenoid relay monitor 2. Battery voltage will not exceed more than 17.0 V within 2.16 sec. 3. Battery voltage will not become less than 9.5 V within 2.16 sec., or after the solenoid relay is ON and AST voltage of ECU terminal does not become 8.0 V or more. 12 Solenoid relay is OFF in the midst of premain routine, and AST voltage of ECU terminal is 8.0 V or more, which continues for 2.04 sec. or more.
ABS & TRAC solenoid relay
ABS & TRAC solenoid relay circuit
ECU Fail safe function: If any trouble occurs in the ABS & TRAC solenoid relay circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. WIRING DIAGRAM ABS & TRAC ECU Engine Room R/B No. 3 ABS & TRAC Solenoid Relay 6 1 4 2 2 ABS 3 3 5 GR GR–R 3 1 11 A15 SR 1 A15 R+ DLC1 3 3 3 W–L ABS & TRAC 4 A8 Actuator B–G 1 F5 ALT Battery 3 W–B ABS & TRAC ECU FL Block 1 F4 B–G MAIN EA 5 A8 R 10 A15 AST F03951 Author: Date: 819 DI–585 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS & TRAC solenoid relay). PREPARATION: Remove ABS & TRAC solenoid relay from Engine Room R/B No. 3. CHECK: Measure the voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS & TRAC solenoid relay). OK: Voltage: 10 – 14 V (–) (+) 123 456 Engine Room R/B No. 3 F00182 NG Check and repair harness or connector. OK 2 Check continuity between terminal 3 of ABS & TRAC solenoid relay and terminal AST of ABS & TRAC ECU. Engine Room R/B No. 3 ABS & TRAC Solenoid Relay ABS & TRAC 3 A8 Actuator 4 CHECK: Check continuity between terminal 3 of Engine Room R/B No. 3 (for ABS solenoid relay) and terminal AST of ABS & TRAC ECU. OK: Continuity HINT: There is a resistance of 4 ∼ 6 Ω between terminals A8 – 4 and A8 – 5 of ABS actuator. A8 5 A15 ECU AST F00055 NG Repair or replace harness or ABS & TRAC actuator. OK Author: Date: 820 DI–586 DIAGNOSTICS 3 – ABS & TRACTION CONTROL SYSTEM Check ABS & TRAC solenoid relay. 3 2 1 6 5 4 CHECK: Check continuity between each terminal of ABS & TRAC solenoid relay. OK: Open Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open 3 2 1 Continuity Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS & TRAC solenoid relay. OK: 6 5 4 Continuity 3 2 1 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Open (–) 6 5 4 (+) F00042 NG Replace ABS & TRAC solenoid relay. OK 4 Check for open and short circuit in harness and connector between ABS & TRAC solenoid relay and ABS & TRAC ECU (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 821 DI–587 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04K–04 DTC 13, 14 ABS & TRAC Motor Relay Circuit CIRCUIT DESCRIPTION The ABS & TRAC motor relay supplies power to the ABS & TRAC pump motor. While the ABS is activated, the ECU switches the ABS & TRAC motor relay ON and operates the ABS & TRAC pump motor. DTC No. DTC Detecting Condition Trouble Area 13 Conditions 1. to 3. are detected: 1. Malfunction of motor relay monitor 2. Battery voltage will not exceed more than 17.0 V within 2.16 sec. 3. Battery voltage will not become less than 9.5 V within 2.16 sec., or after the motor relay is ON and motor relay monitor does not ON. 14 Motor relay is OFF, and motor relay monitor is ON , which continues for 20.16 sec. or more.
ABS & TRAC motor relay
ABS & TRAC motor relay circuit
ECU Fail safe function: If any trouble occurs in the ABS & TRAC motor relay circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. WIRING DIAGRAM B–G 3 Engine Room R/B No. 3 ABS & TRAC Motor Relay 2 1 4 1 ABS & TRAC ECU 3 GR–L 24 A15 MR GR–R 1 A15 R+ R–W 14 A15 MT ABS 3 1 F5 FL Block 1 F4 3 3 2 ALT ABS & TRAC Actuator B–G W–R 2 A8 3 A8 MAIN 1 A8 W–B Battery EA F03413 Author: Date: 822 DI–588 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal 1 of Engine Room R/B No. 3 (for ABS & TRAC motor relay) and body ground. (–) (+) Engine Room R/B No. 3 1 2 3 4 PREPARATION: Remove ABS & TRAC motor relay from Engine Room R/B No. 3. CHECK: Measure voltage between terminal 1 of Engine Room R/B No. 3 (for ABS & TRAC motor relay) and body ground. OK: Voltage: 10 – 14 V F00049 NG Check and repair harness or connector. OK 2 Check continuity between terminal 2 of ABS & TRAC motor relay and terminal MT of ABS & TRAC ECU. Engine Room R/B No. 3 2 ABS & TRAC Motor Relay 2 A8 2 M CHECK: Check continuity between terminal 2 of Engine Room R/B No. 3 (for ABS & TRAC motor relay) and terminal MT of ABS & TRAC ECU. OK: Continuity HINT: There is a resistance of 4 ∼ 6 Ω between terminals A8 – 2 and A8 – 3 of ABS & TRAC actuator. A8 ABS & TRAC Actuator 3 3 A15 ECU MT F00056 NG Repair or replace harness or ABS & TRAC actuator. OK Author: Date: 823 DI–589 DIAGNOSTICS 3 – ABS & TRACTION CONTROL SYSTEM Check ABS & TRAC motor relay. 2 1 4 3 CHECK: Check continuity between each terminal of ABS & TRAC motor relay. OK: Open 2 Continuity Continuity (Reference value 62 Ω) Terminals 1 and 2 Open 1 4 CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals of ABS & TRAC motor relay. OK: 3 Continuity 2 1 Terminals 1 and 2 NG (–) Terminals 3 and 4 4 Continuity Replace ABS & TRAC motor relay. 3 (+) F00044 OK 4 Check for open and short circuit in harness and connector between ABS & TRAC motor relay and ABS & TRAC ECU (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 824 DI–590 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04L–04 DTC 21 to 28 ABS & TRAC Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area 21
ABS actuator
SFRR or SFRH circuit
ECU 22
ABS actuator
SFLR or SFLH circuit
ECU 23
ABS actuator
SRRR or SRRH circuit
ECU 24 25 26 Conditions 1. and 2. or 3. continue for 0.48 sec. or more: 1 Recovery prohibit run pulse is not output 1. output, solenoid relay is ON, AST voltage of ECU terminal is 8.0 V or more, and solenoid output has no change between the last time and this time. 2. Solenoid output is ON, pressure holding solenoid monitor voltage is more than 1.0 V or pressure eduction solenoid monitor voltage g is more than 1.5 V. 3. Solenoid output is OFF, solenoid monitor voltage is more than –1.0 V AST voltage of ECU.
ABS actuator
SRLR or SRLH circuit
ECU
ABS actuator
SMC1 circuit
ECU
ABS actuator
SMC2 circuit
ECU 27
ABS actuator
SRC1 circuit
ECU 28
ABS actuator
SRC2 circuit
ECU Fail safe function: If any trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. Author: Date: 825 DI–591 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM WIRING DIAGRAM ABS & TRAC ECU 11 GR GR–R 3 3 ABS & TRAC 4 6 4 A8 3 9 A7 5 A7 Solenoid 1 2 3 A7 3 3 B–G A7 A7 W–L 1 F5 A7 W–B A7 ALT FL A7 Block MAIN 10 G–Y 25 12 L–B 2 11 W–R 8 3 W–R 26 4 LG–B 12 6 W–L 1 5 R–G 7 7 B–R 5 2 B–Y 4 8 Y–R 12 1 Y–B 6 R 10 A7 1 3 Battery A15 R+ A7 1 F4 EA A7 5 A8 B–G 13 R–B A7 2 ABS SR DLC1 Engine Room R/B No. 3 Relay A15 1 ABS & TRAC Actuator A15 SFRH A15 SRLH A17 SFLH A17 SRRH A15 SFRR A15 SRLR A17 SFLR A17 SRRR A17 SRC1 A17 SRC2 A17 SMC1 A17 SMC2 A15 AST F03952 INSPECTION PROCEDURE 1 Check ABS & TRAC actuator solenoid. 6 5 4 3 2 1 A8 A7 12 11 10 9 8 7 4 F00057 PREPARATION: Disconnect the 2 connectors from ABS & TRAC actuator. CHECK: Check continuity between terminals A8 – 4 and A7 – 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 of ABS & TRAC actuator connector. OK: Continuity HINT: Resistance of each solenoid coil is 1.2 Ω. NG Replace ABS & TRAC actuator. OK Author: Date: 826 DI–592 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check for open and short circuit in harness and connector between ABS & TRAC ECU and actuator (See page IN–31). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. Author: Date: 827 DI–593 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI1JP–03 DTC Speed Sensor Circuit 31, 32, 33, 34 CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS and TRAC system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 –V F00010 DTC No. DTC Detecting Condition 31, 32, 33, 34 Detection of any of conditions from 1. through 3.: 1. ABS is in non–operation, wheel speed is 10 km/h or more, one eighth of maximum wheel speed is greater than the minimum wheel speed, one eighth of maximum wheel speed is smaller than the rear maximum wheel speed or momentary interruption of both the rear wheels are shown in the 15 sec. or more continuously. 2. ABS is in non–operation, momentary interruption of speed sensor occurs 7 times or more in the mean time of switching the ignition switch ON and OFF or vehicle speed is 20 km/h (12 mph) or more and the condition of noise interference or non–noise interference occurs 75 times or more within 5 sec. 3. Vehicle is at a stop, malfunction signal of vehicle speed sensor hardware open circuit is ON for 1.02 sec. continuously since starting the checking of a certain vehicle. Trouble Area
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Speed sensor rotor
ECU HINT:



DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor. DTC No. 34 is for the left rear speed sensor. Fail safe function: If any trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. Author: Date: 828 DI–594 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM WIRING DIAGRAM ABS & TRAC ECU 17 A15 FR+ W 2 Right Front Speed Sensor 18 B A15 FR– 1 R Left Front Speed Sensor 2 G 1 W*1 P*2 Right Rear Speed Sensor 1 B*1 Y*2 2 W*1 Y*2 Left Rear Speed Sensor 2 G*1 BR*2 1 *1: *2: 1 IK2 6 IK2 R 5 A15 FL+ G 4 A15 FL– 2 IL1 W 1 IL1 B 3 ID1 R 9 ID1 G 9 A16 RR+ 10 A16 RR– 2 A16 RL+ 1 A16 RL– TMC Made TMMK Made F00116 Author: Date: 829 DI–595 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check speed sensor. 1 2 R14205 1 2 R14213 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 – 2.5 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 1.2 – 2.3 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–574). OK Author: Date: 830 DI–596 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check for open and short circuit in harness and connector between each speed sensor and ECU (See page IN–31). NG Repair or replace harness or connector. OK 3 Check sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. OK NG BR3795 NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–574). OK 4 Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the ABS & TRAC ECU. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ABS & TRAC ECU. CHECK: Drive the vehicle with about 30 km/h (19 mph), and check the signal waveform. W04200 OK Check and replace ABS & TRAC ECU. NG Author: Date: 831 DI–597 DIAGNOSTICS 5 – ABS & TRACTION CONTROL SYSTEM Check sensor rotor and sensor tip. R00948 R00947 Front: PREPARATION: Remove front drive shaft (See page SA–26). CHECK: Check sensor rotor serrations. OK: No scratches , missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See page BR–68). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. Rear: PREPARATION: Remove the axle hub (See page SA–52). CHECK: Check the sensor rotor serrations. OK: No scratches , missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See page BR–71). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last. (See page DI–574). OK Check and replace ABS & TRAC ECU. Author: Date: 832 DI–598 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04N–04 DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition 41 Detection of any conditions from 1. through 3.: 1. Vehicle speed is 3 km/h (1.9 mph) or more and battery voltage is less than 9.5 V continues for 10 sec. or more. 2. Battery voltage has never exceeded more than 17.0 V and has become less than 9.5 V within 2.16 sec., under malfunction of solenoid relay monitor after the solenoid relay is ON, at ECU AST terminal voltage of ECU has become 8.0 V or more or under malfunction of motor relay monitor and after the motor relay is ON, motor relay monitor has become ON. 3. Battery voltage is more than 17.0 V , which continues for 1.2 sec. or more or battery voltage has become more than 17.0 V within 2.16 sec. and solenoid or motor relay monitor is under malfunction condition. Trouble Area
Battery
Charging system
Power source circuit
ECU Fail safe function: If any trouble occurs in the power source circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. WIRING DIAGRAM ABS & TRAC ECU Ignition Switch Instrument Panel J/B W 2 4 FL Block ALT B–R B–R C ECU–IG Instrument Panel J/B 2 1K AM1 1 F4 9 1J 1 1K B–Y J/C J12 1 1B B–R 1 F9 W–B C 8 A16 IG1 W–B 15 A15 GND1 W–B 9 A17 GND3 W–B 10 A17 GND2 W–B B–G MAIN Battery EA F00175 Author: Date: 833 DI–599 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove ECU–IG fuse from Instrument Panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity ECU–IG Instrument Panel J/B F00073 NG Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). NG Check and repair the charging system 5S–FE engine: (See page CH–1) 1MZ–FE engine: (See page CH–1). OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK Author: Date: 834 DI–600 DIAGNOSTICS 3 – ABS & TRACTION CONTROL SYSTEM Check voltage between terminals IG1 and GND of ABS & TRAC ECU connector. PREPARATION: Remove ABS & TRAC ECU with connectors still connected. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals IG1 and GND of ABS & TRAC ECU connector. OK: Voltage: 10 – 14 V ON IG1 (+) (–) GND F00058 OK Check and replace ABS & TRAC ECU. NG 4 Check continuity between terminals GND of ABS & TRAC ECU connector and body ground. PREPARATION: Disconnect the connector from the ABS & TRAC ECU. CHECK: Measure resistance between terminal GND of ABS & TRAC ECU connector and body ground. OK: Resistance: 1 Ω or less LOCK (–) (+) GND F07003 NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between ABS & TRAC ECU and battery (See page IN–31). Author: Date: 835 DI–601 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04O–04 DTC 43 ABS Control System Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area 43 Detection of any conditions from 1. through 8.: 1. During TRAC is in non–operation and DTC of ABS is output, but TRAC is not during initial lamp checking, terminal WA of ECU is ON and engine speed is 500 rpm or more , which continues for 1 sec. or more. 2. Solenoid relay circuit is open or short. 3. Motor relay circuit is open or short. 4. ABS solenoid circuit is open or short. 5. TRAC solenoid circuit is open or short. 6. Speed sensor is under malfunction condition. 7. IG power source is down or raised. 8. Pump motor is locked.
ABS control system INSPECTION PROCEDURE 1 Check the DTC for the ABS (See page DI–574). *1 Repair ABS control system according to the code output. *2 Check for ECU connected to malfunction indicator lamp. *1: Output NG code *2: Malfunction indicator lamp remains ON. Author: Date: 836 DI–602 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04P–04 DTC 44 NE Signal Circuit CIRCUIT DESCRIPTION The ABS & TRAC ECU receives engine speed signals (NE signals) from the ECM. DTC No. DTC Detecting Condition 44 Condition 1. or 2. is detected: 1. TRAC is in operation and engine speed is 0 rpm continues for 2.4 sec. or more. 2. TRAC is in non–operation, sift lever is not in P or N position, both the front right and left wheels’ speed is 30 km/h (19 mph) or more, engine speed is 0 rpm and does not have communication malfunction, and malfunction information of engine system is OFF. Trouble Area
NEO circuit
ECM
ECU WIRING DIAGRAM ABS & TRAC ECU ECM 16 NEO E8 BR–W 15 A16 NEO F00062 INSPECTION PROCEDURE 1 Check for open and short circuit in harness and connector between terminal NEO of ABS & TRAC ECU and terminal NEO of ECM (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 837 DI–603 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check voltage between terminal NEO of ABS & TRAC ECU and body ground. PREPARATION: (a) Remove ABS & TRAC ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal NEO of ABS & TRAC ECU and body ground for the engine conditions below. OK: ON (–) (+) NEO F00061 Engine condition Voltage OFF (IG ON) 3 – 6 V or below 1 V ON (Idling) 2 – 3 V (Pulse) (Reference) 3–6V Below 1 V 3 ms. 3 ms. F00011 NG Check and replace ABS & TRAC ECU or ECM. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. Author: Date: 838 DI–604 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04Q–04 DTC 49 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. 49 DTC Detecting Condition Trouble Area Battery voltage has never exceeded more than 17.0 V and become less than 9.5 V within 2.16 sec. and the STP terminal voltage of ECU is under open circuit detecting limits continues for 3 sec. or more.
Stop light switch
Stop light switch circuit
ECU WIRING DIAGRAM ABS & TRAC ECU J/C Instrument Panel J/B Stop Light Switch J28 C J27 A 4 1R G–W 1 2 1S 16 A16 STP G–W 7 R Instrument Panel J/B 1 4 1B 7 1C W–B STOP 1 F4 G–W 5 1R W 2 G–W FL Block ALT B–R 1 F9 B–G High H10 2 Mounted Stop H10 1 Light W–B A J/C J40 MAIN Battery A 2 Light Failure Sensor W–B W–B 2 R11 Right 2 R9 Left Stop Stop Light 5 R9 Light 5 R11 W–B W–B W–B W–B BP BL F00124 Author: Date: 839 DI–605 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal STP of ABS & TRAC ECU and body ground. PREPARATION: Remove ABS & TRAC ECU with connectors still connected. CHECK: Measure voltage between terminal STP of ABS & TRAC ECU and body ground when brake pedal is depressed. OK: Voltage: 8 – 14 V (–) (+) STP F00060 OK Check and replace ABS & TRAC ECU. NG 2 Check for open circuit in harness and connector between ABS & TRAC ECU and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–583). Author: Date: 840 DI–606 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI4KX–01 DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area In the midst of initial check, after the current flows to the motor for 3 sec. and motor relay is turned OFF , then within 0.66 sec., the condition that the motor relay monitor is OFF continues for 0.24 sec. or more. 51
ABS pump motor Fail safe function: If any trouble occurs in the ABS & TRAC pump motor, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. WIRING DIAGRAM Engine Room R/B No. 3 ABS B–G 3 3 4 2 1 2 3 1 F5 ALT 1 ABS & TRAC ECU ABS & TRAC Motor Relay 3 3 GR–L 24 A15 MR GR–R 1 A15 R+ FL Block 1 F4 ABS & TRAC Actuator B–G W–R 3 A8 2 A8 R–W 14 A15 MT MAIN 1 A8 W–B Battery EA F03413 Author: Date: 841 DI–607 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of ABS & TRAC pump motor. PREPARATION: Disconnect the ABS & TRAC actuator connector. CHECK: Connect positive
lead to terminal A8 – 2 and negative  lead to terminal A8 – 1 of the ABS & TRAC actuator connector, check that the pump motor is operates. A8 1 2 (–) (+) F03291 OK Check for open circuit in harness and connector between ABS & TRAC motor relay, ABS & TRAC actuator and ECU (See page IN–31). NG Replace ABS & TRAC actuator. Author: Date: 842 DI–608 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04S–04 DTC 53 ECM Communication Circuit Malfunction CIRCUIT DESCRIPTION This circuit is used to send TRAC control information from the ABS & TRAC ECU to the ECM (TRC+, TRC–), and engine control information from the ECM to the ABS & TRAC ECU (EFI+, EFI–). DTC No. 53 DTC Detecting Condition Trouble Area
TRC+ or TRC– circuit
EFI+ or EFI– circuit
ECM
ECU ECM communication data malfunction is detected. WIRING DIAGRAM ABS & TRAC ECU ECM EFI+ 14 E7 W 6 21 E7 B 14 EFI– 13 E7 LG 13 TRC+ TRC– 20 E7 L A16 A16 A16 EFI+ EFI– TRC+ 5 A16 TRC– F00063 INSPECTION PROCEDURE 1 Check for open and short circuit in harness and connector between terminals EFI+, EFI–, TRC+, TRC– of ABS & TRAC ECU and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ECM or ABS & TRAC ECU. Author: Date: 843 DI–609 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04T–04 DTC 61 Engine Control System Malfunction CIRCUIT DESCRIPTION If any trouble occurs in the engine control system, the ECU prohibits TRAC control. DTC No. DTC Detection Condition 61 Conditions 1. and 2. are detected: 1. ECM communication is normal, malfunction information of engine system is ON, and engine speed is 500 rpm or more , which continues for 0.48 sec. or more, and TRAC operation start condition is concluded. 2. ECM communication is normal, malfunction information of engine system is ON, engine speed is 500 rpm and more which continues for 1 sec. or more, and the engine system memorizes DTC. Trouble Area
Engine control system INSPECTION PROCEDURE 1 Check the DTC for the engine (See page DI–197). *1 Repair engine control system according to the code output. *2 Check for ECU connected to malfunction indicator light. *1: Output NG code *2: Malfunction indicator light remains ON. Author: Date: 844 DI–610 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI1JQ–03 DTC Always ON ABS & TRAC ECU Malfunction CIRCUIT DESCRIPTION DTC No. Always ON DTC Detecting Condition ABS & TRAC ECU internal malfunction is detected. Trouble Area
ECU Fail safe function: If any trouble occurs in the power source circuit, the ECU cuts off current to the ABS & TRAC solenoid relay and prohibits ABS control and TRAC control. INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI–574. YES Repair circuit indicated by the code output. YES Check solenoid relay. Check for short circuit in harness and connector between solenoid relay and DLC1 (See page IN–31). NO 2 Is normal code displayed? NO 3 Does ABS warning light go off? YES Check for open and short circuit in harness and connector between ECU–IG fuse and ABS & TRAC ECU (See page IN–31). NO Author: Date: 845 DI–611 DIAGNOSTICS 4 – ABS & TRACTION CONTROL SYSTEM Check battery positive voltage. CHECK: Check the battery positive voltage. OK: 10 – 14 V NG Check and repair the charging system 5S–FE engine: (See page CH–1) 1MZ–FE engine: (See page CH–1). OK 5 Check ABS warning light. PREPARATION: (a) Disconnect the connector from the ABS & TRAC ECU. (b) Turn the ignition switch ON. CHECK: Check the ABS warning light goes off. OK Check and replace ABS & TRAC ECU. NG Check for short circuit in harness and connector between ABS warning light, DLC1, DLC2, and ABS & TRAC ECU (See page IN–31) Author: Date: 846 DI–612 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04V–04 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects a trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Engine Room R/B No. 3 Instrument Panel J/B 2 ABS & TRAC Solenoid Relay 1 Battery 6 4 2 5 GAUGE 3 3 3 4 A8 J/C J4 D R–L 3 W–L D ABS & TRAC ECU 8 R–L R–L IK2 3 3 R–L 1D C10 7 4 II3 R–L ABS & TRAC Actuator ABS Warning Light 23 C10 4 DLC1 R–L 22 G–B 12 IG3 Short Pin W–B ABS & TRAC 5 II3 ECU ABS & TRAC ECU G–B C EA G–B C G–B C 4 A16 WA J/C J29 F00168 INSPECTION PROCEDURE Troubleshoot in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 1 Check ABS warning light. See combination meter troubleshooting on page BE–2. NG Repair bulb or combination meter assembly. OK Author: Date: 847 DI–613 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check ABS & TRAC solenoid relay. 3 2 1 6 5 4 PREPARATION: Remove ABS & TRAC solenoid relay from Engine Room R/B No. 3. CHECK: Check continuity between each terminal of ABS & TRAC solenoid relay. OK: Open 3 2 1 Continuity Continuity 6 5 4 3 2 1 Open 6 5 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS & TRAC solenoid relay. OK: Continuity (–) Terminals 4 and 6 Terminals 2 and 3 Open Terminals 1 and 3 Continuity 4 (+) Continuity (–) 3 21 (+) 654 F00043 CHECK: Connect the
test lead to terminal 5 and the  lead to terminal 3. Check continuity between the terminals. OK: Continuity If there is no continuity, connect the  test lead to terminal 5 and the
lead to terminal 3. Recheck continuity between terminals. NG Replace ABS & TRAC solenoid relay. OK Check for open circuit in harness and connector between DLC1, ABS & TRAC solenoid relay and body ground (See page IN–31). Author: Date: 848 DI–614 DIAGNOSTICS 3 – ABS & TRACTION CONTROL SYSTEM Is DTC output? Check DTC on page DI–574. YES Repair circuit indicated by the code output. NO 4 Does ABS warning light go off? NO Check for short circuit in harness and connector between ABS warning light, DLC1 and ABS & TRAC ECU (See page IN–31). YES 5 Check ABS & TRAC solenoid relay (See step 2). NG Replace ABS & TRAC solenoid relay. OK Check for short circuit in harness and connector between DLC1 and ABS & TRAC solenoid relay (See page IN–31). Author: Date: 849 DI–615 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04X–04 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM ABS & TRAC ECU DLC1 BR 3 E1 Ts R–Y 16 11 II3 R–Y 5 IK2 R–Y 23 A15 Ts A J22 J/C BR A EC F00095 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. ON CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 – 14 V Ts E1 AB0119 S08096 DLC1 F00446 OK If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. NG Author: Date: 850 DI–616 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check for open and short circuit in harness and connector between ABS & TRAC ECU and DLC1, DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS & TRAC ECU. Author: Date: 851 DI–617 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04Y–04 TRAC OFF Indicator, TRAC Cut Switch Circuit CIRCUIT DESCRIPTION This is the TRAC control main switch. When the TRAC cut switch is pushed on, TRAC control goes off and the TRAC OFF indicator lights up. This indicator blinks for warnings when the trouble occurs and for displaying DTC. WIRING DIAGRAM ABS & TRAC ECU TRAC OFF Indicator Light Instrument Panel J/B J/C 19 3 7 2 L R–L R–L IG3 C10 1D C10 D D GAUGE J4 Instrument Panel J/B J/C IG W–B A 7 1J 8 1J L J11 J7 A J/C C J32 L 17 J8 A 12 A16 WT L DLC2 C J32 J/C W–B C J32 TRC TRAC Cut Switch 11 LG W–B A16 CSW 1 4 F00114 INSPECTION PROCEDURE 1 Check DTC. Check DTC on page DI–574. YES Repair circuit indicated by the code output. NO Author: Date: 852 DI–618 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check TRAC cut switch. PREPARATION: (a) Remove TRAC cut switch. (b) Disconnect TRAC cut switch connector. CHECK: Measure resistance between terminals 1 and 4 of TRAC cut switch when TRAC cut switch is ON and OFF. OK: 32 4 (+) 1 (–) F00052 NG TRAC cut switch Resistance Pushed in Continuity Released 1 MΩ or higher Replace TRAC cut switch. OK 3 Check for open and short circuit in harness and connector between terminal CSW of ABS & TRAC ECU and TRAC cut switch and body ground (See page IN–29). NG Repair or replace harness or connector. OK 4 Check TRAC OFF indicator light. See combination meter troubleshooting on page BE–2. NG Repair or replace combination meter. OK Author: Date: 853 DI–619 DIAGNOSTICS 5 – ABS & TRACTION CONTROL SYSTEM Check for open and short circuit in harness and connector between terminal WT of ABS & TRAC ECU and TRAC OFF indicator light (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS & TRAC ECU. Author: Date: 854 DI–620 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI04Z–04 SLIP Indicator Light Circuit CIRCUIT DESCRIPTION The SLIP indicator blinks during TRAC operation. WIRING DIAGRAM Instrument Panel J/B SLIP Indicator Light J/C 5 7 GAUGE 2 R–L R–L LG C10 1D C8 D D J4 ABS & TRAC ECU 18 IG3 LG 3 A16 IND F00097 INSPECTION PROCEDURE 1 Check SLIP indicator light. See combination meter troubleshooting on page BE–2. NG Repair or replace combination meter. OK 2 Check for short circuit in harness and connector between ABS & TRAC ECU and SLIP indicator light (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS & TRAC ECU. Author: Date: 855 DI–621 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI4KY–01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display the DTC by blinking the ABS warning light and TRAC OFF indicator light. WIRING DIAGRAM J/C 6 II3 BR BR J7 C DLC1 A BR J/C J22 3 A BR J8 B DLC2 BR E1 3 LG–R*1 P–B*2 Tc 11 E1 Tc ABS & TRAC ECU J/C J3 LG–R 4 B LG–R B 12 LG–R 9 IK2 A15 Tc B 11 II3 LG–R A EC *1: TMC Made *2: TMMK Made F00120 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC1. DLC2 CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Tc and E1 of DLC2 or DLC1. OK: Voltage: 10 – 14 V DLC1 E1 Tc E1 Tc F02607 F00445 F02612 OK If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. NG Author: Date: 856 DI–622 DIAGNOSTICS 2 – ABS & TRACTION CONTROL SYSTEM Check for open and short circuit in harness and connector between ABS & TRAC ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace ABS & TRAC ECU. Author: Date: 857 DI–623 DIAGNOSTICS – ABS & TRACTION CONTROL SYSTEM DI050–03 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F00070 Author: Date: 858 DI–624 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM DI1AX–04 HOW TO PROCEED WITH TROUBLESHOOTING Vehicle Brought to Workshop 1 Customer Problem Analysis DI–625 5 2 Normal Symptom Simulation Warning Light Check IN–21 DI–626 Remains ON 3 DTC Check DI–626 Warning Light ON Normal and Malfunction Code 4 DTC Chart DI–633 6 7 Circuit Inspection DTC Check DI–626 DI–640 Identification of Problem Repair 8 Warning Light Check DI–626 Normal Warning Light Remains OFF Confirmation Test END Step 3 , 6 : Diagnostic steps permitting the use of the TOYOTA hand–held tester. Author: Date: 859 DI–625 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI15Z–07 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / / km Miles Odometer Reading / Date Problem Occurred Weather Fine Temperature Cloudy Rainy Snowy / Other Approx. Starting Vehicle Operation Driving Idling [ Constant speed Other Acceleration Deceleration ] Road Conditions Details Of Problem Vehicle Inspection, Repair History Prior to Occurrence of Malfunction (Including Supplemental Restraint System) Diagnosis System Inspection SRS Warning Light Inspection 1st Time Remains ON Sometimes Light Up Does Not Light Up 2nd Time Remains ON Sometimes Light Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. ] 2nd Time Normal Code Malfunction Code [ Code. ] DTC Inspection Author: Date: 860 DI–626 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L1–01 PRE–CHECK 1. (a) (b) SRS WARNING LIGHT CHECK Turn the ignition switch to the ACC or ON position and check that the SRS warning light lights up. Check that the SRS warning light goes out after approx. 6 seconds. HINT:
H02309
When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to ”SRS warning light circuit malfunction” on page DI–790, DI–792. 2. (a) DLC1 E1 Tc R13006 DTC CHECK (Using diagnosis check wire) Present troubles codes: Output the DTC. (1) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. (2) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843–18020 NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (b) Past troubles codes: Output the DTC. (1) Using service wire, connect Terminals Tc and E1 of the DLC1. SST 09843–18020 (2) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. Author: Date: 861 DI–627 DIAGNOSTICS 0.25 ON OFF 0.25 Code 11 and 31 4.0 2.5 ON OFF 1.5 DTC 11 AT0716 AB0056 0.5 Repeat DTC 31 H08231 Read the DTC. Read the 2–digit DTC as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are shown in the illustration.
Normal code indication The light will blink 2 times per second.
Malfunction code indication The first blinking output indicates the first digit of a 2–digit DTC. After a 1.5–second pause, the second blinking output will indicate the second digit. If there are 2 or more codes, there will be a 2.5–second pause between each code. After all the codes have been output, there will be a 4.0–second pause and they will all be repeated. HINT:
In the event of a number of trouble codes, indication will start from the smallest numbered code.
If a DTC is not output or a DTC is output without terminal connection, proceed to the Tc terminal circuit inspection on page DI–796. 3. (a) DLC1 (b) TOYOTA Hand–Held Tester H08398 S05331 SUPPLEMENTAL RESTRAINT SYSTEM (c) Normal Code 0.5 – DLC3 H08323 DTC CHECK (Using TOYOTA hand–held tester) Hook up the TOYOTA hand–held tester to the DLC1 or the DLC3. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. 4. DTC CLEARANCE (Not using service wire) When the ignition switch is turned off, the diagnostic trouble code is cleared. HINT: DTC might not be cleared by turning the ignition switch OFF. In this case, proceed to the next step. 5. DTC CLEARANCE (Using service wire) (a) Connect the 2 service wires to terminals Tc and AB of DLC1. (b) Turn the ignition switch to ACC or ON and wait for approx. 6 seconds. Author: Date: 862 DI–628 DIAGNOSTICS (c) – SUPPLEMENTAL RESTRAINT SYSTEM Starting with the Tc terminal, ground alternately terminal Tc and terminal AB twice each in cycles of 1.0 seconds. Make sure that the terminals are grounded. Ensure the terminal Tc remain grounded. HINT: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately ground the other terminal within an interval of 0.2 seconds. If DTCs are not cleared, repeat the above procedure until the codes are cleared. Terminal 1 seconds OFF Tc Tc AB Body Ground 1 seconds (± 0.5 sec.)(± 0.5 sec.) 3 1 5 OFF AB Body Ground 2 4 Several Seconds ON 50 m sec. OFF 50 m sec. H02309 H01461 H02271 (d) 6. Several seconds after doing the clearing procedure, the SRS warning light will blink in a 50 m sec. cycle to indicate the codes which have been cleared. Past troubles codes: DTC CLEARANCE (See step 5.) Author: Date: 863 DI–629 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM 7. RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connectors on the next pages, insert paper which is the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTICE:
Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure.
If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. Author: Date: 864 DI–630 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM TMC made : 8 Side Airbag Assembly (RH) (Squib) 9 Seat Belt Pretensioner (RH) 10 Side Airbag Sensor (RH) 11 12 Front Airbag Sensor (RH) 4 2 Airbag Sensor Assembly 1 Front Passenger Airbag Assembly (Squib) Spiral Cable 7 5 3 Steering Wheel Pad (Squib) 6 No.1 J/B 13 Front Airbag Sensor (LH) 14 Side Airbag Sensor (LH) 15 Seat Belt Pretensioner (LH) 16 Side Airbag Assembly (LH) (Squib) H08316 Author: Date: 865 DI–631 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM TMMK made : 18 8 Side Airbag Assembly (RH) (Squib) 9 Seat Belt Pretensioner (RH) 10 Side Airbag Sensor (RH) 11 12 Front Airbag Sensor (RH) 4 Front Passenger Airbag Assembly (Squib) Spiral Cable 7 2 Airbag Sensor Assembly 5 1 3 Steering Wheel Pad (Squib) 6 No.1 J / B 13 Front Airbag Sensor (LH) 14 Side Airbag Sensor (LH) 15 17 Seat Belt Pretensioner (LH) 16 Side Airbag Assembly (LH) (Squib) H08247 Author: Date: 866 DI–632 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Airbag Sensor Assembly Connector 2 1 3 Short Spring Short Spring Short Spring After Release Before Release Paper Connector 5 Short Spring 7 Connector 8 16 17 18 Short Spring Connector 4 Short Spring After Release Before Release Paper Paper H01356 H01233 AB0130 AB0045 H02249 H00992 AB0046 H02248 H01358 Author: Date: 867 DI–633 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1AZ–04 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Detection Item
Short in D squib circuit B0100/13 (DI–640)
Open in D squib circuit B0101/14 (DI–645)
Short in D squib circuit (to Ground) B0102/11 (DI–649)
Short in D squib circuit (to B+) B0103/12 (DI–653) B0105/53 (DI–657) B0106/54 (DI–661) B0107/51 (DI–664) B0108/52 (DI–667) TMC made: B0110/43 (DI–670) TMMK made: B0110/43 (DI–674) TMC made: B0111/44 (DI–679) TMMK made: B0111/44 (DI–682) TMC made: B0112/41 (DI–686)
Short in P squib circuit
Open in P squib circuit
Short in P squib circuit (to Ground)
Short in P squib circuit (to B+)
Short in side squib (RH) circuit
Short in side squib (RH) circuit
Open in side squib (RH) circuit
Open in side squib (RH) circuit
Short in side squib (RH) circuit (to Ground) SRS Warning Light Trouble Area
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink Author: Date: 868 DI–634 DIAGNOSTICS DTC No. (See Page) TMMK made: B0112/41 (DI–689) TMC made: B0113/42 (DI–693) TMMK made: B0113/42 (DI–696) TMC made: B0115/47 (DI–700) TMMK made: B0115/47 (DI–704) TMC made: B0116/48 (DI–709) TMMK made: B0116/48 (DI–712) TMC made: B0117/45 (DI–716) TMMK made: B0117/45 (DI–719) TMC made: B0118/46 (DI–723) TMMK made: B0118/46 (DI–726) B0130/63 (DI–730) B0131/64 (DI–734) B0132/61 (DI–737) B0133/62 (DI–740) Detection Item – SUPPLEMENTAL RESTRAINT SYSTEM SRS Warning Light Trouble Area
Short in side squib (RH) circuit (to Ground)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Short in side squib (RH) circuit (to B+)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (RH) circuit (to B+)
Side airbag assembly RH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Short in side squib (LH) circuit
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Short in side squib (LH) circuit (to Ground)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit (to Ground)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Short in side squib (LH) circuit (to B+)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit (to B+)
Side airbag assembly LH (squib)
Airbag sensor assembly
Wire harness
Sub wire harness Blink
Short in P/T squib (RH) circuit
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to Ground)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to B+)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in side squib (LH) circuit
Open in side squib (LH) circuit
Open in side squib (LH) circuit
Open in P/T squib (RH) circuit Author: Date: 869 DI–635 DIAGNOSTICS DTC No. (See Page) Detection Item SUPPLEMENTAL RESTRAINT SYSTEM SRS Warning Light Trouble Area
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to Ground)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to B+)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink B1100/31 (DI–756)
Airbag sensor assembly malfunction
Airbag sensor assembly B1140/32 (DI–758)
Side airbag sensor assembly (RH) malfunction
Side airbag sensor assembly (RH)
Wire harness Blink B1141/33 (DI–766)
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Wire harness Blink B1156/B1157/ 15 (DI–774)
Front airbag sensor (RH) malfunction
Front airbag sensor (RH)
Wire harness
Engine room main wire harness ON B1158/B1159/ 16 (DI–782)
Front airbag sensor (LH) malfunction B0135/73 (DI–743) B0136/74 (DI–747) B0137/71 (DI–750) B0138/72 (DI–753) Normall N (DI–787)
Short in P/T squib (LH) circuit –
Open in P/T squib (LH) circuit
Front airbag sensor (LH)
Wire harness
System normal
Voltage source drop ON ON OFF –
Battery
Airbag sensor assembly ON HINT:


When the SRS warning light remains lit up and the DTC is the normal code, this means a voltage source drops. This malfunction is not stored in memory by the airbag sensor assembly and if the power source voltage returns to normal, the SRS warning light will automatically go out. When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. Author: Date: 870 DI–636 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B0–04 PARTS LOCATION Steering Wheel Pad (with Airbag) Front Passenger Airbag Assembly Front Airbag Sensor (RH) Airbag Sensor Assembly Combination Meter (Warning Light) Side Airbag Assembly (RH) Side Airbag Sensor Assembly (RH) Front Airbag Sensor (LH) Seat Belt Pretensioner (RH) Spiral Cable Side Airbag Assembly (LH) Side Airbag Sensor Assembly (LH) Seat Belt Pretensioner (LH) H08283 Author: Date: 871 DI–637 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B1–08 TERMINALS OF ECU C18 C17 B A 6 5 4 B C19 3 2 1 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 12 11 10 9 8 7 6 5 4 3 2 1 17 16 15 14 13 12 12 11 10 9 8 7 28 27 26 A 11 10 B A H01357 No. Symbol A – Electrical Connector Check Mechanism Terminal Name B – Electrical Connector Check Mechanism C18 – 3 LA SRS Warning Light C18 – 5 IG2 Power Source (IGN Fuse) C18 – 6 ACC Power Source (CIG Fuse) C18 – 9 SR+ Front Airbag Sensor (RH) C18 – 10 P+ Squib (Passenger) C18 – 11 P– Squib (Passenger) C18 – 12 SIL Diagnosis C18 – 13 D– Squib (Driver) C18 – 14 D+ Squib (Driver) C18 – 15 SL+ Front Airbag Sensor (LH) C18 – 19 Tc C18 – 20 SR– Front Airbag Sensor (RH) C18 – 26 SL– Front Airbag Sensor (LH) C18 – 27 E1 Ground C18 – 28 E2 Ground C17 – 1 PL– Squib (Seat Belt Pretensioner, LH) C17 – 2 PL+ Squib (Seat Belt Pretensioner, LH) C17 – 5 SFL+ Squib (Side, LH) C17 – 6 SFL– Squib (Side, LH) C17 – 7 VUPL Side Airbag Sensor (LH) C17 – 9 SSL+ Side Airbag Sensor (LH) C17 – 10 FSL Side Airbag Sensor (LH) C17 – 12 ESL Side Airbag Sensor (LH) Diagnosis Author: Date: 872 DI–638 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM No. Symbol Terminal Name C19 – 1 SFR– Squib (Side, RH) C19 – 2 SFR+ Squib (Side, RH) C19 – 5 PR+ Squib (Pretensioner, RH) C19 – 6 PR– Squib (Pretensioner, RH) C19 – 7 ESR Side Airbag Sensor (RH) C19 – 9 FSR Side Airbag Sensor (RH) C19 – 10 SSR+ Side Airbag Sensor (RH) C19 – 12 VUPR Side Airbag Sensor (RH) Author: Date: 873 DI–639 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI164–18 PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom
With the ignition switch in ACC or ON position, the SRS warning light sometimes lights up after approx. 6 seconds have elapsed.
SRS warning light is always lit up even when ignition switch is in the LOCK position.
With the ignition switch in ACC or ON position, the SRS warning light does not light up. Suspect Area See page
SRS warning light circuit (Al (Always lights li ht up when h ignition i iti switch it h is i in i LOCK posii tion.) DI 790 DI–790
SRS warning light circuit (Does not light up when ignition switch is turned to ACC or ON.) DI–792
Tc terminal circuit DI–796
DTC is not displayed.
SRS warning light is always lit up at the time of DTC check procedure.
DTC is displayed without Tc and E1 terminal connection. Author: Date: 874 DI–640 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI18Q–09 CIRCUIT INSPECTION DTC B0100/13 Short in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0100/13 is recorded when a short is detected in the D squib circuit. DTC No. B0100/13 DTC Detecting Condition Trouble Area
Short circuit between D+ wire harness and D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly D Squib 1 Y–B 2 Y 14 C18 D+ 13 C18 D– Spiral Cable H01451 Author: Date: 875 DI–641 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check D squib circuit. Spiral Cable D Squib PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable. (See page DI–626) CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly ←→ D– (–) H01001 R14286 D+ (+) H01134 NG Go to step 5. OK Author: Date: 876 DI–642 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Spiral Cable D Squib ACC →← ON or DTC B0100/13 DLC1 E1 H01002 AB0118 AB0119 R13006 FI1390 Tc H07478 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 877 DI–643 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DTC B0100/13 DLC1 E1 Tc H01003 AB0118 AB0119 R13006 FI1390 H01136 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 878 DI–644 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ D– (–) D+ (+) H01000 R14286 PREPARATION: (a) Disconnect the connector between the airbag sensor assembly and the spiral cable. (b) Release the airbag activation prevention mechanism of the spiral cable connector on the airbag sensor assembly side. (See page DI–626) CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher H01137 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ D– (–) H01004 R14286 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable. (See page DI–626) CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher D+ (+) H01138 NG Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 879 DI–645 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI18R–16 DTC B0101/14 Open in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0101/14 is recorded when an open is detected in the D squib circuit. DTC No. DTC Detecting Condition B0101/14 Trouble Area
Open circuit in D+ wire harness or D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–640. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check D squib circuit. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Spiral Cable D Squib ←→ D– (–) H01001 R14286 D+ (+) H01139 NG Go to step 5. OK Author: Date: 880 DI–646 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← D– D+ ACC ON or DLC1 E1 H01002 AB0069 AB0118 AB0119 R13006 W02044 DTC B0101/14 Tc H01140 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 881 DI–647 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. D Squib Airbag Sensor Assembly Spiral Cable →← ACC ON or DLC1 E1 H01003 AB0118 AB0119 R13006 W02044 DTC B0101/14 Tc H01141 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 882 DI–648 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable D Squib ←→ D– Airbag Sensor Assembly D+ H01000 R14286 PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω H01142 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib D– (–) CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω D+ (+) NG H01004 R14286 H01143 Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 883 DI–649 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L2–01 DTC B0102/11 Short in D Squib Circuit (to Ground) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0102/11 is recorded when a ground short is detected in the D squib circuit. DTC No. B0102/11 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to ground)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–640. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check D squib circuit. Spiral Cable CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly D Squib D+ H01001 R14301 H01126 NG Go to step 5. OK Author: Date: 884 DI–650 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← D– D+ ACC ON or DLC1 E1 – DTC B0102/11 Tc H01002 W01933 AB0069 AB0118 AB0118 R13006 W02042 H01127 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 885 DI–651 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DLC1 E1 H01003 AB0118 AB0119 R13006 W02042 DTC B0102/11 Tc H01128 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 886 DI–652 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ D+ (–) PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the steering wheel pad and the spiral cable, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher (+) H01000 R14301 H01129 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib CHECK: For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher D+ (–) H01004 R14301 (+) H06304 NG Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 887 DI–653 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L3–01 DTC B0103/12 Short in D Squib Circuit (to B+) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0103/12 is recorded when a B+ short is detected in the D squib circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to B+)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction B0103/12
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–640. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check D squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Spiral Cable D Squib D+ (–) AB0119 H01001 R14288 (+) H04530 NG Go to step 5. OK Author: Date: 888 DI–654 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Spiral Cable D Squib D+ D– Airbag Sensor Assembly ACC ON or DTC B0103/12 DLC1 E1 – Tc H01002 AB0069 AB0118 AB0119 R13006 W02043 H01131 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 889 DI–655 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DTC B0103/12 DLC1 E1 – Tc H01003 AB0118 AB0019 R13006 W02043 H01132 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 890 DI–656 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable ←→ D Squib Airbag Sensor Assembly ON D+ (–) (+) H01000 AB0119 R14288 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V H01133 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. ON Airbag Sensor Assembly Spiral Cable D Squib CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the voltage between D+ and body ground. OK: Voltage: 0 V D+ (–) AB0119 H01004 R14288 (+) NG Repair or replace harness between airbag sensor assembly and spiral cable. H08261 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 891 DI–657 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B6–12 DTC B0105/53 Short in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0105/53 is recorded when a short is detected in the P squib circuit. DTC No. B0105/53 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P Squib 1 Y–R 2 Y–G 10 C18 P+ 11 C18 P– H01454 Author: Date: 892 DI–658 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P squib circuit. PREPARATION: Release airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (See page DI–626) CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P– (–) R14286 H02142 P+ (+) H02251 NG Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK Author: Date: 893 DI–659 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01023 AB0118 R13006 – AB0119 H01077 DTC B0105/53 Tc H07479 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 894 DI–660 DIAGNOSTICS 4 →← ACC Airbag Sensor Assembly ON or DLC1 E1 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib H01024 AB0118 R13006 – DTC B0105/53 Tc AB0119 H01077 H01202 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 895 DI–661 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B7–17 DTC B0106/54 Open in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0106/54 is recorded when an open is detected in the P squib circuit. DTC No. B0106/54 DTC Detecting Condition Trouble Area
Open circuit in P+ wire harness or P– wire harness of squib
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–657. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: Below 1 Ω P Squib Airbag Sensor Assembly P– (–) R14286 H02142 P+ (+) NG H02251 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK Author: Date: 896 DI–662 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P– or DLC1 E1 – DTC B0106/54 Tc H01023 H02144 AB0118 AB0119 R13006 H01078 H02253 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 897 DI–663 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01024 AB0118 AB0119 R13006 H01078 DTC B0106/54 Tc H01205 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 898 DI–664 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B8–11 DTC B0107/51 Short in P Squib Circuit (to Ground) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0107/51 is recorded when ground short is detected in the P squib circuit. DTC No. B0107/51 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to ground)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–657. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and body ground. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P+ (–) (+) NG H01227 H02145 H02254 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK Author: Date: 899 DI–665 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P– or DTC B0107/51 DLC1 E1 Tc H01023 H02144 AB0118 AB0118 R13006 H01075 H02255 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 900 DI–666 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B0107/51 Tc H01024 AB0118 AB0119 R13006 H01075 H01196 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See stpe 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 901 DI–667 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B9–16 DTC B0108/52 Short in P Squib Circuit (to B+) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0108/52 is recorded when a B+ short is detected in the P squib circuit. DTC No. B0108/52 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to B+)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–657. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the voltage between the P+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P Squib P+ (–) AB0119 H01022 H02146 (+) H08262 NG Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. OK Author: Date: 902 DI–668 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P– or DTC B0108/52 DLC1 E1 Tc H01023 H02144 AB0118 AB0118 R13006 H01076 H02257 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 903 DI–669 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B0108/52 Tc H01024 AB0118 AB0119 R13006 H01076 H01199 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 904 DI–670 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16G–08 DTC B0110/43 Short in Side Squib (RH) Circuit (TMC Made) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0110/43 is recorded when a short is detected in the side squib (RH) circuit. DTC No. B0110/43 DTC Detecting Condition Trouble Area
Short circuit between SFR+ wire harness and SFR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (RH) 1 Y–R 2 C19 SFR+ 2 Y–G 1 C19 SFR– H01454 Author: Date: 905 DI–671 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. Airbag Sensor Assembly Squib (RH) SFR– (–) H01019 W03859 SFR+ PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (RH). (See page DI–626) CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and SFR–. OK: Resistance: 1 MΩ or Higher (+) H01180 NG Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK Author: Date: 906 DI–672 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H01020 AB0118 AB0119 R13006 H01069 DTC B0110/43 Tc H07481 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 907 DI–673 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01069 DTC B0110/43 Tc H01179 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 908 DI–674 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1KY–02 DTC B0110/43 Short in Side Squib (RH) Circuit (TMMK Made) CIRCUIT DESCRIPTION The side squib (RH) circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0110/43 is recorded when a short is detected in the side squib (RH) circuit. DTC No. B0110/43 DTC Detecting Condition Trouble Area
Short circuit between SFR+ wire harness and SFR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (RH) Y–R 1 BW1 Y–R 2 C19 SFR+ Y–G 2 BW1 Y–G 1 C19 SFR– 1 2 H04507 Author: Date: 909 DI–675 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. Squib (RH) Airbag Sensor Assembly SFR– H02272 W03859 SFR+ PREPARATION: Release airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (RH). (See page DI–626) CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and SFR–. OK: Resistance: 1 MΩ or Higher H02315 NG Go to step 5. OK Author: Date: 910 DI–676 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 H08250 W03860 AB0118 AB0119 R13006 H01069 DTC B0110/43 H08249 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 911 DI–677 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H02274 AB0118 AB0119 R13006 H01069 DTC B0110/43 Tc H02317 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0110/43 is not output. HINT: Codes other than code B0110/43 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK For the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 912 DI–678 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Sub Wire Harness Airbag Sensor Assembly Squib (RH) ← → SFR– (–) SFR+ (+) H02275 W03859 H03247 PREPARATION: (a) Disconnect sub wire harness connector on the airbag sensor assembly side. (b) Release the airbag activation prevention mechanism of the sub wire harness connector on the airbag sensor assembly side. (See page DI–626) CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFR+ and SFR–. OK: Resistance: 1 MΩ or Higher NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. Sub Wire Harness PREPARATION: Release the airbag activation prevention mechanism of the airbag sensor assembly connector. (See page DI–626) CHECK: For the connector (on the sub wire harness side) between the airbag sensor assembly and sub wire harness, measure the resistance between SFR+ and SFR–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) ← → SFR– (–) H02276 W03859 SFR+ (+) NG H03248 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK For the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 913 DI–679 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BA–03 DTC B0111/44 Open in Side Squib (RH) Circuit (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0111/44 is recorded when an open is detected in the side squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in SFR+ wire harness or SFR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction B0111/44
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–670. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. Airbag Sensor Assembly Squib (RH) SFR– (–) H01019 W03859 CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and SFR–. OK: Resistance: Below 1 Ω SFR+ (+) NG H01180 Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK Author: Date: 914 DI–680 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC SFR– ON SFR+ or DLC1 H01020 W03860 AB0118 AB0119 R13006 H01070 E1 DTC B0111/44 Tc H01181 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 915 DI–681 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01070 DTC B0111/44 Tc H01182 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 916 DI–682 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1L0–02 DTC B0111/44 Open in Side Squib (RH) Circuit (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0111/44 is recorded when an open is detected in the side squib (RH) circuit. DTC No. B0111/44 DTC Detecting Condition Trouble Area
Open circuit in SFR+ wire harness or SFR– wire harness of squib
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–674. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. Squib (RH) Airbag Sensor Assembly SFR– H02272 W03859 CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and SFR–. OK: Resistance: Below 1 Ω SFR+ H02315 NG Go to step 5. OK Author: Date: 917 DI–683 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC SFR– ON SFR+ or DLC1 H02273 W03860 AB0118 AB0119 R13006 H01070 E1 DTC B0111/44 Tc H03249 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 918 DI–684 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H02274 AB0118 AB0119 R13006 H01070 DTC B0111/44 Tc H03250 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0111/44 is not output. HINT: Codes other than code B0111/44 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 919 DI–685 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Sub Wire Harness Airbag Sensor Assembly ←→ Squib (RH) SFR– (–) SFR+ PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFR+ and SFR–. OK: Resistance: Below 1 Ω (+) H02275 W03859 H03247 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. Sub Wire Harness CHECK: For the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the sub wire harness, measure the resistance SFR+ and SFR–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (RH) ← → SFR– (–) H02276 W03859 SFR+ (+) NG H03248 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 920 DI–686 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BB–03 DTC B0112/41 Short in Side Squib (RH) Circuit (to Ground) (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0112/41 is recorded when ground short is detected in the side squib (RH) circuit. DTC No. B0112/41 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to ground)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–670. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) SFR+ NG (–) H01019 H02118 (+) Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. H02126 OK Author: Date: 921 DI–687 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Squib (RH) →← ACC SFR– ON SFR+ or DLC1 E1 – DTC B0112/41 Tc H01020 W03860 AB0118 AB0119 R13006 H01067 H01172 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 922 DI–688 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 DTC B0112/41 E1 H01021 AB0118 AB0119 R13006 H01067 Tc H01173 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 923 DI–689 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L4–01 DTC B0112/41 Short in Side Squib (RH) Circuit (to Ground) (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0112/41 is recorded when ground short is detected in the side squib (RH) circuit. DTC No. B0112/41 DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to ground)
Side squib (RH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–674. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the resistance between SFR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Squib (RH) SFR+ (–) H02272 H02118 (+) H03251 NG Go to step 5. OK Author: Date: 924 DI–690 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (RH) Airbag Sensor Assembly →← ACC SFR– ON SFR+ or DLC1 E1 – DTC B0112/41 Tc H02273 W03860 AB0118 AB0119 R13006 H01067 H03252 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 925 DI–691 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 DTC B0112/41 E1 H02274 AB0118 AB0119 R13006 H01067 Tc H03253 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0112/41 is not output. HINT: Codes other than code B0112/41 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 926 DI–692 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Sub Wire Harness Airbag Sensor Assembly Squib (RH) ← → SFR+ (–) PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFR+ and body ground. OK: Resistance: 1MΩ or Higher (+) H02275 H02118 H03254 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. Sub Wire Harness CHECK: For the connector (on the sub wire harness side) between the sub wire harness and the airbag sensor assembly, measure the resistance between SFR+ and body ground. OK: Resistance: 1MΩ or Higher Airbag Sensor Assembly Squib (RH) SFR+ (–) H02276 H02118 (+) NG H08251 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 927 DI–693 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BC–03 DTC B0113/42 Short in Side Squib (RH) Circuit (to B+) (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0113/42 is recorded when a B+ short is detected in the side squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to B+)
Side squib (RH) malfunction
Airbag sensor assembly malfunction B0113/42
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–670. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–626) 2 Check side squib (RH) circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the voltage between SFR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Squib (RH) SFR+ AB0119 H01019 H02119 (–) (+) H08263 NG Repair or replace harness or connector between side airbag assembly (RH) and airbag sensor assembly. OK Author: Date: 928 DI–694 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (RH) Airbag Sensor Assembly →← ACC ON SFR+ SFR– or DLC1 E1 – DTC B0113/42 Tc H01020 AB0118 AB0119 R13006 H01068 H01175 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 929 DI–695 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Squib (RH) ACC Airbag Sensor Assembly →← ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01068 DTC B0113/42 Tc H01176 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 930 DI–696 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L5–01 DTC B0113/42 Short in Side Squib (RH) Circuit (to B+) (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0113/42 is recorded when a B+ short is detected in the side squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (RH) wire harness (to B+)
Side squib (RH) malfunction
Airbag sensor assembly malfunction B0113/42
Side airbag assembly (RH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–674. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (RH) circuit. ON Airbag Sensor Assembly Squib (RH) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag assembly (RH) and the airbag sensor assembly, measure the voltage between the SFR+ and body ground. OK: Voltage: 0 V SFR+ (–) AB0119 H02272 H02119 (+) H08264 NG Go to step 5. OK Author: Date: 931 DI–697 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (RH) Airbag Sensor Assembly →← ACC ON SFR+ SFR– or DLC1 E1 – DTC B0113/42 Tc H02273 AB0118 AB0119 R13006 H01068 H03256 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFR+ and SFR– of the connector (on the side airbag assembly side) between the side airbag assembly (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 932 DI–698 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (RH). Airbag Sensor Assembly Squib (RH) →← ACC ON or DLC1 E1 H02274 AB0118 AB0119 R13006 H01068 DTC B0113/42 Tc H03257 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0113/42 is not output. HINT: Codes other than code B0113/42 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 933 DI–699 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. ON Sub wire Harness Airbag Sensor Assembly Squib (RH) SFR+ (–) PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the voltage between SFR+ and body ground. OK: Voltage: 0 V (+) AB0119 H02275 H02119 H08260 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. ON Sub Wire Harness Airbag Sensor Assembly Squib (RH) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the sub wire harness side) between the sub wire harness and the airbag sensor assembly, measure the voltage between SFR+ and body ground. OK: Voltage: 0 V SFR+ (–) AB0119 H02276 H02119 (+) NG H08252 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 934 DI–700 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16K–08 DTC B0115/47 Short in Side Squib (LH) Circuit (TMC Made) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0115/47 is recorded when a short is detected in the side squib (LH) circuit. DTC No. B0115/47 DTC Detecting Condition Trouble Area
Short circuit between SFL+ wire harness and SFL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (LH) 1 Y–R 5 C17 SFL+ 2 Y–G 6 C17 SFL– H01454 Author: Date: 935 DI–701 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. Airbag Sensor Assembly Squib (LH) SFL– (–) H01019 W03859 SFL+ PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (LH). (See page DI–626) CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and SFL–. OK: Resistance: 1 MΩ or Higher (+) H01191 NG Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK Author: Date: 936 DI–702 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Airbag Sensor Assembly Squib (LH) ACC ON or DLC1 DTC B0115/47 E1 Tc H01017 AB0118 AB0119 R13006 H01073 H07483 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 937 DI–703 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← ACC Airbag Sensor Assembly ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01073 DTC B0115/47 Tc H01190 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 938 DI–704 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1L6–02 DTC B0115/47 Short in Side Squib (LH) Circuit (TMMK Made) CIRCUIT DESCRIPTION The side squib (LH) circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0115/47 is recorded when a short is detected in the side squib (LH) circuit. DTC No. B0115/47 DTC Detecting Condition Trouble Area
Short circuit between SFL+ wire harness and SFL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM Airbag Sensor Assembly Side Squib (LH) Y–R 1 Y–G 2 BV1 BV1 Y–R 5 C17 SFL+ Y–G 6 C17 SFL– H04507 Author: Date: 939 DI–705 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. Airbag Sensor Assembly Squib (LH) SFL– (–) H02277 W03859 SFL+ PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the side airbag assembly (LH). (See page DI–626) CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and SFL–. OK: Resistance: 1 MΩ or Higher (+) H03259 NG Go to step 5. OK Author: Date: 940 DI–706 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Airbag Sensor Assembly Squib (LH) ACC ON or DLC1 DTC B0115/47 E1 Tc H08254 W03860 AB0118 AB0119 R13006 H01073 H08253 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 941 DI–707 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 E1 H02279 AB0118 AB0119 R13006 H01073 DTC B0115/47 Tc H03261 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0115/47 is not output. HINT: Codes other than code B0115/47 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 942 DI–708 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Squib (LH) Airbag Sensor Assembly ←→ Sub Wire Harness SFL– (–) SFL+ (+) H02280 W03859 H03262 PREPARATION: (a) Disconnect sub wire harness connector on the airbag sensor assembly side. (b) Release the airbag activation prevention mechanism of the sub wire harness connector on the airbag sensor assembly side. (See page DI–626) CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFL+ and SFL–. OK: Resistance: 1 MΩ or Higher NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. PREPARATION: Release the airbag activation prevention mechanism of the airbag sensor assembly connector. (See page DI–626) CHECK: For the connector (on the sub wire harness side) between the airbag sensor assembly and sub wire harness, measure the resistance between SFL+ and SFL–. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly Sub Wire Harness SFL– (–) H02281 W03859 SFL+ NG (+) Repair or replace harness or connector between airbag sensor assembly and sub wire harness. H03263 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 943 DI–709 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BD–03 DTC B0116/48 Open in Side Squib (LH) Circuit (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0116/48 is recorded when an open is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in SFL+ wire harness or SFL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction B0116/48
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–700. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and SFL–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Squib (LH) SFL– SFL+ NG (–) H01019 W03859 (+) Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. H01191 OK Author: Date: 944 DI–710 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly ACC SFL– ON SFL+ or DLC1 DTC B0116/48 E1 Tc H01017 AB0118 AB0119 R13006 H01074 H01192 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 945 DI–711 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01074 DTC B0116/48 Tc H01193 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 946 DI–712 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1L8–02 DTC B0116/48 Open in Side Squib (LH) Circuit (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0116/48 is recorded when an open short is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in SFL+ wire harness or SFL– wire harness of squib
Side squib (LH) malfunction
Airbag sensor assembly malfunction B0116/48
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–704. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. Squib (LH) Airbag Sensor Assembly SFL– (–) H02277 W03859 CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and SFL–. OK: Resistance: Below 1 Ω SFL+ (+) H03259 NG Go to step 5. OK Author: Date: 947 DI–713 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ACC SFL– ON SFL+ or DLC1 DTC B0116/48 E1 Tc H02278 AB0118 AB0119 R13006 H01074 H03264 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 948 DI–714 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H02279 AB0118 AB0119 R13006 H01074 DTC B0116/48 Tc H03265 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0116/48 is not output. HINT: Codes other than code B0116/48 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 949 DI–715 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Squib (LH) Airbag Sensor Assembly Sub Wire harness SFL– (–) SFL+ PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFL+ and SFL–. OK: Resistance: Below 1 Ω (+) H02280 W03859 H03266 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. CHECK: For the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the sub wire harness, measure the resistance between SFL+ and SFL–. OK: Resistance: Below 1 Ω Squib (LH) Airbag Sensor Assembly Sub Wire harness SFL– SFL+ NG (–) H02281 W03859 (+) Repair or replace harness or connector between airbag sensor assembly and sub wire harness. H03267 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 950 DI–716 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BE–03 DTC B0117/45 Short in Side Squib (LH) Circuit (to Ground) (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0117/45 is recorded when ground short is detected in the side squib (LH) circuit. DTC No. B0117/45 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to ground)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–700. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and body ground. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly SFL+ NG (–) H01016 H02118 (+) Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. H02128 OK Author: Date: 951 DI–717 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ACC ON SFL+ SFL– or DLC1 E1 H01017 W03860 AB0118 AB0119 R13006 H01071 DTC B0117/45 Tc H01184 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 952 DI–718 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01071 DTC B0117/45 Tc H01185 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 953 DI–719 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L6–01 DTC B0117/45 Short in Side Squib (LH) Circuit (to Ground) (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0117/45 is recorded when a ground short is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition B0117/45 Trouble Area
Short circuit in side squib (LH) wire harness (to ground)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–704. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. CHECK: For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the resistance between SFL+ and body ground. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly SFL+ NG (–) H02277 H02118 (+) Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. H03268 OK Author: Date: 954 DI–720 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Squib (LH) Airbag Sensor Assembly SFL– SFL+ ACC ON or DLC1 E1 H02278 W03860 AB0118 AB0119 R13006 H01071 DTC B0117/45 Tc H03269 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 955 DI–721 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H02279 AB0118 AB0119 R13006 H01071 DTC B0117/45 Tc H03270 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0117/45 is not output. HINT: Codes other than code B0117/45 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 956 DI–722 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Squib (LH) Airbag Sensor Assembly Sub Wire Harness SFL+ (–) PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFL+ and body ground. OK: Resistance: 1 MΩ or Higher (+) H02280 H02118 H03271 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. CHECK: For the connector (on the sub wire harness side) between the airbag sensor assembly and sub wire harness, measure the resistance between SFL+ and body ground. OK: Resistance: 1 MΩ or Higher Squib (LH) Airbag Sensor Assembly Sub Wire Harness SFL+ (–) H02281 H02118 (+) NG H08255 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 957 DI–723 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BF–03 DTC B0118/46 Short in Side Squib (LH) Circuit (to B+) (TMC Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0118/46 is recorded when a B+ short is detected in the side squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to B+)
Side squib (LH) malfunction
Airbag sensor assembly malfunction B0118/46
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–700. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. ON Airbag Sensor Assembly Squib (LH) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the voltage between SFL+ and body ground. OK: Voltage: 0 V SFL+ (–) AB0119 H01016 H02119 (+) NG H08265 Repair or replace harness or connector between side airbag assembly (LH) and airbag sensor assembly. OK Author: Date: 958 DI–724 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ACC ON SFL+ SFL– or DLC1 H01017 DTC B0118/46 E1 Tc AB0118 AB0119 R13006 H01072 H01187 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 959 DI–725 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01072 DTC B0118/46 Tc H01234 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 960 DI–726 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L7–01 DTC B0118/46 Short in Side Squib (LH) Circuit (to B+) (TMMK Made) CIRCUIT DESCRIPTION The side squib circuit consists of the airbag sensor assembly and side airbag assembly (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0118/46 is recorded when a B+ short is detected in the side squib (LH) circuit. DTC No. B0118/46 DTC Detecting Condition Trouble Area
Short circuit in side squib (LH) wire harness (to B+)
Side squib (LH) malfunction
Airbag sensor assembly malfunction
Side airbag assembly (LH)
Airbag sensor assembly
Wire harness
Sub wire harness WIRING DIAGRAM See page DI–704. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check side squib (LH) circuit. ON Airbag Sensor Assembly Squib (LH) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly, measure the voltage between SFL+ and body ground. OK: Voltage: 0 V SFL+ (–) AB0119 H02277 H02119 (+) H08266 NG Go to step 5. OK Author: Date: 961 DI–727 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Squib (LH) →← Airbag Sensor Assembly ACC ON SFL+ SFL– or DLC1 H02278 DTC B0118/46 E1 Tc AB0118 AB0119 R13006 H01072 H03273 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect SFL+ and SFL– of the connector (on the side airbag assembly side) between the side airbag assembly (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 962 DI–728 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check side squib (LH). Squib (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H02279 AB0118 AB0119 R13006 H01072 DTC B0118/46 Tc H03274 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag assembly (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0118/46 is not output. HINT: Codes other than code B0118/46 may be output at this time, but they are not relevant to this check. NG Replace side airbag assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 963 DI–729 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check sub wire harness. Sub Wire Harness Squib (LH) ←→ Airbag Sensor Assembly ON SFL+ (–) H02280 AB0119 H02119 PREPARATION: Disconnect the sub wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the sub wire harness side) between the side airbag assembly and the sub wire harness, measure the resistance between SFL+ and body ground. OK: Voltage: 0 V (+) H08267 NG Repair or replace sub wire harness. OK 6 Check harness between airbag sensor assembly and sub wire harness. ON Sub Wire Harness Airbag Sensor Assembly Squib (LH) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the sub wire harness side) between the airbag sensor assembly and sub wire harness, measure the voltage between SFL and body ground. OK: Voltage: 0 V SFL+ (–) AB0119 H02281 H02119 (+) NG H08256 Repair or replace harness or connector between airbag sensor assembly and sub wire harness. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 964 DI–730 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16S–17 DTC B0130/63 Short in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0130/63 is recorded when a short is detected in the P/T squib (RH) circuit. DTC No. B0130/63 DTC Detecting Condition Trouble Area
Short circuit between PR+ wire harness and PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (RH) 1 Y–B 5 C19 PR+ 2 Y 6 C19 PR– H01454 Author: Date: 965 DI–731 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (RH) circuit. Airbag Sensor Assembly P/T Squib (RH) PR+ (+) H01019 H02141 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (RH). (See page DI–626). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: 1 MΩ or Higher PR– (–) H02203 NG Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK Author: Date: 966 DI–732 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 DTC B0130/63 E1 H01020 AB0118 AB0119 R13006 H01082 Tc H07485 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 967 DI–733 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0130/63 E1 H01021 AB0118 AB0119 R13006 H01082 Tc H01214 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 968 DI–734 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BG–13 DTC B0131/64 Open in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (RH) consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0131/64 is recorded when an open is detected in the P/T squib (RH) circuit. DTC No. B0131/64 DTC Detecting Condition Trouble Area
Open circuit in PR+ wire harness or PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–730. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (RH) circuit. P/T Squib (RH) PR+ (+) H01019 H02141 CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly PR– (–) H02205 NG Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK Author: Date: 969 DI–735 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01083 DTC B0131/64 Tc H02206 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 970 DI–736 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01083 DTC B0131/64 Tc H01217 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 971 DI–737 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BH–10 DTC B0132/61 Short in P/T Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0132/61 is recorded when a ground short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (RH) wire harness (to ground)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0132/61
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–730. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (RH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly P/T Squib (RH) PR+ (–) (+) NG H01019 H08392 H08393 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK Author: Date: 972 DI–738 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01079 DTC B0132/61 Tc H02208 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 973 DI–739 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01079 DTC B0132/61 Tc H01208 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 974 DI–740 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BI–13 DTC B0133/62 Short in P/T Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0133/62 is recorded when a B+ short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (RH) wire harness (to B+)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0133/62
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–730. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (RH) circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the voltage between PR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P/T Squib (RH) PR+ (–) H01019 AB0119 H08394 (+) H08268 NG Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. OK Author: Date: 975 DI–741 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 E1 – H01020 H02139 AB0118 AB0119 R13006 H01081 DTC B0133/62 Tc H02210 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 976 DI–742 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01081 DTC B0133/62 Tc H01211 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 977 DI–743 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16W–17 DTC B0135/73 Short in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0135/73 is recorded when a short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0135/73
Short circuit between PL+ wire harness and PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (LH) 1 Y–B (*1) L–B (*2) 2 Y 2 C17 PL+ 1 C17 PL– *1: TMC Made *2: TMMK Made H01454 Author: Date: 978 DI–744 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (LH) circuit. Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (LH). (See page DI–626) CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: 1 MΩ or Higher PL– (–) H02211 NG Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK Author: Date: 979 DI–745 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 E1 H01017 AB0118 AB0119 R13006 H01086 DTC B0135/73 Tc H07487 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 980 DI–746 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01086 DTC B0135/73 Tc H01229 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–626) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–626) OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 981 DI–747 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BJ–14 DTC B0136/74 Open in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (LH) consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0136/74 is recorded when an open is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in PL+ wire harness or PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0136/74
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–743. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly P/T Squib (LH) PL+ PL– NG (+) H01016 H02141 (–) Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. H02213 OK Author: Date: 982 DI–748 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) Airbag Sensor Assembly PL+ PL– ACC ON or DLC1 DTC B0136/74 E1 H01017 H02139 AB0118 AB0119 R13006 H01087 Tc H02214 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 983 DI–749 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← ACC Airbag Sensor Assembly ON or DLC1 E1 DTC B0136/74 Tc H01018 AB0118 AB0119 R13006 H01087 H01232 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 984 DI–750 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BK–10 DTC B0137/71 Short in P/T Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0137/71 is recorded when a ground short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (LH) wire harness (to ground)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0137/71
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–743. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and body ground. OK: Resistance: 1 MΩ or Higher P/T Squib (LH) Airbag Sensor Assembly (–) PL+ (+) NG H01016 H08392 H08396 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK Author: Date: 985 DI–751 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← P/T Squib (LH) PL+ PL– Airbag Sensor Assembly ACC ON or DLC1 E1 H01017 H02139 AB0118 AB0119 R13006 H01084 DTC B0137/71 Tc H02216 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 986 DI–752 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 DTC B0137/71 E1 H01018 AB0118 AB0119 R13006 H01084 Tc H01220 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 987 DI–753 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BL–14 DTC B0138/72 Short in P/T Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see OPERATION on page RS–2. DTC B0138/72 is recorded when a B+ short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (LH) wire harness (to B+)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0138/72
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–743. INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check P/T squib (LH) circuit. ON Airbag Sensor Assembly P/T Squib (LH) (–) AB0119 H01016 H08394 CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the voltage between PL+ and body ground. OK: Voltage: 0 V PL+ (+) NG H08269 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. OK Author: Date: 988 DI–754 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly PL+ PL– ACC ON or DLC1 E1 H01017 H02139 AB0118 AB0119 R13006 H01085 DTC B0138/72 Tc H02217 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 989 DI–755 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 DTC B0138/72 E1 H01018 AB0118 AB0119 R13006 H01085 Tc H01222 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. Author: Date: 990 DI–756 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BM–18 DTC B1100/31 Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The airbag sensor assembly consists of a airbag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when occurrence of a malfunction in the airbag sensor assembly is detected. DTC No. DTC Detecting Condition Trouble Area
Airbag sensor assembly malfunction B1100/31
Airbag sensor assembly INSPECTION PROCEDURE HINT: When a malfunction code other than code B1100/31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code B1100/31. 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check voltage at IG2 and ACC of airbag sensor assembly. ON Airbag Sensor Assembly ACC (–) AB0119 H01298 IG2 (+) CHECK: (a) Turn ignition switch to ON. (b) Measure the voltage between body ground and terminals each of IG2 and ACC of the airbag sensor assembly connector. OK: Voltage: 10 – 14 V H01299 NG Check that an abnormality occurs on the battery and charging system. OK Author: Date: 991 DI–757 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1100/31 output again? ACC ON or DLC1 E1 AB0118 AB0119 R13006 FI1394 DTC B1100/31 Tc H00022 PREPARATION: Clear DTC. (See step 5 on page DI–626) CHECK: (a) Turn ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Repeat operation in step (a) and (b) at least 5 times. (d) Check DTC. (See page DI–626) HINT: Codes other than code B1100/31 may be output at this time, but they are not relevant to this check. NO Using simulation method, reproduce malfunction symptoms. (See page IN–21) YES Replace airbag sensor assembly. Author: Date: 992 DI–758 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L8–01 DTC B1140/32 Side Airbag Sensor Assembly (RH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (RH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and diagnosis system malfunction. DTC B1140/32 is recorded when occurrence of a malfunction in the side airbag sensor assembly (RH) is detected. DTC No. B1140/32 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (RH)
Wire harness
Airbag sensor assembly
Side airbag sensor assembly (RH) malfunction WIRING DIAGRAM Side Aribag Sensor Assembly (RH) 4 GR 7 C19 ESR 3 LG 9 C19 FSR 2 L–Y 10 C19 SSR+ 1 P 12 C19 VUPR ESR FSR SSR+ VUPR Airbag Sensor Assembly H01450 Author: Date: 993 DI–759 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1140/32 out put? ACC ON or DLC1 E1 DTC B1140/32 Tc AB0118 AB0119 R13006 H09528 H09527 CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. YES The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. NO 2 Is connector of side airbag sensor assembly (RH) properly connected? 3 Prepare for inspection. (See step 1 on DI–787) Author: Date: 994 DI–760 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Side Airbag Sensor Assembly (RH) ←→ Airbag Sensor Assembly Airbag Sensor Assembly SSR+ ESR PREPARATION: (a) Disconnect the side airbag sensor assembly (RH) connector. (b) Using a service wire, connect SSR+ and ESR of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between SSR+ and ESR. OK: Resistance: Below 1 Ω (+) (–) H01015 H01058 H01036 SSR+ ESR H01160 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author: Date: 995 DI–761 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. PREPARATION: Using a service wire, connect VUPR and FSR of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (RH) and airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between VUPR and FSR. OK: Resistance: Below 1 Ω Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly Airbag Sensor Assembly VUPR FSR VUPR FSR (+) (–) H01015 H01059 H01037 H01161 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author: Date: 996 DI–762 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). Side Airbag Sensor Assembly (RH) CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SSR+, VUPR and FSR. OK: Resistance: Below 1 Ω Airbag Sensor Assembly Airbag Sensor Assembly VUPR FSR (+) (–) H01013 H01038 SSR+ H01162 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK 7 Check wire harness (to B+). ON Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly Airbag Sensor Assembly SSR+ AB0119 H01013 H01039 (–) VUPR (+) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (RH) and the airbag sensor assembly, measure the voltage between the body ground and each of SSR+, VUPR, ESR and FSR. OK: Voltage: 0 V FSR ESR H08270 NG Repair or replace harness or connector between side airbag sensor assembly (RH) and airbag sensor assembly. OK Author: Date: 997 DI–763 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1140/32 out put again? Side Airbag Sensor Assembly (RH) Airbag Sensor Assembly →← →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (RH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Go to step 9. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 998 DI–764 DIAGNOSTICS 9 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (RH) from the connector and connect the side airbag sensor (LH) to the connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 999 DI–765 DIAGNOSTICS 10 SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (RH). →← Side Airbag Sensor Assembly (RH) ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (RH) to the connector that the side airbag sensor (LH) was connected to. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1000 DI–766 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L9–01 DTC B1141/33 Side Airbag Sensor Assembly (LH) Malfunction CIRCUIT DESCRIPTION The side airbag sensor assembly (LH) consists of the safing sensor, diagnosis circuit and lateral deceleration sensor, etc. It receives signals from the lateral deceleration sensor, judges whether or not the SRS must be activated, and diagnosis system malfunction. DTC B1141/33 is recorded when occurrence of a malfunction in the side airbag sensor assembly (LH) is detected. DTC No. B1141/33 DTC Detecting Condition Trouble Area
Side airbag sensor assembly (LH) malfunction
Side airbag sensor assembly (LH)
Wire harness
Airbag sensor assembly WIRING DIAGRAM Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly 4 GR–L 12 C17 ESL 3 LG–B 10 C17 FSL 2 L–W 9 C17 SSL+ 1 P–L 7 C17 VUPL ESL FSL SSL+ VUPL H01450 Author: Date: 1001 DI–767 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Is DTC B1141/33 out put? ACC ON or DLC1 DTC B1141/33 E1 Tc AB0118 AB0119 R13006 H09530 H09529 CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. YES The malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. NO 2 Is connector of side airbag sensor assembly (LH) properly connected? 3 Prepare for inspection. (See step 1 on page DI–787) Author: Date: 1002 DI–768 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. ←→ Side Airbag Sensor Assembly (LH) SSL+ Airbag Sensor Assembly Airbag Sensor Assembly ESL PREPARATION: (a) Disconnect the side airbag sensor assembly (LH). (b) Using a service wire, connect SSL+ and ESL of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between SSL+ and ESL. OK: Resistance: Below 1 Ω ESL (+) H01010 H01058 H01050 (–) SSL+ NG H01166 Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author: Date: 1003 DI–769 DIAGNOSTICS 5 SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Side Airbag Sensor Assembly (LH) PREPARATION: Using a service wire, connect VUPL and FSL of the connector (on the side airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly. CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between VUPL and FSL. OK: Resistance: Below 1 Ω Airbag Sensor Assembly VUPL FSL FSL (+) H01010 H01059 H01051 – Airbag Sensor Assembly VUPL NG (–) H01167 Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author: Date: 1004 DI–770 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SSL+, VUPL and FSL. OK: Resistance: 1 MΩ or Higher SIde Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly SSL+ FSL VUPL (+) (–) NG H01008 H01052 H01168 Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK 7 ON Check wire harness (to B+). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly Airbag Sensor Assembly FSL SSL+ ESL VUPL H01008 AB0119 H01053 (+) (–) H08271 CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the side airbag sensor assembly (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SSL+, ESL, VUPL and FSL. OK: Voltage: 0 V NG Repair or replace harness or connector between side airbag sensor assembly (LH) and airbag sensor assembly. OK Author: Date: 1005 DI–771 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1141/33 out put again? Side Airbag Sensor Assembly (LH) →← ACC Airbag Sensor Assembly →← ON or DLC1 E1 DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Connect the connector to the side airbag sensor assembly (LH). (b) Connect the connector to the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NO Go to step 9. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1006 DI–772 DIAGNOSTICS 9 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← Side Airbag Sensor Assembly (RH) ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B1141/33 Tc H01007 AB0118 AB0119 R13006 H01066 H01170 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the side airbag sensor (LH) from the connector and connect the side airbag sensor (RH) to the connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See step 5 on page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1141/33 is not output. HINT: Codes other than code B1141/33 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK Author: Date: 1007 DI–773 DIAGNOSTICS 10 – SUPPLEMENTAL RESTRAINT SYSTEM Check side airbag sensor assembly (LH). Side Airbag Sensor Assembly (LH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01012 AB0118 AB0119 R13006 H01065 DTC B1140/32 Tc H01164 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the side airbag sensor (LH) to the connector that the side airbag sensor (RH) was connected to. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1140/32 is not output. HINT: Codes other than code B1140/32 may be output at this time, but they are not relevant to this check. NG Replace side airbag sensor assembly (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1008 DI–774 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4LA–01 DTC B1156/B1157/15 Front Airbag Sensor (RH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (RH) circuit consists of the airbag sensor assembly and front airbag sensor (RH). For details of the function of each component, see OPERATION on page RS–2. DTC B1156/B1157/15 is recorded when malfunction is detected in the front airbag sensor (RH) circuit. DTC No. B1156/B1157/15 DTC Detecting Condition Trouble Area
Front airbag sensor (RH)
Wire harness
Engine room main wire harness
Airbag sensor assembly
Front airbag sensor (RH) malfunction WIRING DIAGRAM Airbag Sensor Assembly Front Airbag Sensor (RH) SR+ SR– B–W 2 IU1 B–W 9 C18 SR+ BR–W 1 IU1 BR–W 20 C18 SR– 2 1 H02750 Author: Date: 1009 DI–775 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (RH) ON (+) H03355 AB0119 H03363 (–) Airbag Sensor Assembly CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the voltage between body ground and each of SR+ and SR–. OK: Voltage: Below 1 V SR+ SR– H03445 NG Go to step 8. OK 3 Check wire harness (to ground). Airbag Sensor Assembly Front Airbag Sensor (RH) (+) (–) H03353 H03361 Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SR+ and SR–. OK: Resistance: 1 MΩ or Higher SR+ SR– H03443 NG Go to step 9. OK Author: Date: 1010 DI–776 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR–. OK: Resistance: 1 MΩ or Higher SR+ (+) (–) SR– H03355 H03356 H09518 NG Go to step 10. OK 5 Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly SR+ SR– (+) (–) H03353 H09521H03356 Airbag Sensor Assembly SR+ PREPARATION: Using a service wire, connect SR+ and SR– of the connector (on the front airbag sensor (RH) side) between the airbag sensor assembly and the front airbag sensor (RH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR–. OK: Resistance: Below 1 Ω SR– H09523 NG Go to step 11. OK Author: Date: 1011 DI–777 DIAGNOSTICS 6 SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (RH). Front Airbag Sensor (RH) Airbag Sensor Assembly SR+ H04504 H01062 – (+) CHECK: For the connector (on the front airbag sensor (RH)), measure the resistance between SR+ and SR–. OK: Resistance: 300 – 1500 Ω SR– (–) H08346 NG Replace front airbag sensor (RH). OK Author: Date: 1012 DI–778 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (RH) Airbag Sensor Assembly →← ACC →← ON or DLC1 DTC B1156/B1157/15 E1 H02757 AB0118 AB0119 R13006H01063 Tc H04014 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (RH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See Pub. No. RM572E1 on page DI–95) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See Pub. No. RM572E1 on page DI–95) OK: DTC B1156/B1157/15 is not output. HINT: Codes other than code B1156/B1157/15 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1013 DI–779 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness (to B+). Front Airbag Sensor (RH) ←→ Airbag Sensor Assembly Engine Room Main Wire Harness ON SR+ (–) SR– (+) PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the RH front door wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the voltage between body ground and each of SR+ and SR–. OK: Voltage: Below 1 V NG H03354 AB0119 H06141 H08272 Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 9 Check engine room main wire harness (to ground). Front Airbag Sensor (RH) Airbag Sensor Assembly Engine Room Main Wire Harness (–) SR+ SR– PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between body ground and each of SR+ and SR–. OK: Resistance: 1 MΩ or Higher (+) NG H03354 H06140 Repair or replace engine room main wire harness. H08258 OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. Author: Date: 1014 DI–780 DIAGNOSTICS 10 SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Front Airbag Sensor (RH) Engine Room Main Wire Harness ←→ SR+ H03354 H09519 – (+) Airbag Sensor Assembly SR– PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SR+ and SR–. OK: Resistance: 1 MΩ or Higher (–) H09520 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. Author: Date: 1015 DI–781 DIAGNOSTICS 11 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Engine Room Main Wire Harness Front Airbag Sensor (RH) Airbag Sensor Assembly ←→ SR+ SR– SR+ (+) H03352 H09521 H09519 SR– (–) PREPARATION: (a) Disconnect the engine room main wire harness connector on the airbag sensor assembly side. (b) Using a service wire, connect SR+ and SR– of the connector (on the engine room main wire harness side) between the engine room main wire harness and the front airbag sensor (RH). CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SR+ and SR–. OK: Resistance: Below 1 Ω H09522 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. Author: Date: 1016 DI–782 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4LB–01 DTC B1158/B1159/16 Front Airbag Sensor (LH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (LH) circuit consists of the airbag sensor assembly and front airbag sensor (LH). For details of the function of each component, see OPERATION on page RS–2. DTC B1158/B1159/16 is recorded when malfunction is detected in the front airbag sensor (LH) circuit. DTC No. B1158/B1159/16 DTC Detecting Condition Trouble Area
Front airbag sensor (LH)
Wire harness
Airbag sensor assembly
Front airbag sensor (LH) malfunction WIRING DIAGRAM Front Airbag Sensor (LH) SL+ SL– Airbag Sensor Assembly W–R 15 C18 SL+ BR 26 C18 SL– 2 1 H02751 Author: Date: 1017 DI–783 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (LH) ON Airbag Sensor Assembly CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SL+ and SL–. OK: Voltage: Below 1 V SL+ (+) NG H01370 AB0119 H08065 (–) SL– Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. H08066 OK 3 Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SL+ and SL–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Front Airbag Sensor (LH) (+) Airbag Sensor Assembly SL+ NG H01370 H08399 (–) SL– Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. H08400 OK Author: Date: 1018 DI–784 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL–. OK: Resistance: 1 MΩ or Higher Front Airbag Sensor (LH) Airbag Sensor Assembly Airbag Sensor Assembly SL+ (+) NG (–) SL– H01370 H08058 Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. H09524 OK 5 Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly SL+ Airbag Sensor Assembly SL– (+) (–) H09526 H09521H08058 SL+ SL– H09525 PREPARATION: Using a service wire, connect SL+ and SL– of the connector (on the front airbag sensor (LH) side) between the airbag sensor assembly and the front airbag sensor (LH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL–. OK: Resistance: Below 1 Ω NG Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. OK Author: Date: 1019 DI–785 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (LH). Airbag Sensor Assembly CHECK: For the connector (on the front airbag sensor (LH)), measure the resistance between SL+ and SL–. OK: Resistance: 300 – 1500 Ω Front Airbag Sensor (LH) SL+ H01371 H01009 (+) SL– (–) H01155 NG Replace front airbag sensor (LH). OK Author: Date: 1020 DI–786 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (LH) Airbag Sensor Assembly →← ACC →← ON or DLC1 E1 H01369 AB0118 AB0119 R13006 H01064 DTC B1158/B1159/16 Tc H01154 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (LH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory. (See page DI–626) (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC. (See page DI–626) OK: DTC B1158/B1159/16 is not output. HINT: Codes other than code B1158/B1159/16 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1021 DI–787 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BN–08 DTC Normal Source Voltage Drop CIRCUIT DESCRIPTION The SRS is equipped with a voltage–increase circuit (DC–DC converter) in the airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage–increase circuit (DC–DC converter) functions to increase the voltage of the SRS to normal voltage. The diagnosis system malfunction display for this circuit is different from other circuits that is when the SRS warning light remains lit up and the DTC is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the airbag sensor assembly, and the source voltage returns to normal, the SRS warning light automatically goes off. DTC No. Diagnosis (Normal) Source voltage drop WIRING DIAGRAM Battery FL MAIN B–G Instrument Panel J/B 40A AM1 1 2 2 1K W Fusible Link Block 1 1 F6 F4 100A ALT 2 F9 Instrument Panel J/B 4 5 W–R 5 W–R 2L 1K 1B Ignition Switch 7 6 B–R 3 1K 2 3 L–R 6 1K Junction Connector A W–B IG 30A AM2 5A IGN 15A CIG 7 1J B B–R 1 1B 1 2A Airbag Sensor Assembly 4 1N B–O 5 C18 IG2 2 1N GR 6 C18 ACC 1 1N W–B 27 C18 E1 Instrument Panel J/B H02288 Author: Date: 1022 DI–788 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. LOCK Airbag Sensor Assembly P Squib D Squib Spiral Cable Front Airbag Sensor (RH) Front Airbag Sensor (LH) P/T Squib (LH) Side Airbag Sensor (LH) Side Squib (LH) PREPARATION: (a) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (b) Remove the steering wheel pad. (See page SR–11) (c) Disconnect the connector of the front passenger airbag assembly. (See page RS–28) (d) Disconnect the connector of the side airbag assembly RH and LH. (See page RS–40 and RS–52) (e) Disconnect the connector of the seat belt pretensioner RH and LH. (See page BO–126) (f) Disconnect the connectors of the airbag sensor assembly. (See page RS–59) (g) Disconnect the connector of the front airbag sensor LH and RH. (See page RS–64) (h) Disconnect the connector of the side airbag sensor assembly RH and LH. (See page RS–69) CAUTION: Store the steering wheel pad with the front surface facing upward. P/T Squib (RH) Side Airbag Sensor (RH) Side Squib (RH) H06508 H01026 H06509 Author: Date: 1023 DI–789 DIAGNOSTICS 2 – SUPPLEMENTAL RESTRAINT SYSTEM Check source voltage. ON Airbag Sensor Assembly ACC (–) AB0119 H01298 IG2 (+) H01299 PREPARATION: Connect negative (–) terminal cable to the battery. CHECK: (a) Turn ignition switch ON. (b) Measure the voltage each of IG2 and ACC on the sensor and operate electric system. (defogger, wiper, headlight, heater blower, etc.) OK: Voltage: 10 – 14 V NG Check harness between battery and airbag sensor assembly, and check battery and charging system. OK 3 Does SRS warning light turn off? ON H01249 PREPARATION: (a) Turn ignition switch to LOCK. (b) Connect the steering wheel pad connector. (c) Connect the front passenger airbag assembly connector. (d) Connect the airbag sensor assembly connectors. (e) Connect the side airbag assembly connectors. (f) Connect the seat belt pretensioner connectors. (g) Connect the side airbag sensor assembly connectors. (h) Connect the front airbag sensor connectors. (i) Turn ignition switch to ON. CHECK: Operate electric system (defogger, wiper, headlight, heater blower, etc.) and check that SRS warning light goes off. NO Check for DTCs. If a DTC is output, perform troubleshooting for the DTC. If a normal code is output, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Author: Date: 1024 DI–790 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BO–08 SRS Warning Light Circuit Malfunction (Always lights up, when ignition switch is in LOCK position.) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM Battery FL MAIN Airbag Sensor Assembly 3 LA C18 Fusible Link Block 1 1 F4 F6 B–G J3 Junction Connector B–Y 1 2A B A W–R LG 13 7 2J Instrument Panel J/B SRS Warning Light 2 IG2 LG A Engine Room J/B No.2 10A ECU–B Short Pin 12 2 1G 3 1W W–R A LG 7 II3 DLC1 B–Y (*1) LG (*2) 5 AB J3 Junction Connector 19 TC C18 P–B B LG–R B 11 II3 LG–R (*3) P–B (*4) 11 TC DLC2 4 LG–R B TC *1: TMMK Made, 1MZ–FE *2: Except *1 *3: TMC Made *4: TMMK Made H02289 Author: Date: 1025 DI–791 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. (See step 1 on page DI–787) 2 Does SRS warning light turn off? Airbag Sensor Assembly LOCK AB0117 H01293 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery. CHECK: Check operation of SRS warning light. H01295 NO Check SRS warning light circuit or terminal AB circuit of DLC1. YES Replace airbag sensor assembly. Author: Date: 1026 DI–792 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BP–08 SRS Warning Light Circuit Malfunction (Does not light up, when ignition switch is turned to ACC or ON.) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM See page DI–790. INSPECTION PROCEDURE 1 Check ECU–B Fuse. Fuse N14677 PREPARATION: Remove ECU–B fuse. CHECK: Check continuity of ECU–B fuse. OK: Continuity HINT:
Fuse may be burnt out even if it appears to be OK during visual inspection.
If fuse is OK, install it. NG Go to step 5. OK 2 Prepare for inspection. (See step 1 on page DI–787) Author: Date: 1027 DI–793 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check SRS warning light circuit. Airbag Sensor Assembly ON (+) LA (–) AB0119 H01300 – PREPARATION: (a) Connect negative (–) terminal cable to the battery. (b) Turn ignition switch to ACC or ON. CHECK: Measure the voltage LA terminal of the harness side connector of the airbag sensor assembly. OK: Voltage: 10 – 14 V H01301 NG Check SRS warning light bulb or repair SRS warning light circuit. OK Author: Date: 1028 DI–794 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Does SRS warning light come on? PREPARATION: (a) Disconnect negative (–) terminal cable from the battery. (b) Connect the airbag sensor assembly connector. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. (d) Turn ignition switch to ACC or ON. CHECK: Check operation of SRS warning light. P Squib D Squib Spiral Cable Front Airbag Sensor (RH) Front Airbag Sensor (LH) P/T Squib (LH) Side Airbag Sensor (LH) Side Squib (LH) P/T Squib (RH) Side Airbag Sensor (RH) Side Squib (RH) ON H08325 AB0119 H02309 Airbag Sensor Assembly H08324 NO Check terminal LA of airbag sensor assembly. If normal, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. Author: Date: 1029 DI–795 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Is new ECU–B fuse burnt out again? NO Using simulation method, reproduce malfunction symptoms. (See page IN–21) YES Check harness between ECU–B fuse and SRS warning light. Author: Date: 1030 DI–796 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BQ–08 Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by blinking the SRS warning light. WIRING DIAGRAM BR 3 A Tc E1 Airbag Sensor Assembly J3 Junction Connector DLC1 LG–R (*1) P–B (*2) 11 J22 (1MZ–FE) J23 (5S–FE) Junction Connector 11 II3 LG–R B P–B B 19 A21 Tc DLC2 A 3 E1 Tc LG–R 4 B BR BR (*3) BR (*4) B Junction Connector C J7 B J8 BR J26 Junction Connector 6 II3 J22 Junction Connector BR A A BR B BR (*3) EC EC *1: TMC Made *2: TMMK Made *3: California, 1MZ–FE *4: Except California H08301 Author: Date: 1031 DI–797 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE If the DTC is not displayed, do the following troubleshooting. 1 Does SRS warning light up for approx. 6 seconds? LOCK ACC ON PREPARATION: Check operation of the SRS warning light after ignition switch is turned from LOCK position to ACC or ON position. or AB0117 AB0118 H02309 AB0119 H02314 NO Check SRS warning light system. (See page DI–626) YES 2 Check voltage between terminals Tc and E1 of DLC1. ACC ON or E1 (–) AB0118 AB0119 R14305 Tc PREPARATION: Turn ignition switch to ACC or ON. CHECK: Measure the voltage between terminals Tc and E1 of DLC1. OK: Voltage: 10 – 14 V (+) H00030 OK Go to step 4. NG Author: Date: 1032 DI–798 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check voltage between terminal Tc of DLC1 and body ground. CHECK: Measure the voltage between terminal Tc of DLC1 and body ground. OK: Voltage: 10 – 14 V ON ACC Tc or (–) (+) OK AB0118 AB0119 R14304 H00031 Check harness between terminal E1 of DLC1 and body ground. NG 4 Check airbag sensor assembly. LOCK ACC ON or Airbag Sensor Assembly Tc AB0117 AB0118 AB0119 H01302 H01303 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Insert service wire into terminal Tc from back side as shown in the illustration. (e) Connect the airbag sensor assembly connector with service wire. (f) Connect negative (–) terminal cable to the battery. (g) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (h) Connect service wire of terminal Tc to body ground. CHECK: Check operation of SRS warning light. OK: SRS waning light comes on. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. OK Check harness between the airbag sensor assembly and DLC1. NG Replace airbag sensor assembly. Author: Date: 1033 DI–799 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM If the DTC is displayed without a DTC check procedure, perform the following troubleshooting. 1 Check resistance between terminal Tc of airbag sensor assembly and body ground. Airbag Sensor Assembly LOCK Tc (–) AB0119 H01304 (+) H01305 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of the airbag sensor assembly connector and body ground. OK: Resistance: 1 MΩ or Higher NG Repair or replace harness or connector. OK Replace airbag sensor assembly. Author: Date: 1034 DI–800 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM DI05L–03 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshooting of the wireless door lock control system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the wireless door lock control system, first make certain that the door lock control system is operating normally. Perform troubleshooting in accodnce with procedure on the following page. Vehicle Brought to Workshop 1 Customer Problem Analysis Titles inside are titles of pages in this manual, with the page number indicated in the bottom position. See the indicated pages for detailed explanations. DI–801 3 2 Symptom Simulation Problem Symptom Confirmation IN–21 Whole wireless door lock control system does not operate 4 Some functions of wireless door lock control system do not operate Diagnostic Procedure DI–802 5 Transmitter Inspection DI–802 Transmitter Malfunction Problem Symptoms Table DI–809 6 Circuit Inspection DI–810 Identification of Problem 7 8 Repair Confirmation Test END Author: Date: 1035 DI–801 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05M–02 CUSTOMER PROBLEM ANALYSIS CHECK WIRELESS DOOR LOCK CONTROL System Check Sheet Inspector’s Name Registration No. Customer’s Name Registration Year / / Frame No. / Date Vehicle Brought In / / Date Problem First Occurred Frequency Problem Occurs Weather Weather Conditions When Problem Occurred Outdoor Temperature Place km Miles Odometer Reading / Constant Sometimes ( times per day, month) Once only Fine Cloudy Rainy Snowy Various/Others Warm Hot Cold (Approx. °F ( Specific Locality( Everywhere / Date Transmitter Battery Last Replaced Cool °C)) ) / Problem Symptom Whole wireless door lock control system does not operate. Only door unlock operation is not possible. Only door lock operation is not possible. Only key confinement prevention function is not possible. Wireless door lock function operates even each door is opened. Only PANIC operation is not possible. Wireless door lock functions incorrectly. ( Although one door is unlocked, when the transmitter switch is pressed, all doors become unlocked.) When Front RH door is unlocked When Front LH door is unlocked When Rear RH door is unlocked When Rear LH door is unlocked Others Author: Date: 1036 DI–802 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05N–03 PRE–CHECK 1. 1 N13160 N13161 INSPECT TRANSMITTER Check the transmitter operation. HINT: This inspection is not directly for the purpose of checking the capaciy of the transmitter battery, but is performed when remote control operation becomes difficult or impossible, in order to ascertain if this is caused by low battery capacity. PREPARATION: (a) Using a screwdriver, pry outward the cover. (b) Remove the battery. CHECK: (a) Connect 4 new 1.5–V dry–cell batteries in series. Connect the battery
terminal to the battery receptacle side terminal and the battery  terminal to the bottom terminal to provide 6 V to the transmitter. (b) Push the wireless door lock remote control switch on the side of the transmitter body and operate the door lock by remote control. OK: Remote control operation is possible. I00239 OK Replace the battery for transmitter. (See page DI–802) NG Replace transmitter and registration of recognition code. (See page DI–802) Author: Date: 1037 DI–803 DIAGNOSTICS 2. WIRELESS DOOR LOCK CONTROL SYSTEM REPLACE WIRELESS DOOR LOCK ECU AND TRANSMITTER HINT: Disassembly and assembly of the transmitter includes details of spare parts and replacement procedure for detective parts found through troubleshooting. Each part is a precision electronic component so handle with care. (a) Spare parts and replacement procedure for malfunctioning parts (transmitter malfunction): (1) Prepare a new transmitter. (2) Registration of recogition code. (3) Check that door lock remote control operation works. Destroy Transmitter New Parts Transmitter ECU EPROM Registration of recogition code. – ECU I00306 New Part (b) Spare parts and replacement procedure for malfunctioning parts (battery malfunction): (1) Prepare a new battery. (2) Remove the battery from transmitter. (3) Install a new battery into transmitter. (c) Spare parts and replacement procedure for malfunctioning parts (ECU malfunction): (1) Prepare a new ECU. (2) Remove the ECU from the vehicle. (3) Install a new ECU in the vehicle. (4) Registration of recogition code. Dispose of N13157 New Parts Destory ECU Registration of recogition code I00307 Author: Date: 1038 DI–804 DIAGNOSTICS (d) – WIRELESS DOOR LOCK CONTROL SYSTEM Replace the battery for transmitter. (1) Using a screwdriver, pry outward the cover. N13159 (2) (3) (4) Remove the battery. Set a new battery into the transmitter. Install the cover to the transmitter. N13160 3. REGISTRATION OF RECOGNITION CODE The recognition code of the transmitter is electronically registered (written to and stored) in an EEPROM contained in the wireless door lock ECU. This makes it possible to register up to 2 different codes in the EEPROM. New recognition codes can be registered after all previous codes have been erased. A transmitter code can be registered into the EEPROM by following the steps numbered (1) to (5). (1) GND PRG PRG Wireless Door Lock ECU GND Remote Control Mirror Switch Connector The wireless door lock ECU and remote control mirror switch are connected to each other via a PRG terminal, and the GND terminal of the remote control mirror switch connector is grounded to body. Remove the connector from the remote control mirror switch, and use a test lead to short the PRG and GND connector together. As a result, the PRG terminal of the wireless door lock ECU will be grounded to body and will cause all transmitter recognition codes previously registered in the EEPROM to be erased. At the same time, the ECU will respond by operating once the lock and unlock functions of all the doors, and the open function of the trunk lid. I08491 Author: Date: 1039 DI–805 DIAGNOSTICS – (2) (3) (4) (5) 4. WIRELESS DOOR LOCK CONTROL SYSTEM A transmitter recognition code is registered by pressing any single button of the transmitter to be registered. Once the code is registered, the ECU responds again by operating once the lock and unlock functions of all the doors. To register the recognition code of an additional transmitter, follow the procedure shown in (2). After completing the registration of the codes, remove the test lead from the remote control mirror switch connector terminals to allow the system to revert to the normal operation. Using the registered transmitter, verify that the system operates properly. DIAGNOSTIC PROCEDURE Start HINT: Diagnostic mode may be exited at any time by ungrounding terminal 9 Unlock all doors manually Insert key in ignition key cylinder and open driver’s door Ground terminal 9 of the wireless door lock ECU and wait more 1 second. Remove key from ignition key cylinder and close driver’s door within 10 seconds. If not performing this operation within 10 seconds after the above operation, the mode will not change into the diagnostic mode. Press any button on transmitter within 10 seconds. If not performing this operation within 10 seconds after the above operation, the mode will not change into the diagnostic mode. CONTINUED ON NEXT PAGE Author: Date: 1040 DI–806 DIAGNOSTICS Does each door lock knob operate? Yes How does it opetate? Door lock motor of all the doors operate to lock side 3 times. Motor feedback failure – WIRELESS DOOR LOCK CONTROL SYSTEM No RF (ECU failure) DATA reception error (Transmitter of ECU failure) Exit diagnostic mode, and check transmitter batteries. If bad, replace batteries and go to start. If not starting, replace transmitter and go to start. If still not starting, replace ECU and go to start. Door lock motor of all the doors operate to lock side 1 time. Valid recognition code received Diagnostic check OK Check motor feedback for input line to receiver: If bad, fix wiring or replace motor. Other wise, replace receiver and go to start. Author: Date: 1041 DI–807 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05O–03 PARTS LOCATION Ignition Switch Key Unlock Warning Switch Wireless Door Lock ECU Transmitter Instrument Panel Junction Block Integration Relay Door Key Lock and Unlock Switch Engine Room Junction Block
DOME Fuse
Door Lock Motor
Door Unlock Detection Switch
Door Lock Motor
Door Unlock Detection Switch Door Courtesy Switch
Door Lock Motor
Door Unlock Detection Switch Door Courtesy Switch Door Courtesy Switch I00217 I00216 I00215 I00241 Author: Date: 1042 DI–808 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI1KR–03 TERMINALS OF ECU 7 6 5 15 14 4 3 13 12 11 10 2 1 9 8 I00227 Symbols (Terminals No.) Wiring Color 1 – Ground (GND – Ground ) W–B 4–G Ground d ( TAIL – G Ground d) G–R 5 – Ground G d ( PINI – Ground G d) LG Condition STD Voltage (V) Always. Below 1 V TAIL lamps ”ON” Below 1 V TAIL lamps ”OFF” 10 – 14 V Always. 7–G Ground d ( UL3 – G Ground d) R–G 4–6V Push the PANIC switch. Below 1.5 V Door key lock and unlock switch ”UNLOCK”. (Driver’s Door) Below 1.5 V Door key lock and unlock switch ”OFF” or ”LOCK”. (Driver’s Door) 8 – 10 V 8 – 1 (+B – E ) R Always. 10 – 14 V 9 – Ground (PRG – Ground ) V Ignition switch ”ON” 10 – 14 V Key unlock warning switch ”ON”. (Key is inserted into key cylinder) Below 1 V Key unlock warning switch ”OFF”. 10 – 14 V Door unlock detection switch ”ON”. (Driver’s Door) Below 1 V Door unlock detection switch ”OFF”. (Driver’s Door) 10 – 14 V Door unlock detection switch ”ON”. (Passenger’s Door) Below 1 V Door unlock detection switch ”OFF”. (Passenger’s Door) 10 – 14 V Door unlock detection switch ”ON”. (Either Rear Door) Below 1 V Door unlock detection switch ”OFF”. (All Rear Doors) 10 – 14 V Door courtesy switch ”ON” Below 1 V Door courtesy switch ”OFF” 10 – 14 V Door key lock and unlock switch ”LOCK” Below 1 V 10 – Ground (KSW – Ground ) 11 – G Ground d (LSWD – G Ground) d) 12 – G Ground d (LSWP – G Ground) d) 13 – G Ground(LSWR d(LSWR – G Ground) d) L–B L–R Y L–Y 14 – G Ground d (CTY – G Ground d) R–W 15 – Ground G d (L – Ground G d) L–W Door key lock and unlock switch ”OFF” or ”UNLOCK” Author: 8 – 10 V Date: 1043 DI–809 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05Q–03 PROBLEM SYMPTOMS TABLE Perform troubleshooting of the circuit for the applicable problem symptom in the order given in the chart below. Proceed to the page located for each circuit. HINT:
Troubleshooting of the wireless door lock control system is based on the premise that the door lock control system and theft deterrent system are operating normally. Accordingly, before troubleshooting the wireless door lock control system, first make certain that the door lock control system and theft deterrent system are operating normally.
If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still reappears even through there are no abnormalities in any of the other circuits, check and replace the Wireless Door Lock ECU as the last step. Symptom Suspect Area See page 3. ECU Power Source Circuit. 4. Door Courtesy Switch Circuit. 5. Door Key Lock and Unlock Switch Circuit. (Unlock Side) 6. Door Key Lock and Unlock Switch Circuit. (Lock Side) 7. Key Unlock Warning Switch Circuit. 8. Wireless Door Lock ECU. DI–810 DI–821 DI–815 1. Door Key Lock and Unlock Switch Circuit (Unlock Side) 2. Door Unlock Detection Switch Circuit 3. Wireless Door Lock ECU. DI–815 Only door unlock operation is not possible (Lock operation is possible). Only door lock operation is not possible (Unlock operation is possible). 1. Door Key Lock and Unlock Switch Circuit (Lock Side) 2. Wireless Door Lock ECU DI–817 Only key confinement prevention function is not possible. 1. Key Unlock Warning Switch Circuit 2. Wireless Door Lock ECU DI–819 IN–31
Wireless door lock function operates even when each door is opened.
Automatic lock function operates even if any door is opened within 30 seconds after all doors are unlocked by wireless door lock control system. 1. Door Courtesy Switch Circuit 2. Wireless Door Lock ECU DI–821 IN–31 Wireless door lock functions incorrectly. (Although one door is unlocked, when the transmitter switch is pressed, all doors are unlocked.) 1. Door Unlock Detection Switch Circuit 2. Wireless Door Lock ECU DI–813 IN–31 Warning operation will not be performed even if the panic button is pressed. 1. Panic Circuit 2. Wireless Door Lock ECU DI–823 IN–31 All functions of wireless door lock control system do no operate. Author: Date: DI–817 DI–819 IN–31 DI–819 IN–31 IN–31 1044 DI–810 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05R–03 CIRCUIT INSPECTION ECU Power Source Circuit CIRCUIT DESCRIPTION Battery positive voltage is always applied to the terminal +B of the wireless door lock ECU. WIRING DIAGRAM Wireless Door Lock ECU Engine Room J/B No.2 B 1 2A SHORT PIN 12 2J R DOME 1 1W 1 F6 Instrument panel J/B FL BLOCK 8 1G 1 F4 B–G R–Y DIODE(DOME) E 2 R J16 1 J/C D J17 R 8 RR– FL MAIN J5 W–B A A W–B 1 GND Battery IF I00225 Author: Date: 1045 DI–811 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check DOME fuse. PREPARATION: Remove DOME fuse from engine room junction block. CHECK: Check continuity of DOME fuse. OK: Below 1.0 Ω or continuity N14677 NG Check for short in all the harness and components connected to DOME fuse. (See attached wiring diagram.) OK 2 Check voltage between terminals +B and E of wireless door lock ECU connector. PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between terminals +B and GND of wireless door lock ECU. OK: Voltage: 10 – 14 V LOCK E(–) AB0117 N14690 +B(+) I00242 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Author: Date: 1046 DI–812 DIAGNOSTICS 3 – WIRELESS DOOR LOCK CONTROL SYSTEM Check for open in harness and connector between terminal GND of wireless door lock ECU and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and repair harness and connector between wireless door lock control ECU and battery. Author: Date: 1047 DI–813 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05S–03 Door Unlock Detection Switch Circuit CIRCUIT DESCRIPTION The door unlock detection switch is built into the door lock motor assembly. The switch is OFF when the door lock knob is in Lock position, and is ON When the Knob is in Unlock position. Furthermore, the door unlock detection switch circuit has terminal +B connected inside the theft deterrent ECU, when the door unlock detection switch is OFF, battery positive voltage is applied to the terminal of the door unlock detection switch circuit of the wireless door lock ECU. WIRING DIAGRAM F F 15 LSWP T4 L–R J37 J/C F Y Y C 11 IE1 L–R L–R J38 W–B*1 W–B*1 A 1 3 A 20 IE1 W–B J/C E J10 L–Y E J10 4 L–Y BO1 L–Y 1 4 2 3 2 IF2 W–B L–Y 1*1 4*2 4*1 1*2 J39 3 A Door Unlock Detection Switch Rear LH A J/C Door Unlock Detection Switch Front RH W–B IJ D J9 13 W6 LSWR L–Y J9 D L–Y 3 L–Y IN2 4 BP1 1 L–Y 2 6 BO1 W–B*1 W–B*1 20 IM1 3 7 Door Unlock W–B Detection Switch 1V 1G Front LH IE Instrument Panel J/B 16 LSWR T4 W–B*2 Y 2 J/C C C 11 IM1 Y W–B*2 4 2 Wireless Door Lock ECU 11 W6 LSWD 12 W6 LSWP J6 J/C Theft Deterrent ECU 14 L–R LSWD T4 4 W–B 6 BP1 W–B 3 J40 W–B W–B J/C BL Door Unlock Detection Switch Rear RH BN IK *1: TMC Made *2: TMMK Made I08425 Author: Date: 1048 DI–814 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals LSWD, LSWP and LSWR of wireless door lock ECU connector and body ground. LSWR(+) I00273 N14691 LSWD(+) LSWP(+) I00243 PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between each of terminals LSWD, LSWP and LSWR of wireless door lock ECU connector and body ground, when the respective door lock knobs involved are pushed to the lock side. OK: Voltage 10 – 14 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Check and repair harness and connector between wireless door lock ECU and door unlock detection switch. Author: Date: 1049 DI–815 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05T–03 Door Key Lock and Unlock Switch Circuit (Unlock Side) CIRCUIT DESCRIPTION The Key–operated switch is built into the door key cylinder. When the key is turned to the lock side, the lock terminal of the switch is grounded, and when the key is turned to the unlock side the unlock terminal is grounded. Furthermore, the door key lock and unlock switch circuit has terminal +B connected inside the theft deterrent ECU, when neither the lock nor unlock terminal of the key lock and unlock switch are grounded, battery positive voltage is applied to the door key lock and unlock switch circuit of the wireless door lock ECU. ( Tr inside the ECU coming ON causes the wireless door lock ECU to output a signal to unlock all the doors.) WIRING DIAGRAM Integration Relay Wireless Door Lock ECU 7 UL2 W6 I18 4*1 19*2 Theft Deterrent ECU 5*1 20*2 I18 R–G B B B R–G J6 J/C R–G B L J37 J/C A A R–G W–B UNLOCK L 3 2 Door Key Lock and Unlock Switch LOCK LH J38 1 *3 A W–B A 10 T4 UL2 W–B 3 IM1 R–G 3 W–B*3 UL3 L A 3 IE1 20 IE1 L 9 T4 2 UNLOCK RH LOCK IM1 20 1 J39 W–B*3 *3 A W–B A J/C J/C W–B*4 W–B*4 Instrument Panel J/B 7 1G 3 1V IE *1: w/o Theft Deterrent System *2: w/ Theft Deterrent System *3: TMC Made *4: TMMK Made IJ I08426 Author: Date: 1050 DI–816 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals UL2 of wireless door lock ECU connector and body ground. PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between terminal UL2 of wireless door lock ECU connector and body ground. OK: Voltage: 10 – 14 V UL2(+) I00300 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Check and repair harness and connector between wireless door lock ECU and door key lock and unlock switch. Author: Date: 1051 DI–817 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05U–03 Door Key Lock and Unlock Switch Circuit (Lock Side) CIRCUIT DESCRIPTION Refer to page DI–815. Tr inside the wireless door lock ECU coming ON causes the theft deterrent ECU to output a signal to lock all the doors. WIRING DIAGRAM Integration Relay I18 3*1 18*2 Wireless Door Lock ECU L–W 15 L W6 *1: w/o Theft Deterrent System *2: w/ Theft Deterrent System *3: TMC Made *4: TMMK Made Theft Deterrent ECU J37 J/C B L–W B L–W B B B L–W 4 IE1 W–B 3 20 IE1 LH UNLOCK J38 4 IM1 L–W 2 LOCK 3 Door Key Lock and Unlock Switch UNLOCK L2 W–B L–W 2 LOCK IM1 20 1 J39 W–B*3 A RH 1 W–B*3 W–B*3 A A A W–B*3 J/C J/C W–B*4 W–B*4 Instrument Panel J/B 7 1G 8 T4 L–W 3 1V W–B IE IJ I08427 Author: Date: 1052 DI–818 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal L of wireless door lock ECU connector and body ground. PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between terminal L of wireless door lock ECU connector and body ground. OK: Voltage 10 – 14 V L(+) N14693 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Check and repair harness and connector between wireless door lock ECU and door key lock and unlock switch. Author: Date: 1053 DI–819 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05V–03 Key Unlock Warning Switch Circuit CIRCUIT DESCRIPTION When the key is inserted in the ignition key cylinder, the key unlock warning switch comes ON, and when the key is not inserted the switch is OFF. When the key unlock warning switch is ON, the ECU operates the key confinement prevention function. WIRING DIAGRAM Wireless Door Lock ECU Instrument Panel J/B 7 Integration Relay 5 1D L–B B J9 B J10 10 W6 KSW L–B 5 1M L–B 1 Key Unlock Warning Switch 2 Instrument Panel J/B W–B 3 1M 7 1J J11 J/C W–B A IG I00224 Author: Date: 1054 DI–820 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal KSW of wireless door lock ECU connector and body ground. KSW N14694 PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between terminal KSW of wireless door lock ECU connector and body ground, when key plate is not inserted in the key cylinder. OK: Voltage: 10 – 14 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Check and repair harness and connector between wireless door lock ECU and key unlock warning switch. Author: Date: 1055 DI–821 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05W–03 Door Courtesy Switch Circuit CIRCUIT DESCRIPTION The door courtesy switch comes ON when the door is opened and goes OFF when door is closed. Furthermore. the door courtesy switch circuit has terminal +B connected inside the theft deterrent ECU . Battery positive voltage is applied to terminal DSWD of the theft deterrent ECU when all doors are closed, i.e., when the door courtesy switches of all doors are OFF. WIRING DIAGRAM Theft Deterrent ECU 4 A DSWD T4 R–G J10 Wireless Door Lock ECU Instrument Panel J/B Integration Relay 1 C J9 R–G 1G 4 6 4 1G 7 1S 12 1S R–W 14 W6 CTY R–W 1 CTY T4 D J33 E J34 D E J33 J34 R–W D J33 R–W R–G 1 IN2 8 R–W R–G 5 DSWP T4 R–W 2 E J33 E J33 R–G R–W D J34 R–G 1 1 6 R–G IN2 Door Courtesy Switch 1 1 Front RH Rear RH Front LH Rear LH I00223 Author: Date: 1056 DI–822 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of open door warning light. CHECK: Check that open door warning light comes ON when each door is opened, and goes OFF when all doors are closed. NG Check open door warning light circuit OK 2 Check voltage between terminal CTY of wireless door lock ECU connector and body ground. PREPARATION: Remove the wireless door lock ECU from No.1 instrument panel brace. CHECK: Measure voltage between terminal CTY of wireless door lock ECU connector and body ground, when all doors are closed. OK: Voltage: 10 – 14 V CTY(+) N14695 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). NG Check and repair harness and connector between wireless door lock ECU and door courtesy switch. Author: Date: 1057 DI–823 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM DI05X–04 Panic Circuit CIRCUIT DESCRIPTION This circuit will transmit a panic signal from a wireless door lock ECU to a theft deterrent ECU. When the key is not inserted in the ignition key cylinder and the theft deterrent ECU receives the panic signal from the wireless door lock ECU, warning operation will be performed. WIRING DIAGRAM Theft Deterrent ECU Wireless Door Lock ECU 5 PANI W6 18 T4 PANI LG I00301 Author: Date: 1058 DI–824 DIAGNOSTICS – WIRELESS DOOR LOCK CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal PANI of theft deterrent ECU connector and body ground. CHECK: Measure voltage between terminal PANI of theft deterrent ECU connector and body ground. OK: Voltage: 4 – 6 V PANI I00310 OK Exchange theft deterrent ECU. NG 2 Check the panic signal (Theft deterrent ECU side) CHECK: Check the signal of the terminal PANI when pushing the PANIC switch of the transmitter. PANI HINT: Check the signal using the oscilloscope or oscilloscope function of TOYOTA hand–held tester. OK: Output the signal as shown in the illustration. Output signal Push the panic switch 4–6V Below 1 V 300m sec I00309 OK Exchange theft deterrent ECU. NG Author: Date: 1059 DI–825 DIAGNOSTICS 3 – WIRELESS DOOR LOCK CONTROL SYSTEM Check the panic signal (Wireless door lock ECU side) CHECK: Check the signal of the terminal PANI when pressing the PANIC switch of the transmitter. PANI OK: Output the signal shown on the previous page. I00308 NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–809). OK Check and repair harness and connector between wireless door lock ECU and theft deterrent ECU. Author: Date: 1060 DI–826 DIAGNOSTICS – THEFT DETERRENT SYSTEM THEFT DETERRENT SYSTEM DI06M–04 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. For troubleshooting use a volt/ohm meter. Be sure to use troubleshooting procedure appropriate to the diagnostic tool being used. Perform troubleshooting in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Customer Problem Analysis Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. P. DI–827 Symptom does not occur 2 Problem Symptom Confirmation 3 Symptom Simulation P. IN–21 Symptom occur 4 Problem Symptoms Table P. DI–837 5 Circuit Inspection P. DI–838 ∼ DI–866 Identification of Problem 6 7 Repair Confirmation Test Step 5, 7 : Diagnostic steps permitting the use of the TOYOTA hand–held tester and TOYOTA break–out–box. End Author: Date: 1061 DI–827 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06N–05 CUSTOMER PROBLEM ANALYSIS CHECK THEFT DETERRENT SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date of Vehicle Brought in / / / Date Problem First Occurred
Constant
Once only Frequency Problem Occurs Weather Conditions When Problem Occurred km Mile Odometer Reading
Sometimes ( / Times per day, month)
Fine
Cloudy
Rainy
Various/Others
Hot
Warm
Cool Outdoor temperature
Cold (Approx. °F ( °C)) Weather
Snowy Problem Symptom
Theft deterrent system cannot be set.
Indicator light does not flash when the theft deterrent system is set. (It stays on or does not light at all.)
Theft deterrent system does not operate.
When unlocked using the door lock knob.
When the engine hood is opened.
System cannot be canceled once set.
When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON position. (However, only when the system has never operated)
When the luggage compartment door is opened with the key.
System cannot be canceled during warning operation.
When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON position. Malfunction
Horns only
Theft deterrent horn only
Headlights only
Taillights only
Starter cut only
Door lock operation only
Warning operation starts when the system is set and the door or luggage compartment door is opened with the key.
Others. Author: Date: 1062 DI–828 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI1KU–02 PRE–CHECK 1. Active arming mode: SETTING THE THEFT DETERRENT MODE The system will be automatically set to the theft deterrent mode about 30 seconds after the setting processes listed below are performed. Setting Processes: (do processes (1)
(4) in the order) (1) Remove the ignition key from the key cylinder. (2) Close all entry points (door, hood and luggage compartment door). (3) Use any one of the following methods to lock all the doors depending on a given condition.  Use the key to lock the driver or passenger side door. (as a result, all the doors(including the engine hood and luggage compartment door) will be closed and locked), or  Use the remote control to lock any door (as a result, all the doors(including the engine hood and luggage compartment door) will be closed and locked), or  If the front right or left door is unlocked when both the rear doors are already locked, lock and close the remaining unlocked door by hand (as a result, all the doors(including the engine hood and luggage compartment door) will be closed and locked).  Close all doors and lock with the engine hood or luggage compartment door opened, and close the engine hood or all the doors(including the engine hood and luggage compartment door). (4) About 30 seconds after the above process (3), the theft deterrent mode will automatically start. HINT: The closing/locking of all the entry points (doors, hood and luggage) must remain unchanged for about 30 seconds, the system will start the theft deterrent mode. 2. Passive arming mode: SETTING THE THEFT DETERRENT MODE The system will be automatically set to the theft deterrent mode about 30 seconds after the setting processes listed below are performed. Setting Processes: (1) Remove the ignition key from the key cylinder. (2) Open and close any entry points (door, hood and luggage compartment door). Now, all the entry points are closed. Author: Date: 1063 DI–829 DIAGNOSTICS – (3) THEFT DETERRENT SYSTEM About 30 seconds after the process–(2), on the previous page the Theft Deterrent mode will automatically start. HINT: If, while following above steps, you use the key or the remote control to lock the door, the system will be set to ACTIVE ARMING MODE. 3. THEFT DETERRENT OPERATION When the system is set to the theft deterrent mode and any of the following conditions are met, the system sounds the horns and flashes the headlights and the taillights for about 1 minute. At the same time locks all doors (If all doors are not locked at once, the system repeats door locking operation every 0.55 seconds during the one–minute alarm time). Condition (1) Any of the doors (Including the engine hood and luggage compartment door) is unlocked or opened without the key. *1 (2) The battery terminal is disconnected and reconnected. *2 (3) The system receives panic signal from remote keyless entry. *3 *1: Only active arming mode. *2: When the ignition key is not inserted in the key cylinder. 0.25 ± 0.05 sec. 0.25 ± 0.05 sec. ON OFF Horns Sounding and Lights Flashing Pattern 0.2 ± 0.05 sec. ON OFF 0.55 ± 0.05 sec. Output of Key Lock Pattern I00228 Author: Date: 1064 DI–830 DIAGNOSTICS – THEFT DETERRENT SYSTEM 4. CANCELLATION OF THEFT DETERRENT OPERATION OR MODE The theft deterrent operation of mode can be cancelled when any of the following conditions is met. No. Condition Cancel of Operation Cancel of Mode 1 Unlock front doors with the key Effective Effective 2 Unlock doors with remote keyless entry Effective Effective 3 Insert key into ignition key cylinder and turn it to ACC or ON position Effective Effective 4 About 1 minute passes after theft deterrent operation begins Automatic stop *1 – 5 Unlock the luggage compartment door with the key or keyless entry. Uneffective Effective 6 Unlock the luggage compartment door with the keyless entry. Uneffective Effective 7 If the system receives panic signal again or unlock signal when the system is activated by panic signal Effective *2 Uneffective 6 If the system receives unlock signal when the system is activated by panic signal Effective Effective *1: The system is set to the theft deterrent mode again in about 2 seconds after the operation stops, if all doors are closed. *2: The alarm caused by the panic signal malces the system in the previous condition. 5. INDICATOR LIGHT (LED) The indicator light functions as shown below according to the system condition in the theft deterrent mode. It remains OFF in the initial state. Security only: 0.75 ± 0.1 sec. 1.25 ± 0.1 sec. ON System Condition OFF Blinking Pattern I00229 Indicator Light During set preparation time ON When the mode is set* OFF When alarm is activated ON When the system is temporally cancelled* OFF *: The indicator flashes with the output from the immobiliser. 6. KEEPING POWER SUPPLY FUNCTION IN CASE OF DOME FUSE OPEN Even if the dome fuse blows open on the theft deterrent mode, the system will keep working on the theft deterrent mode. Author: Date: 1065 DI–831 DIAGNOSTICS 7. – THEFT DETERRENT SYSTEM CHANGING METHOD OF PASSIVE MODE (ON or OFF) Remove the ignition key from key cylinder. All the doors, engine hood and luggage compartment door are closed and unlocked. Any of doors is locked and unlocked by turns 3 times by the key or remote control. Input to the vehicle Output from the vehicle Within 30 sec. Driver’s side doors is opened. Driver’s side knob for doorlock is locked and unlocked 3 times. The system starts force lock at once after 2 sec. Driver’s side knob for door lock is unlocked. Within 20 sec. Driver’s side door is closed and opened 2 times Driver’s side door is closed and opened 4 times Driver’s side knob for door lock is locked and unlocked. Driver’s side knob for door lock is locked and unlocked. The system starts force lock at once after 2 sec. The system starts force lock at once after 2 sec. PASSIVE MODE OFF PASSIVE MODE ON HINT:
Initial mode is PASSIVE MODE OFF.
If there is a different signal in the middle of changing, it is invalied. Author: Date: 1066 DI–832 DIAGNOSTICS TOYOTA hand–held tester ECU 8. (a) (b) TOYOTA Break–out–box N09348 – THEFT DETERRENT SYSTEM ECU TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND– HELD TESTER Hook up the TOYOTA break–out–box and TOYOTA hand–held tester to the vehicle. Read the ECU input/ output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester / TOYOTA break–out–box operator’s manual for further details. Author: Date: 1067 DI–833 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06P–05 PARTS LOCATION Theft Deterrent Horn E/G Room J/B No.2
DOME Fuse
HORN Fuse
ECU–IG Fuse
CIG Fuse
ST Relay
HORN Relay
Headlight Control Relay Horn Engine Hood Courtesy Switch Key Unlock Warning Switch Theft Deterrent ECU Ignition Switch I00233 I00234 Instrument Panel J/B
DOOR Fuse
ST Fuse
Taillight Control Relay I00236 Author: Date: 1068 DI–834 DIAGNOSTICS – THEFT DETERRENT SYSTEM Door Key Lock and Unlock Switch Door Lock Assembly
Door Unlock Detection Switch Luggage Compartment Door Key Lock and Unlock Switch Door Courtesy Switch Door Lock Assembly
Door Unlock Detection Switch Door Courtesy Switch Luggage Compartment Door Courtesy Switch Door Lock Assembly
Door Unlock Detection Switch I00235 Author: Date: 1069 DI–835 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI1KV–03 TERMINALS OF ECU T4 T3 I01920 Symbols (Terminals No.) CTY ↔ E (T4–1 ↔ T3–7) DSWL ↔ E (T4–2 ↔ T3–7) DSWH ↔ E (T4–3 ↔ T3–7) DSWD ↔ E (T4–4 ↔ T3–7) DSWP ↔ E (T4–5 ↔ T3–7) Wiring Color R W ↔ W–B R–W W B R Y ↔ W–B R–Y W B B ↔ W–B W B R G ↔ W–B R–G W B R G ↔ W–B R–G W B KSW ↔ E (T4–6 ↔ T3–7) L B ↔ W–B L–B W B LUG ↔ E (T4–7 ↔ T3–7) G W ↔ W–B G–W W B L2 ↔ E (T4–8 ↔ T3–7) UL3 ↔ E (T4–9 ↔ T3–7) UL2 ↔ E (T4–10 ↔ T3–7) L W ↔ W–B L–W W B R G ↔ W–B R–G W B L↔W W–B B Condition STD Value Door courtesy switch ”ON” (Rear door opened) Below 1 Ω Door courtesy switch ”OFF” (Rear door closed) 1 MΩ or higher Luggage compartment door courtesy switch ”ON” (Luggage compartment door opened) Below 1 Ω Luggage compartment door courtesy switch ”OFF” (Luggage compartment door closed) 1 MΩ or higher Engine hood courtesy switch ”ON” (Engine hood opened) Below 1 Ω Engine hood courtesy switch ”OFF” (Engine hood closed) 1 MΩ or higher Door courtesy switch ”ON” (Driver’s door opened) Below 1 Ω Door courtesy switch ”OFF” (Driver’s door Closed) 1 MΩ or higher Door courtesy switch ”ON” (Passenger’s door opened) Below 1 Ω Door courtesy switch ”OFF” (Passenger’s door closed) 1 MΩ or higher Key unlock warning switch ”ON” (Key inserted) Below 1 Ω Key unlock warning switch ”OFF” (Key removed) 1 MΩ or higher Luggage compartment door key lock and unlock switch ”ON” Below 1 Ω Luggage compartment door key lock and unlock switch ”OFF” 1 MΩ or higher Door key lock and unlock switch ”LOCK” (Driver’s and passenger’s doors) Below 1 Ω Door key lock and unlock switch ”UNLOCK” (Driver’s and passenger’s doors) 1 MΩ or higher Door key lock and unlock switch ”UNLOCK” (Driver’s door) Below 1 Ω Door key lock and unlock switch ”LOCK” (Driver’s door) 1 MΩ or higher Door key lock and unlock switch ”UNLOCK” (passenger’s door) Below 1 Ω Door key lock and unlock switch ”LOCK” (passenger’s door) Author: 1 MΩ or higher Date: 1070 DI–836 DIAGNOSTICS +B1 ↔ Body ground (T4–12 ↔ Body ground) IG ↔ E (T4–13 ↔ T3–7) LSWD ↔ E (T4–14 ↔ T3–7) LSWP ↔ E (T4–15 ↔ T3–7) R ↔ W–B B–R ↔ W–B L R ↔ W–B L–R W B Y ↔ W–B W B LSWR ↔ E (T4–16 ↔ T3–7) L Y ↔ W–B L–Y W B PANI ↔ E (T4–18 ↔ T3–7) LG ↔ W–B W B – THEFT DETERRENT SYSTEM Always 10 – 14 V Ignition switch is turned to ”ON” position 10 – 14 V Door unlock detection switch ”ON” (Driver’s door) Below 1 Ω Door unlock detection switch ”OFF” (Driver’s door) 1 MΩ or higher Door unlock detection switch ”ON” (Passenger’s door) Below 1 Ω Door unlock detection switch ”OFF” (Passenger’s door) 1 MΩ or higher Door unlock detection switch ”ON” (Rear door) Below 1 Ω Door unlock detection switch ”OFF” (Rear door) 1 MΩ or higher Below 1 Ω It is receiving panic signal from remote keyless entry Except above mention 1 MΩ or hegher +B2 ↔ Body ground (T3–1 ↔ Body ground) L–W ↔ Body ground Always IND ↔ E (T3–6 ↔ T3–7) R–Y ↔ W–B During set preparation E ↔ Body ground (T3–7 ↔ Body ground) W–B ↔ Body ground Always 10 – 14 V SH ↔ E (T3–9 ↔ T3–7) W–L ↔ W–B Always 10 – 14 V HEAD ↔ E (T3–10 ↔ T3–7) R–B ↔ W–B Light control switch ”HEAD” 10 – 14 V TAIL ↔ E (T3–11 ↔ T3–7) G–R ↔ W–B Light control switch ”TAIL” or ”HEAD” 10 – 14 V HORN ↔ E (T3–12 ↔ T3–7) G–B ↔ W–B Horn switch ”OFF” 10 – 14 V 10 – 14 V 3–5V Author: Date: 1071 DI–837 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06R–06 PROBLEM SYMPTOMS TABLE Proceed to the reference page shown in the matrix chart below for each malfunction symptom and troubleshoot for each circuit. HINT: Troubleshooting of the theft deterrent system is based on the premise that the door lock control system is operating normally. Accordingly, before troubleshooting the theft deterrent system, first make certain that the door lock control system is operating normally. Details of Problem Inspecting Circuit*1 1. Indicator light circuit DI–838 2. ECU power source circuit DI–840 3. Key unlock warning switch circuit DI–853 4. Luggage compartment door key lock and unlock switch circuit DI–855 5. Luggage compartment door courtesy switch circuit DI–858 6. Door key lock and unlock switch circuit DI–855 7. Door courtesy switch circuit DI–864 8. Door unlock detection switch circuit DI–862 9. Engine hood courtesy switch circuit DI–866 Indicator light circuit DI–838 Door unlock detection switch circuit DI–862 Luggage compartment door courtesy switch circuit DI–858 Engine hood courtesy switch circuit DI–866 Horns do not sound Horn relay circuit DI–845 Theft deterrent horn does not sound Theft deterrent horn circuit DI–843 Headlight control relay circuit DI–847 Taillight control relay circuit DI–849 Door unlock detection switch circuit DI–862 It is not canceled when the ignition key is turned to ACC or ON position Ignition switch circuit DI–851 It still operates when the luggage compartment door is opened with the key Luggage compartment door key lock and unlock switch circuit DI–855 Door courtesy switch circuit DI–864 Horns sound Horn relay circuit DI–845 Theft deterrent horn sounds Theft deterrent horn circuit DI–843 Headlights stay on Headlight control relay circuit DI–847 Taillights stay on Taillight control relay circuit DI–849 The theft deterrent system cannot be set The indicator light does not blink when system is set When the rear doors are unlocked When the system is set When the luggage compartment door is opened by a method other than the key When the engine hood is opened While the system is Headlights do not flash in warning operation Taillights do not flash The door lock is not locked in unlock condition When the system is set See page System is still set even when a rear door is open Even when the system is not set The system does not operate *1: If numbers are given to the circuit proceed with troubleshooting in the order indicated by those numbers. Author: Date: 1072 DI–838 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06S–04 CIRCUIT INSPECTION Indicator Light Circuit CIRCUIT DESCRIPTION When the theft deterrent system is preparing to set, this circuit lights up the indicator light. When the system has been set, it continuously turns the indicator light on for 1 second and turns it off for 1 second, thus blinking the indicator light. WIRING DIAGRAM Theft Deterrent Indicator Light BR 5 Theft Deterrent ECU Junction Connector D R–Y 6 R–Y E J10 J9 T3 IND 9 IH I04447 INSPECTION PROCEDURE 1 Check indicator light. PREPARATION: Remove combination meter. CHECK: Connect the positive (+) lead from the battery to terminal C9 and the negative (–) lead to terminal B16 of combination meter connector then check indicator light comes ON. (See combination meter on page BE–46) NG Replace combination meter. OK Author: Date: 1073 DI–839 DIAGNOSTICS 2 – THEFT DETERRENT SYSTEM Check harness and connector between theft deterrent ECU and indicator light, indicator light and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1074 DI–840 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06T–06 ECU Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the theft deterrent ECU. WIRING DIAGRAM E/G Room J/B No.2 1 2A B 1 F6 SHORT PIN DOME 12 2J R 8 DIODE (DOME) E 1 2 J16 1G R R–Y 1 1W 4 1B B–R DOOR 1 1D J/C D 11 J17 R J34 J/C Instrument Panel J/B FL BLOCK 1 ALT F9 1 Theft Deterrent ECU Instrument Panel J/B C +B1 1 C L–W L–W T4 T3 +B2 F4 7 B–G A FL MAIN W–B T3 E J5 J/C A Battery W–B IF I00238 Author: Date: 1075 DI–841 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check DOME and DOOR fuses. PREPARATION: (a) Remove DOME fuse from engine room junction block No.2. (b) Remove DOOR fuse from instrument panel junction block No.1. CHECK: Check continuity of DOME and DOOR fuses. OK: Continuity E/G room J/B No.2: DOME Fuse Instrument panel J/B: DOOR Fuse I00268 I00269 I00275 NG Check for short in all the harness and components connected to the DOME and DOOR fuses (See attached wiring diagram). OK 2 Check voltage between terminals each of +B1 and +B2 and E of theft deterrent ECU connector. PREPARATION: Disconnect the theft deterrent ECU connector. CHECK: Measure voltage between terminals each of +B1 and +B2 and E of theft deterrent ECU connector. OK: Voltage: 10 – 14 V +B1 (+) +B2 (–) E I01922 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–837). NG Author: Date: 1076 DI–842 DIAGNOSTICS 3 – THEFT DETERRENT SYSTEM Check for open in harness and connector between ECU and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and repair harness and connector between ECU and battery. Author: Date: 1077 DI–843 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06V–06 Theft Deterrent Horn Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, the relay in the ECU turns ON and OFF cycles of approximately 0.2 sec., causing the theft deterrent horn to blow (See the wiring diagram below). In this condition, if any of the following operations is done, the relay in the ECU turns OFF, thus stopping the theft deterrent horn from blowing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. WIRING DIAGRAM E/G Room J/B No.2 B–G FL BLOCK 1 1 1 F4 2A F6 B HORN Theft Deterrent ECU HORN 2 1 3 2F W W–L 4 5 IK1 IG3 W–L W–L 9 T3 SH FL MAIN Battery I00261 Author: Date: 1078 DI–844 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal 1 of theft deterrent horn connector and body ground. PREPARATION: Remove the theft deterrent horn and disconnect the connector. CHECK: Measure voltage between terminal 1 of theft deterrent horn connector and body ground. OK: Voltage: 10 – 14 V 1 NG I00294 Check and repair harness and connector between HORN fuse and theft deterrent horn. OK 2 Check theft deterrent horn. CHECK: Connect positive (+) lead to terminal 1 and negative (–) lead to terminal 2 to theft deterrent horn connector. OK: Theft deterrent horn blows. 1 (+) 2 (–) I00295 NG Replace theft deterrent horn. OK 3 Check harness and connector between theft deterrent ECU and theft deterrent horn (See page IN–29). NG Check and repair harness or connector. OK Check and replace theft deterrent ECU. Author: Date: 1079 DI–845 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06W–06 Horn Relay Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, it causes the Tr in the ECU to switch ON and OFF in approximately 0.4 sec. cycles. This switches the horn relay ON and OFF, thus the horns blow (See the wiring diagram below). In this condition, if any of the following operations is done, the Tr in the ECU goes off and the horn relay switches off, thus stopping the horns from blowing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. WIRING DIAGRAM 1 E/G Room J/B No.2 HORN Relay 5 3 FL BLOCK 1 1 B–G F4 F6 1 B 2A HORN 1 2 1 Horn G–W 1 2F 10 2K Theft Deterrent ECU J/C J2 C C G–B G–B 11 IG1 12 G–B T3 HORN FL MAIN Battery I00262 Author: Date: 1080 DI–846 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE HINT: The flow chart below is based on the premise that the horns blow normally whenever the horn switch is operated. If horn operation is not normal when the horn switch is operated, check the horn switch. 1 Check voltage between terminal HORN of theft deterrent ECU connector and body ground. PREPARATION: Disconnect the theft deterrent ECU connectors. CHECK: Measure voltage between terminal HORN of theft deterrent ECU connector and body ground. OK: Voltage: 10 – 14 V HORN I01923 NG Check and repair harness and connector between theft deterrent ECU and horn relay. OK Check and replace theft deterrent ECU. Author: Date: 1081 DI–847 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06X–06 Headlight Control Relay Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, it causes the Tr in the ECU to switch ON and OFF at approximately 0.4 sec. intervals. This switches the headlight control relay ON and OFF, thus flashing the headlights (See the wiring diagram below). In this condition, if any of the following operations is done, the Tr in the ECU goes OFF and the headlight control relay switches OFF, thus stopping the headlights flashing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. WIRING DIAGRAM E/G Room J/B No.2 B 3 2B MAIN Headlight Control Realy 4 1 3 8 2K R–B*1 B R–B*2 2 R*2 19 2 FL MAIN B–G B Theft Deterrent ECU 7 10 R–B IG3 T3 HEAD Daytime Running Light Relay 3 2G FL BLOCK 1 1 F6 F4 J32*1 J6*2 J/C R–B Light Control Switch (COMB. SW)*1 Daytime Running Light Relay*2 Battery *1: w/o Daytime Running Light *2: w/ Daytime Running Light I08428 Author: Date: 1082 DI–848 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE HINT:The flow chart below is based on the premise that the headlights light up normally whenever the light control switch is operated. If headlight operation is not normal when the light control switch is operated, proceed to troubleshooting on page BE–2. 1 Check voltage between terminal HEAD of theft deterrent ECU connector and body ground. PREPARATION: Disconnect the theft deterrent ECU connector. CHECK: Measure voltage between terminal HEAD of theft deterrent ECU connector and body ground. OK: Voltage: 10 – 14 V HEAD I01924 NG Check and repair harness and connector between theft deterrent ECU and headlight control relay (See page IN–31). OK Check and replace theft deterrent ECU. Author: Date: 1083 DI–849 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06Y–06 Taillight Control Relay Circuit CIRCUIT DESCRIPTION When the theft deterrent system is activated, it causes the Tr in the ECU to switch ON and OFF at approximately 0.4 sec. intervals. This switches the taillight control relay ON and OFF, thus flashing the taillights (See the wiring diagram below). In this condition, if any of the following operations is done, the Tr in the ECU goes OFF and the taillight control relay switches OFF, thus stopping the taillights flashing: (1) Unlock the front LH or RH door with key. (2) Turn the ignition switch to ACC or ON position. (3) Unlock the doors with the wireless door lock control system. (4) Wait for approximately 60 seconds. (5) Push the panic switch of the wireless door lock control system. WIRING DIAGRAM Instrument Panel J/B J2 J/C Taillight Control Relay 4 B–R 5 Light F9 Sensor 9 BLOCK 1 A G–R A G–R 10 IG1 B G–R B G–R 11 T3 TAIL 3 1S FL ALT 6 1C Theft Deterrent ECU TAIL 8 Failure 1 2 1 1B J33 J/C 1C F4 Turn & Clearance B–G Light FL MAIN Battery I00266 Author: Date: 1084 DI–850 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE HINT: The flow chart below is based on the premise that the taillights light up normally whenever the light control switch is operated. If taillight operation is not normal when the light control switch is operated, proceed to troubleshooting on page BE–2. 1 Check voltage between terminal TAIL of theft deterrent ECU connector and body ground. PREPARATION: Disconnect the theft deterrent ECU connector. CHECK: Measure voltage between terminal TAIL of theft deterrent ECU connector and body ground. OK: Voltage: 10 – 14 V TAIL I01925 NG Check and repair harness and connector between theft deterrent ECU and taillight control relay (See page IN–31). OK Check and replace theft deterrent ECU. Author: Date: 1085 DI–851 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI06Z–06 Ignition Switch Circuit CIRCUIT DESCRIPTION When the ignition switch is turned to the ACC position, battery positive voltage is applied to the terminal ACC of the ECU. Also, if the ignition switch is turned to the ON position, battery positive voltage is applied to the terminals ACC and IG of the ECU. When the battery positive voltage is applied to the terminal ACC of the ECU while the theft deterrent system is activated, the warning stops. Furthermore, power supplied from the terminals ACC and IG of the ECU is used as power for the door courtesy switch, and position switch, etc. WIRING DIAGRAM Instrument Panel J/B Theft Deterrent ECU Ignition Switch AM1 4 B–Y 2 1 ECU–IG 8 1D 1K B–R C B J16 J17 B–R 13 T4 IG IG1 W 2 1K AM1 1 1B B–R FL BLOCK B–G 1 F4 ALT 1 F9 B–R FL MAIN Battery I01927 Author: Date: 1086 DI–852 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check CIG and ECU–IG fuses. PREPARATION: (a) Remove the fuse box opening cover. (b) Remove ECU–IG fuses from instrument panel junction block No.1. CHECK: Check continuity of ECU–IG fuses. OK: Continuity Instrument panel J/B: ECU–IG Fuse I00269 NG Check for short in all the harness and components connected to the ECU–IG fuses (See attached wiring diagram). OK 2 Check voltage between terminal IG of theft deterrent ECU and body ground. (–) (+) PREPARATION: (a) Disconnect the theft deterrent ECU connectors. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal IG of theft deterrent ECU connector and body ground. OK: Voltage: 10 – 14 V IG I01926 NG Check and repair harness and connector between theft deterrent ECU and battery (See page IN–31). OK Check and replace theft deterrent ECU. Author: Date: 1087 DI–853 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI070–06 Key Unlock Warning Switch Circuit CIRCUIT DESCRIPTION The key unlock warning switch goes ON when the ignition key is inserted in the key cylinder and goes OFF when the ignition key is removed. The ECU operates the key confinement prevention function while the key unlock warning switch is ON. WIRING DIAGRAM Theft Deterrent ECU Key Unlock Warning Switch 2 1 L–B Instrument Panel J/B 5 1M 7 1D L–B B J9 J/C B J9 L–B 6 T4 KSW W–B Instrument Panel J/B 3 1M 7 1J W–B A J11 J/C IG I08429 Author: Date: 1088 DI–854 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check key unlock warning switch. PREPARATION: Disconnect key unlock warning switch connector. CHECK: Check continuity between terminal 1 and 2 of key unlock warning switch connector, when the key is inserted to the key cylinder or removed. OK: 2 (–) 1 (+) I00297 I00296 I00305 Switch position Tester connection Specified condition ON (Key inserted) 1–2 Continuity OFF (Key removed) – No continuity NG Replace key unlock warning switch. OK 2 Check harness and connectors between ECU and key unlock warning switch, key unlock warning switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1089 DI–855 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI071–04 Luggage Compartment Door Key Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The luggage compartment door key lock and unlock switch goes ON when the luggage compartment door key cylinder is turned to the unlock side with the key. WIRING DIAGRAM Theft Deterrent ECU Luggage Compartment Door Key Lock and Unlock Switch 1 J33 J/C 2 2 G–W IF1 C G–W 7 C G–W T4 LUG W–B BP I00252 Author: Date: 1090 DI–856 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal 1 of luggage compartment door key lock and unlock switch connector and body ground. ON 1 (–) (+) AB0119 I00271 I00277 PREPARATION: (a) Remove luggage compartment door trim. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal 1 of luggage compartment door key lock and unlock switch connector and body ground, when the key is turned to the unlock side and not turned respectively. OK: OK Key operation Voltage Turned to the unlock side 0V Not turned Battery positive voltage Check and replace theft deterrent ECU.*1 NG 2 Check luggage compartment door key lock and unlock switch. 2 PREPARATION: Disconnect luggage compartment door key lock and unlock switch connector. CHECK: Check continuity between terminals 1 and 2, when the key is turned to the unlock side and not turned respectively. OK: 1 I00270 Key operation Tester connection Specified condition Turned to unlock 1–2 Continuity Not turned – No continuity NG Repair or replace luggage compartment door key lock and unlock switch. OK Author: Date: 1091 DI–857 DIAGNOSTICS 3 – THEFT DETERRENT SYSTEM Check harness and connector between theft deterrent ECU and key lock and unlock switch, key lock and unlock switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU. *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1092 DI–858 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI072–06 Luggage compartment Door Courtesy Switch Circuit CIRCUIT DESCRIPTION The luggage compartment door courtesy switch goes ON when luggage compartment door is opened and goes off when the luggage compartment door is closed. WIRING DIAGRAM Theft Deterrent ECU R–Y 6 IF1 R–Y 2 T4 DSWL 1 Luggage Compartment Door Courtesy Switch I00253 Author: Date: 1093 DI–859 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check operation of luggage compartment door courtesy light. CHECK: Check that luggage compartment door courtesy light goes OFF when luggage compartment door courtesy switch is pushed, and comes ON when switch is not pushed. NG Check and repair luggage compartment door courtesy light circuit (See page BE–32). OK 2 Check for open in harness and connector between theft deterrent ECU and luggage compartment door courtesy switch (See page IN–31). NG Repair or replace harness or connectors. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1094 DI–860 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI073–06 Door Key Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The door key lock and unlock switch is built in the door key cylinder. When the key is turned to the lock side, terminal 1 of the switch is grounded and when the key is turned to the unlock side, terminal 2 of the switch is grounded. WIRING DIAGRAM Door Key Lock and Unlock Switch LH 20 IE1 J38 J/C UNLOCK A W–B*1 A 1 W–B*1 LOCK W–B Theft Deterrent ECU 3 IE1 3 R–G 2 L–W J6 J/C B R–G B R–G B B L–W 4 IE1 L–W 9 T4 UL3 8 T4 L2 W–B*2 Instrument Panel J/B 7 1G 3 1V W–B J37 J/C IE Door Key Lock and Unlock Switch RH W–B 20 IM1 J39 J/C A W–B*1 LOCK A 1 *1 W–B 3 UNLOCK IJ W–B*2 2 L–W L 4 IM1 3 IM1 B L–W A L A L 10 T4 UL2 *1: TMC Made *2: TMMK Made I08430 Author: Date: 1095 DI–861 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check door key lock and unlock switch. 1 2 3 (+) (–) I00272 PREPARATION: (a) Remove the door trim and service hole cover. (b) Disconnect the door key lock and unlock switch connector. CHECK: Check continuity between terminals 1, 2 and 3 of door key lock and unlock switch connector, when each of door key lock and unlock switch is turned to the lock side, unlock side and not turned. OK: Switch position Tester connection Specified condition Lock side 2–3 Continuity Unlock side 1–3 Continuity OFF – No continuity NG Replace door key lock and unlock switch. OK 2 Check harness and connectors between ECU and switch, switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1096 DI–862 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI074–06 Door Unlock Detection Switch Circuit CIRCUIT DESCRIPTION The door unlock detection switch is built in the door lock motor assembly. This switch is ON when the door lock knob is in the unlock position and OFF when the lock knob is in the lock position. The ECU detects the door lock knob conditions in this circuit. It is used as one of the operating conditions for the key confinement prevention function. WIRING DIAGRAM Instrument Panel J/B 7 1G 3 1V W 20 IE1 J38 J/C A W–B*1 W–B Door Unlock Detection Switch Front LH 11 A 1 4 IE1 W–B*1 L–R Theft Deterrent ECU J6 J/C 14 F T4 LSWD L–R F L–R W–B*2 IE W–B IJ 20 IM1 J39 J/C A W–B*1 Door Unlock Detection Switch Front RH *1 4 1*1 11 A 1*2 4*2 IM1 Y W–B*1 J37 J/C C C Y Y 15 T4 LSWP W–B*2 J40 J/C A W–B Door Unlock Detection Switch Rear LH 4 6 4 1 BO1 BO1 L–Y W–B L–Y 2 IF2 E L–Y J10 J/C 16 E J10 L–Y T4 LSWR BL W–B W–B Door Unlock Detection Switch Rear RH 4 6 4 1 BP1 BP1 L–Y W–B D 3 L–Y IN2 L–Y J9 W–B BN IK *1: TMC Made *2: TMMK Made I08431 Author: Date: 1097 DI–863 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check Door Unlock Detection Switch. PREPARATION: (a) Remove the door trim and service hole cover. (b) Disconnect door unlock detection switch connector. CHECK: Check continuity between terminals 1 and 4 of door unlock detection switch connector, when the door lock knob is operated to the lock side and unlock side. OK: LOCK UNLOCK 4 (–) I00273 I00274 1 Switch Condition Tester connection Specified condition Door unlock 1–4 Continuity Door lock – No continuity (+) I00278 NG Replace door unlock detection switch. OK 2 Check harness and connectors between ECU and door unlock detection switch, door unlock detection switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1098 DI–864 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI075–06 Door Courtesy Switch Circuit CIRCUIT DESCRIPTION The door courtesy switch goes ON when the door is opened and goes OFF when the door is closed. WIRING DIAGRAM Theft Deterrent ECU Door Courtesy Switch Front LH Instrument panel J/B J/C R–G 1 7 1 1S 1G Integration A C J9 R–G J10 R–G 4 T4 DSWD R–W 1 T4 CTY 5 T4 DSWP 6 Relay Door Courtesy Switch Rear LH R–B 1 J/C 4 12 1S 4 1G R–W D J33 E J34 Door Courtesy Switch Rear RH R–W 1 D 8 IN2 R–W J33 D J33 R–W 1 Door Courtesy Switch Front RH R–G 1 Diode J/C 6 IN2 R–G D J34 E J33 2 R–G E J33 R–G I04444 Author: Date: 1099 DI–865 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check operation of open door warning light. CHECK: Check that open door warning light comes ON when each door is opened, and goes OFF when all doors are closed. NG Check and repair open door warning light circuit. OK 2 Check for open in harness and connector between theft deterrent ECU and door courtesy switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU.*1 *1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered circuit inspection shown on problem symptoms table (See page DI–837). Author: Date: 1100 DI–866 DIAGNOSTICS – THEFT DETERRENT SYSTEM DI076–06 Engine Hood Courtesy Switch Circuit CIRCUIT DESCRIPTION The engine hood courtesy switch is built into the engine hood lock assembly and goes ON when the engine hood is opened and goes OFF when the engine hood is closed. WIRING DIAGRAM Theft Deterrent ECU Engine Hood Courtesy Switch 2 W–B 1 B 3 IK1 B 1 IG3 B 3 T3 DSWH EB I00257 Author: Date: 1101 DI–867 DIAGNOSTICS – THEFT DETERRENT SYSTEM INSPECTION PROCEDURE 1 Check engine hood courtesy switch. PREPARATION: (a) Remove engine hood lock assembly. (b) Disconnect engine hood courtesy switch connector. CHECK: Check continuity between terminals 1 and 2 when engine hood lock is locked and unlocked. OK: 1 (+) 2 (–) Engine hood lock Tester connection Specified condition LOCK – No continuity UNLOCK 1–2 Continuity I00298 NG Replace engine hood courtesy switch. OK 2 Check harness and connector between theft deterrent ECU and switch, switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace theft deterrent ECU (See page IN–31). Author: Date: 1102 DI–868 DIAGNOSTICS – CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DI08F–11 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Items inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Customer Problem Analysis P. DI–869 2 Check and Clear DTC (Precheck) P. DI–870 Symptom does not occur 3 4 Problem Symptom Confirmation Symptom Simulation P. IN–21 Symptom occurs 5 Normal code DTC Check P. DI–870 Malfunction code 6 7 DTC Chart Problem Symptoms Table P. DI–879 P. DI–875 9 8 Circuit Inspection Input Signal Check Parts Inspection P. DI–881 Identification of Problem Repair NG 10 Confirmation Test OK Step 2, 5: Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. End Author: Date: 1103 DI–869 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08G–08 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / Date of Problem Occurrence Condition of How Often does Problem Occurrence Problem Occurs / Continuous Symptoms / Intermittent ( Vehicle Speed when Problem Occurred Auto cancel occurs km Mile Odometer Reading Times a day) km Mile
Driving condition  City driving  Freeway  Up hill  Down hill
After cancel occurred, did the driver activate cruise control again?  Yes  No  Cancel does not occur  With brake ON  Except D position shift  At 40 km/h (25 mph) or less  When control SW turns to CANCEL position  Cruise control malfunction  Slip to acceleration side  Slip to deceleration side  Hunting occurs  O/D cut off does not occur  O/D does not return  Switch malfunction   SET  ACCEL  COAST  RESUME  CANCEL  Remains ON  Does not light up 1st Time  Normal Code  Malfunction Code (Code ) 2nd Time  Normal Code  Malfunction Code (Code ) DTC Check Author: Date:  Blinking 1104 DI–870 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI1KS–03 PRE–CHECK 1. (a) CRUISE MAIN Indicator Light I00279 HINT: If the indicator check result is not normal, proceed to troubleshooting (See page BE–2) for the combination meter section. (b) Check the DTC. HINT: If a malfunction occurs in the No. 1 vehicle speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a DTC. Indicator light 1.5 sec. DIAGNOSIS SYSTEM Check the indicator. (1) Turn the ignition switch ON. (2) Check that the CRUISE MAIN indicator light comes ON when the cruise control main switch is turned ON, and that the indicator light goes OFF when the main switch is turned OFF. 0.5 sec. ON OFF BE4034 (c) DLC2 Tc Output of DTC using diagnosis check wire. (1) Turn the ignition switch ON. (2) Using SST, connect terminals Tc and E1 of DLC2. SST 09843–18020 (3) Read the DTC on the CRUISE MAIN indicator light. E1 I00169 Author: Date: 1105 DI–871 DIAGNOSTICS – CRUISE CONTROL SYSTEM HINT: If the DTC is not output, inspect the diagnosis circuit (See page DI–916). As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. Normal code 0.25 sec. 0.25 sec. ON OFF Malfunction codes 11 and 21 0.5 sec. 4 sec. 0.5 sec. 1.5 sec. 2.5 sec. 1.5 sec. ON OFF BE4032 BE4033 Code 11 Code 21 I00021 2. (a) (b) H07517 (b) E1 (d) 5 times within 3 seconds DLC1 TC (c) I08438 USING TOYOTA HAND–HELD TESTER Hook up the TOYOTA hand–held tester to the DLC2. Monitor the ECU data by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” function which records the monitored data. Please refer to the TOYOTA hand–held tester operator’s manual for further details. 3. DTC CLEARANCE (ERASE MODE) HINT: During in the erase mode, diag detection does not work. (a) Stop the vehicle. (b) Using SST, connect terminals Tc and E1 of DLC1. SST 09843–18020 (c) Pull the cruise control switch to CANCEL. (d) On the above metioned condition, turn on the cruise control main switch 5 times within 3 seconds. Author: Date: 1106 DI–872 DIAGNOSTICS 4. (a) N17520 CRUISE CONTROL SYSTEM PROBLEM SYMPTOM CHECK (ROAD TEST) Inspect the SET switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Press the control switch to the SET/COAST. (4) After releasing the switch, check that the vehicle cruises at the desired speed. (b) Inspect the ACCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. (4) Momentarily raise the control switch upward to the RES/ACC position and then immediately release it. Check that the vehicle speed increases by approx. 1.5 km/h (Tap–up function). (c) Inspect the COAST switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed decreases while the control switch is turned to SET/COAST, and the vehicle cruises at the set speed when the switch is released. (4) Momentarily pull the control switch down to SET/ COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap–down function). N17520 N17520 – Author: Date: 1107 DI–873 DIAGNOSTICS CRUISE CONTROL SYSTEM (d) Inspect the CANCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Depress the clutch pedal (M/T)
Shift to except D position (A/T)
Push the main switch OFF
Pull the cruise control switch to CANCEL (e) Inspect the RESUME switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Depress the clutch pedal (M/T)
Shift to except D position (A/T)
Push the main switch OFF
Pull the cruise control switch to CANCEL (4) After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. N17520 N17520 – Author: Date: 1108 DI–874 DIAGNOSTICS (1) (2) (1) No. N17520 – 5. INPUT SIGNAL CHECK HINT: (1) For check No.1 ∼ No.3
Turn ignition switch ON. (2) For check No.4
Jack up the vehicle.
Start the engine.
Shift to D position. (a) Pull the control switch to SET/COAST or RES/ACC position and hold it down or up (1). (b) Push the main switch ON (2). (c) Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. (d) Turn the SET/COAST or RES/ACC switch OFF. (e) Operate each switch as listed in the table below. (f) Read the blinking pattern of the CRUISE MAIN indicator light. (g) After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. CRUISE MAIN Indicator Light Blinking Pattern Operation Method 0.25 sec. 1 Turn SET/COAST switch ON CRUISE CONTROL SYSTEM Light ON 0.25 sec. SET/COAST switch circuit is normal 1sec. OFF ON 2 Turn RES/ACC switch ON Light RES/ACC switch circuit is normal OFF Turn CANCEL switch ON ON Switch ON OFF Turn stop light switch ON Depress brake pedal Turn PNP switch OFF (Shift to except D position) ON Light OFF Turn clutch switch OFF (Depress clutch pedal) Drive at about 40 km/h (25 mph)or higher Light Drive at about 40 km/h (25 mph) or below Light 4 CANCEL switch circuit is normal Switch OFF Light 3 Diagnosis Stop light switch circuit is normal PNP switch circuit is normal Switch ON Switch OFF Clutch switch circuit is normal ON OFF Vehicle Speed Sensor is normal ON OFF Author: Date: 1109 DI–875 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08I–08 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. DTC No. (See Page) Circuit Inspection Trouble Area Actuator Motor Circuit
Actuator motor
Harness or connector between cruise control ECU and actuator motor
Cruise control ECU 12 (DI–883) Actuator Magnetic Clutch Circuit
STOP Fuse
Stop light switch
Actuator magnetic clutch
Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground
Cruise control ECU 14 (DI–886) Actuator Mechanical Malfunction
Actuator motor (actuator lock: motor, arm)
Cruise control ECU 21 (DI–888) Open in Vehicle Speed Sensor Circuit
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU 23 (DI–891) Vehicle Speed Signal Abnormal
Vehicle speed sensor
Cruise control ECU Control Switch Circuit
Cruise control switch
Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground
Cruise control ECU 41 Cruise control ECU
Cruise control ECU 42 Source voltage drop
Power source Idle Signal Circuit
Throttle position sensor
Harness or connector between ECM and throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU 11, 15 (DI–881) 32 (DI–892) 51 (DI–895) Author: Date: 1110 DI–876 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08J–08 PARTS LOCATION Cruise Control Actuator  Actuator Motor  Actuator Magnetic Clutch Cruise Control switch  Main Switch  Control Switch Stop Light Switch Cruise Control ECU Instrument Panel Junction Block No.1  ECU–IG Fuse  STOP Fuse DLC2 5S–FE engine: 1MZ–FE engine: Vehicle Speed Sensor Vehicle Speed Sensor Park/Neutral Position Switch Park/Neutral Position Switch I08439 Author: Date: 1111 DI–877 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI1KT–06 TERMINALS OF ECU C15 I00293 Symbols (Terminals No.) Wiring Color STP ↔ GND STP– (C15–2 ↔ C15–16) G W ↔ W–B G–W W B D ↔ GND (C15–3 (C15 3 ↔ C15–16) C15 16) B R ↔ W–B B–R W B PI ↔ GND (C15–4 (C15 4 ↔ C15–16) C15 16) TC ↔ GND (C15–5 ↔ C15–16) ECT ↔ GND (C15–6 ↔ C15–16) O ↔ W–B W B LG–R ↔ W–B L B ↔ W–B L–B W B MC ↔ GND (C15–7 ↔ C15–16) R B ↔ W–B R–B W B L ↔ GND (C15–8 ↔ C15–16) G B ↔ W–B G–B W B B ↔ GND (C15–9 ↔ C15–16) B–R ↔ W–B CCS ↔ GND (C15–10 ↔ C15–16) W ↔ W–B Condition STD Voltage (V) Depress brake pedal 10 – 16 V Release brake pedal Below 1 V Shift to positions except D Below 1 V Shift to D position 10 – 16 V Ignition switch ON Cruise control main switch ON Below 1.2 V Ignition switch ON Cruise control main switch OFF 10 – 16 V Ignition switch ON 10 – 16 V Ignition switch ON Connect terminals Tc and E1 of diagnostic check connector Below 1 V During driving Gear position 3rd 10 – 16 V During driving Gear position O/D Below 1 V During cruise control driving COAST switch held ON 9 – 15 V During cruise control driving ACC switch held ON Below 1 V During cruise control driving 9 – 15 V Except during cruise control driving Below 1 V Ignition switch ON 10 – 16 V Ignition switch ON 10 – 16 V Ignition switch ON CANCEL switch held ON 4.2 – 8.8 V Ignition switch ON SET/COAST switch held ON 2.5 – 6.3 V Ignition switch ON RES/ACC switch held ON 0.8 – 3.7 V Author: Date: 1112 DI–878 DIAGNOSTICS Symbols (Terminals No.) W L ↔ W–B W–L W B SPD ↔ GND (C15 12 ↔ C15–16) (C15–12 C15 16) V–W V W↔W W–B B OD ↔ GND (C15–14 ↔ C15–16) CRUISE CONTROL SYSTEM Wiring Color CMS ↔ GND (C15–11 ↔ C15–16) IDL ↔ GND (C15–13 ↔ C15–16) – Condition STD Voltage (V) Ignition switch ON Main switch OFF 10 – 16 V Ignition switch ON Main switch ON Below 0.5 V Engine start Car stoppage. Below 1.5 V or 4.7 – 16 V During driving (Pulse generated). L R ↔ W–B L–R W B Y B ↔ W–B Y–B W B MO ↔ GND (C15–15 ↔ C15–16) R G ↔ W–B R–G W B GND ↔ Body Ground (C15–16 ↔ Body Ground) W–B ↔ Body Ground 3–7V Ignition switch ON Throttle valve fully opened. 10 – 16 V Ignition switch ON Throttle valve fully closed. Below 1.5 V During cruise control driving OD switch ON. 10 – 16 V During cruise control driving OD switch OFF (3rd driving) Below 1 V During cruise control driving ACC switch hold ON 9 – 15 V During cruise control driving COAST switch hold ON Below 1 V Constant Below 1 V Author: Date: 1113 DI–879 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08L–13 PROBLEM SYMPTOMS TABLE Symptom See pageSee page Suspect AreaSuspect Area SET not occourring or CANCEL occurring. (DTC is Normal) 3. Main Switch Circuit (Cruise control switch) 4. Vehicle Speed Sensor 5. Control Switch Circuit (Cruise control switch) 6. Stop Light Switch Circuit 7. Park/Neutral Position Switch Circuit 8. Clutch Switch 9. Actuator Motor Circuit 10.Cruise Control Cable 11.Cruise Control ECU SET not occurring or CANCEL occurring. (DTC dose not output) 1. ECU Power Source Circuit 2. Cruise Control ECU DI–909 IN–31 DI–918 DI–891 Actual vehicle speed deviates above or below the set speed. 1. Cruise Control Cable 2. Vehicle Speed Signal Abnormal 3. Electronically Controlled Transmission Communication Circuit 4. Actuator Motor Circuit 5. Idle Signal Circuit (Main throttle position sensor) 6. Cruise Control ECU DI–912 DI–888 DI–892 DI–898 DI–904 DI–907 DI–881 DI–918 IN–31 DI–901 DI–881 DI–895 IN–31 Gear shifting frequent between 3rd O/D when driving on uphill road. (Hurting) 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU DI–901 IN–31 Cruise control not cancelled, even when brake pedal is depressed. 1. 2. 3. 4. Cruise Control Cable Stop Light Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–918 DI–898 DI–881 IN–31 Cruise control not cancelled, even when transmission is shifted to ”N” postion. 1. 2. 3. 4. Cruise Control Cable Park/Neutral Position Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–918 DI–904 DI–881 IN–31 Cruise control not cancelled, even when clutch pedal is depressed. 1. 2. 3. 4. Cruise Control Cable Clutch Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–918 DI–907 DI–881 IN–31 Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) 1. 2. 3. 4. Cruise Control Cable Control Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–918 DI–892 DI–881 IN–31 SET possible at 40 km/h (25 mph) or less, or CANCEL does not operate at 40 km/h (25 mph) or less. 1. 2. 3. 4. Cruise Control Cable Vehicle Speed Signal Abnormal Actuator Motor Circuit Cruise Control ECU DI–918 DI–891 DI–881 IN–31 Poor response is in ACCEL and RESUME modes. 1. Cruise Control Cable 2. Electronically Controlled Transmission Communication Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU O/D does not resume, even though the road is not uphill. 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU Author: DI–918 DI–901 DI–881 IN–31 DI–901 IN–31 Date: 1114 DI–880 DIAGNOSTICS – CRUISE CONTROL SYSTEM DTC memory is erased. 1. Cruise Control ECU IN–31 DTC is not output, or is output when should not be. 1. Diagnosis Circuit 2. Cruise Control ECU DI–916 IN–31 Cruise MAIN indicator light remains ON or falls to light up. 1. Cruise MAIN Indicator Light Switch Circuit DI–914 Author: Date: 1115 DI–881 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08M–12 CIRCUIT INSPECTION DTC 11, 15 Actuator Motor Circuit CIRCUIT DESCRIPTION The actuator motor is operated by signals from the ECU. Acceleration and deceleration signals are transmitted according to changes in the Duty Ratio (See below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity. A A Duty Ratio = A+B DTC No. ON x 100 (%) OFF B 1 cycle Detection Item Trouble Area 11 Short in actuator motor circuit.  Actuator motor  Harness or connector between cruise control ECU and actuator motor  Cruise control ECU 15 Open in actuator motor circuit.  Actuator motor WIRING DIAGRAM Cruise Control ECU Cruise Control Actuator
Actuator Motor 7 2 C15 R–B MC 15 1 C15 MO R–G I00280 Author: Date: 1116 DI–882 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check resistance between terminals MO and MC of actuator motor. ON 2 1 I00004 I00151 PREPARATION: (a) Turn ignition switch ON. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 1 and 2. HINT: If control plate is in fully opened or fully closed positions, resistance can not be measured. OK: Resistance: more than 4.2 Ω NG Replace cruise control actuator. OK 2 Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. (See page IN–31). Author: Date: 1117 DI–883 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08N–12 DTC 12 Actuator Magnetic Clutch Circuit CIRCUIT DESCRIPTION This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control operation, the rotor shaft between the motor and control plate is released. When the brake pedal is depressed, the stop light switch turns on, supplying electrical power to the stop light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF. When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph), cruise control at the set speed is resumed. DTC No. Detection Item Trouble Area  STOP Fuse  Stop light switch  Actuator magnetic clutch  Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground  Cruise control ECU Short in actuator magnetic clutch circuit. Open (0.8 sec.) in actuator magnetic clutch circuit. 12 WIRING DIAGRAM Cruise Control ECU A J7 J/C Cruise Control Actuator
Actuator Magnetic Clutch A J7 4 W–B 3 R–Y Stop Light Switch 4 3 1 2 8 C15 G–B L W–B 8 1J Instrument Panel J/B 7 1J Stop Lights STOP Fuse W–B A J11 J/C IG I00281 Author: Date: 1118 DI–884 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check STOP fuse. Instrument panel junction block No.1: STOP Fuse PREPARATION: (a) Turn ignition switch OFF. (b) Remove the STOP fuse from instrument panel junction block No.1. CHECK: Check fuse continuity. OK: There is continuity. I00157 NG Replace STOP fuse. OK 2 Check stop light switch. 2 4 1 PREPARATION: Disconnect the stop light switch connector. CHECK: Check continuity between terminals. 3 I00133 NG Switch position Continuity Switch pin free (Brake pedal depressed) 1–2 Switch pin pushed in (Brake pedal released) 3–4 Replace stop light switch. OK Author: Date: 1119 DI–885 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check resistance between terminals L and GND of actuator magnetic clutch. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 3 and 4. OK: Resistance: 34.65 – 42.35 Ω. 4 3 I00311 NG Replace cruise control actuator. OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1120 DI–886 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08O–12 DTC 14 Actuator Mechanical Malfunction CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No. 14 Detection Item Trouble Area Cruise control actuator mechanical malfunction.
Actuator lock: (motor, arm)
Actuator motor
Cruise control ECU WIRING DIAGRAM See page DI–881. INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation 4 (+) (–) 3 I00055 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to the terminal 3 of actuator and the negative (–) lead to terminal 4. NOTICE: Do not connect the high tension cables to the wrong battery terminal. The cruise control actuator will be damaged. Move the control plate by hand. OK: Control plate doesn’t move. NG Replace cruise control actuator. OK Author: Date: 1121 DI–887 DIAGNOSTICS 2 – CRUISE CONTROL SYSTEM Check cruise control actuator operation. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to terminals 1 and 3 of actuator, connect the negative (–) lead to terminals 2 and 4 of actuator. OK: Control arm moves to fully open side Fully open side 4 1 3 2 Control plate CHECK: Connect the positive (+) lead from the battery to terminals 2 and 3 of actuator, connect the negative (–) lead to terminals 1 and 4 of actuator. OK: Control arm moves to fully colsed side Fully Closed side 4 1 3 2 Control plate I08437 NG Replace cruise control actuator. OK 3 Check harness and connector between cruise control ECU and cruise control actuator (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1122 DI–888 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08P–12 DTC 21 Open in Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The signal from the vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. The rotor shaft is driven by the gear of the transmission. For each rotation of the shaft, the vehicle speed sensor sends a 4–pulse signal through the combination meter to the cruise control ECU (See the following installation). This signal is converted inside the combination meter and sent as a 4–pulse signal to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. 4 pulses/ 4 pulses/ 1 rotation 1 rotation of rotor shaft of rotor shaft Vehicle Speed Sensor Combination Meter ECU DTC No. 21 Cruise Control ECU Detection Item I00292 Trouble Area Speed signal is not input to the cruise control ECU while cruise control is set.
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU WIRING DIAGRAM Cruise Control ECU Combination Meter 15 C9 L P 7 2 IJ1 14 3 C9 IG3 V–W B V–W 12 B C15 V–W SPD 6 IJ1 L 3 SI C10 Speedo –meter J15 J/C P 2 SE Speed Sensor IG+ 1 to GAUGE Fuse R–L I00282 Author: Date: 1123 DI–889 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Input Signal Indicator Light Blinking Pattern Drive at about 40 km/h (25 mph) or below Light Drive at about 40 km/h (25 mph) or higher Light ON OFF ON OFF CHECK: (a) See input signal check on page DI–870. (b) Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph). OK: Vehicle speed above 40 km/h (25 mph): Indicator light blinks Vehicle speed below 40 km/h (25 mph): Indicator light stays on OK Check and replace cruise control ECU (See page IN–31). NG 2 Check speedometer circuit (See Combination meter troubleshooting on page BE–2). NG Repair or replace harness, connector or combination meter assembly. OK 3 Check harness and connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor (See page IN–31). NG Repair or replace harness or connector. OK Author: Date: 1124 DI–890 DIAGNOSTICS 4 – CRUISE CONTROL SYSTEM Check vehicle speed sensor (See page BE–47). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1125 DI–891 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08Q–10 DTC 23 Vehicle Speed Signal Abnormal CIRCUIT DESCRIPTION See page DI–888. DTC No. 23 Detection Item Trouble Area
Vehicle speed sensor
Cruise control ECU Vehicle speed sensor pulse is abnormal. WIRING DIAGRAM See page DI–888. INSPECTION PROCEDURE 1 Check vehicle speed sensor (See page BE–47). NG Replace vehicle speed sensor. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1126 DI–892 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08R–12 DTC 32 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. DTC No. 32 Detection Item Trouble Area  Cruise control switch  Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground  Cruise control ECU Short in control switch circuit. WIRING DIAGRAM Cruise Control Switch
Main Switch
Control Switch MAIN Cruise Control ECU 11 CMS 5 C15 W–L CANCEL CMS SET/COAST RES/ACC 3 EP 10 CCS 4 C15 W A J7 W–B J11 J/C Instrument Panel J/B A W–B 7 8 1J 1J A J/C CCS A J8 16 C15 W–B GND J7 W–B IG I00283 Author: Date: 1127 DI–893 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Indicator Light Blinking Pattern Input Signal SET/COAST switch 2 Pulses ON OFF RESUME/ACCEL switch OFF ON CANCEL switch 3 Pulses ON SW OFF OFF SW ON PREPARATION: See input signal check on page DI–870. CHECK: Check the indicator light operation when each of the SET/ COAST, RESUME/ACCEL and CANCEL is turned on. OK: SET/COAST, RESUME/ACCEL switch The signals shown in the table on the left should be output when each switch is ON. The signal should disappear when the switch is turned OFF. CANCEL switch The indicator light goes off when the cancel switch is turned ON. OK Wait and see. NG 2 Check voltage between terminals CCS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals 18 of ECU connector and body ground, when each of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON. ON CCS (–) (+) AB0119 I00168 I00171 NG Switch position Resistance (V) Neutral 10 – 16 V RES/ACC 0.8 – 3.7 V SET/COAST 2.5 – 6.3 V CANCEL 4.2 – 8.8 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). OK Author: Date: 1128 DI–894 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check control switch. 4 PREPARATION: (a) Remove steering wheel center pad. (b) Disconnect the control switch connector. CHECK: Measure resistance between terminals 3 and 4 of control switch connector when control switch is operated. 3 N16045 NG Switch position Resistance (Ω) Neutral ∞ (No continuity) RES/ACC 50 – 80 SET/COAST 180 – 220 CANCEL 400 – 440 Replace control switch. OK 4 Check harness and connector between cruise control ECU and cruise control switch, cruise control switch and body ground (See page IN–31). NG Repair or replace harness or connector. OK Wait and see. OK 5 Input signal check (See step 1). NG Check and replace cruise control ECU (See page IN–31). Author: Date: 1129 DI–895 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08S–10 DTC 51 Idle Signal Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. DTC No. 51 Detection Item Trouble Area
Harness or connector between ECM and throttle position sensor
Throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU Short in idle signal circuit. WIRING DIAGRAM ECM Cruise Control ECU 1 2 3* 4 * E7 E8 IDL 13 C15 L–R IDL *1: 5S–FE Engine *2: 1MZ–FE Engine I00284 Author: Date: 1130 DI–896 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal IDL of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Disconnect the ECM connector. (c) Turn ignition switch ON. CHECK: Measure voltage between terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened. OK: ON IDL (–) AB0119 I00167 (+) I00172 OK Throttle valve position Voltage Fully opened 10 – 14 V Fully closed Below 2 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 2 Check harness and connector between ECM and throttle position sensor (See page IN–31). NG Repair or replace harness or connector. OK 3 Check throttle position sensor circuit (See page DI–243). NG Replace throttle position sensor. OK Author: Date: 1131 DI–897 DIAGNOSTICS 4 – CRUISE CONTROL SYSTEM Check throttle position sensor. PREPARATION: Disconnect the throttle position sensor connector. CHECK: Measure resistance between terminals 3 and 4 of throttle position sensor connector when the throttle valve is fully closed and fully opened. OK: Throttle Position Sensor 3 4 I00052 NG Throttle valve position Resistance Fully opened 1 MΩ or higher Fully closed Below 2.3 kΩ Replace throttle position sensor. OK 5 Check for open and short in harness and connector between cruise control ECU and ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1132 DI–898 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08T–11 Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECU. When the ECU receives this signal, it cancels the cruise control. A fail–safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. The cancel conditions are: Battery positive voltage at terminal STP– When the brake is ON, battery positive voltage normally is applied through the STOP fuse and stop light switch to terminal STP– of the ECU, and the ECU turns the cruise control OFF. If the harness connected to terminal STP– has an open circuit, terminal STP– will have battery positive voltage and the cruise control will be turned OFF. Also, when the brake is ON, the magnetic clutch circuit is cut mechanically by the stop light switch, turning the cruise control OFF. (See page DI–883 for operation of the magnetic clutch) WIRING DIAGRAM Cruise Control ECU Stop Light Switch Instrument Panel J/B 2 1 G–W 3 J27 J/C 5 1R 4 1R A G–W 2 A G–W C15 STP– 4 R–Y 8 W Instrument Panel J/B 7 1C STOP 4 1B 1 F4 B–G ALT A J7 B–R FL BLOCK 1 F9 C15 G–B J/C L Cruise Control Actuator A J7 3 4 W–B W–B Instrument Panel J/B 8 1J 7 1J J11 J/C A W–B FL MAIN Battery IG I00285 Author: Date: 1133 DI–899 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light comes ON when brake pedal is depressed, and turns OFF when brake pedal is released. NG Check stop light system (See page BE–2). OK 2 Input signal check. Input Signal Stop Light switch ON Indicator Light Blinking Pattern OFF Light ON SW OFF SW ON CHECK: (a) See input signal check on DI–870. (b) Check the indicator light when the brake pedal is depressed. OK: The indicator light goes OFF when the brake pedal is depressed. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1134 DI–900 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal STP– of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal STP– of cruise control ECU connector and body ground, when the brake pedal is depressed and released. OK: ON STP– (–) (+) OK AB0119 I00142 – Depressed 10 – 14 V Released Below 1 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). I00173 NG 4 Check for open in harness and connectors between terminal STP– of cruise control ECU and stop light switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1135 DI–901 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08U–11 Electronically Controlled Transmission Communication Circuit CIRCUIT DESCRIPTION When driving uphill under the cruise control, in order to reduce shifting due to ON–OFF overdrive operation and to provide smooth driving, when down shifting in the electronically controlled transmission occurs, a signal to prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the electronically controlled transmission. Terminal ECT of the cruise control ECU detects the shift change signal (output to electronically controlled transmission No. 2 solenoid) from the ECM. If the vehicle speeds down, also when terminal ECT of the cruise control ECU receives down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. WIRING DIAGRAM *1: 1MZ–FE *2: 5S–FE (w/ Immobiliser) *3: 5S–FE (w/o Immobiliser) ECM OD1 24 18 20 E8 E7 E7 *1 S2 *2 *2 14 OD C15 Y–B *3 8 21 6 E11 E9 E9 *1 Cruise Control ECU *3 J26*1 J25*2 J/C L–B L–B A A 7 II2 L–B 6 ECT C15 A ECT No.2 Solenoid I08432 Author: Date: 1136 DI–902 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of overdrive. PREPARATION: Test drive after engine warms up. CHECK: Check that overdrive ON ↔ OFF occurs by operation of OD switch ON–OFF. NG Check and repair electronically controlled transmission (See page DI–389). OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. (c) Disconnect the ECU connector. CHECK: Measure voltage between terminal OD of harness side connector of ECU and body ground. OK: Voltage: 10 – 14 V ON O/D (–) (+) AB0119 I00143 I00174 NG Go to step 5. OK Author: Date: 1137 DI–903 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). (–) (+) ECT PREPARATION: (a) Connect the ECU connector. (b) Test drive after engine warms up. CHECK: Check voltage between terminal ECT of ECU connector and body ground when OD switch is ON and OFF. OK: I00141 OK OD switch position Voltage ON 8 – 14 V OFF Below 0.5 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transmission solenoid (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. 5 Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1138 DI–904 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08V–11 Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Cruise Control ECU For M/T Instrument Panel J/B 1 1K 1 GAUGE 1J F J28 R–L J/C D J27 J29 J/C Clutch Switch 2 1 A B–R R–L A F J28 B–Y Ignition Switch 4 R–L 2 Instrument Panel J/B For A/T AM1 II2 W 2 1K R–L II2 A A 2 ALT 1 F4 10 B–R J/C J21 (5S–FE) J24 (1MZ–FE) FL BLOCK 1 F9 9 PNP Switch R–L B–R D AM1 2 IG1 1 1B 3 A C15 B–R B–G FL MAIN Battery I08433 Author: Date: 1139 DI–905 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting. (5S–FE: See page ST–1) (1MZ–FE: See page ST–1). OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Turn PNP switch ON SW ON OFF (Shift to posi- Light SW OFF tions except D ) OFF PREPARATION: See input signal check on page DI–870. CHECK: Check the indicator light when shifting into positions except D. OK: The indicator light goes off when shifting into positions except D. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1140 DI–906 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU connector and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of ECU connector and body ground when shifting into D position and other positions. OK: ON D (–) AB0119 I00139 – Shift Position Voltage D position 10 – 14 V Other positions Below 1 V (+) I00175 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 4 Check harness and connector between cruise control ECU and park/neutral position switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1141 DI–907 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08W–04 Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. WIRING DIAGRAM Refer to PNP switch circuit on page DI–904. INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting (5S–FE: See page ST–1) (1MZ–FE: See page ST–1). OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Clutch switch ON SW ON OFF (Depress Light SW OFF clutch pedal) OFF PREPARATION: See input signal check on page DI–870. CHECK: Check the indicator lights when clutch pedal is depressed. OK: The indicator light goes off when shifting into clutch pedal is depressed. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1142 DI–908 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of cruise control ECU connector and body ground when clutch pedal is depressed and pushed in. OK: ON D (–) AB0119 I00139 – (+) Shift Position Voltage Clutch pedal depressed 10 – 14 V Clutch pedal pushed in Below 1 V I00175 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 4 Check for open in harness and connector between ECU and GAUGE fuse (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1143 DI–907 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08W–04 Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. WIRING DIAGRAM Refer to PNP switch circuit on page DI–904. INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting (5S–FE: See page ST–1) (1MZ–FE: See page ST–1). OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Clutch switch ON SW ON OFF (Depress Light SW OFF clutch pedal) OFF PREPARATION: See input signal check on page DI–870. CHECK: Check the indicator lights when clutch pedal is depressed. OK: The indicator light goes off when shifting into clutch pedal is depressed. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1142 DI–908 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of cruise control ECU connector and body ground when clutch pedal is depressed and pushed in. OK: ON D (–) AB0119 I00139 – (+) Shift Position Voltage Clutch pedal depressed 10 – 14 V Clutch pedal pushed in Below 1 V I00175 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 4 Check for open in harness and connector between ECU and GAUGE fuse (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1143 DI–909 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08X–11 ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc, when terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Cruise Control ECU Instrument Panel J/B Ignition Switch 2 AM1 IG1 4 B–Y 1 1K ECU–IG J12 J/C 9 1J C B–R 9 C15 C B–R B W Instrument Panel J/B FL BLOCK 1 B–G ALT 1 F9 F4 J11 J/C B–R 1 1B AM1 2 1K Instrument Panel J/B 7 8 A A 1J J7 1J W–B W–B J/C A J8 W–B 16 C15 GND FL MAIN Battery IG I08434 Author: Date: 1144 DI–910 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU–IG fuse. Instrument panel junction block No.1: ECU–IG Fuse PREPARATION: Remove the ECU–IG fuse from instrument panel junction block No.1. CHECK: Check continuity of ECU–IG fuse. OK: Continuity I00157 NG Check for short in all the harness and components connected to ECU–IG fuse. OK 2 Check voltage between terminals B and GND of cruise control ECU connector. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals B and GND of ECU connector. OK: 10 – 14 V ON B GND (–) (+) AB0119 I00147 I00176 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1145 DI–911 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check resistance between terminal GND of cruise control ECU connector and body ground. CHECK: Measure resistance between terminal GND of ECU connector and body ground. OK: Resistance: Below 1 Ω GND I00140 NG Repair or replace harness or connector. OK Check and repair harness and connector between cruise control ECU and battery (See page IN–31). Author: Date: 1146 DI–912 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08Z–16 Main Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION When the cruise control main switch is turned OFF, the cruise control does not operate. WIRING DIAGRAM See page DI–892. INSPECTION PROCEDURE 1 Check voltage between terminal CMS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal CMS of cruise control ECU connector when main switch is held ON and OFF. OK: ON CMS (–) (+) Main switch Voltage OFF 10 – 14 V ON Below 0.5 V AB0119 I00145 I00177 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG Author: Date: 1147 DI–913 DIAGNOSTICS 2 – CRUISE CONTROL SYSTEM Check main switch continuity. 3 PREPARATION: (a) Remove steering wheel center pad. (See page SR–11) (b) Disconnect the control switch connector. CHECK: Check continuity between terminals 3 and 5 of control switch connector when main switch is held ON and OFF. OK: 5 Switch position Tester connection Specified condition OFF 3–5 No continuity Hold ON 3–5 Continuity N15969 NG Replace control switch. OK 3 Check harness and connector between cruise control ECU and main switch (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1148 DI–914 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI090–17 CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM J4 J/C D D R–L CRUISE MAIN Indicator Light (in Combination Meter) 10 7 C10 C10 O Cruise Control ECU J2 J/C 5 IG2 D 4 D O O PI C15 R–L Instrument Panel J/B 2 1D GAUGE 1 1K Ignition Switch 4 B–G ALT W Instrument Panel J/B FL BLOCK 1 F4 AM1 2 IG1 B–Y 1 F9 B–R 1 1B AM1 2 1K FL MAIN Battery I00290 Author: Date: 1149 DI–915 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals PI and GND of cruise control ECU connector. PREPARATION: Tun ignition switch ON. CHECK: Measure voltage between terminals PI and GND of cruise control ECU connector when main switch is ON and OFF. OK: ON PI (–) AB0119 I00144 Switch position Voltage OFF 10 – 16 V ON Below 1.2 V (+) I00178 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 2 Check combination meter (See page BE–2). NG Replace combination meter. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1150 DI–916 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI091–11 Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that outputs DTC. WIRING DIAGRAM Cruise Control ECU J2 J/C D 4 D C15 PI O O 10 D4 DLC2 J3 J/C 4 D4 B 5 B C15 LG–R LG–R TC B LG–R 11 II3 DLC1 11 D1 LG–R*1 P–B*2 *1: TMC Made, TMMK Made (5S–FE) *2: TMMK Made (1MZ–FE) I00291 Author: Date: 1151 DI–917 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals Tc and E1 of DLC2. OK: Voltage: 10 – 14 V ON AB0119 I00169 TC E1 I00179 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–879). NG 2 Check harness and connector between cruise control ECU and DLC2, DLC2 and body ground (See page IN–31). NG Repair or replace harness or connector. OK Check and replace cruise control ECU (See page IN–31). Author: Date: 1152 DI–918 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI092–07 Actuator Control Cable INSPECTION PROCEDURE 1 Actuator control cable inspection OK: (a) Check that the actuator and control cable throttle link are properly installed and that the cable and link are connected correctly. (b) Check that the actuator and bell crank operate smoothly. (c) Check that the cable is not loose or too tight. OK: Freeplay: less than 10 mm HINT:
If the control cable is very loose, the vehicle’s loss of speed going uphill will be large.
If the control cable is too tight, the idle RPM will become high. Author: Date: 1153 DI–919 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM DI1KE–04 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshooting in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI–920 2 Check and Clear DTC (Precheck) P. DI–921 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN–21 7 Problem Symptoms Table P. DI–927 Symptom occurs 5 Normal code DTC Check P. DI–921 Malfunction code 6 DTC Chart P. DI–924 8 Circuit Inspection and part Inspection P. DI–928 – DI–935 Identification of Problem 9 10 Repair Confirmation Test End Step 2, 5 : Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. Author: Date: 1154 DI–920 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KF–04 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE IMMOBLISER Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / km miles Odometer Reading / Date Problem First Occurred / Frequency Problem Occurs Continuous / Intermittent ( times a day) Immobiliser is not set. (Engine starts with key codes other than the registered key code.) Symptoms Engine does not start. Check Item Malfunction Indicator Lamp Normal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check Author: Date: 1155 DI–921 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KG–04 TOYOTA hand–held tester DLC3 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Description ECM controls the function of immobiliser on this vehicle. Data of the immobiliser or DTC can be read form DLC3 of the vehicle. When a trouble occurs in immobiliser, MIL does not light ON but DTC inspection is performed. Therefore when there seems to be a trouble with immobiliser, use TOYOTA hand–held tester or SST to check and troubleshoot it. (b) DLC3 INSPECTION The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAEJ1962 and matches the ISO 9141–2 format. S05335 N09214 Tester connection condition Specified condition 7 (Bus
Line) – 5 (Signal ground) During communication 4 (chassis Ground) – Body Always 1 Ω or less 5 (Signal Ground) – Body Always 1 Ω or less 16 (B+) – Body Always 9 – 14 V Pulse generation HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of OBD ll scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. (2) If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. Author: Date: 1156 DI–922 DIAGNOSTICS E1 DLC1 – ENGINE IMMOBILISER SYSTEM 2. (a) INSPECT DIAGNOSIS Check the DTC (Using TOYOTA hand–held tester) (1) Prepare the OBD ll scan tool (complying with SAEJ 1978) or TOYOTA hand–held tester. (2) Connect the OBD ll scan tool or TOYOTA hand– held tester to DLC3 under the instrument panel lower pad. (3) Turn the ignition switch ON and turn the OBD ll scan tool or TOYOTA hand–held tester switch ON. (4) Use the OBD ll scan tool or TOYOTA hand–held tester to check the DTCs and freeze frame data; note them down. (For operating instructions, see the OBD ll scan tool’s instruction book.) (5) See page DI–924 to confirm the details of the DTCs. (b) Check the DTC (Using diagnosis check wire) (1) Turn ignition switch ON. (2) Using SST, connect between terminals 8 (TE1) and 3 (E1) of DLC1. SST 09843–18040 (3) Read the diagnostic trouble code from malfunction indicator lamp. HINT: TE1 F02201

As an example, the blinking patterns for codes; normal, 12 and 99 are as shown in the illustration. Normal code 0.25 Sec. If a diagnostic trouble code is not output, check the Tc terminal circuit . ECM controls the immobiliser function on this vehicle, DTC is out put with DTC of engine. 0.25 Sec. BR3904 Author: Date: 1157 DI–923 DIAGNOSTICS 0.5 Sec. 0.5 Sec. 1.5 Sec. 2.5 Sec. – ENGINE IMMOBILISER SYSTEM Malfunction Code (Example Code 12, 99) 4.5 Sec. One Cycle I02680 (4) (5) When DTC ”99” is output, there is a trouble with immobiliser. Start troubleshooting referring to PROBLEM SYMPTOM TABLE. After completing the check, disconnect terminals 13 (TC) and 4 (CG) and turn OFF the display. HINT: In the event of 2 or more malfunction codes. indication will begin from the smaller numbered code and continue in order to the larger. (c) Clear the DTC The following procedures will erase the DTCs and freeze frame data. (1) Operating the OBD ll scam tool (complying with SAEJ1978) or TOYOTA hand–held tester to erase the codes. (See the OBD ll scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. Author: Date: 1158 DI–924 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KH–03 DIAGNOSTIC TROUBLE CODE CHART DTC No. (See page) Detection Item Trouble Area Unmatched key code
Key
Unregistered key inserted before B2796 (DI–929) No communication in immobiliser system
Key
Transponder key coil
Amplifier
Wirehaness
ECM B2797 (DI–932) Communication malfunction No.1
Communication contests
Unregistered key inserted before Communication malfunction No.2
Key
Transponder key coil
Amplifier
Wirehaness
ECM B2795 (DI–928) B2798 (DI–935) HINT: To reduce the unnecessary exchange of ECM, check that a trouble occurs with the original ECM at the time of exchanging ECM and the trouble will disappear with a new ECM. Author: Date: 1159 DI–925 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KI–04 PARTS LOCATION Engine Room J/B No.2  EFI Fuse Transponder Key Amplifier Transponder Key Coil ECM Instrument Panel J/B  IGN Fuse I02682 Author: Date: 1160 DI–926 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KJ–04 TERMINALS OF ECM E7 E8 E9 E10 E11 D01054 5S–FE engine: Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) CODE – E1 (E10–8 ↔ E9–24) G–W ↔ BR Ignition Switch ON 10 – 14 TXCK – E1 (E10–9 ↔ E9–24) L–Y ↔ BR Ignition Switch ON 10 – 14 RXCK – E1 (E10–3 ↔ E9–24) R–L ↔ BR Ignition Switch ON 10 – 14 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) CODE – E1 (E9–4 ↔ E10–17) G–W ↔ BR Ignition Switch ON 10 – 14 TXCK – E1 (E9–10 ↔ E10–17) L–Y ↔ BR Ignition Switch ON 10 – 14 RXCK – E1 (E9–5 ↔ E10–17) R–L ↔ BR Ignition Switch ON 10 – 14 1MZ–FE engine: Author: Date: 1161 DI–927 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KK–03 PROBLEM SYMPTOMS TABLE Symptom Suspect Area Immobiliser is not set. (Engine starts with key codes other than the registered key code.) 2. ECM Engine does not start. 1. 2. 3. 4. 5. See page IN–31 Key Wire harness Transponder key coil Amplifier ECM *1 IN–31 BE–128 IN–31 *2 IN–31 IN–31 Security indicator is always ON. 1. Security indicator 2. Wire harness 3. ECM Security indicator is always ON. (Although code has been registered in the automatic registration mode, indicator is not OFF.) 1. 2. 3. 4. Wire harness Transponder key coil Amplifier ECM IN–31 BE–128 Security indicator is OFF (When DTC of immobiliser is output) 1. 2. 3. 4. Wire harness Transponder key coil Amplifier ECM IN–31 BE–128 IN–31 IN–31 Security indicator is OFF. (When DTC of immobiliser is not output) 1. Wire harness 2. ECM IN–31 IN–31 Security indicator is abnormally brinking. 1. Wire harness 2. ECM IN–31 IN–31 *1 : Check that the key which did not start the engine has been registered and that it is possible to start with other already registered key codes. *2 : Finish the automatic registration mode because the mode might still remain. Author: Date: 1162 DI–928 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI1KN–02 CIRCUIT INSPECTION DTC B2795/99 Unmatched Key Code This DTC is output when an unregistered key is inserted. When this DTC is output, delete DTC and insert the key that a customer keeps to check that B2795 is output. When a key that outputs B2795 is found, register this key. When B2795 is not output, there is a possibility that the unregistered key has been inserted before. (ECM is normal.) Inquire of a customer about the condition of using the system to find the cause of the trouble. (Example: Another key has been inserted, etc.) Author: Date: 1163 DI–929 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI4FF–01 DTC B2796/99 No Communication in Immobiliser system CIRCUIT DESCRIPTION DTC No. B2796/99 DTC Detecting Condition Trouble Area
Key
Transponder Key Coil
Transponder Key Amplifier
Wireharness
ECM No communication WIRING DIAGRAM 5S–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 1 II4 4 II4 2 II4 G–W 8 E10 CODE 3 R–L E10 RXCK 9 L–Y E10 TXCT I08435 Author: Date: 1164 DI–930 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM 1MZ–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 4 E9 CODE 5 E9 RXCK 10 E9 TXCT I03114 Author: Date: 1165 DI–931 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Check transponder key coil (See page BE–128). NG Replace transponder key coil. OK 2 Check harness and connector between transponder key amplifier and ECM. NG Repair or replace harness and connector. OK 3 Does it operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. Author: Date: 1166 DI–932 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI4FG–01 DTC B2797/99 Communication Malfunction No.1 CIRCUIT DESCRIPTION This code is detected when although the communication has been performed normally, an error occurs. (Example. Some noise is inclueded in communication line.) DTC No. B2797/99 DTC Detecting Condition Trouble Area
Wire Harness
Transponder Key Amplifier
ECM Communication error WIRING DIAGRAM 5S–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 1 II4 4 II4 2 II4 G–W 8 E10 CODE 3 R–L E10 RXCK 9 L–Y E10 TXCT I08435 Author: Date: 1167 DI–933 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM 1MZ–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 4 E9 CODE 5 E9 RXCK 10 E9 TXCT I03114 Author: Date: 1168 DI–934 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Noise check PREPARATION: Insert already registered master key in the key cylinder. CHECK: Using an oscilloscope or TOYOTA hand–held tester, check that noise is included in the CODE terminal of ECM. OK: No noise is detected. Noise I02681 NG Try to find the cause of the noise and remove it. OK 2 Does it operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. Author: Date: 1169 DI–935 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI4FH–01 DTC B2798/99 Communication malfunction No.2 CIRCUIT DESCRIPTION DTC No. B2798/99 DTC Detecting Condition Trouble Area
Key
Transponder Key Coil
Transponder Key Amplifier
Wireharness
ECM Communication error WIRING DIAGRAM 5S–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 1 II4 4 II4 2 II4 G–W 8 E10 CODE 3 R–L E10 RXCK 9 L–Y E10 TXCT I08435 Author: Date: 1170 DI–936 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM 1MZ–FE engine: ECM Transponder Key Amplifier 2 G–W 3 R–L 4 L–Y 4 E9 CODE 5 E9 RXCK 10 E9 TXCT I03114 Author: Date: 1171 DI–937 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE 1 Check transponder key coil (See page BE–128). NG Replace transponder key coil OK 2 Check harness and connector between transponder key amplifier and ECM. NG Repair or replace harness and connector OK 3 Does it operate normally after replacement of transponder key amplifier? Yes Replace transponder key amplifier. No Replace ECM. Author: Date: 1172 DI–1 DIAGNOSTICS – ENGINE ENGINE DI00F–10 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Titles inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 2 Customer Problem Analysis P. DI–2 Connect OBD II scan tool or TOYOTA hand–held tester to DLC3 P. DI–3 If display indicates a communication fault in tool, inspect DLC3 P. DI–3 3 Check DTC and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P. DI–3 4 Clear DTC and Freezed Frame Data P. DI–3 5 Visual Inspection 6 Setting Check Mode Diagnosis P. DI–3 7 Problem Symptom Confirmation If engine does not start perform steps 10 and 12 first Malfunction occurs. 9 10 DTC Check P. DI–3 Normal Basic Inspection P. DI–3 12 14 8 Malfunction code. 11 DTC Chart P. DI–3 Problem Symptoms Table P. DI–21 Parts Inspection 15 Malfunction does not occur. Symptom Simulation P. IN–19 13 Circuit Inspection P. DI–22 Check for Intermittent Problems P. DI–3 Identification of Problem 16 Adjustment, Repair 17 Confirmation Test End Author: Date: 71 DI–2 DIAGNOSTICS – ENGINE DI00G–07 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Driveability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other km miles No initial combustion Back fire Other No complete combustion High ( rpm) Low ( Muffler explosion (after–fire) Surging Others Datas Problem Occurred Constant Other Condition When Problem Occurs Problem Frequency Sometimes ( times per day/month) Weather Fine Cloudy Rainy Snowy Outdoor Temperature Hot Warm Cool Cold (approx. Place Highway Rough road Engine Temperature Engine Operation Cold Suburbs Other Warming up Inner city After warming up Just after starting ( Starting Driving Constant speed A/C switch ON/OFF Other Condition of MIL Normal Mode (Precheck) Once only Various/Other °F/ °C) Uphill Downhill Any temperature min.) Idling Acceleration Other Racing Deceleration Remains on Sometimes lights up Does not light up Normal Malfunction code(s) (code Freezed frame data ( ) Malfunction code(s) (code Freezed frame data ( ) ) DTC Inspection Check Mode Normal ) rpm) DI–3 DIAGNOSTICS – ENGINE DI64S–01 PRE–CHECK 1. (a) DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBD II scan tool complying with SAE J1978 or TOYOTA hand– held tester, and read off various data output from the vehicle’s ECM.
S05347 TOYOTA Hand–Held Tester DLC3 S05331 OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the emission control system/components or in the power train control components which affect vehicle emissions, or a malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the applicable Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory. (See page DI–14) If the malfunction does not reoccur in 3 consecutive trips, the MIL goes off automarially but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect the OBD II scan tool or TOYOTA hand–held tester to the Data Link Connector 3 (DLC3) on the vehicle. The OBD II scan tool or TOYOTA hand–held tester also enables you to erase the DTCs and check freezed frame data and various forms of engine data (For operating instructions, see the OBD II scan tool’s instruction book.) DTCs include SAE controlled codes and manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits. (See DTC chart on page DI–14) DI–4 DIAGNOSTICS
– ENGINE The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simulate malfunction symptoms and troubleshoot. Most DTCs use 2 trip detection logic* to prevent erroneous detection, and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily. (TOYOTA hand–held tester only) (See page DI–3)
*2 trip detection logic: When a malfunction is first detected, the malfunction is temporarily stored in the ECM memory. (1st trip) If the same malfunction is detected again during the second drive test, this second detection causes the MIL to light up. (2nd trip) (However, the ignition switch must be turned OFF between the 1st trip and 2nd trip.)
Freeze frame data: Freeze frame data records the engine condition when a misfire (DTCs P0300 – P0304) or fuel trim malfunction (DTCs P0171 and P0172) or other malfunction (first malfunction only), is detected. Because freeze frame data records the engine conditions (fuel system, calculated load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
Priorities for troubleshooting. If troubleshooting priorities for multiple DTCs are given in the applicable DTC chart, these should be followed. If no instructions are given, troubleshoot DTCs according to the following priorities. (1) DTCs other than fuel trim malfunction (DTCs P0171 and P0172), EGR (DTCs P0401 and P0402), and misfire (DTCs P0300 – P0304). (2) Fuel trim malfunction (DTCs P0171 and P0172), and EGR (DTCs P0401 and P0402). (3) Misfire (DTCs P0300 – P0304). DI–5 DIAGNOSTICS (b) 1 2 3 4 5 6 7 8 – ENGINE Check the DLC3. The vehicle’s ECM uses ISO 9141–2 for communication. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141–2 format. 9 10 11 12 1314 15 16 DLC3 A04550 Terminal No. Connection/Voltage or Resistance Condition 7 Bus  Line/Pulse generation During transmission 4 Chassis Ground ↔ Body Ground/1 Ω or less Always 5 Signal Ground ↔ Body Ground/1 Ω or less Always 16 Battery Positive ↔ Body Ground/9 – 14 V Always HINT: If your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the OBD II scan tool or TOYOTA hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. 2. (a) S05347 INSPECT DIAGNOSIS (Normal Mode) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See Pub. No. RM654U, page BE–2). (2) When the engine started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: TOYOTA hand–held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester. DI–6 DIAGNOSTICS (2) (3) (4) – ENGINE Connect the OBD II scan tool or TOYOTA hand– held tester to DLC3 under the instrument panel lower pad. Turn the ignition switch ON and turn the OBD II scan tool or TOYOTA hand–held tester switch ON. Use the OBD II scan tool or TOYOTA hand–held tester to check the DTCs and freezed frame data and note them down. (For operating instructions, see the OBD II scan tool’s instruction book.) See page DI–3 to confirm the details of the DTCs. (5) NOTICE:
When simulating symptoms with an OBD II scan tool (excluding TOYOTA hand–held tester) to check the DTCs, use normal mode. For code on the DTC chart subject to ”2 trip detection logic”, perform the following either action.
Turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the DTCs are recorded in the ECM.
Check the 1st trip DTC using Mode 7 (Continuous Test Results) for SAE J1979. (c) Clear the DTC. The DTCs and freezed frame data will be erased by either action. (1) Operating the OBD II scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) (2) Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the DTCs and freezed frame data will be erased. 3. INSPECT DIAGNOSIS (Check Mode) HINT: TOYOTA hand–held tester only: Compared to the normal mode, the check mode has an increased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. (a) Check the DTC. (1) Initial conditions
Battery positive voltage 11 V or more
Throttle valve fully closed
Transmission in P or N position
Air conditioning switched OFF (2) Turn ignition switch OFF. DI–7 DIAGNOSTICS – (3) (4) (5) (6) Flashing ON OFF 0.13 Second FI3605 ENGINE Prepare the TOYOTA hand–held tester. Connect the TOYOTA hand–held tester to the DLC3 under the instrument panel lower pad. Turn the ignition switch ON and push the TOYOTA hand–held tester ON. Switch the TOYOTA hand–held tester from the normal mode to the check mode. (Check that the MIL flashes.) NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or LOCK during check mode, the DTCs and freezed frame data will be erased. (7) Start the engine. (The MIL goes out after the engine start.) (8) Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTC, etc. (9) After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the DTCs and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode. So all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. 4. FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. DTC No. Fail–Safe Operation Fail–Safe Deactivation Conditions P0105 Ignition timing fixed at 5° BTDC Returned to normal condition P0110 Intake air temperature is fixed at 20°C (68°F) Returned to normal condition P0115 Engine coolant temperature is fixed at 80°(176°F) Returned to normal condition P0120 VTA is fixed at 0° The following condition must be repeated at least 2 times consecutively VTA  0.1 V and  0.95 V P0141 The heater circuit in witch an abnormality is detected is turned off Ignition switch OFF P1135 The heater circuit in which an abnormality is detected is turned off Ignition switch OFF P1300 P1310 Fuel cut IGF signal is detected for 2 consecutive ignitions DI–8 DIAGNOSTICS – ENGINE 5. CHECK FOR INTERMITTENT PROBLEMS TOYOTA hand–held tester only: By putting the vehicle’s ECM in the check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (1) Clear the DTC (See step 2). (2) Set the check mode (See step 3). (3) Perform a simulation test (See page IN–19). (4) Check the connector and terminal (See page IN–29). (5) Handle the connector (See page IN–29). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? NO Charge or replace battery. YES 2 Is engine cranked? NO Proceed to Pub. No. RM654U, page ST–2 and continue to troubleshoot. NO Go to step 7. YES 3 YES Does engine start? DI–9 DIAGNOSTICS 4 – ENGINE Check air filter. PREPARATION: Remove the air filter. CHECK: Visually check that the air filter is not dirty or excessive oily. HINT: If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow from outside of the air filter. Outside Inside P00495 NG Repair or replace. OK 5 Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift the transmission into the N position. (e) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3 on the vehicle. CHECK: Use the CURRENT DATA to check the idle speed. OK: Idle speed: 650 – 750 rpm NG OK Proceed to problem symptoms table on page DI–21. DI–10 DIAGNOSTICS 6 TE1 – Check ignition timing. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Shift the transmission into the N position. (c) Keep the engine speed at idle. (d) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (e) Using a timing light, connect the tester to the No.1 high– tension cord. CHECK: Check the ignition timing. OK: Ignition timing: 10° BTDC at idle E1 SST DLC1 NG A07370 S05309 ENGINE A07664 Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–21. 7 Check fuel shutoff valve for fuel tank. A09429 PREPARATION: (a) Be sure that enough fuel is in the tank. (b) Connect the TOYOTA hand–held tester to the DLC3. (c) Turn the ignition switch ON and push TOYOTA hand–held tester main switch ON. (d) Use the ACTIVE TEST mode to operate the fuel shutoff valve for the fuel tank. (e) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (f) If you have no TOYOTA hand–held tester, Connect between terminal FC of the ECM connector and body ground. CHECK: Check the operating sound of the fuel shutoff valve for the fuel tank when it is operated. DI–11 DIAGNOSTICS – ENGINE OK: There is operating sound from the shutoff valve. NG Proceed to page SF–34 and continue to troubleshoot. OK 8 Check for spark. A00359 PREPARATION: (a) Disconnect the high–tension cord from the spark plug. (b) Remove the spark plug. (c) Install the spark plug to the high–tension cord. (d) Disconnect the injector connector. (e) Ground the spark plug. CHECK: Check if spark occurs while the engine is being cranked. NOTICE: To prevent excess fuel from being injected from the injectors during this test, don’t crank the engine for more than 5 – 10 seconds at a time. NG Proceed to page IG–1 and continue to troubleshoot. OK Proceed to problem symptoms table on page DI–21. 7. ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. (a) CARB mandated signals. TOYOTA hand–held tester display Measurement Item Normal Condition*1 FUEL SYS #1 Fuel System Bank 1 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warming up: CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 19.7 – 50.4 % Racing without load (2,500rpm): 16.8 – 47.4 % Engine Coolant Temp. Sensor Value After warming up: 80 – 95°C (176 – 203°F) COOLANT TEMP DI–12 DIAGNOSTICS – ENGINE SHORT FT #1 Short–term Fuel Trim Bank 1 0 ± 20 % LONG FT #1 Long–term Fuel Trim Bank 1 0 ± 20 % ENGINE SPD Engine Speed Idling: 650 – 750 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped: 0 km/h (0 mph) IGN ADVANCE Ignition Advance: Ignition Timing of Cylinder No.1 Idling: BTDC 0 – 10° Intake Air Temp. Sensor Value Equivalent to Ambient Temp. Absolute Pressure inside Intake Manifold Idling: 20 – 51 kPa Racing without load (2,500 rpm): 17 – 48 kPa THROTTLE POS Voltage Output of Throttle Position Sensor Calculated as a percentage: 0 V → 0 %, 5 V → 100 % Throttle Fully Closed: 6 – 16 % Throttle Fully Open: 64 – 98 % O2S B1 S1 Voltage Output of Heated Oxygen Sensor Bank 1 Sensor 1 Idling: 0.1 – 0.9 V (0.56 – 0.76 V*2) O2FT B1 S1 Heated Oxygen Sensor Fuel Trim Bank 1 Sensor 1 (Same as SHORT FT #1) 0 ± 20 % A/FS B1 S1 Voltage Output of A/F Sensor Idling: 2.8 – 3.8 V A/FFT B1 S1 A/F Sensor Fuel Trim (Same as SHORT FT #1) 0 ± 20 % Voltage Output of Heated Oxygen Sensor Bank 1 Sensor 2 Driving at 50 km/h (31 mph): 0.05 – 0.95 V INTAKE AIR MAP O2S B1 S2 *1: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. *2: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). (b) TOYOTA Enhanced Signals. TOYOTA hand–held tester display Measurement Item Normal Condition* MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 rpm MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r Fuel injection time for cylinder No.1 Idling: 2.9 – 5.1 ms Intake Air Control Valve Duty Ratio Opening ratio rotary solenoid type IAC valve Idling: 25 – 62 % Starter Signal Cranking: ON CTP SIG Closed Throttle Position Signal Throttle fully closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SIG Park/Neutral Position Switch Signal P or N position: ON Electrical Load Signal Defogger S/W ON: ON Stop Light Switch Signal Stop light switch ON: ON Power Steering Oil Pressure Switch Signal Turn steering wheel: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON CYL#1, CYL#2, CYL#3, CYL#4 Abnormal revolution variation for each cylinder 0% IGNITION Total number of ignition for every 1,000 revolutions 0 – 2,000 EGR system operating condition Idling: OFF FUEL PUMP Fuel Pump Signal Idling: ON A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON A/C MAG CLUTCH A/C Switch Signal A/C ON: ON EVAP (PURGE) VSV EVAP VSV Signal VSV operating: Avove 30 % INJECTOR IAC DUTY RATIO STARTER SIG ELECTCL LOAD SIG STOP LIGHT SW PS OIL PRESS SW EGR SYSTEM DI–13 DIAGNOSTICS VAPOR PRESS VSV TOTAL FT B1 – ENGINE Vapor Pressure VSV Signal VSV operating: ON Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 – 1.2 V *: If no conditions are specifically stated for ”ldling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. DI–14 DIAGNOSTICS – ENGINE DI00I–11 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ’’See page ’’ for the respective ’’DTC No.’’ in the DTC chart. 1. SAE CONTROLLED DTC No. (See page) Detection Item P0105 (DI–22) Manifold Absolute Pressure/ Barometric Pressure Circuit Malfunction P0106 (DI–25) MIL* Memory
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM   Manifold Absolute Pressure Circuit Range/Performance Problem
Vacuum line
Manifold absolute pressure sensor   P0110 (DI–26) Intake Air Temp. Circuit Malfunction
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM   P0115 (DI–30) Engine Coolant Temp. Circuit Malfunction
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM   P0116 (DI–34) Engine Coolant Temp. Circuit Range/Performance Problem
Cooling system
Engine coolant temp. sensor   P0120 (DI–35) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM   P0121 (DI–39) Throttle/Pedal Position Sensor/ Switch ”A” Circuit Range/Performance Problem
Throttle position sensor   P0125 (DI–40) Insufficient Coolant Temp. for Closed Loop Fuel Control
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
Air induction system
EGR system
Fuel pressure
Injector
Gas leakage on exhaust system
ECM   P0136 (DI–45) Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2)
Open or short in heated oxygen sensor circuit
Heated oxygen sensor   P0141 (DI–47) Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2)
Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
ECM   System too Lean (Fuel Trim)
Air induction system
Injector blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
Fuel shutoff valve for delivery pipe
Gas leakage on exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
ECM   P0171 (DI–49) Trouble Area DI–15 DIAGNOSTICS – ENGINE P0172 (DI–49) System too Rich (Fuel Trim)
Injector leak, blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
Ignition system
Fuel shutoff valve for delivery pipe
Gas leakage on exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
ECM P0180 (DI–54) Fuel Temperature Sensor ”A” Circuit Malfunction
Open or short in fuel temperature sensor circuit for delivery pipe
Fuel temperature sensor for delivery pipe
ECM   P0190 (DI–56) Fuel Rail Pressure Sensor Circuit Malfunction
Open or short in fuel pressure sensor circuit for delivery pipe
Fuel pressure sensor for delivery pipe
ECM   P0335 (DI–59) Crankshaft Position Sensor ”A” Circuit Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM   P0340 (DI–61) Camshaft Position Sensor Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Camshaft timing pulley
ECM   P0400 (DI–63) Exhaust Gas Recirculation Flow Malfunction
Vacuum or EGR hose is connected to wrong post
Open or short in VSV circuit for EGR
VSV for EGR
EGR system
EGR vacuum modulator
EGR valve
Manifold absolute pressure sensor
ECM   P0500 (DI–69) Vehicle Speed Sensor Malfunction
Combination meter
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
ECM   Idle Control System Malfunction
Open or short in IAC valve circuit
IAC valve is stuck or closed
Open or short in A/C switch circuit
Air induction system
ECM   MIL* Memory     P0505 (DI–72)   *: MIL lights up 2. MANUFACTURER CONTROLLED DTC No. (See Page) Detection Item Trouble Area P1130 (DI–79) A/F Sensor Circuit Range/Performance Malfunction (Bank 1 Sensor 1)
Open or short in A/F sensor circuit
A/F sensor
Air induction system
EGR system
Fuel pressure
Injector
ECM P1135 (DI–84) A/F Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
Open or short in heater circuit of A/F sensor
A/F sensor heater
ECM DI–16 DIAGNOSTICS – ENGINE P1190 (DI–86) Fuel Pressure Regulator Malfunction
Open or short in fuel shutoff valve circuit for fuel tank
Fuel shutoff valve for fuel tank
Open or short in fuel shutoff valve circuit for fuel pressure regulator
Fuel shutoff valve for fuel pressure regulator
Fuel pressure regulator
Open or short in fuel shutoff valve circuit for fuel delivery pipe
Fuel shutoff valve for fuel delivery pipe
ECM P1240 (DI–95) Fuel Fuel Shutoff Valve Circuit for Delivery Pipe Malfunction
Open or short in fuel shutoff valve circuit for fuel delivery pipe
Fuel shutoff valve for fuel delivery pipe
ECM –  P1245 (DI–98) Fuel Fuel Shutoff Valve Circuit for Pressure Regulator Malfunction
Open or short in fuel shutoff valve circuit for fuel pressure regulator
Fuel shutoff valve for fuel pressure regulator
ECM –  Igniter Circuit Malfunction (No.1)
Ignition system
Open or short in IGF or IGT1 circuit from No.1 ignition coil with igniter to ECM
No.1 ignition coil with igniter
ECM   P1310 (DI–102) Igniter Circuit Malfunction (No.2)
Ignition system
Open or short in IGF or IGT2 circuit from No.2 ignition coil with igniter to ECM
No.2 ignition coil with igniter
ECM   P1335 (DI–107) Crankshaft Position Sensor Circuit Malfunction (During engine running)
Open short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM –  P1520 (DI–108) Stop Light Switch Signal Malfunction
Short in stop light switch signal circuit
Stop light switch
ECM   ECM BATT Malfunction
Open in back up power source circuit
ECM   Park/Neutral Position Switch Malfunction
Short in park/neutral position switch circuit
Park/neutral position switch
ECM   P1300 (DI–102) P1600 (DI–110) P1780 (DI–112) *:  ... MIL lights up. – ... MIL does not light up.   DI–17 DIAGNOSTICS – ENGINE DI1JS–04 PARTS LOCATION Manifold Absolute Pressure Sensor Combination Meter for Speedometer Throttle Position Sensor ECM Injector DLC3 Fuel Temperature Sensor for Delivery Pipe Fuel Pressure Sensor for Delivery Pipe Heated Oxygen Sensor (Bank 1 Sensor 2) Fuel Temperature Sensor for Fuel Tank DLC1 Camshaft Position Sensor VSV for EGR Crankshaft Position Sensor Fuel Shutoff Valve for Fuel Tank A/F Sensor Bank 1 Sensor 1) Engine Coolant Temperature Sensor Intake Air Temperature Sensor P ar k/ N eut ral Position Switch Fuel Pressure Sensor for Fuel Pipe Fuel Pressure Regulator Fuel Shutoff Valve for Pressure Regulator Idle Air Control Valve Ignition Coil (No.1, No.2) A09176 DI–18 DIAGNOSTICS – ENGINE DI64T–01 TERMINALS OF ECM ECM Terminals E5 E6 E7 E4 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 1110 9 8 7 6 5 4 3 2 1 262524 2322 2120191817 16 1514 16 151413 12 1110 9 12 11 10 9 8 7 22 21 201918 171615 1413 12 A02958 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) BATT (E4–1) – E1 (E6–16) B–Y ↔ BR Always 9 – 14 +B (E4–12) – E1 (E6–16) B–Y ↔ BR IG switch ON 9 – 14 VC (E5–1) – E2 (E5–9) Y ↔ BR IG switch ON 4.5 – 5.5 IG switch ON 3.3 – 3.9 PIM (E5–2) (E5 2) – E2 (E5–9) (E5 9) B Y ↔ BR B–Y Apply vacuum 26.7 kPa (200 mmHg, 7.9 in.Hg) 2.5 – 3.1 THA (E5–3) – E2 (E5–9) Y–B ↔ BR Idling, Intake air temp. 20°C (68° F) 0.5 – 3.4 THW (E5–4) – E2 (E5–9) G–B ↔ BR Idling, Engine coolant temp. 80°C (176°F) 0.2 – 1.0 LG ↔ BR IG switch ON, Throttle valve fully closed 0.3 – 1.0 VTA (E5 (E5–11) 11) – E2 (E5 (E5–9) 9) IG switch ON, Throttle valve fully open 3.2 – 4.9 AF+ (E5–6) – E1 (E6–16) L ↔ BR Always (IG switch ON) 3.3 fixed* AF– (E5–14) – E1 (E6–16) B–W ↔ BR Always (IG switch ON) 3.0 fixed* Idling Below 3.0 HT2 (E6–21) (E6 21) – E1 (E6–16) (E6 16) P B ↔ BR P–B THCNG2 (E7–6) – E2 (E5–9) P–B ↔ BR PCNG2 (E7–5) – E2 (E5–9) G–B ↔ BR Idling ON, Fuel temperature 20°C (68° F) STA (E4–11) (E4 11) – E1 (E6 (E6–16) 16) GR ↔ BR C ki Cranking IGT1 (E6–20) – E1 (E6–16) B ↔ BR Idling Pulse generation (See page DI–102) IGT2 (E6–19) – E1 (E6–16) Y–R ↔ BR Idling Pulse generation (See page DI–102) IGF (E6–3) – E1 (E6–16) W–R ↔ BR G (E6–5) – NE– (E6–17) NE (E6–4) – NE– (E6–17) IG switch ON IG switch ON, Fuel temperature 9 – 14 –20°C (4° F) 20°C (68° F) 80°C (176° F) IG switch ON, Disconnect ignition coil connector EGR (E6–23) – E01(E6–13) 0.66 – 0.78 2.5 – 2.75 4.42 – 4.52 3.1 – 3.6 6 0 or more 6.0 4.5 – 5.5 Idling Pulse generation (See page DI–102) B–W ↔ L Idling Pulse generation (See page DI–59) B–R ↔ L Idling Pulse generation (See page DI–59) P–B ↔ BR IG switch ON 0–3 OX2 (E5–5) – E1 (E6–16) B ↔ BR Maintain engine speed at 2,500 rpm for 2 min. after warming up RSD (E6–10) – E1 (E6–16) W ↔ BR IG switch ON 9 ∼ 14 FC (E4–14) – E01 (E6–13) G–R ↔ BR IG switch ON 9 – 14 Pulse generation DI–19 DIAGNOSTICS – ENGINE VCNG2 (E7–9) – E01 (E6–13) Y–G ↔ BR Idling ON, 9 – 14 VCNG3 (E7–4) – E01 (E6–13) P ↔ BR Idling ON, 9 – 14 IG switch ON, Other shift position in P or N 9 – 14 NSW (E4–6) (E4 6) – E1 (E6–16) (E6 16) B W ↔ BR B–W IG switch ON, Shift position in P or N 0 – 3.0 Pulse generation (See page DI–69) SPD (E4–9) – E1 (E6–16) V–W ↔ BR IG switch ON, Rotate driving wheel slowly TE1 (E5–15) – E1 (E6–16) L–W ↔ BR IG switch ON 9 – 14 G R ↔ BR G–R Idling 9 – 14 W (E4–5) (E4 5) – E1 (E6 (E6–16) 16) HTAF (E4–2) (E4 2) – E04 (E4–13) (E4 13) IG switch ON Below 3.0 Idling Below 3.0 G ↔ BR IG switch ON LOCK IN (E6–18) – E1 (E6–16) W–L ↔ BR A/C compressor is operating LOCK (E4–15) – E1 (E6–16) R–W ↔ BR A/C indicator light lights up A/C SW (E4 (E4–10) 10) – E1 (E6 (E6–16) 16) R B ↔ BR R–B PRS (E7–10) – E1 (E6–16) G ↔ BR MGC (E4–21) (E4 21) – E01 (E6–13) (E6 13) L Y ↔ BR L–Y STP (E4–4) (E4 4) – E1 (E6–16) (E6 16) G W ↔ BR G–W SIL (E4–16) – E1 (E6–16) W ↔ BR TACH (E4–8) – E1 (E6–16) B–O ↔ BR LG–B ↔ BR #10 (E6–12) – E01 (E6–13) B – W ↔ BR A/C switch OFF Below 1.0 A/C pressure is normally Below 1.0 A/C magnetic clutch ON Below 1.0 A/C magnetic clutch OFF 9 – 14 IG switch ON, Brake pedal depressed R ↔ BR Below 1.5 During transmission Pulse generation Idling Pulse generation Idling Idling IG switch ON #30 (E6–25) – E01 (E6–13) 7.5 – 14 IG switch ON, Brake pedal released IG switch ON B –R ↔ BR Below 4.0 9 – 14 IG switch ON #20 (E6–11) – E01 (E6–13) Pulse generation (See page DI–119) A/C switch ON IG switch ON at fuel temperature THCNG1 (E7–1) – E2 (E5–9) 9 – 14 Idling IG switch ON –30°C (22° F) 25°C (77° F) 40°C (104° F) 100°C (212° F) 0.56 – 0.45 3.39 – 3.29 4.0 – 3.9 4.85 – 4.82 9 ∼ 14 Pulse generation (See page DI–127) 9 ∼ 14 Pulse generation (See page DI–127) 9 ∼ 14 Pulse generation (See page DI–127) 9 ∼ 14 #40 (E6–24) – E01 (E6–13) B – W ↔ BR #10 (E6–2) #10+ (E6 2) – E01 (E6–13) (E6 13) L ↔ BR IG switch it h ON 9 ∼ 14 #20 (E6–1) #20+ (E6 1) – E01 (E6–13) (E6 13) B ↔ BR IG switch it h ON 9 ∼ 14 #30 (E6–15) #30+ (E6 15) – E01 (E6–13) (E6 13) G ↔ BR IG switch it h ON 9 ∼ 14 #40+ (E6–14) – E01 (E6–13) L ↔ BR IG switch ON 9 ∼ 14 Idling Pulse generation (See page DI–127) DI–20 DIAGNOSTICS – ENGINE IG switch ON, Needle position of fuel level gauge PCNG1 (E7–7) – E2 (E5–9) G–R ↔ BR 4/4 3/4 2/4 1/4 *: The ECM terminal voltage is fixed regardless of the output voltage from the sensor. 3.3 2.7 2.0 1.3 DI–21 DIAGNOSTICS – ENGINE DI00L–08 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page *1 *2 Engine does not crank (Does not start) 6. Starter 7. Starter relay No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel shutoff valve circuit 3. ECM No complete combustion (Does not start) 1. Fuel shutoff valve circuit DI–86 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel shutoff valve circuit 3. Compression DI–113 DI–86 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel shutoff valve circuit DI–113 DI–86 Hot engine (Difficult to start) 1. Starter signal circuit 2. Fuel shutoff valve circuit DI–113 DI–86 High engine idle speed (Poor idling) 1. A/C switch circuit 2. ECM power source circuit *3 DI–116 Low engine idle speed (Poor idling) 1. A/C switch circuit 2. Fuel shutoff valve circuit *3 DI–86 Rough idling (Poor idling) 1. Compression 2. Fuel shutoff valve circuit EM–3 DI–86 Hunting (Poor idling) 1. ECM power source circuit 2. Fuel shutoff valve circuit DI–116 DI–86 Hesitation/Poor acceleration (Poor driveability) 1. Fuel shutoff valve circuit 2. A/T faulty DI–86 DI–148 Surging (Poor driveability) 1. Fuel shutoff valve circuit DI–86 Soon after starting (Engine stall) 1. Fuel shutoff valve circuit DI–86 During A/C operation (Engine stall) 1. A/C switch circuit 2. ECM *3 IN–29 A/C switch indicatior blinking 1. A/C Compressor lock sensor circuit 2. A/C Evaporator temp. sensor circuit DI–119 DI–121 *1: See Pub. No. RM654U, page ST–2. *2: See Pub. No. RM654U, page ST–20. *3: See Pub. No. RM654U, page AC–84. DI–116 DI–86 IN–29 DI–22 DIAGNOSTICS – ENGINE DI00M–07 CIRCUIT INSPECTION DTC P0105 Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction CIRCUIT DESCRIPTION V Output Voltage (3.96) 3.6 2.4 1.2 150 450 20 60 mmHg 750 (840) kPa 100 (112) By a built–in sensor unit, the manifold absolute pressure sensor detects the intake manifold pressure as a voltage. The ECM then determines the basic injection duration and basic injection advance angle based on this voltage. Since the manifold absolute pressure sensor does not use the atmospheric pressure as a criterion, but senses the absolute pressure inside the intake manifold (the pressure in proportion to the present absolute vacuum 0), it is not influenced by fluctuations in the atmospheric pressure due to high altitude and other factors. This permits it to control the air–fuel ratio at the proper lever under all conditions. Manifold Absolute Pressure P01242 DTC No. P0105 DTC Detecting Condition Trouble Area Open or short in manifold absolute pressure sensor circuit
Open or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM HINT: After confirming DTC P0105, use the OBD II scan tool or TOYOTA hand–held tester to confirm the manifold absolute pressure from the CURRENT DATA. Manifold Absolute Pressure (kPa) Approx. 0 130 or more Malfunction
PIM circuit short
VC circuit open or short
PIM circuit open
E2 circuit open DI–23 DIAGNOSTICS – ENGINE WIRING DIAGRAM Manifold Absolute Pressure Sensor ECM 3 Y 1 VC E5 2 B–Y 2 PIM E5 1 BR 9 E2 E5 5V E1 A00309 INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
1 Connect OBD II scan tool or TOYOTA hand–held tester, and read value of manifold absolute pressure. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the value of the manifold absolute pressure on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as atmospheric pressure. OK NG Check for intermittent problems (See page DI–3). DI–24 DIAGNOSTICS 2 – ENGINE Check voltage between terminals VC and E2 of ECM connector. ON BE6653 A03008 E2 (–) (+) VC A09254 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG Check and replace ECM (See page IN–29). OK 3 Check voltage between terminals PIM and E2 of ECM connector. PIM BE6653 A03009 (+) (–) PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals PIM and E2 of the ECM connector. OK: Voltage: 3.3 – 3.9 V E2 A09255 OK Check and replace ECM (See page IN–29). NG 4 Check for open and short in harness and connector between manifold absolute pressure sensor and ECM (See page IN–29). NG OK Replace manifold absolute pressure sensor (See Pub. No. RM654U, page SF–52). Repair or replace harness or connector. DI–25 DIAGNOSTICS – ENGINE DI00N–06 DTC P0106 Manifold Absolute Pressure Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0105 on page DI–22. DTC No. DTC Detecting Condition Trouble Area After engine is warmed up, conditions (a) and (b) continue with engine speed 400 – 1,000 rpm: (2 trip detection logic) (a) Throttle valve fully closed (b) Manifold absolute pressure sensor output > 3.0 V P0106 Conditions (c) and (d) continue with engine speed 2,500 rpm or less: (2 trip detection logic) (c) VTA > 1.85 (d) Manifold absolute pressure sensor output < 1.0 V
Vacuum line
Manifold absolute pressure sensor INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106, P0110, P0115, P0120 and P0180 are output simultaneously, manifold absolute pressure sensor circuit may be open. Perform troubleshooting of DTC P0105 first. If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.

1 Are there any other codes (besides DTC P0106) being output? YES Go to relevant DTC chart. NO 2 Check manifold absolute pressure sensor operation (See Pub. No. RM654U, page SF–53). OK NG Replace manifold absolute pressure sensor. Check vacuum line between intake air chamber and manifold absolute pressure sensor. DI–26 DIAGNOSTICS – ENGINE DI00O–07 DTC P0110 Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION (Fig.1) 30 20 10 Acceptable Resistance kΩ 5 3 2 1 0.5 0.3 0.2 0.1 – 20 (– 4) 0 (32) 20 (68) 40 (104) 60 (140) 80 100 (176) (212) Temp.°C (F°) A09428 DTC No. P0110 The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature, the lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See Fig.1). The intake air temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from terminal THA via a resistor R. That is, resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0110, it operates the fail safe function in which the intake air temperature is assumed to be 20°C (68°F). DTC Detecting Condition Open or short in intake air temp. sensor circuit Trouble Area
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM HINT: After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand–held tester to confirm the intake air temperature from the CURRENT DATA. Temperature Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit DI–27 DIAGNOSTICS – ENGINE WIRING DIAGRAM ECM Intake Air Temp. Sensor 2 Y–B 3 THA E5 1 BR 9 E5 5V R E2 E1 A00310 INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
1 Connect OBD II scan tool or TOYOTA hand–held tester, and read value of intake air temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual air intake temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (–40°F).
If there is short circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG OK Check for intermittent problems (See page DI–3). –40°C (–40°F) .... Go to step 2. 140°C (284°F) or more .... Go to step 4. DI–28 DIAGNOSTICS 2 – ENGINE Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 2 3 1 9 E5 E5 THA E2 E1 A00391 PREPARATION: (a) Disconnect the intake air temperature sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temp. value: 140°C (284°F) or more OK Confirm good connection at sensor. If OK, replace intake air temperature sensor. NG 3 Check for open in harness or ECM. ON Intake Air Temp. Sensor ECM 5V 3 E5 THA 9 E5 THA A03010 E2 E1 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Connect between terminals THA and E2 of the ECM connector. HINT: The intake air temperature sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–29). (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more E2 A09256 OK NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–29). Open in harness between terminals E2 or THA, repair or replace harness. DI–29 DIAGNOSTICS 4 – ENGINE Check for short in harness and ECM. ON Intake Air Temp. Sensor 2 1 ECM 5V 3 E5 9 E5 THA E2 E1 PREPARATION: (a) Disconnect the intake air temperature sensor connector. (b) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) A00393 OK Replace intake air temperature sensor. NG 5 Check for short in harness or ECM. ON Intake Air Temp. Sensor ECM 5V THA E2 E1 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Disconnect the E5 connector from the ECM. HINT: The intake air temperature sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) E5 Connector A03011 A09257 OK NG Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–30 DIAGNOSTICS – ENGINE DI00P–07 DTC P0115 Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temperature circuit malfunction shown on page DI–26. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). DTC No. P0115 Detection Item Trouble Area
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM Open or short in engine coolant temp. sensor circuit HINT: After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand–held tester to confirm the engine coolant temp. from the CURRENT DATA. Temp. Displayed Malfunction –40°C (–40°F) Open circuit 140°C (284°F) or more Short circuit WIRING DIAGRAM ECM Engine Coolant Temp. Sensor 5V 2 G–B 4 THW E5 1 BR 9 E5 R E2 E1 A00310 INSPECTION PROCEDURE HINT:

If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. DI–31 DIAGNOSTICS 1 – ENGINE Connect OBD II scan tool or TOYOTA hand–held tester, and read value of engine coolant temperature. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Same as actual engine coolant temperature. HINT:
If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates –40°C (–40°F).
If there is open circuit, OBD II scan tool or TOYOTA hand−held tester indicates 140°C (284°F) or more. NG –40°C (–40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. OK Check for intermittent problems (See page DI–3). 2 Check for open in harness or ECM. ON ECM Engine Coolant Temp. Sensor 5V 2 1 4 E5 9 E5 THW E2 E1 A00395 PREPARATION: (a) Disconnect the engine coolant temperature sensor connector. (b) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more OK NG Confirm good connection at sensor. If OK, replace engine coolant temperature sensor. DI–32 DIAGNOSTICS 3 – ENGINE Check for open in harness or ECM. ON Engine Coolant Temp. Sensor 2 ECM 4 E5 1 9 E5 5V THW E2 E1 THW PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Connect between terminals THW and E2 of the ECM connector. HINT: The engine coolant temperature sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ECM connector (See page IN–29). (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: 140°C (284°F) or more E2 A03012 A09258 OK Open in harness between terminals E2 or THW, repair or replace harness. NG Confirm good connection at ECM. If OK, check and replace ECM (See page IN–29). 4 Check for short in harness and ECM. ON Engine Coolant Temp. Sensor ECM 5V 4 E5 9 E5 THW E2 E1 A00397 PREPARATION: (a) Disconnect the engine coolant temperature sensor connector. (b) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: – 40°C (– 40°F) OK NG Replace engine coolant temperature sensor. DI–33 DIAGNOSTICS 5 – ENGINE Check for short in harness or ECM. ON Engine Coolant Temp. Sensor 5V THW E2 E1 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Disconnect the E5 connector from the ECM. HINT: The engine coolant temp. sensor connector is disconnected. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the OBD II scan tool or TOYOTA hand–held tester. OK: Temperature value: –40°C (–40°F) E5 Connector A03011 A09257 OK NG Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–34 DIAGNOSTICS – ENGINE DI00Q–07 DTC P0116 Engine Coolant Temp. Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 on page DI–30. DTC No. DTC Detecting Condition Trouble Area If THW < –7°C (19.4°F) or THA < –7°C (19.4°F) 20 min. or more after starting engine, engine coolant temp. sensor value is –10°C (–50°F)* or less (2 trip detection logic) P0116 When THW 35°C (95°F) and 60°C (140°F), THA
–6.7°C (19.9°F) when starting the engine, conditions (a) and (b) continue: (2 trip detection logic) (a) Vehicle speed is changing (Not stable) (b) Water temperature change is lower than 3°C (37.4°F) from water temperature since when starting the engine
Cooling system
Engine coolant temp. sensor INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, engine coolant temperature sensor circuit may be open. Perform troubleshooting of DTC P0115 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0116) being output? YES Go to relevant DTC chart. NO 2 Check thermostat (See Pub. No. RM654U, page CO–10). NG OK Replace engine coolant temperature sensor. Replace thermostat. DI–35 DIAGNOSTICS – ENGINE DI00R–07 DTC P0120 Throttle/Pedal Position Sensor/Switch ”A” Circuit Malfunction CIRCUIT DESCRIPTION Throttle Position Sensor The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, a voltage of approximately 0.3 – 0.8 V is applied to terminal VTA of the ECM. The voltage applied to the terminals VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 – 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from this signal input from terminal VTA, and uses it as one of the conditions to decide the air–fuel ratio correction, power increase correction and fuel–cut control etc. ECM VC VTA E2 P24296 DTC No. P0120 DTC Detecting Condition Trouble Area
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Condition (a) or (b) continues with more than 5 sec. (a) VTA < 0.1 V (b) VTA > 4.9 V HINT: After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand–held tester to confirm the throttle valve opening percentage. Throttle valve opening position expressed as percentage Throttle valve fully closed Throttle valve fully open 0% 0% Approx. 100 % Approx. 100 % T bl A Trouble Area
VC circuit open
VTA circuit open or ground short
E2 circuit open WIRING DIAGRAM Throttle Position Sensor ECM 1 VC E5 1 Y 3 LG 11 E5 2 BR 9 E2 E5 5V VTA A09396 DI–36 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
1 Connect OBD II scan tool or TOYOTA hand–held tester, and read the throttle valve opening percentage. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the OBD II scan tool or TOYOTA hand–held tester main switch ON. CHECK: Read the throttle valve opening percentage. OK: FI7052 OK Throttle valve Throttle valve opening position expressed as percentage Fully open Approx. 70 % Fully closed Approx. 10 % Check for intermittent problems (See page DI–3). NG 2 Check voltage between terminal VC of throttle position sensor connector and body ground. PREPARATION: (a) Disconnect the throttle position sensor connector. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal VC of the throttle position connector and body ground. OK: Voltage: 4.5 – 5.5 V ON VC (+) (–) A00369 NG OK Go to step 5. DI–37 DIAGNOSTICS 3 – ENGINE Check throttle position sensor (See Pub. No. RM654U, page SF–29). NG Replace throttle position sensor. OK 4 Check voltage between terminals VTA and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VTA and E2 of the ECM connector. OK: ON VTA BE6653 A09283 E2 (+) (–) A09264 NG Throttle valve Voltage Fully closed 0.3 – 1.0 V Fully open 3.2 – 4.9 V Check for open and short in harness and connector in VTA and E2 circuits between ECM and throttle position sensor (See page IN–29). OK Check and replace ECM (See page IN–29). 5 Check voltage between terminals VC and E2 of ECM connector. ON E2 BE6653 A03008 (–) (+) VC A09254 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG Check and replace ECM (See page IN–29). DI–38 DIAGNOSTICS OK Check for open in harness and connector in VC circuit between ECM and throttle position sensor (See page IN–29). – ENGINE DI–39 DIAGNOSTICS – ENGINE DI00S–06 DTC P0121 Throttle/Pedal Position Sensor/Switch ”A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0120 on page DI–35. DTC No. P0121 Detection Item Trouble Area After vehicle speed has been exceeded 30 km/h (19 mph) even once, output value of throttle position sensor is out of applicable range while vehicle speed between 30 km/h (19 mph) and 0 km/h (0 mph) (2 trip detection logic)
Throttle position sensor INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0121) being output? YES NO Replace throttle position sensor. Go to relevant DTC chart. DI–40 DIAGNOSTICS – ENGINE DI1JU–04 DTC P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control CIRCUIT DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The A/F sensor has the characteristic that provides output voltage* approximately proportional to the existing air–fuel ratio. The A/F sensor output voltage* is used to provide feedback for the ECM to control the air– fuel ratio. By the A/F sensor output, the ECM can determine the deviation amount from the stoichiometric air–fuel ratio and control the proper injection time immediately. If the A/F sensor is malfunctioning, ECM is unable to perform accurate air–fuel ratio control. The A/F sensor is equipped with a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low), current flows to the heater to heat the sensor for accurate oxygen concentration detection. *: The voltage value changes at the inside of the ECM only. Platinum Electrode Solid Electrolyte (Zirconia Element) Platinum Electrode Heater Coating (Ceramic) ECM Monitored A/F Sensor Voltage Atmosphere (V) 4.0 3.8 3.6 3.4 3.2 3.0 2.8 2.6 2.4 14 15 16 17 19 21 22 Air–Fuel Ratio Cover Exhaust Gas A00477 DTC No. P0125 DTC Detecting Condition After engine is warmed up, A/F sensor output* does not change when conditions (a), (b) and (c) continue for at least 1.5 min.: *: Output value changes at inside of ECM only (a) Engine speed: 1,500 rpm or more (b) Vehicle speed: 40 – 100 km/h (25 – 62 mph) (c) Throttle valve is not fully closed Trouble Area
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
Air induction system
EGR system
Fuel pressure
Injector
Gas leakage on exhaust system
ECM HINT:

After confirming DTC P0125, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of A/F sensor from the CURRENT DATA. The ECM controls the voltage of the AF+ and AF– terminals of the ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand– held tester. DI–41 DIAGNOSTICS
– ENGINE OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester. WIRING DIAGRAM 9 J23 J/C E B–Y B–R 2 5 Instrument Panel J/B W–R 2L 4 6 1 7 W–R 1 F9 B–G FL Block 2 2 MAIN FL Battery AF+ 3.3V 4 1 7 IG1 B IG3 G 2 HTAF E4 5 OX2 E5 E04 3 Heated Oxygen Sensor 4 BR (Bank 1 Sensor 2) IG3 12 IG3 A J20 A J/C BR 1 F11 5 1K 3 1K G E1 B–W BR B 1 2A B EB 3 to Analog–Digital Converter A/F Sensor 1 5 1B 6 E5 L 2 7 1W 4 W–B 2F AM2 EFI EFI Relay E ECM B B IGN Engine Room R/B No.2 1 3 B B–Y J23 J/C 2K 7 2 2J J18 J/C P–B B B B–R B–Y B–Y IG1 IG Switch B–Y B–Y P–B 14 AF– E5 3.0V 21 HT2 E6 EC E03 A09395 (*1) INSPECTION PROCEDURE HINT:
If the vehicle run out of fuel, the air–fuel ratio is LEAN and DTC P0125 will be recorded. The MIL then comes on. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
1 Are there any other codes (besides DTC P0125) being output? YES NO Go to relevant DTC chart. DI–42 DIAGNOSTICS 2 – ENGINE Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of A/F sensor (bank 1 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of the AF+ terminal of the ECM is 3.3 V fixed and the A/F– terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF+/AF–) of the ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*) V)
Not remains at 4.5 V (0.76 V*) or more *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normal.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, A/F the sensor circuit may be open.
If the output voltage of the A/F sensor remains at 4.5 V (0.76 V*) or more, even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 10. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (bank 1 sensor 1) (See page IN–29). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (bank 1 sensor 1) (See Pub. No. RM654U, page SF–59). DI–43 DIAGNOSTICS NG – ENGINE Replace A/F sensor. OK 5 Check air induction system (See Pub. No. RM654U, page SF–1). NG Replace or replace. OK 6 Check EGR system (See Pub. No. RM654U, page EC–12). NG Repair EGR system. OK 7 Check fuel shutoff valve operation (See page DI–86). NG Replace and repair. OK 8 Check injector injection (See Pub. No. RM654U, page SF–23). NG Replace injector. OK 9 Check gas leakage on exhaust system. DI–44 DIAGNOSTICS NG – ENGINE Repair or replace. OK Replace A/F sensor (bank 1 sensor 1). 10 Perform confirmation driving pattern (See page DI–79). Go 11 Is there DTC P0125 being output again? YES Check and replace ECM. NO 12 Did vehicle runs out of fuel in past? NO YES DTC P0125 is caused by running out of fuel. Check for intermittent problems. DI–45 DIAGNOSTICS – ENGINE DI00Y–10 DTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–40. DTC No. DTC Detecting Condition Trouble Area P0136 Voltage output of heated oxygen sensor remains at 1.0 V or more, or 0.55 V or less when vehicle is driven at 40 km/h (25 mph) or more after engine is warmed up (2 trip detection logic)
Open or short in heated oxygen sensor circuit
Heated oxygen sensor HINT: Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC P0125 on page DI–40. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P0136) being output? YES Go to relevant DTC chart. NO 2 Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–29). NG Repair or replace harness or connector. OK 3 Check output voltage of heated oxygen sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the engine to normal operating temp. DI–46 DIAGNOSTICS – ENGINE CHECK: Read the voltage output of the heated oxygen sensor when the engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 min. using the accelerator pedal. OK: Heated oxygen sensor output voltage: Alternates from 1.0 V or less to 0.55 V or more. OK NG Replace heated oxygen sensor. Check that each connector is properly connected. DI–47 DIAGNOSTICS – ENGINE DI00X–05 DTC P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–40. DTC No. DTC Detecting Condition Trouble Area P0141 When heater operates, heater current exceeds 2 A (2 trip detection logic) P0141 Heater current of 0.2 A or less when heater operates (2 trip detection logic)
Open or short in heater circuit of heated oxygen sensor
Heated H t d oxygen sensor heater h t
ECM HINT: Sensor 1 refers to the sensor closer to the engine body. Sensor 2 refers to the sensor farther away from the engine body.

WIRING DIAGRAM Refer to DTC P0125 on page DI–40. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check voltage between terminals HT2 of ECM connector and body ground. ON HT2 (+) BE6653 A09296 (–) A09265 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals HT2 of the ECM connector and body ground. HINT: OK: Voltage: 9 – 14 V OK NG Check and replace ECM (See page IN–29). DI–48 DIAGNOSTICS 2 – ENGINE Check resistance of heated oxygen sensor heater (See Pub. No. RM654U, page SF–63). NG Replace heated oxygen sensor. OK Check and repair harness or connector between EFI main relay (Marking: EFI) and heated oxygen sensor, and heated oxygen sensor and ECM (See page IN–29). DI–49 DIAGNOSTICS – ENGINE DI1JW–04 DTC P0171 System too Lean (Fuel Trim) DTC P0172 System too Rich (Fuel Trim) CIRCUIT DESCRIPTION Fuel trim refers to the feedback compensation value compared to the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. Short–term fuel trim is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the A/F sensor is approximately proportional to the existing air–fuel ratio, and ECM comparing it with the ideal theoretical value, the ECM reduces fuel volume immediately if the air–fuel ratio is rich and increases fuel volume if it is lean. Long–term fuel trim compensates for the deviation from the central value of the short–term fuel trim stored up by each engine tolerance, and the deviation from the central value due to the passage of time and changes of environment. If both the short–term fuel trim and long–term fuel trim exceed a certain value, it is detected as a malfunction and the MIL lights up. DTC No. P0171 P0172 DTC Detecting Condition Trouble Area When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on RICH side (2 trip detection logic)
Air induction system
Injector blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
Fuel shutoff valve for delivery pipe
Gas leakage on exhaust system
Air induction system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
ECM When air–fuel ratio feedback is stable after engine warming up, fuel trim is considerably in error on LEAN side (2 trip detection logic)
Injector leak, blockage
Manifold absolute pressure sensor
Engine coolant temp. sensor
Ignition system
Fuel shutoff valve for delivery pipe
Gas leakage on exhaust system
Open or short in A/F sensor (bank 1 sensor 1) circuit
A/F sensor (bank 1 sensor 1)
ECM HINT:



When the DTC P0171 is recorded, the actual air–fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air–fuel ratio is on the RICH side. If the vehicle runs out of fuel, the air–fuel ratio is lean and DTC P0171 is recorded. The MIL then comes on. If the total of the short–term fuel trim value and long–term fuel trim value is within ±38 %, the system is functioning normally. The A/F sensor output voltage and the short–term fuel trim value can be read using the OBD II scan tool or TOYOTA hand–held tester. DI–50 DIAGNOSTICS
– ENGINE The ECM controls the voltage of AF+ and AF– terminals of ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand–held tester. OBD II scan tool (excluding TOYOTA hand–held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand–held tester.
WIRING DIAGRAM Refer to DTC P0125 on page DI–40. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air¯fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check air induction system (See Pub. No. RM654U, page SF–1). NG Repair or replace. OK 2 Check injector injection (See Pub. No. RM654U, page SF−23). NG Replace injector. OK 3 Check manifold absolute pressure sensor (See Pub. No. RM654U, page SF–53) and engine coolant temperature sensor (See Pub. No. RM654U, page SF–49). NG Repair or replace. OK 4 Check for spark and ignition (See page IG–1). NG Repair or replace. DI–51 DIAGNOSTICS – ENGINE OK 5 Check fuel shutoff valve operation (See page DI–86). NG Replace or repair. OK 6 Check gas leakage on exhaust system. NG Repair or replace. OK Check and replace ECM (See page IN–29). 7 Check output voltage of A/F sensor (bank 1 sensor 1). PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of the AF+ terminal of the ECM is 3.3 V fixed and the AF– terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF+/AF–) of the ECM. OK: Condition A/F Sensor Voltage value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V*)
Not remains at 3.8 3 8 V (0.76 (0 76 V*) or more
Not remains at 2.8 V (0.56 V*) or less *: When you use OBD II scan tool (excluding TOYOTA hand–held tester) HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal. DI–52 DIAGNOSTICS – ENGINE
During fuel cut, there is a case that the output voltage of the A/F sensor is above 3.8 V (0.76 V*), it is normally.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 4.5 V (0.76 V*) or more, even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG 8 Check for open and short in harness and connector between ECM and oxygen sensor (See page IN–29). NG Repair or replace harness or connector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI–79). Go 10 Is there DTC P0171 or P0172 being output again? YES Check and replace ECM (See page IN–29). NO 11 Did vehicle runs out of fuel in the past? NO Check for intermittent problems (See page DI–3). DI–53 DIAGNOSTICS – ENGINE YES DTC P0171 or P0172 is caused by running out of fuel. DI–54 DIAGNOSTICS – ENGINE DI64U–01 DTC P0180 Fuel Temperature Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION (Fig.1) 30 20 10 Acceptable Resistance kΩ 5 3 2 1 0.5 0.3 0.2 0.1 – 20 (– 4) 0 (32) 20 (68) 40 (104) 60 (140) 80 100 (176) (212) Temp.°C (F°) A09428 DTC No. P0180 The fuel temperature sensor is built into the delivery pipe and senses the fuel temperature. A thermistor built in the sensor changes the resistance value according to the fuel temperature, the lower the fuel temperature, the greater the thermistor resistance value, and the higher the fuel temperature, the lower the thermistor resistance value (See Fig.1). The fuel temperature sensor is connected to the ECM (See below). The 5 V power source voltage in the ECM is applied to the fuel temperature sensor from terminal THCNG2 via a resistor R. That is, resistor R and the fuel temperature sensor are connected in series. When the resistance value of the fuel temperature sensor changes in accordance with changes in the fuel temperature, the potential at terminal THCNG2 also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0180, it operates the fail safe function in which the fuel temperature is assumed to be 20°C (68°F). DTC Detecting Condition Trouble Area
Open or short in fuel temperature sensor circuit for delivery pipe
Fuel temperature sensor for delivery pipe
ECM Open or short in fuel temperature sensor circuit HINT: After confirming DTC P0180, use the OBD II scan tool or TOYOTA hand–held tester to confirm the fuel temperature from the CURRENT DATA. WIRING DIAGRAM ECM Fuel Temperature Sensor for Delivery Pipe 2 1 P–B BR 6 E7 5V R THCNG2 9 E2 E5 E1 A00310 DI–55 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: If DTCs P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. 1 Check voltage between terminals THCNG2 and E2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals THCNG2 and E2 of the ECM connector. ON E2 BE6653 A09295 THCNG2 (–) (+) A09298 Temperature °C (°F) Voltage V –20 (–40) 0.66 – 0.78 20 (68) 2.5 – 2.75 80 (176) 4.42 – 4.52 OK: OK Check for intermittent problem (See page DI–3). NG 2 Check fuel temperature sensor for delivery pipe (See page SF–42). NG Replace. OK 3 Check for open and short in harness and connector between engine ECU and fuel temperature sensor for delivery pipe (See page IN–29). NG OK Check and replace ECM (See page SF–42). Repair or replace harness or connector. DI–56 DIAGNOSTICS – ENGINE DI64V–01 DTC P0190 Fuel Rail Pressure Circuit Malfunction CIRCUIT DESCRIPTION By a built–in sensor unit, the fuel rail pressure sensor detects the intake manifold pressure as a voltage. The ECM then determines the basic injection duration and basic injection advance angle based on this voltage. Since the fuel rail pressure sensor does not use the atmospheric pressure as a criterion, but senses the absolute pressure inside the intake manifold (the pressure in proportion to the present absolute vacuum 0), it is not influenced by fluctuations in the atmospheric pressure due to high altitude and other factors. This permits it to control the air–fuel ratio at the proper lever under all conditions. DTC No. P0190 DTC Detecting Condition Trouble Area Open or short in fuel pressure sensor circuit for delivery pipe
Open or short in fuel pressure sensor circuit for delivery pipe
Fuel pressure sensor for delivery pipe
ECM HINT: After confirming DTC P0190, use the OBD II scan tool or TOYOTA hand–held tester to confirm the fuel rail pressure from the CURRENT DATA. WIRING DIAGRAM Fuel Pressure Sensor for Delivery Pipe ECM 3 Y 2 G–B 1 BR 1 VC E5 5V 5 PCNG2 E7 9 E2 E5 E1 A00309 DI–57 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: If DTC P0105, P0106, P0110, P0115, P0120, P0180 and P0190 are output simultaneously, E2 (sensor ground) may be open. 1 Check voltage between terminals VC and E2 of ECM connector. ON E2 (–) (+) VC BE6653 A03008 A09254 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG Check and replace ECM (See page IN–29). OK 2 Check voltage between terminals PCNG2 and E2 of ECM connector. ON E2 BE6653 A09293 PCNG2 (–) (+) A09297 PREPARATION: (a) Remove the glove compartment. (b) Start the engine (See Pub. No. RM654U, page SF–64). CHECK: Measure the voltage between terminals PCNG2 and E2 of the ECM connector. OK: Voltage: 3.1 – 3.6 V at 20°C (68°F) HINT: The fuel pressure in the delivery pipe is 784 – 1,078 kPa (8.0 – 11.0 kgf/cm2, 114 – 156 psi) OK Check and replace ECM (See page IN–29). NG 3 Check for open and short in harness and connector between fuel pressure sensor for delivery pipe and ECM (See page IN–29). NG Repair or replace harness or connector. DI–58 DIAGNOSTICS OK Replace fuel pressure sensor for delivery pipe (See page SF–43). – ENGINE DI–59 DIAGNOSTICS – ENGINE DI013–12 DTC P0335 Crankshaft Position Sensor ”A” Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consists of a magnet, iron and pickup coil. The NE signal plate has 34 teeth and is installed on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal, and the actual crankshaft angle and the engine speed by the NE signal. DTC No. DTC Detecting Condition Trouble Area No crankshaft position sensor signal to ECM during cranking (2 trip detection logic) P0335 No crankshaft position sensor signal to ECM with engine speed 600 rpm or more (2 trip detection logic)
Open or short in crankshaft position sensor circuit
Crankshaft position osition sensor
Crankshaft timing pulley
ECM WIRING DIAGRAM ECM Camshaft Position Sensor 1 5 G E6 B–W 2 L 1 B–R B–R 4 NE+ E6 2 BR L 17 NE– E6 E1 Crankshaft Position Sensor A09394 INSPECTION PROCEDURE HINT:

Perform troubleshooting of DTC 335 first. If no trouble is found, troubleshoot the following mechanical system. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. DI–60 DIAGNOSTICS 1 – ENGINE Check resistance of crankshaft position sensor (See Pub. No. RM654U, page IG–1). G G and NE Signal Waveforms 5 V/ Division Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check the waveform between terminals G and G–, and NE and NE– of the ECM connector. HINT: The correct waveforms are as shown. NE 20 msec./Division (Idling) 5 V/ Division G NE A01991 A01992 NG 10 msec./Division (Idling) Replace crankshaft position sensor. A02359 OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN–29). NG Repair or replace harness or connector. OK 3 Inspect sensor installation (See Pub. No. RM654U, page IG–2) and teeth of crankshaft timing pulley (See Pub. No. RM654U, page EM–17). NG OK Check and replace ECM (See page IN–29). Tighten sensor. Replace crankshaft timing pulley. DI–61 DIAGNOSTICS – ENGINE DI014–11 DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G signal) consists of magnet, iron core and pickup coil. The G signal plate has one tooth on its outer circumference and is installed on the camshaft timing pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is installed on the crankshaft timing pulley. The NE signal sensor generates 34 signals at every engine revolution. The ECM detects the standard crankshaft angle based on the G signal and the actual crankshaft angle and the engine speed by the NE signal. DTC No. DTC Detecting Condition Trouble Area No camshaft position sensor signal to ECM during cranking (2 trip detection logic) P0340 No camshaft position sensor signal to ECM with engine speed 600 rpm or more
Open or short in camshaft position sensor circuit
Camshaft position osition sensor
Camshaft timing pulley
ECM WIRING DIAGRAM Refer to DTC P0335 on page DI–59. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check resistance of camshaft position sensor (See Pub. No. RM654U, page IG–1). Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC P0335 on page DI–59. NG Replace camshaft position sensor. OK 2 Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN–29). NG Repair or replace harness or connector. DI–62 DIAGNOSTICS – ENGINE OK 3 Inspect sensor installation (See Pub. No. RM654U, page IG–9) and tooth of camshaft timing pulley (See Pub. No. RM654U, page EM–17). NG OK Check and replace ECM (See page IN–29). Tighten pulley. sensor. Replace camshaft timing DI–63 DIAGNOSTICS – ENGINE DI64W–01 DTC P0400 Exhaust Gas Recirculation Flow Malfunction CIRCUIT DESCRIPTION ← The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. Throttle Body This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut–off). Under the following conditions, EGR is cut to maintain driveabilThrottle ity. Valve ECM
Before engine is warmed up. EGR Valve
During deceleration (throttle valve closed).
Light engine load (amount of intake air very small).
Engine idling. VSV
Engine speed over 4,400 rpm.
High engine load (amount of intake air very large). EGR Exhaust Gas Vacuum Modulator P25430 DTC No. P0400 DTC Detecting Condition After engine is warmed up, intake manifold absolute pressure is larger than value calculated by ECM while EGR system is ON (2 trip detection logic) Trouble Area
Vacuum or EGR hose is connected to wrong post
Open or short in VSV circuit for EGR
VSV for EGR
EGR system
EGR vacuum modulator
EGR valve
Manifold absolute pressure sensor
ECM DI–64 DIAGNOSTICS – ENGINE WIRING DIAGRAM ECM 9 IG3 J18 J/C B−Y B B VSV for EGR B−Y 2 1 23 EGR E6 P−B E01 B−Y B W−B From Battery 1 2A EFI 5 3 2 2J 4 2F 2 1 7 2K B−Y From Ignition SW EFI Relay Engine Room J/B No.2 EB A09397 SYSTEM CHECK DRIVING PATTERN Vehicle Speed Idling IG SW OFF (6) (3) 60 – 80 km/h (38 – 50 mph) (2) (7) (4) (5) (1) Warm up 3 – 5 min. 2 min. 3 – 5 min. 2 min. Time P20769 (1) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (2) Start and warm up the engine with all the accessories switched OFF. (3) Run the vehicle at 60 – 80 km/h (38 – 50 mph) for 3 min. or more. (4) Idle the engine for about 2 min. (5) Do steps (3) and (4) again. (6) Stop at safe place and turn the ignition switch OFF. (7) Do steps (2) to (5) again. (8) Check the READINESS TESTS mode on the OBD II scan tool or TOYOTA hand–held tester. If COMPL is displayed and the MIL does not light up, the system is normal. If INCMPL is displayed and the MIL does not light up, run the vehicle again and check it. HINT: INCMPL is displayed when either condition (a) or (b) exists. (a) The system check is incomplete. DI–65 DIAGNOSTICS (b) – ENGINE There is a malfunction in the system. If there is a malfunction in the system, the MIL will light up after steps (2) to (5) above are done. (2 trip detection logic) INSPECTION PROCEDURE HINT:
If DTCs P0105, P0106 and P0400 are output simultaneously, perform troubleshooting of DTC P0105 first. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction.
TOYOTA hand–held tester: 1 Check connection of vacuum hose and EGR hose (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 2 Check VSV for EGR. Air Air E G E Air Filter System: OFF G System: ON A00407 PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. CHECK: Check the operation of the VSV when it is operated by the TOYOTA hand–held tester. OK: EGR system is OFF: Air from port E is flowing out through the air filter. EGR system is ON: Air from port E is flowing out port G. OK Go to step 4. NG 3 Check operation of VSV for EGR (See Pub. No. RM654U, page SF–43). DI–66 DIAGNOSTICS NG – ENGINE Replace VSV for EGR. OK Check for open and short in harness and connector between engine room J/B No.2 and ECM (See page IN–29). 4 Check EGR system (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 5 Check EGR vacuum modulator (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 6 Check EGR valve (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 7 Check manifold absolute pressure sensor (See Pub. No. RM654U, page SF–53). NG OK Repair or replace. DI–67 DIAGNOSTICS – ENGINE Check and replace ECM (See page IN–29). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check connection of vacuum hose and EGR hose (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 2 Check VSV for EGR. PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Disconnect the E6 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Check the VSV function. (1) Connect between terminal EGR of the ECM connector and body ground (ON). (2) Disconnect between terminal EGR of the ECM connector and body ground (ON). OK: (1) VSV is ON: Air from port E is flowing out through the air filter. (2) VSV is OFF: Air from port E is flowing out port G. ON E6 Connector EGR OFF ON Air Air E E G Air Filter VSV is ON G VSV is OFF OK A09281 Go to step 4. A09423 NG 3 Check operation of VSV for EGR (See Pub. No. RM654U, page SF–43). NG OK Replace VSV for EGR. DI–68 DIAGNOSTICS – ENGINE Check for open and short in harness and connector between engine room J/B No.2 and ECM (See page IN–29). 4 Check EGR system (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 5 Check EGR vacuum modulator (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 6 Check EGR valve (See Pub. No. RM654U, page EC–12). NG Repair or replace. OK 7 Check manifold absolute pressure sensor (See Pub. No. RM654U, page SF–53). NG OK Check and replace ECM (See page IN–29). Repair and replace. DI–69 DIAGNOSTICS – ENGINE DI01B–12 DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The No.1 vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. 4–Pulse 4–Pulse Vehicle Speed Sensor Combination Meter ECM Transaxle Vehicle Speed Sensor A00414 DTC No. P0500 DTC Detecting Condition Trouble Area During vehicle is being driven, no vehicle speed sensor signal to ECM (2 trip detection logic)
Combination meter
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
ECM WIRING DIAGRAM ECM Combination Meter 14 C11 5V V–W 3 IF1 J15 J/C V–W V–W B B 9 SPD E4 A09398 DI–70 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. See combination meter troubleshooting (See Pub. No. RM654U, page BE–2). OK 2 Check voltage between terminal SPD of ECM connector and body ground. ON (–) BE6653 A09289 SPD (+) A09267 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn the ignition switch ON. CHECK: Measure the voltage between terminal SPD of the ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. 4.5 – 5.5 V 0 Turn the wheel NG AT7809 Check and repair harness and connector between combination meter and ECM. DI–71 DIAGNOSTICS OK Check and replace ECM (See page IN–29). – ENGINE DI–72 DIAGNOSTICS – ENGINE DI3A3–03 DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle–up and provide feedback for the target idling speed. Intake Air Chamber Throttle Valve From Air Cleaner Signal ECM To Cylinder Valve IAC Valve A01758 DTC No. DTC Detecting Condition Trouble Area
Open or short in IAC valve circuit
IAC valve is stuck or closed
Open or short in A/C switch circuit
Air induction system
ECM Open or short in IAC valve circuit P0505 Idle speed continues to vary greatly from the target speed (2 trip detection logic) WIRING DIAGRAM ECM IAC Valve 10 E6 w 1 J18 J/C B–Y 2 B RSD 3 B IG3 9 From Battery Driver Side J/B 3 7 IGN 1K 1W From IG Switch 1 2A B B–R 7 2K EFI 2 1 EFI Relay 5 3 1 2 2 2J B–Y W–B 4 2F W–B Engine Room R/B No.2 EB EC A09420 DI–73 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. TOYOTA hand–held tester: 1 Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift the transmission into the N or neutral position. (e) Remove the fuse cover on the instrument panel. (f) Connect the TOYOTA hand–held tester to the DLC3 on the vehicle and select the ACTIVE TEST mode. CHECK: Check the difference of engine speed between the ones, less than 5 sec. and more than 5 sec. after switching the TE1 from OFF to ON by the TOYOTA hand–held tester. OK: Difference of engine speed: More than 100 rpm OK Go to step 8. NG 2 Check for IAC duty signal. PREPARATION: (a) Remove the fuse cover on the instrument panel. (b) Connect the TOYOTA hand–held tester to the DLC3 on the vehicle. (c) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. CHECK: Read the IAC duty ratio on the TOYOTA hand–held tester. OK: IAC duty ratio: 27 – 47 % OK NG Check and replace ECM (See page IN–29). Go to step 3. DI–74 DIAGNOSTICS 3 – ENGINE Check operation of IAC valve (See page SF–22). NG Go to step 5. OK 4 Check blockage of IAC valve and passage to bypass throttle valve. NG Repair or replace IAC valve and throttle body. OK Go to step 8. 5 Check voltage between terminal 2 of IAC valve connector and body ground. ON PREPARATION: (a) Disconnect the IAC valve connector. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal 2 of the IAC valve connector and body ground. OK: Voltage: 9 – 14 V 2 (+) (–) BE6653 A01553 A01584 NG Check for open and short in harness and connector between IAC valve and J/B. OK 6 Check for open and short in harness and connector between terminal 3 of IAC valve connector and body ground. NG Repair or replace. DI–75 DIAGNOSTICS – ENGINE OK 7 Check for open and short in harness and connector in RSD circuit. NG Repair or replace. OK Replace IAC valve. 8 Check for A/C signal circuit (See Pub. No. RM654U, page AC–84). NG Repair or replace. OK Check air induction system (See page SF–1). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check idle speed. PREPARATION: (a) Warm up the engine to normal operating temperature. (b) Switch off all the accessories. (c) Switch off the A/C. (d) Shift the transmission into the N or neutral position. (e) Remove the fuse cover on the instrument panel. (f) Connect the OBD II scan tool to the DLC3 on the vehicle. (g) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 CHECK: Check the difference of engine speed between the ones, less than 5 sec. and more than 5 sec. after connecting terminals TE1 and E1 of the DLC1. OK: Difference of engine speed: More than 100 rpm DI–76 DIAGNOSTICS OK – ENGINE Go to step 8. NG 2 Check for IAC duty signal. PREPARATION: (a) Warm up the engine normal operating temperature. (b) Connect the oscilloscope between RSD of the ECM connector and body ground. CHECK: Check if IAC duty signal is output. OK: 5 V /Division GND 1 msec. /Division HINT: IAC duty ratio changes in response to engine operating condition. OK Go to step 6. NG 3 Check voltage between terminal RSD of ECM and body ground. ON BE6653 A09303 PREPARATION: (a) Remove the lower center finish panel. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal RSD of the ECM connector and body ground. OK: Voltage: 9 – 14 V RSD (+) (–) A09648 OK Check and replace ECM (See page IN–29). DI–77 DIAGNOSTICS – ENGINE NG 4 Check voltage between terminal 2 of IAC valve connector and body ground. ON PREPARATION: (a) Disconnect the IAC valve connector. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal 2 of the IAC valve connector and body ground. OK: Voltage: 9 14 V 2 (+) (–) BE6653 A01553 A01584 NG Check for open and short in harness and connector between IAC valve and J/B. OK 5 Check for open and short in harness and connector in RSD circuit. NG Repair or replace. OK Replace IAC valve. 6 Check operation of IAC valve (See page SF–25). OK Go to step 8. NG 7 Check for open in harness and connector between terminal 3 of IAC valve connector and body ground. DI–78 DIAGNOSTICS NG – ENGINE Repair or replace. OK Replace IAC valve. 8 Check blockage of IAC valve and the passage to bypass throttle valve. NG Repair or replace IAC valve and throttle body. OK 9 Check for A/C signal circuit (See Pub. No. RM654U, page AC–84). NG OK Check air induction system (See Pub. No. RM654U, page SF–1). Repair or replace. DI–79 DIAGNOSTICS – ENGINE DI01D–08 DTC P1130 A/F Sensor Circuit Range/Performance Malfunction (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–40. DTC No. DTC Detecting Condition Trouble Area Voltage output* of A/F sensor remains at 4.5 V or more, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at the inside of ECM only P1130 Voltage output* of A/F sensor does not change from 3.30 V, during engine running after engine is warmed up (2 trip detection logic) *: Output value changes at inside of ECM only
Open or short in A/F sensor circuit
A/F sensor
Air induction system
EGR system
Fuel pressure
Injector
ECM Open or short in A/F sensor circuit (2 trip detection logic) HINT:



After confirming DTC P1130, use the OBD II scan tool or TOYOTA hand−held tester to confirm voltage output of the A/F sensor (AFS B1 S1/O2S B1 S1) from the CURRENT DATA. The A/F sensor’s output voltage and the short−term fuel trim value can be read using the OBD II scan tool or TOYOTA hand−held tester. The ECM controls the voltage of the AF+ and AF– terminals of the ECM to the fixed voltage. Therefore, it is impossible to confirm the A/F sensor output voltage without OBD II scan tool or TOYOTA hand– held tester. OBD II scan tool (excluding TOYOTA hand−held tester) displays the one fifth of the A/F sensor output voltage which is displayed on the TOYOTA hand−held tester. WIRING DIAGRAM Refer to DTC P0125 on page DI–40. CONFIRMATION DRIVING PATTERN Vehicle Speed 60 – 120 km/h (38 – 75 mph) Idling IG SW OFF (4) (3) (1)(2) 3 – 5 min. Time A00364 DI–80 DIAGNOSTICS (1) (2) – ENGINE Connect the TOYOTA hand–held tester to the DLC3. Switch the TOYOTA hand–held tester from the normal mode to the check mode (See page DI–3). Start the engine and warm it up with all accessory switches OFF. Drive the vehicle at 60 – 120 km/h (38 – 75 mph) and engine speed at 1,600 – 3,200 rpm for 3 − 5 min. (3) (4) HINT: If a malfunction exists, the MIL will light up during step (4). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not have a TOYOTA hand–held tester, turn the ignition switch OFF after performing steps (3) and (4), then perform steps (3) and (4) again. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Are there any other codes (besides DTC P1130) being output? YES Go to relevant DTC chart. NO 2 Connect OBD II scan tool or TOYOTA hand–held tester, and read value for voltage output of A/F sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC3. (b) Warm up the A/F sensor with the engine speed at 2,500 rpm for approx. 90 sec. CHECK: Read the voltage value of the A/F sensor on the screen of OBD II scan tool or TOYOTA hand–held tester when you perform all the following conditions. HINT: The voltage of the AF+ terminal of the ECM is 3.3 V fixed and the AF– terminal is 3.0 V fixed. Therefore, it is impossible to check the A/F sensor output voltage at the terminals (AF+/AF–) of the ECM. OK: Condition A/F Sensor Voltage Value Engine idling Engine racing Driving at engine speed 1,500 rpm or more and vehicle speed 40 km/h (25 mph) or more, and operate throttle valve open and close
Not remains at 3.30 V (0.660 V V*))
Not remains at 4.5 V (0.76 V*) or more *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester) DI–81 DIAGNOSTICS – ENGINE HINT:
During fuel enrichment, there is a case that the output voltage of the A/F sensor is below 2.8 V (0.56 V*), it is normal.
During fuel cut, there is a case that the output voltage of the A/F sensor is above 4.5 V (0.76 V*), it is normal.
If the output voltage of the A/F sensor remains at 3.30 V (0.660 V*) even after performing all the above conditions, A/F sensor circuit may be open.
If the output voltage of the A/F sensor remains at 3.8 V (0.76 V*) or more, even after performing all the above conditions, A/F sensor circuit may be short. *: When you use the OBD II scan tool (excluding TOYOTA hand–held tester). OK Go to step 9. NG 3 Check for open and short in harness and connector between ECM and A/F sensor (See page IN–29). NG Repair or replace harness or connector. OK 4 Check resistance of A/F sensor heater (See Pub. No. RM654U, page SF–59). NG Replace A/F sensor. OK 5 Check air induction system (See Pub. No. RM654U, page SF–1). NG OK Repair or replace. DI–82 DIAGNOSTICS 6 – ENGINE Check EGR system (See Pub. No. RM654U, page EC–12). NG Repair EGR system. OK 7 Check fuel shutoff valve operation (See page DI–86). NG Repair or repair. OK 8 Check injector injection (See Pub. No. RM654U, page SF–53). NG Replace injector. OK Replace A/F sensor. 9 Perform confirmation driving pattern (See page DI–79). Go 10 Is there DTC P1130 being output again? YES NO Check and replace ECM. DI–83 DIAGNOSTICS 11 – ENGINE Did vehicle runs out of fuel in past? NO YES DTC P0125 is caused by running out of fuel. Check for intermittent problems. DI–84 DIAGNOSTICS – ENGINE DI01F–07 DTC P1135 A/F Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 on page DI–40. DTC No. DTC Detecting Condition Trouble Area When heater operates, heater current exceeds 8 A (2 trip detection logic) P1135 Heater current of 0.25 A or less when heater operates (2 trip detection logic)
Open or short in heater circuit of A/F sensor
A/F sensor h heater t
ECM WIRING DIAGRAM Refer to DTC P0125 on page DI–40. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check voltage between terminal HTAF of ECM connector and body ground. ON HTAF BE6653 A09280 (–) (+) A09427 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal HTAF of the ECM connector and body ground. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–29). NG 2 Check resistance of A/F sensor heater (See Pub. No. RM654U, page SF–59). NG OK Replace A/F sensor. DI–85 DIAGNOSTICS – ENGINE Check and repair harness or connector between EFI main relay (Marking: EFI) and A/F sensor, and A/F sensor and ECM (See page IN–29). DI–86 DIAGNOSTICS – ENGINE DI64X–01 DTC P1190 Fuel Pressure Regulator Malfunction CIRCUIT DESCRIPTION The fuel pressure regulator regulates the fuel pressure by reducing the pressure of the compressed fuel from the fuel tank to the fuel injection pressure, which is 785 kPa (8 kgf/cm2, 114 psi). Similar to the fuel shutoff valve for the fuel tank, a fuel shutoff valve is provided on the fuel inlet side of the fuel pressure regulator to shutoff the supply of fuel when the engine is stopped or during abnormal conditions. A reservoir that traps the moisture and oil in the fuel is provided on the low pressure side. A built–in relief valve is provided to protect the parts located on the low pressure side. While the fuel pressure is being reduced by the fuel pressure regulator, the Joule–Thompson effect associated with the expansion of the fuel causes the fuel pressure regulator to be cooled excessively, exerting unfavorable influence on the rubber parts such as diaphragms and fuel hoses. Therefore, to raise the fuel temperature, a water passage is provided in the fuel pressure regulator to allow the engine coolant to warm the regulator. DTC No. P1190 DTC Detecting Condition After engine is warmed up, detection of pressure control malfunction (2 trip detection logic) Trouble Area
Open or short in fuel shutoff valve circuit for fuel tank
Fuel shutoff valve for fuel tank
Open or short in fuel shutoff valve circuit for fuel pressure regulator
Fuel shutoff valve for fuel pressure regulator
Fuel fuel pressure regulator
Open or short in fuel shutoff valve circuit for fuel delivery pipe
Fuel shutoff valve for fuel delivery pipe
ECM IG Switch B–R 6 Instrument Panel J/B 3 7 IGN 1K 1W R 8 B–R 7 2K 1 STARTER 3 1J 5 5 1B 1K 5 1 CIR OPN Relay 14 FC E4 2 3 1 ST Relay 5 B–R 2D 11 GR 2J MAIN 3 5 W–B B B–W II2 II2 J/C 1 S1 1 S2 Starter ID1 1 2 W–B 6 II4 Fuel ShutOff Valve For Pressure Regulator MAIN FL 7 J8 IG B–R J7 1 2 A Battery L–B 6 GR C L–B 5 B 10 Fuel ShutOff Valve For Fuel Tank J29 J/C 11 Park/Neutral Position Switch GR B–W L–B B–G B L–B B–W A ENGINE G–R J11 J/C 4 E7 VCNG3 5 EB1 EB1 4 – 1 1 L–B 2 ECM 1 L–B B 1 DIAGNOSTICS B P G–R 1 B 2A 3 B 2B 9 W–B 2K B–Y B–R EB EFI 1 1 F6 F4 FL Block W–R 4 2L B–Y II3 4 W–B 2F 2 4 1K AM2 W–R EFI Relay 5 3 9 B–Y Engine Room R/B No.1 7 2 2J 10 2C WIRING DIAGRAM J19 Fuel ShutOff Valve For Delivery Pipe B J/CB 2 1 Engine Room J/B No.2 J40 J/C Y–G 9 E7 VCNG2 13 E6 E01 BL EC DI–87 A09426 DI–88 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Check fuel shutoff valve for delivery pipe. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operating sound of the fuel shutoff valve for delivery pipe for fuel tank when it is operated by the TOYOTA hand–held tester. HINT: Use a sound scope or your finger to check the operating sound. OK: There is operating sound from the shutoff valve. OK 2 Go to step 9. Check fuel shutoff valve for fuel pressure regulator and fuel shutoff valve for fuel tank. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operating sound of the fuel shutoff valve for fuel pressure regulator and fuel shutoff valve for fuel tank when it is operated by the TOYOTA hand–held tester. HINT: Fuel shutoff valve for fuel pressure regulator: Use a sound scope or your finger to check the operating sound. OK: There is operating sound from the shutoff valve. NG NG Fuel shutoff valve for fuel pressure regulator ... Go to step 7. NG Fuel shutoff valve for fuel tank ... Go to step 4. DI–89 DIAGNOSTICS 3 – ENGINE Check circuit opening relay (Marking: CIR OPN) (See Pub. No. RM654U, page SF–41). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground. ON FC (–) (+) A09277 PREPARATION: (a) Remove the glove compartment. (b) Disconnect the E4 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM connector and body ground. OK: Voltage 9 – 14 V OK Go to step 5. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: CIR OPN), and circuit opening relay and ECM (See page IN–29). 5 Check fuel shutoff valve for fuel tank (See page SF–34). NG Replace. OK 6 Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel tank, and fuel shutoff valve for fuel tank and body ground (See page IN–29). NG Repair or replace harness or connector. DI–90 DIAGNOSTICS – ENGINE OK 7 Check voltage between terminals VCNG2 and E01 of ECM connectors. ON E01 (–) (+) VCNG2 A09424 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VCNG2 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–29). NG 8 Check fuel shutoff valve for fuel pressure regulator (See page SF–30). NG Replace fuel shutoff valve with fuel pressure regulator. OK Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel pressure regulator, and fuel shutoff valve for fuel pressure regulator and ECM (See page IN–29). 9 Check voltage between terminals VCNG3 and E01 of ECM connectors. PREPARATION: (a) Remove the glove compartment. (b) Start the engine. CHECK: Measure the voltage between terminals VCNG3 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V ON E01 (–) (+) VCNG3 A09425 DI–91 DIAGNOSTICS OK – ENGINE Check and replace ECM (See page IN–29). NG 10 Check fuel shutoff valve for delivery pipe (See page SF–28). NG Replace. OK Check for open in harness and connector between EFI main relay (Marking: EFI) and fuel shutoff valve for delivery pipe, and fuel shutoff valve for delivery pipe and ECM (See page IN–29). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check operation of fuel shutoff valve for fuel tank. ON OFF A03030 ON FC A09432 PREPARATION: Remove the glove compartment (See Pub. No. RM654U, page SF–64). CHECK: (a) Connect between terminal FC of the ECM connector and body ground. (b) Check for operating sound from the fuel shutoff valve for fuel tank when the ignition switch turned ON. OK: There is operating sound from the fuel shutoff valve. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–21). NG 2 Check for ECM power source circuit (See page DI–116). NG OK Repair or replace. DI–92 DIAGNOSTICS 3 – ENGINE Check circuit opening relay (Marking: CIR OPN) (See Pub. No. RM654U, page SF–41). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground (See page DI–86, step 4). OK Go to step 5. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: CIR OPN), and circuit opening relay and ECM (See page IN–29). 5 Check fuel shutoff valve for fuel tank (See page SF–34). NG Replace. OK 6 Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel tank, and fuel shutoff valve for fuel tank and body ground (See page IN–29). NG OK Repair or replace harness or connector. DI–93 DIAGNOSTICS 7 ENGINE Check voltage between terminals VCNG2 and E01 of ECM connectors. ON E01 – (–) (+) VCNG2 A09424 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VCNG2 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–29). NG 8 Check fuel shutoff valve for fuel pressure regulator (See page SF–30). NG Replace fuel shutoff valve with fuel pressure regulator. OK Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel pressure regulator, and fuel shutoff valve for fuel pressure regulator and ECM (See page IN–29). 9 Check voltage between terminals VCNG3 and E01 of ECM connectors. PREPARATION: (a) Remove the glove compartment. (b) Start the engine. CHECK: Measure the voltage between terminals VCNG3 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V ON E01 (–) (+) VCNG3 A09425 OK Check and replace ECM (See page IN–29). DI–94 DIAGNOSTICS – ENGINE NG 10 Check fuel shutoff valve for delivery pipe (See page SF–28). NG Replace. OK Check for open in harness and connector between EFI main relay (Marking: EFI) and fuel shutoff valve for delivery pipe, and fuel shutoff valve for delivery pipe and ECM (See page IN–29). DI–95 DIAGNOSTICS – ENGINE DI64Y–01 DTC P1240 Fuel Fuel Shutoff Valve Circuit for Delivery Pipe Malfunction CIRCUIT DESCRIPTION Refer to DTC P1190 on page DI–86. DTC No. P1240 DTC Detecting Condition Trouble Area
Open or short in fuel shutoff valve circuit for fuel delivery pipe
Fuel shutoff valve for fuel delivery pipe
ECM Open in fuel shutoff valve circuit for fuel delivery pipe WIRING DIAGRAM Refer to DTC P1190 on page DI–86. INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Check fuel shutoff valve for delivery pipe. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operating sound of the fuel shutoff valve for delivery pipe when it is operated by the TOYOTA hand–held tester. HINT: Use a sound scope or your finger to check the operating sound. OK: There is operating sound from the shutoff valve. OK Go to step 5. NG 2 Check for ECM power source circuit (See page DI–116). NG Repair or replace. DI–96 DIAGNOSTICS – ENGINE OK 3 Check voltage between terminals VCNG3 and E01 of ECM connectors. ON E01 (–) (+) VCNG3 A09425 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Start the engine. CHECK: Measure the voltage between terminals VCNG3 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–29). NG 4 Check fuel shutoff valve for delivery pipe (See page SF–28). NG Replace. OK Check for open in harness and connector between EFI main relay (Marking: EFI) and fuel shutoff valve for delivery pipe, and fuel shutoff valve for delivery pipe and ECM (See page IN–29). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check for ECM power source circuit (See page DI–116). NG OK Repair or replace. DI–97 DIAGNOSTICS 2 ENGINE Check voltage between terminals VCNG3 and E01 of ECM connectors. ON E01 – (–) (+) VCNG3 A09425 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Start the engine. CHECK: Measure the voltage between terminals VCNG3 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V OK Check and replace ECM (See page IN–29). NG 3 Check fuel shutoff valve for delivery pipe (See page SF–28). NG Replace. OK Check for open in harness and connector between EFI main relay (Marking: EFI) and fuel shutoff valve for delivery pipe, and fuel shutoff valve for delivery pipe and ECM (See page IN–29). DI–98 DIAGNOSTICS – ENGINE DI64Z–01 DTC P1245 Fuel Fuel Shutoff Valve Circuit for Pressure Regulator Malfunction CIRCUIT DESCRIPTION Refer to DTC P1190 on page DI–86. DTC No. P1245 DTC Detecting Condition Trouble Area Open in fuel shutoff valve circuit for fuel pressure regulator
Open or short in fuel shutoff valve circuit for fuel pressure regulator
Fuel shutoff valve for fuel pressure regulator
ECM WIRING DIAGRAM Refer to DTC P1190 on page DI–86. INSPECTION PROCEDURE TOYOTA hand–held tester: 1 Check fuel shutoff valve circuit for fuel pressure regulator. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. (c) Select the ACTIVE TEST mode on the TOYOTA hand–held tester. CHECK: Check the operating sound of the fuel shutoff valve for the pressure regulator when it is operated by the TOYOTA hand–held tester. HINT: Use a sound scope or your finger to check the operating sound. OK: There is operating sound from the shutoff valve. OK Go to step 4. NG 2 Check for ECM power source circuit (See page DI–116). NG OK Repair or replace. DI–99 DIAGNOSTICS 3 – ENGINE Check circuit opening relay (Marking: CIR OPN) (See Pub. No. RM654U, page SF–41). NG Replace circuit opening relay. OK 4 Check voltage between terminal FC of ECM connector and body ground. ON FC (–) (+) A09277 PREPARATION: (a) Remove the glove compartment. (b) Disconnect the E4 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM connector and body ground. OK: Voltage 9 – 14 V OK Go to step 5. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: CIR OPN), and circuit opening relay and ECM (See page IN–29). 5 Check voltage between terminals VCNG2 and E01 of ECM connectors. PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VCNG2 and E01 of the ECM connectors. OK: Voltage: 9 – 14 V ON E01 (–) (+) VCNG2 A09424 OK NG Check and replace ECM (See page IN–29). DI–100 DIAGNOSTICS 6 – ENGINE Check fuel shutoff valve for fuel pressure regulator (See page SF–30). NG Replace fuel shutoff valve for fuel pressure regulator. OK Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel pressure regulator, and fuel shutoff valve for fuel pressure regulator and ECM (See page IN–29). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check for ECM power source circuit (See page DI–116). NG Repair or replace. OK 2 Check fuel shutoff valve for fuel pressure regulator (See page SF–30). NG Replace circuit opening relay. OK 3 Check voltage between terminal FC of ECM connector and body ground. ON FC (–) (+) A09277 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Disconnect the E4 connector from the ECM. (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal FC of the ECM connector and body ground. OK: Voltage 9 – 14 V DI–101 DIAGNOSTICS OK – ENGINE Go to step 4. NG Check for open in harness and connector between EFI main relay (Marking: EFI) and circuit opening relay (Marking: CIR OPN), and circuit opening relay and ECM (See page IN–29). 4 Check voltage between terminals VCNG2 and E01 of ECM connectors. ON E01 (–) (+) VCNG2 A09424 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VCNG2 and E01 of the ECM connectors. OK: Voltage 9 – 14 V OK Check and replace ECM (See page IN–29). NG 5 Check fuel shutoff valve for fuel pressure regulator (See page SF–30). NG Replace fuel shutoff valve for fuel pressure regulator. OK Check for open in harness and connector between circuit opening relay (Marking: CIR OPN) and fuel shutoff valve for fuel pressure regulator, and fuel shutoff valve for fuel pressure regulator and ECM (See page IN–29). DI–102 DIAGNOSTICS – ENGINE DI01G–07 DTC P1300 Igniter Circuit Malfunction (No.1) DTC P1310 Igniter Circuit Malfunction (No.2) CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (°CA) before the desired ignition timing and outputs and ignition signal (IGT) 1 to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr2 turns on. When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal O. This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, the counter electromotive force is generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel injection as a fail safe function when the IGF signal is not input to the ECM. DTC No. P1300 P1310 DTC Detecting Condition Trouble Area No IGF signal to ECM for 4 consecutive IGT1 signals during engine running
Ignition system
Open or short in IGF or IGT1 circuit from No.1 ignition coil with igniter to ECM
No.1 ignition coil with igniter
ECM No IGF signal to ECM for 4 consecutive IGT2 signals during engine running
Ignition system
Open or short in IGF or IGT2 circuit from No.2 ignition coil with igniter to ECM
No.2 ignition coil with igniter
ECM HINT: No.1 ignition coil with igniter is for cylinder No.1 and No.4, and No.2 ignition coil is for cylinder No.2 and No.3. DI–103 DIAGNOSTICS – ENGINE WIRING DIAGRAM IG Switch 7 6 B–R W–R 3 1K 5 1K 5 12 8 1C 5 1B B–R IG3 W–R Instrument Panel J/B B 2A AM2 C J9 J/C B–R No.1 Ignition Coil with Igniter 1 C Igniter No.1 C BR 2L 20 E6 IGT1 19 E6 IGT2 3 E6 IGF Tr1 BR Spark Plug 1 Igniter No.2 B–G J/C A A BR EC BR 4 2 Tr2 W–R 3 No.2 Ignition Coil with Igniter Y–R W–R A J18 W–R 1 F9 Battery 5V 3 Engine Room FL Block J/B No.2 MAIN FL B 2 Tr2 4 4 B–R 1 F11 1 ECM Spark Plug Tr1 A09399 INSPECTION PROCEDURE HINT:


If DTC P1300 is displayed, check No.1 ignition coil circuit. If DTC P1300 is displayed, check No.2 ignition coil circuit. Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check for spark plug and spark of misfiling cylinder (See page IG–1). NG Go to step 4. OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and ignition coil with igniter (See page IN–29). NG OK Repair or replace harness or connector. DI–104 DIAGNOSTICS 3 – ENGINE Disconnect ignition coil with igniter connector, and check voltage between terminal IGF of ECM connector and body ground. ON IGF (+) (–) BE6653 A09288 A09269 PREPARATION: (a) Disconnect the ignition coil with igniter connector. (b) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (c) Turn the ignition switch ON. CHECK: Measure the voltage between terminal IGF of the ECM connector and body ground. OK: Voltage: 4.5 – 5.5 V OK Replace ignition coil with igniter. NG Check and replace ECM (See page IN–29). 4 Check for open and short in harness and connector in IGT1 and IGT2 signal circuits between ECM and ignition coil with igniter (See page IN–29). NG Repair or replace harness or connector. OK 5 Check voltage between terminals IGT1, IGT2 of ECM connector and body ground. PREPARATION: Remove the glove compartment (See Pub. No. RM654U, page SF–64). CHECK: Measure the voltage between terminal IGT1, IGT2 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 4.5 V START IGT2 IGT1 (+) BE6653 A09287 (–) A09268 DI–105 DIAGNOSTICS IGT and IGF Signal Waveforms 2 V/ Division IGT 0V IGF – ENGINE Reference: INSPECTION USING OSCILLOSCOPE During idling, check the waveform between terminals IGT1 and E1, IGT2 and E1, and IGF and E1 of the ECM connector. HINT: The correct waveforms are as shown. 0V NG 10 msec./Division (Idling) Check and replace ECM (See page IN–29). FI6680 NG 6 Disconnect ignition coil with igniter connector, and check voltage between terminals IGT1, IGT2 of ECM connector and body ground. START IGT2 IGT1 (+) (–) BE6653 A09287 A09268 PREPARATION: (a) Disconnect the ignition coil with igniter connector. (b) Remove the glove compartment (See Pub. No. RM654U, page SF–64). CHECK: Measure the voltage between terminals IGT1, IGT2 of the ECM connector and body ground when the engine is cranked. OK: Voltage: More than 0.1 V and less than 5 V OK Replace ignition coil with igniter. NG 7 Check ignition coil with igniter power source circuit. PREPARATION: Disconnect the ignition coil with igniter connector. CHECK: Measure the voltage between terminal 1 of the ignition coil with the igniter connector and body ground when the ignition switch is turned to ON and STA position. OK: Voltage: 9 – 14 V ON START (–) (+) 1 BE6653 A01761 A01861 NG OK Repair ignition coil with igniter power source circuit. DI–106 DIAGNOSTICS 8 – ENGINE Check for open and short in harness and connector between ignition switch and ignition coil with igniter (See page IN–29). NG OK Replace ignition coil with igniter. Repair or replace harness or connector. DI–107 DIAGNOSTICS – ENGINE DI1K1–03 DTC P1335 Crankshaft Position Sensor Circuit Malfunction (During engine running) CIRCUIT DESCRIPTION Refer to DTC P0335 on page DI–59. DTC No. P1335 DTC Detecting Condition If conditions (a) through (c) are met: (a) NE
1,000 rpm (b) NE signal is not detected for over 50 msec. (c) Not during cranking WIRING DIAGRAM Refer to DTC P0335 on page DI–59. INSPECTION PROCEDURE Refer to DTC P0335 on page DI–59. Trouble Area
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Crankshaft timing pulley
ECM DI–108 DIAGNOSTICS – ENGINE DI01H–09 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut–off engine speed. (The fuel cut–off engine speed is reduced slightly when the vehicle is braking.) DTC No. DTC Detecting Condition Trouble Area Stop light switch does not turn off even once vehicle is driven (2 trip detection logic) P1520
Short in stop light switch signal circuit
Stop light switch
ECM WIRING DIAGRAM Stop Light Switch W G–W 2 1 Instrument Panel J/B A J27 J/C C 4 5 G–W 1R 1R J23 J24 Light Failure Sensor 1 F9 R B–R MAIN FL W–B FL Block ALT 1 F14 2 F14 Battery B–G E4 STP J34 J/C 7 1 2 1 A 2 High Mount Stop Light W–B A G–R 2 Stop Light (RH) 5 W–B 2 Stop Light (LH) 5 W–B Instrument Panel J/B 4 1B B–R G–W 2 1S G–W STOP 7 1C ECM 4 BM BL A09400 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. 1 Check operation of stop light. PREPARATION: Check if the stop lights go on and off normally when the brake pedal is operated and released. NG Check and repair stop light circuit (See Pub. No. RM654U, page BE–37). DI–109 DIAGNOSTICS – ENGINE OK 2 Check STP signal. When using TOYOTA hand–held tester: PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. CHECK: Read the STP signal on the TOYOTA hand–held tester. OK: ON Brake Pedal Depressed BE6653 Q06993 A09282 (–) Brake Pedal Released (+) STP Signal Depressed ON Released OFF When not using TOYOTA hand–held tester: PREPARATION: Turn the ignition switch ON. CHECK: Check the voltage between terminal STP of the ECM connector and body ground. OK: OK STP Brake Pedal Brake Pedal Voltage Depressed 7.5 – 14 V Released Below 1.5 V Check for intermittent problems (See page DI–3). A09270 NG 3 Check harness and connector between ECM and stop light switch (See page IN–29). NG OK Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–110 DIAGNOSTICS – ENGINE DI01I–12 DTC P1600 ECM BATT Malfunction CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air–fuel ratio adaptive control value memory, etc. DTC No. P1600 DTC Detecting Condition Trouble Area
Open in back up power source circuit
ECM Open in back up power source circuit HINT: If DTC P1600 appear, the ECM does not store another DTC. WIRING DIAGRAM ECM Engine Room J/B No.2 B–G 1 F9 1 F11 B 1 2A EFI 8 2J B–Y 1 E4 BATT FL Block MAIN FL Battery A09401 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. DI–111 DIAGNOSTICS 1 ENGINE Check voltage between terminal BATT of ECM connector and body ground. LOCK AB0117 A09286 – (–) (+) BATT PREPARATION: Remove the glove compartment (See Pub. No. RM654U, page SF–64). CHECK: Measure the voltage between terminal BATT of the ECM connector and body ground. OK: Voltage 9 – 14 V A09271 OK Check and replace ECM (See page IN–29). NG 2 Check EFI fuse. PREPARATION: Remove the EFI fuse from the engine room J/B No.2. CHECK: Check the continuity of the EFI fuse. OK: Continuity Engine Room J/B No.2 NG EFI Fuse A00356 OK Check and repair harness or connector between battery and EFI fuse, and EFI fuse and ECM (See page IN–29). Check for short in all harness and components connected to EFI fuse. DI–112 DIAGNOSTICS – ENGINE DI01J–07 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery positive voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. DTC No. DTC Detecting Condition Trouble Area 2 or more switches are ON simultaneously for P, R, N, D, 2 and L positions (2 trip detection logic) P1780 When driving under conditions (a) and (b) for 30 sec. or more park/neutral position switch is ON (N position): (2 trip detection logic) (a) Vehicle speed: 80 km/h (50 mph) or more (b) Engine speed: 2,000 – 5,000 rpm
Short in park/neutral position switch circuit
Park/neutral position switch
ECM HINT: After confirming DTC P1780, use the TOYOTA hand–held tester to confirm the PNP switch signal from the CURRENT DATA. WIRING DIAGRAM Refer to DTC P1780 on page DI–165. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. Refer to DTC P1780 on page DI–165. DI–112 DIAGNOSTICS – ENGINE DI01J–07 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery positive voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. DTC No. DTC Detecting Condition Trouble Area 2 or more switches are ON simultaneously for P, R, N, D, 2 and L positions (2 trip detection logic) P1780 When driving under conditions (a) and (b) for 30 sec. or more park/neutral position switch is ON (N position): (2 trip detection logic) (a) Vehicle speed: 80 km/h (50 mph) or more (b) Engine speed: 2,000 – 5,000 rpm
Short in park/neutral position switch circuit
Park/neutral position switch
ECM HINT: After confirming DTC P1780, use the TOYOTA hand–held tester to confirm the PNP switch signal from the CURRENT DATA. WIRING DIAGRAM Refer to DTC P1780 on page DI–165. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand–held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc. at the time of the malfunction. Refer to DTC P1780 on page DI–165. DI–113 DIAGNOSTICS – ENGINE DI01K–12 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after–start injection control. WIRING DIAGRAM Instrument Panel J/B 8 IG Switch R 4 1K 3 1J STARTER 5 7 1K W–R J29 J/C B–W B–W B B 11 IG2 Park/Neutral Position Switch 10 5 6 IG2 B–W GR ECM GR C J/C B J7 J6 5 1B W–R GR 11 STA E4 B J6 E1 GR B B 1 2A 3 2B 11 2J MAIN FL 1 Block 1 F9 F11 AM2 4 2L 5 1 Engine Room J/B No.2 ST Relay 3 2 W–B B–G 5 2D 9 2K A MAIN FL B–R 1 S1 1 S2 B–R J9 J/C Starter Battery IF A03606 INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the problem symptoms table on page DI–21. DI–114 DIAGNOSTICS – ENGINE TOYOTA hand–held tester: 1 Connect TOYOTA hand–held tester, and check STA signal. PREPARATION: (a) Connect the TOYOTA hand–held tester to the DLC3. (b) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. CHECK: Read the STA signal on the TOYOTA hand–held tester while the starter operates. OK: Ignition Switch Position ON START STA signal OFF ON OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–21). NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN–29). NG Repair or replace harness or connector. OK Check and replace ECM (See page IN–29). OBD II scan tool (excluding TOYOTA hand–held tester): 1 Check voltage between terminal STA of ECM connector and body ground. START (–) BE6653 A03027 (+) STA A09272 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal STA of the ECM connector and body ground, during the engine cranking. OK: Voltage: 6 V or more OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–3). DI–115 DIAGNOSTICS – ENGINE NG 2 Check for open in harness and connector between ECM and starter relay (Marking: ST) (See page IN–29). NG OK Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–116 DIAGNOSTICS – ENGINE DI01L–07 ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM ECM B–Y B J23 J/C B J24 12 +B E4 B–Y B–R 2 4 2F W–B EB Instrument Panel J/B 3 1K 6 IG Switch 16 E6 E1 4 2L B 7 W–R BR 1 2A 5 1B 5 1K AM2 5 EFI Relay IGN 1 7 1W B–R 3 Engine Room J/B No.2 W–R 7 2K EFI 2 2J 1 F11 FL Block A 1 F9 J20 J/C MAIN FL BR A B–G Battery EC A09403 DI–117 DIAGNOSTICS – ENGINE INSPECTION PROCEDURE Check voltage between terminals +B and E1 of ECM connector. 1 ON +B E1 BE6653 A09291 (–) (+) A09273 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals +B and E1 of the ECM connector. OK: Voltage: 9 – 14 V OK Proceed to next circuit inspection shown on Problem symptoms table (See page DI–21). NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN–29). NG Repair or replace harness or connector. OK 3 Check EFI main relay (Marking: EFI) (See Pub. No. RM654U, page SF–40). NG Replace EFI main relay. OK 4 Check EFI fuse (See page DI–110, step 2). NG OK Check for short in all harness and components connected to EFI fuse. DI–118 DIAGNOSTICS 5 – ENGINE Check for open in harness and connector between EFI main relay (Marking: EFI) and battery, and EFI main relay and ECM (See page IN–29). NG Repair or replace harness or connector. OK 6 Check IGN fuse. PREPARATION: Remove the IGN fuse from the instrument panel J/B. CHECK: Check the continuity of the IGN fuse. OK: Continuity IGN Fuse Instrument Panel J/B NG A00355 Check for short in all harness and components connected to IGN fuse. OK 7 Check ignition switch (See Pub. No. RM654U, page BE–14). NG Replace ignition switch. OK Check for open in harness and connector between ignition switch and EFI main relay, and EFI main relay and body ground (See page IN–29). DI–119 DIAGNOSTICS – ENGINE DI01N–05 A/C Compressor Lock Sencor Circuit CIRCUIT DESCRIPTION This sensor sends 1 pulse par engine revolution to the ECM. If the number ratio of the compressor speed divided by the engine speed is smaller than a predetermined value, the ECM turns the compressor off. And, the indicator flashes at about 1 second intervals. WIRING DIAGRAM ECM 9 W–L IJ2 10 W–L 18 W–L IG3 LOCK IN E6 1 A/C Compressor Lock Sensor 2 10 BR BR IJ2 J7 J/C 6 BR B J20 J/C B IG3 16 BR BR A A E1 BR A E6 EC A09404 INSPECTION PROCEDURE 1 Check A/C compressor. PREPARATION: (a) Check the compressor drive belt tension (See Pub. No. RM654U, page AC–16). (b) Check if the compressor does not lock during operation with the engine started, and the blower switch and A/C switch ON. NG OK Adjust drive belt tension or repair compressor (See Pub. No. RM654U, page AC–17). DI–120 DIAGNOSTICS 2 – ENGINE Check A/C compressor lock sensor. 1 PREPARATION: Disconnect the compressor lock sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of the compressor lock sensor connector. OK: Resistance: 65 – 125 Ω at 20°C (68°F) 2 N15622 Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check the waveform between terminals LOCK IN and E1 of the ECM connector. HINT: The correct waveform appears as shown. 0.2 V/Div. LOCK IN Signal Waveform 0V NG 20 msec./Division (Idling) Replace compressor lock sensor (See Pub. No. RM654U, page AC–40). N02774 OK 3 Check harness and connector between A/C compressor lock sensor and ECM (See page IN–29). NG OK Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–121 DIAGNOSTICS – ENGINE DI01O–05 A/C Evaporator Temp. Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the ECM. WIRING DIAGRAM ECM 5V 1 L–W 10 L–R IG2 E5 THR 1 A/C Evaporator Temp. Sensor 2 9 3 BR BR IG2 E5 E2 A09405 INSPECTION PROCEDURE 1 Check voltage between terminals THR and E2 of ECM connector. ON E1 BE6653 A09290 THR (–) (+) A09361 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals THR and E1 of the ECM connector at each temperature. OK: Voltage: 2.2 – 2.6 V at 0°C (32 F) 1.4 – 1.8 V at 15°C (59°F) HINT: As the temperature increases, the voltage decreases. OK Check and replace ECM (See page IN–29). DI–122 DIAGNOSTICS – ENGINE NG 2 Check A/C evaporator temperature sensor. Thermometer Ice Ohmmeter Thermistor More than 10 cm (3.94 in.) AC0175 PREPARATION: Remove the A/C evaporator temperature sensor (See Pub. No. RM654U, page AC–30). CHECK: Check the resistance between terminals 1 and 2 of the A/C evaporator temperature sensor connector at each temperature. OK: Resistance: 4.6 – 5.1 kΩ at 0°C (32°F) 2.1 – 2.6 kΩ at 15°C (59°F) HINT: As the temperature increases, the voltage decreases. NG Replace A/C evaporator temperature sensor. OK 3 Check harness and connector between A/C evaporator temperature sensor and ECM (See page IN–29). NG OK Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–123 DIAGNOSTICS – ENGINE DI650–01 Fuel Pressure Sensor Circuit for Fuel Pipe CIRCUIT DESCRIPTION Refer to DTC P0190 on page DI–56. WIRING DIAGRAM Fuel Pressure Sensor for Fuel Pipe ECM 1 VC E5 3 Y 2 G–R 5 PCNG1 E7 1 BR 9 E2 E5 5V E1 A00309 INSPECTION PROCEDURE 1 Check voltage between terminals VC and E2 of ECM connector. ON E2 BE6653 A03008 (–) (+) VC A09254 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECM connector. OK: Voltage: 4.5 – 5.5 V NG OK Check and replace ECM (See page IN–29). DI–124 DIAGNOSTICS 2 A09292 ENGINE Check voltage between terminals PCNG1 and E2 of ECM connector. ON BE6653 – E2 PCNG1 (–) (+) A09419 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals PCNG1 and E2 of the ECM connector. OK: Needle position of fuel level gauge Voltage (V) at 20°C (68°F) 4/4 3.3 3/4 2.7 2/4 2.0 1/4 1.3 OK Check and replace ECM (See page IN–29). NG 3 Check for open and short in harness and connector between fuel pressure sensor for fuel pipe and ECM (See page IN–29). NG OK Replace fuel pressure sensor for fuel pipe (See page SF–46). Repair or replace harness or connector. DI–125 DIAGNOSTICS – ENGINE DI652–01 Fuel Temperature Sensor Circuit for Fuel Tank CIRCUIT DESCRIPTION A fuel temperature sensor that detects the temperature in the fuel tank is provided on the tank valve assembly. A fuel pressure sensor that detects the pressure in the fuel main pipe is provided immediately upstream of the fuel pressure regulator. The pressure and the temperature of the fuel are detected by these sensors and are input into the ECM. Those values are then converted by the ECM into the equipment pressure at 20°C (68°F) to actuate the the fuel gauge. WIRING DIAGRAM ECM Fuel Temperature Sensor for Fuel Tank 5V 3 4 LG–B BR 4 IB1 LG–B 2 IB1 BR 2 IG2 LG–B 3 IG2 BR 1 E7 9 E5 R THCNG1 E2 E1 A09421 INSPECTION PROCEDURE 1 Check voltage between terminals THCNG1 and E2 of ECM connector. PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals THCNG1 and E2 of ECM connector. ON E2 BE6653 A09294 THCNG1 (–) (+) A09393 Temperature°C (°F) Voltage V –30 (22) 0.56 – 0.45 25 (77) 3.39 – 3.29 40 (104) 4.0 – 3.9 100 (212) 4.85 – 4.82 OK: OK Check for intermittent problem (See page DI–3). DI–126 DIAGNOSTICS – ENGINE NG 2 Check fuel pressure sensor for fuel tank (See page SF–40). NG Replace fuel pressure sensor for fuel tank. OK 3 Check for open and short in harness and connector brtween ECM and fuel pressure sensor for fuel tank (See page IN–29). NG OK Check and replace ECM (See page IN–29). Repair or replace harness or connector. DI–127 DIAGNOSTICS – ENGINE DI651–01 Injector Circuit CIRCUIT DESCRIPTION For the injection of fuel in the gaseous state, injectiors that allow the flow of a large volume of fuel and provide improved sealing performance have been adopted. These injectors are actuated by the voltage (150 V) that has been increased by the voltage booster circuit provided in the ECM. WIRING DIAGRAM ECM +B L Injector 2 1 No. 1 B–W BR Injector 2 1 B–R No. 2 G Injector 2 R 1 No. 3 L Injector 2 1 No. 4 BR EC EC B–W BR A BR A 2 E6 12 E6 1 E6 11 E6 15 E6 25 E6 14 E6 24 E6 13 E6 26 E6 Voltage #10+ #10 Booster Circuit Voltage #20+ #20 Booster Circuit Voltage #30+ #30 Booster Circuit Voltage #40+ #40 Booster Circuit E01 E05 J19 J/C A09422 INSPECTION PROCEDURE 1 Check wire harness, connector and vacuum hose in engine room. CHECK: (a) Check the connection conditions of the wire harness and connector. (b) Check the disconnection, piping and break of the vacuum hose. NG OK Repair or replace, then confirm that there is no misfire (See the confirmation driving pattern). DI–128 DIAGNOSTICS 2 – ENGINE Check spark plug and spark of misfiring cylinder (See page IG–1). NG Replace or check ignition system (See page IG–1). OK 3 Check voltage of ECM terminals #10 – #40 for injector of failed cylinder. ON #10 #20 #30 BE6653 A09304 #40 (+) (–) A09431 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 – 14 V Reference: INSPECTION USING OSCILLOSCOPE With the engine idling, check the waveform between terminals #10 – #40 and E01 of the ECM connector. HINT: The correct waveforms are shown. Injector Signal Waveform (Magnification) 10 V/ Division 10 V/ Division GND GND 100 msec./Division (Idling) Injection duration FI6588 FI6538 1 msec./Division (Idling) A00064 OK NG Go to step 5. DI–129 DIAGNOSTICS 4 ENGINE Check voltage of ECM terminalls #10+ – #40+ for injector of failed cylinder. ON #30+ – #10+ #20+ #40+ (+) BE6653 A09430 (–) A09649 PREPARATION: (a) Remove the glove compartment (See Pub. No. RM654U, page SF–64). (b) Turn the ignition switch ON. CHECK: Measure the voltage between applicable terminal of the ECM connector and body ground. OK: Voltage: 9 – 14 V HINT: 150 V is loaded on the injector at 100 msec. (in an instance) when starting the engine. OK Go to step 5. NG Replace ECM. 5 Check resistance of injector of misfiring cylinder (See page IG–1). NG Replace injector. OK Check for open and short in harness and connector between injector and ECM (See page IN–29). 6 Check fuel shutoff valve operation (See page DI–86). NG OK Replace or repair. DI–130 DIAGNOSTICS 7 – ENGINE Check injector injection (See Pub. No. RM654U, page SF–23). NG Replace injector. OK 8 Check EGR system (See Pub. No. RM654U, page EC–12). NG Repair EGR system. OK 9 Check manifold absolute pressure sensor (See Pub. No. RM654U, page SF–53) and engine coolant temp. sensor (See Pub. No. RM654U, page SF–49). NG OK Check compression pressure (See page *1), valve clearance (See page *2) and valve timing (See page *3). *1: See Pub. No. RM654U, page EM–3. See Pub. No. RM654U, page EM–4. *1: See Pub. No. RM654U, page EM–23. *1: Repair or replace. DI–131 DIAGNOSTICS – AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE DI02U–04 HOW TO PROCEED WITH TROUBLESHOOTING Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop 1 Customer Problem Analysis P. DI–132 2 Connect an OBD II scan tool or TOYOTA hand–held tester to DLC3. If the display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the scan tool / TOYOTA hand–held tester, inspect DLC3 P. DI–133 3 Check DTC and Freeze Frame Data (Precheck) Record or Print DTC and Freeze Frame Data P. DI–133 4 Clear DTC and Freeze Frame Data P. DI–133 5 Visual Inspection 6 Setting the Check Mode Diagnosis P. DI–133 Symptom does not occur 8 7 Problem Symptom Confirmation Symptom Simulation P. IN–19 Symptom occurs 9 DTC Check P. DI–133 10 DTC Chart P. DI–145 OK Code 11 OK Mechanical System Test P. DI–133 OK 12 OK Manual Shifting Test P. DI–133 NG NG Problem Symptoms Table– P. DI–148 13 Chapter 1 (Electronic) P. DI–148 NG 14 Preliminary Check NG P. DI–133 Circuit Inspection Chapter 2 (On–Vehicle) P. DI–148 OK OK Chapter 3 (Off–Vehicle) P. DI–148 NG NG
O/D Cancel Signal Check
O/D Main Switch & O/D OFF Indicator Light Circuit Check 15 Parts Inspection P. DI–151 to DI–171 Identification of Problem 16 Repair 17 Confirmation Test Author: End Date: 201 DI–132 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI02V–02 CUSTOMER PROBLEM ANALYSIS CHECK Transaxle Control System Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / Date Problem Occurred How Often Problem Occurs ? / km mile Odometer Reading /  Continuous /  Intermittent (  Vehicle does not move (  Any position  No up–shift (  1st → 2nd  No down–shift (  O/D → 3rd times a day)  Particular position )  2nd → 3rd  3rd → 2nd  3rd → O/D )  2nd → 1st )  Lock–up malfunction Symptoms  Shift point too high or too low  Harsh engagement (  N → D  Lock–up  Any drive position )  Slip or shudder  No kick–down  Others Check Item Malfunction Indicator Lamp  Normal  Remains ON 1st Time  Normal code  Malfunction code (Code ) 2nd Time  Normal code  Malfunction code (Code ) DTC Check DI–133 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI02W–05 PRE–CHECK 1. (a) FI0534
Hand–held Tester DLC3 DIAGNOSIS SYSTEM Description
When troubleshooting OBD II vehicles, the only difference from the usual troubleshooting procedure is that you connect an OBD II scan tool complying with SAE J1987 or hand–held tester to the vehicle, and read off various data output from the vehicle’s ECM. OBD II regulations require that the vehicle’s on– board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which affect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable DTCs prescribed by SAE J2012 are recorded in the ECM memory (See page DI–14). If the malfunction only occurs in 3 trips, the MIL goes off but the DTCs remain recorded in the ECM memory. S05335 To check the DTCs, connect an OBD II scan tool or hand–held tester to DLC3 on the vehicle. The OBD II scan tool or hand–held tester also enables you to erase the DTCs and check freeze frame data and various forms of engine data (For instruction book). DTCs include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as the codes prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI–14) DI–134 DIAGNOSTICS –

(b) AUTOMATIC TRANSAXLE The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and for a malfunction that is only detected once or momentarily. (hand–held tester) (See page DI–145) *2 trip detection logic: When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunction is detected again during the 2nd test drive, this 2nd detection causes the MIL to light up. Inspect the DLC3. The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC3 complies with SAE J1962 and matches the V.P.W. format. DLC3 N09214 Tester connection Condition Specified condition 2 (Bus
Line) – 5 (Signal ground) During communication 4 (Chassis Ground) – Body Always 1 Ω or less 5 (Signal Ground) – Body Always 1 Ω or less 16 (B+) – Body Always 9 – 14 V Pulse generation HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of OBD II scan tool or hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle.
If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. DI–135 DIAGNOSTICS 2. (a) FI0534 Hand–held Tester DLC3 S05335 – AUTOMATIC TRANSAXLE INSPECT DIAGNOSIS (NORMAL MODE) Check the MIL. (1) The MIL comes on when the ignition switch is turned ON and the engine is not running. HINT: If the MIL does not light up, troubleshoot the combination meter (See page BE–4). (2) When the engine is started, the MIL should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. (b) Check the DTC. NOTICE: (hand–held tester only): When the diagnostic system is switched from normal mode to check mode, it erases all DTCs and freeze frame data recorded in normal mode. So before switching modes, always check the DTCs and freeze frame data, and note them down. (1) Prepare an OBD II scan tool (complying with SAE J1978) or hand–held tester. (2) Connect the OBD II scan tool or hand–held tester to DLC3 at the lower portion of the instrument panel. (3) Turn the ignition switch ON and turn the OBD II scan tool or hand–held tester switch ON. (4) Use the OBD II scan tool or hand–held tester to check the DTCs and freeze frame data and note them down (For operating instructions, see the OBD II scan tool’s instruction book). (5) See page DI–145 to confirm the details of the DTCs. NOTICE: When simulating symptoms with an OBD II scan tool (excluding hand–held tester) to check the DTCs, use normal mode. For codes on the DTCs chart subject to ”2 trip detection logic”, turn the ignition switch off after the symptoms have been simulated the 1st time. Then repeat the simulation process again. When the program has DTCs, the DTCs are recorded in the ECM. DI–136 DIAGNOSTICS – AUTOMATIC TRANSAXLE 3. INSPECT DIAGNOSIS (CHECK MODE) HINT: Hand–held tester only: Compared to the Normal mode, the Check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in Check mode. (a) Check the DTC. (1) Check the initial conditions.
Battery positive voltage 11 V or more
Throttle valve fully closed
Transaxle in P position
Air conditioning switched off (2) Turn the ignition switch OFF. (3) Prepare a hand–held tester. (4) Hand–held tester (5) DLC3 S05335 (6) 0.13 sec. Connect the hand–held tester to DLC3 at the lower side of the instrument panel. Turn the ignition switch ON and switch the hand– held tester ON. (7) 0.13 sec. ON (8) OFF BR3904 Switch the hand–held tester from Normal mode to Check mode (Check that the MIL flashes). Start the engine (MIL goes out after the engine starts). Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc. (9) After simulating the malfunction conditions, use the hand–held tester diagnosis selector to check the DTCs and freeze frame data, etc. HINT: Take care not to turn the ignition switch OFF, as turning it off the diagnosis system switches from Check mode to Normal mode, so all DTCs, etc. are erased. (10) After checking the DTC, inspect the applicable circuit. DI–137 DIAGNOSTICS (b) – AUTOMATIC TRANSAXLE Clearance the DTC. The following actions will erase the DTC and freeze frame data. Operating an OBD II scan tool (complying with SAE J1978) or hand–held tester to erase the codes. (See the OBD II scan tool’s instruction book for operating instructions.) 4. ROAD TEST NOTICE: Perform the test at normal operating ATF temperature 50 – 80 °C (122 – 176 °F). (a) D position test Shift into the D position and fully depress the accelerator pedal and and check the following points: (1) Check up–shift operation. 1 → 2, 2 → 3 and 3 → O/D up–shifts take place, at the shift point shown in the automatic shift schedule (See Pub. No. RM654U on page SS–54). HINT:
O/D Gear Up–shift Prohibition Control (1. Coolant temp. is 50 °C (122 °F) or less. 2. If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed.)
O/D Gear Lock–up Prohibition Control (1. Brake pedal is depressed. 2. Coolant temp. is 50 °C (122 °F) or less.) (2) Check for shift shock and slip. Check for shock and slip at the 1 → 2, 2 → 3 and 3 → O/D up–shifts. (3) Check for abnormal noises and vibration. Run at the D position lock–up or O/D gear and check for abnormal noises and vibration. HINT: The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential or torque converter clutch, etc. (4) Check kick–down operation. While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick–down vehicle speed limits for 2 → 1, 3 → 2 and O/D → 3 kick–downs conform to those indicated on the automatic shift schedule (See Pub. No. RM654U on page SS–54). (5) Check abnormal shock and slip at kick–down. (6) Check the lock–up mechanism.
Drive in D position, O/D gear, at a steady speed (lock–up ON) of about 75 km/h (47 mph).
Lightly depress the accelerator pedal and check that the engine speed does not change abruptly. If there is a big jump in engine speed, there is no lock–up. (b) 2 position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check up–shift operation. Check to see that the 1 → 2 up–shift takes place and that the shift point conforms to the automatic shift schedule (See Pub. No. RM654U on page SS–54). HINT: There is no O/D up–shift and lock–up in the 2 position. (2) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. DI–138 DIAGNOSTICS – AUTOMATIC TRANSAXLE (3) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down–shift. (c) L position test Shift into the 2 position and fully depress the accelerator pedal and check the following points: (1) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear. (2) Check engine braking. While running in the L position, release the accelerator pedal and check the engine braking effect. (3) Check for abnormal noises during acceleration and deceleration. (d) R position test Shift into the R position and fully depress the accelerator pedal and check for slipping. CAUTION: Before conducting this test ensure that the test area is free from people and obstruction. (e) P position test Stop the vehicle on a grade (more than 5°) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. Q00519 5. BASIC INSPECTION (a) Check the fluid level. HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70 – 80 °C (158 – 176 °F)
Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (1) OK if hot Add if hot AT3417 Park the vehicle on a level surface and set the parking brake. (2) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (3) Pull out the dipstick and wipe it clean. (4) Push it back fully into the pipe. (5) Pull it out and check that the fluid level is in the HOT range. If the level is not within the range, add new fluid. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) NOTICE: Do not overfill. (b) Check the fluid condition. If the level is not within the hot range. DI–139 DIAGNOSTICS (c) – AUTOMATIC TRANSAXLE Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. Q00061 (3) With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF D–II or DEXRON®III (DEXRON®II) Capacity: 2.5 liters (2.6 US qts, 2.1 Imp. qts) (4) Start the engine and shift the shift lever into all positions from P to L position and then shift into P position. AT8562 (5) OK if hot (6) Add if hot AT3417 With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. Check the fluid level is at the normal operating temperature, 70 – 80 °C (158 – 176 °F), and add as necessary. NOTICE: Do not overfill. (d) Check the fluid leaks. Check for leaks in the transaxle. If there are leaks, it is necessary to repair or replace O–rings, gasket, oil seals, plugs or other parts. (e) Inspect and adjust the throttle cable. (1) Check that the accelerator pedal is fully released. (2) Check that the inner cable is not slack. (3) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0 – 1 mm (0 – 0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. 0 – 1 mm (0 – 0.04 in.) AT4252 DI–140 DIAGNOSTICS – AUTOMATIC TRANSAXLE (f) Q00199 Inspect and adjust the shift lever position. When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator is aligned with the correct position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (1) Loosen the nut on the shift lever. (2) Push the control shaft fully rearward. (3) P R N Q01561 Neutral Basic line Groove AT4478 Return the control shaft lever 2 notches to N position. (4) Set the shift lever to N position. (5) While holding the shift lever lightly toward the R position side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (6) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R position. (g) Inspect and adjust the park/neutral position. Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If it is not as stated above, carry out the following adjustment procedures. (1) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (2) Align the groove and neutral basic line. (3) Hold the switch in position and tighten the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in·lbf) For continuity inspection of the park/neutral position switch, see page DI–165. (h) Check the idle speed. Idle speed : 700 ± 50 rpm (In N position and air conditioning OFF) DI–141 DIAGNOSTICS – AUTOMATIC TRANSAXLE 6. (a) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Do not continuously run this test for longer than 5 seconds.
To ensure safety, conduct this test in a wide, clear level area which provides good traction.
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test. (1) Chock the 4 wheels. (2) Connect an OBD II scan tool or hand–held tester to DLC3. (3) Fully apply the parking brake. (4) Keep your left foot depressing firmly on the brake pedal. (5) Start the engine. (6) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 2,450 ± 150 rpm (7) Do the same test in R position. Stall speed: 2,450 ± 150 rpm Evaluation: Problem Possible cause (a) Stall speed low in D and R positions
Engine output may be insufficient
Stator one–way clutch is operating properly
HINT: If more than 600 rpm below the specified value, the torque converter clutch could be faulty. (b) Stall speed high in D position
Line pressure too low
Forward clutch slipping
No.2 one–way clutch not operating properly
O/D clutch slipping (c) Stall speed high in R position
Line pressure too low
Direct clutch slipping
1st & reverse brake slipping
O/D clutch slipping (d) Stall speed high in D and R positions
Line pressure too low
Improper fluid level
O/D one–way clutch not operating properly DI–142 DIAGNOSTICS – AUTOMATIC TRANSAXLE (b) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, and 1st & reverse brake. NOTICE:
Do the test at normal operating fluid temperature 50 – 80 °C (122 – 176 °F).
Be sure to allow 1 minute interval between tests.
Take 3 measurements and take the average value. (1) Connect an OBD II scan tool or hand–held tester to DLC3. (2) Fully apply the parking brake. (3) Start the engine and check idle speed. Idle speed: 700 ± 50 rpm (In N position and air conditioning OFF) (4) Shift the shift lever from N to D position. Using a stop watch, measure the time from when the lever is shifted until the shock is felt. Time lag: N → D Less than 1.2 seconds (5) In the same manner, measure the time lag for N → R. Time lag: N → R Less than 1.5 seconds Evaluation (If N → D time or N → R time lag is longer than the specified): Problem Possible cause N → D time lag is longer
Line pressure too low
Forward clutch worn
O/D one–way clutch not operating N → R time lag is longer
Line pressure too low
Direct clutch worn
1st & reverse brake worn
O/D one–way clutch not operating properly DI–143 DIAGNOSTICS – AUTOMATIC TRANSAXLE 7. HYDRAULIC TEST Measure the line pressure. NOTICE:
Do the test at normal operation fluid temperature 50 – 80 °C (122 – 176 °F).
The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
Be careful to prevent SST’s hose from interfering with the exhaust pipe. (1) Warm up the ATF. (2) Remove the test plug on the transaxle case front left side and connect SST. (See Pub. No. RM654U on page AX–17 for the location to connect SST) SST 09992–00095 (09992–00231, 09992–00271) (3) Fully apply the parking brake and chock the 4 wheels. (4) Connect an OBD II scan tool or hand–held tester to DLC3. (5) Start the engine and check idling speed. (6) Keep your left foot pressing firmly on the brake pedal and shift into D position. (7) Measure the line pressure when the engine is idling. (8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (9) In the same manner, do the test in R position. Specified line pressure: Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling 362 – 422 (3.7 – 4.3, 53 – 61) 618 – 794 (6.3 – 8.1, 90 – 115) Stall 735 – 862 (7.5 – 8.8, 107 – 125) 1,373 – 1,608 (14.0 – 16.4, 199 – 233) If the measured pressure is not up to the specified value, recheck the throttle cable adjustment and retest. Evaluation: Problem Possible cause If the measured values at all positions are higher
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective If the measured values at all positions are lower
Throttle cable out of adjustment
Throttle valve defective
Regulator valve defective
Oil pump defective
O/D direct clutch defective If pressure is low in the D position only
D position circuit fluid leakage
Forward clutch defective If pressure is low in the R position only
R position circuit fluid leakage
Direct clutch defective
1st & reverse brake defective DI–144 DIAGNOSTICS Q00200 – AUTOMATIC TRANSAXLE 8. MANUAL SHIFTING TEST HINT: By this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. (a) Disconnect the solenoid wire. (b) Inspect the manual driving operation. Check that the shift and gear positions correspond to the table below. While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. Shift Position Gear Position D O/D 2 3rd L 1st R Reverse P Pawl Lock HINT: If the L, 2 and D gear positions are difficult to distinguish, do the above test. If any abnormality is found in the above test, the problem is in the transaxle itself. (c) Connect the solenoid wire. (d) Clear out the DTC (See page DI–133). DI–145 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI02X–05 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given. * :
...MIL light up DTC No. (See Page) Detection Item Trouble Area MIL * Memory P0500 (DI–151) Vehicle Speed Sensor Malfunction (No.1 Vehicle Speed Sensor)  Open or short in No.1 vehicle speed sensor circuit  No.1 vehicle speed sensor  Combination meter  ECM  Automatic transaxle (clutch, brake or gear etc.)
 P0750 (DI–154) Shift Solenoid A Malfunction (Shift Solenoid Valve No.1)  Shift solenoid valve No.1 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0753 (DI–156) Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No.1)  Open or short in shift solenoid valve No.1 circuit  Shift solenoid valve No.1  ECM
 P0755 (DI–154) Shift Solenoid B Malfunction (Shift Solenoid Valve No.2)  Shift solenoid valve No.2 is stuck open or closed  Valve body is blocked up or stuck  Automatic transaxle (clutch, brake or gear etc.)
 P0758 (DI–156) Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No.2)  Open or short in shift solenoid valve No.2 circuit  Shift solenoid valve No.2  ECM
 P0770 (DI–159) Shift Solenoid E Malfunction (Shift Solenoid Valve SL)  Shift solenoid valve SL is stuck open or closed  Valve body is blocked up or stuck  Lock–up clutch  Automatic transaxle (clutch, brake or gear etc.)
 P0773 (DI–161) Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL)  Open or short in shift solenoid valve SL circuit  Shift solenoid valve SL  ECM
 P1520 (DI–164) Stop Light Switch Signal Malfunction  Open or short in stop light switch circuit  Stop light switch  ECM
 P1780 (DI–165) Park/Neutral Position Switch Malfunction  Short in park/neutral position switch circuit  Park/neutral position switch  ECM
 DI–146 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI02Y–05 PARTS LOCATION O/D Main Switch O/D OFF Indicator Light ECM Vehicle Speed Sensor Shift Solenoid Valve SL DLC3 Stop Light Switch Park/Neutral Position Switch Shift Solenoid Valve No.2 Shift Solenoid Valve No.1 D00938 DI–147 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI64Q–01 TERMINALS OF ECM E6 E5 13 12 11 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 16 15 14 13 12 11 10 9 E7 E4 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 12 11 10 9 8 7 22 21 20 19 18 17 16 15 14 13 12 FI6526 Symbols (Terminals No.) S1 ↔ E1 (E6–7 (E6 7 ↔ E6 E6–16) 16) S2 ↔ E1 (E6–6 (E6 6 ↔ E6 E6–16) 16) SL ↔ E1 (E6–8 (E6 8 ↔ E6–16) E6 16) Wiring Color V ↔ BR L–B L B ↔ BR P ↔ BR OD1 ↔ E1 (E4–20 ↔ E6–16) Y–B ↔ BR OD2 ↔ E1 (E4–7 (E4 7 ↔ E6–16) E6 16) G O ↔ BR G–O L ↔ E1 (E4–19 (E4 19 ↔ E6–16) E6 16) Y ↔ BR 2 ↔ E1 (E4–18 (E4 18 ↔ E6–16) E6 16) L W ↔ BR L–W R ↔ E1 (E4 (E4–17 17 – E6 E6–16) 16) R B ↔ BR R–B NSW ↔ E1 (E4–6 (E4 6 ↔ E6–16) E6 16) B W ↔ BR B–W Condition STD Voltage (V) IG ON 9 – 14 1st or 2nd gear 9 – 14 3rd or O/D gear Below 1 IG ON Below 1 1st or 2nd gear 9 – 14 3rd or O/D gear Below 1 IG ON Below 1 Vehicle driving under lock–up position 9 – 14 IG ON 9 – 14 O/D main switch ON 9 – 14 O/D main switch OFF Below 1 IG ON and Shift lever L position IG ON and Shift lever other than L position IG ON and Shift lever 2 position IG ON and Shift lever other than 2 position IG ON and Shift lever R position IG ON and Shift lever other than R position IG ON and Shift lever P or N position IG ON and Shift lever other than P or N position 9 – 14 Below 1 9 – 14 Below 1 9 – 14 Below 1 9 – 14 Below 1 DI–148 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI030–05 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On–vehicle Repair Matrix Chart Chapter 3: Off–vehicle repair Matrix Chart  If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check.  If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and replace the ECM. Chapter 1: Electronic Circuit Matrix Chart Symptom Suspect Area See page No up–shift (A particular gear, from 1st to 3rd gear, is not up–shifted) 3. ECM IN–29 No up–shift (3rd → O/D) 1. O/D main switch & O/D OFF indicator light circuit 2. O/D cancel signal circuit 3. ECM DI–171 DI–169 IN–29 No down–shift (O/D → 3rd) 1. ECM IN–29 No down–shift (A particular gear, from 3rd to 1st gear, is not down–shifted) 1. ECM IN–29 No lock–up or No lock–up off 1. Stop light switch circuit 2. ECM DI–164 IN–29 Shift point too high or too low 1. ECM IN–29 Up–shift to O/D from 3rd while O/D main switch is OFF 1. O/D main switch & O/D OFF indicator light circuit 2. ECM DI–171 IN–29 Up–shift to O/D from 3rd while engine is cold 1. ECM IN–29 Poor acceleration 1. ECM IN–29 No kick–down 1. ECM IN–29 Engine stalls when starting off or stopping 1. ECM IN–29 DI–149 DIAGNOSTICS – AUTOMATIC TRANSAXLE Chapter 2: On–Vehicle Repair (
: A140E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM385U) Symptom Suspect Area See page Vehicle does not move in any forward positions and reverse position 1. 2. 3. 4. Manual valve Throttle valve Primary regulator valve Off–vehicle repair matrix chart


– Vehicle does not move in R position 1. Off–vehicle repair matrix chart – No up–shift (1st → 2nd) 1. 1–2 shift valve 2. Off–vehicle repair matrix chart
– No up–shift (2nd → 3rd) 1. 2–3 shift valve 2. Off–vehicle repair matrix chart
– No up–shift (3rd → O/D) 1. 3–4 shift valve 2. Off–vehicle repair matrix chart
– No down–shift (O/D → 3rd) 1. 3–4 shift valve
No down–shift (3rd → 2nd) 1. 2–3 shift valve
No down–shift (2nd → 1st) 1. 1–2 shift valve
No lock–up or No lock–up off 1. Lock–up relay valve 2. Off–vehicle repair matrix chart
– Harsh engagement (N → D) 1. C1 accumulator 2. Off–vehicle repair matrix chart
– Harsh engagement (N → R) 1. C2 accumulator 2. Off–vehicle repair matrix chart
– Harsh engagement (N → L) 1. Low coast modulator valve
Harsh engagement (Lock–up) 1. Lock–up relay valve 2. Off–vehicle repair matrix chart
– Harsh engagement (1st → 2nd → 3rd → O/D) 1. Throttle modulator valve 2. Cut back valve 3. Throttle valve


Harsh engagement (2nd → 3rd) 1. C2 accumulator
Harsh engagement (3rd → O/D) 1. B0 accumulator
Harsh engagement (O/D → 3rd) 1. C0 accumulator 2. B0 accumulator

Slip or shudder (Forward and reverse) 1. Throttle valve 2. Oil strainer 3. Off–vehicle repair matrix chart

– No engine braking (1st: L position) 1. Low coast modulator valve 2. Off–vehicle repair matrix chart
– No engine braking (2nd: 2 position) 1. 2nd coast modulator valve 2. Off–vehicle repair matrix chart
– No kick–down 1. 1–2 shift valve 2. 2–3 shift valve 3. 3–4 shift valve


DI–150 DIAGNOSTICS – AUTOMATIC TRANSAXLE Chapter 3: Off–Vehicle Repair (
: A140E AUTOMATIC TRANSAXLE Repair Manual Pub. No. RM385U) (*: 1999 CAMRY Repair Manual Pub. No. RM654U AUTOMATIC TRANSAXLE (A140E) Section) Symptom Suspect Area See page Vehicle does not move in any forward positions and reverse position 1. 2. 3. 4. 5. 6. Front and rear planetary gear O/D planetary gear O/D one–way clutch (F0) O/D direct clutch (C0) O/D brake (B0) Forward clutch (C1)





Vehicle does not move in R position 1. 2. 3. 4. Front and rear planetary gear unit Direct clutch (C2) O/D direct clutch (C0) 1st & reverse brake (B3)



No up–shift (1st → 2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

No up–shift (2nd → 3rd) 1. Direct clutch (C2)
No up–shift (3rd → O/D) 1. O/D brake (B0) No lock–up or No lock–up off 1. Torque converter clutch Harsh engagement (N → D) 1. Forward clutch (C1) 2. O/D one–way clutch (F0) 3. No. 2 one–way clutch (F2)


Harsh engagement (N → R) 1. Direct clutch (C2) 2. 1st & reverse brake (B3)

Harsh engagement (Lock–up) 1. Torque converter clutch *AX–26 Slip or shudder (Forward position: After warm–up) 1. 2. 3. 4. *AX–26


Slip or shudder (R position) 1. Direct clutch (C2) 2. 1st & reverse brake (B3) 3. O/D direct clutch (C0)


Slip or shudder (1st) 1. No. 2 one–way clutch (F2)
Slip or shudder (2nd) 1. No. 1 one–way clutch (F1) 2. 2nd brake (B2)

Slip or shudder (3rd) 1. Direct clutch (C2)
Slip or shudder (O/D) 1. O/D brake (B0)
No engine braking (1st ∼ 3rd: D position) 1. 2nd brake (B2)
No engine braking (1st: L position) 1. 1st & reverse brake (B3)
No engine braking (2nd: 2 position) 1. 2nd coast brake (B1)
Poor acceleration (All positions) 1. Torque converter clutch 2. O/D planetary gear Poor acceleration (O/D) 1. O/D direct clutch (C0) 2. O/D planetary gear Large shift shock or engine stalls when starting off or stopping 1. Torque converter clutch Torque converter clutch O/D direct clutch (C0) Forward clutch (C1) O/D one–way clutch (F0)
*AX–26 *AX–26


*AX–26 DI–151 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI1J0–02 CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular wave form by the wave form shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pluse signals. 4–Pulse 4–Pulse Vehicle Speed Sensor Combination Meter ECM Transaxle Vehicle Speed Sensor A00414 DTC No. DTC Detecting Condition P0500 During vehicle is being driven, no vehicle speed sensor signal to ECM (2 trip detection logic) Clutch or brake slips or gear is broken WIRING DIAGRAM See page DI–69. Trouble Area
Combination meter
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
ECM
Automatic transaxle (clutch, brake or gear etc.) DI–152 DIAGNOSTICS – AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. NG Check speedometer circuit. See combination meter troubleshooting (See page BE–4). OK 2 Check voltage between terminal SPD of ECM connector and body ground. ON SPD D06505 PREPARATION: (a) Remove glove compartment (See Pub. No. RM654U on page BO–75). (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn ignition switch to ON. CHECK: Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly. OK: Voltage is generated intermittently. 4.5 ∼ 5.5 V 0 Turn the wheel NG OK AT7809 Check and repair harness and connector between combination meter and ECM (See page IN–29). DI–153 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE Check the ECM (See page IN–29). NG OK Check and repair the transaxle (clutch, brake or gear etc.). Replace the ECM. DI–154 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI032–05 DTC P0750, P0755 Shift Solenoid A/B Malfunction (Shift Solenoid Valve No.1/No.2) SYSTEM DESCRIPTION The ECM uses signals from the vehicle speed sensor and crankshaft position sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves, valve body or automatic transaxle (clutch, brake or gear etc.). DTC No. P0750 P0755 DTC Detecting Condition Trouble Area During normal driving, the gear required by the ECM does not match the actual gear (2 trip detection logic)
Shift solenoid valve No.1/No.2 is stuck open or closed
Valve body is blocked up or stuck
Automatic transaxle (clutch, brake or gear etc.) Check the shift solenoid valve No.1 when DTC P0750 is output and check the shift solenoid valve No.2 when DTC P0755 is output. INSPECTION PROCEDURE 1 Check shift solenoid valve No.1 or No.2 operation. Q07741 PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) By applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. NG OK Replace the shift solenoid valve No.1 or No.2. DI–155 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE Check the valve body (See page DI–148). NG OK Repair or replace the transaxle. Repair or replace the valve body. DI–156 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI033–05 DTC P0753, P0758 Shift Solenoid A/B Electrical Malfunction (Shift Solenoid Valve No.1/No.2) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by ECM. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function: If either of the shift solenoid valve circuits develops an open or short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunction, hydraulic control cannot be performed electronically and must be done manually. Manual shifting as shown in the following table must be done (In the case of a short circuit, the ECM stops sending current to the short circuited solenoid). SHIFT SOLENOID NO.1 MALFUNCTIONING NORMAL Position D 2 L Solenoid valve No.1 No.2 ON OFF ON Gear 1st Solenoid valve No.1 No.2 ON X ON 2nd X OFF ON 3rd X OFF OFF O/D X SHIFT SOLENOID NO.2 MALFUNCTIONING Gear BOTH SOLENOIDS MALFUNCTIONING Gear when shift selector is manually operated 3rd Solenoid valve No.1 No.2 X ON 1st O/D 3rd OFF X O/D O/D ON 3rd OFF X O/D O/D OFF O/D OFF X O/D O/D 3rd ON X 1st 3rd 3rd OFF X 3rd 3rd ON Gear ON OFF 1st X ON ON ON 2nd X ON OFF ON 3rd X ON 3rd OFF X 3rd 3rd ON OFF 1st X OFF 1st ON X 1st 1st ON ON 2nd X ON 2nd ON X 1st 1st X: Malfunctions Check the shift solenoid valve No.1 when DTC P0753 is output and check the shift solenoid valve No.2 when DTC P0758 is output. DTC No. DTC Detecting Condition P0753 P0758 The ECM checks for an open or short circuit in the shift solenoid valves No.1 and No.2 circuit when it changes gear position. The ECM records DTC P0753 or P0758 if condition (a) or (b) is detected once, but it does not light up MIL. After 1 sec. ECM detects condition (a) or (b) in a trip again, it causes the MIL to light up. (a) When the solenoid is energized, the solenoid resistance is 8 Ω or less and is counted. (b) When the solenoid is not energized, the solenoid resistance is 100 kΩ or more and is counted. Trouble Area
Open or short in shift solenoid valve No.1/No.2 circuit
Shift solenoid valve No.1/No.2
ECM DI–157 DIAGNOSTICS – AUTOMATIC TRANSAXLE WIRING DIAGRAM Transaxle Shift Solenoid Valve No. 1 Shift Solenoid Valve No. 2 ECM B+ 3 E2 1 E2 7 E6 V L–B Junction Connector B B 19 19 S1 B+ L–B 6 E6 S2 B 19 from Cruise Control ECU D01841 INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground. PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal S1 or S2 of ECM and body ground. OK: Resistance: 11 – 15 Ω S1 S2 D05157 OK NG Check and replace the ECM. DI–158 DIAGNOSTICS 2 AUTOMATIC TRANSAXLE Check harness and connector between ECM and automatic transaxle solenoid connector. PREPARATION: Disconnect the solenoid connector from the automatic transaxle. CHECK: Check the harness and connector between terminal S1 or S2 of ECM and terminal S1 or S2 of solenoid connector. OK: There is no open and no short circuit. S2 S2 – S1 S1 D05156 NG Repair or replace the harness or connector. OK 3 Check shift solenoid valve No.1 or No.2. PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the solenoid connector. (d) Remove the shift solenoid valve No.1 or No.2. CHECK: (a) Measure resistance between solenoid connector and body ground. (b) Connect the positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 – 15 Ω (b) The solenoid makes an operating noise. Q07744 NG OK Repair or replace the solenoid wire. Replace the shift solenoid valve. DI–159 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI034–05 DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION Drain Line Pressure Drain Q07745 The ECM uses the signals from the throttle position sensor, air– flow meter and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the ECM compares the engagement condition of the lock–up clutch with the lock–up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body, torque converter clutch or automatic transaxle (clutch, brake or gear etc.). DTC No. DTC Detecting Condition Trouble Area P0770
Lock–up does not occur when driving in the lock–up range (normal driving at 80 km/h [50 mph]), or lock–up remains ON in the lock–up OFF range. (2 trip detection logic)
When lock–up is ON, clutch or brake slips or gear is broken.
Shift solenoid valve SL is stuck open or closed
Valve body blocked up or stuck
Lock–up clutch
Automatic transaxle (clutch, brake or gear etc.) INSPECTION PROCEDURE 1 Check solenoid valve SL operation. Q07746 PREPARATION: (a) Remove the oil pan. (b) Remove the shift solenoid valve SL. CHECK: (a) By applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air, check that the solenoid valve does not leak air. (b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens. OK: (a) Solenoid valve does not leak air. (b) Solenoid valve opens. NG OK Replace the solenoid valve SL. DI–160 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE Check valve body (See page DI–148). NG Repair or replace the valve body. OK 3 Check the torque converter clutch (See Pub. No. RM654U on page AX–26). NG OK Repair or replace the transaxle. Replace the torque converter clutch. DI–161 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI035–05 DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. Fail safe function If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. P0773 DTC Detecting Condition Trouble Area Either (a) or (b) is detected for 1 time.(2 trip detection logic) (a) Solenoid resistance is 8 Ω or less short circuit when solenoid is energized. (b) Solenoid resistance is 100 kΩ or more open circuit when solenoid is not energized.
Open or short in shift solenoid valve SL circuit
Shift solenoid valve SL
ECM WIRING DIAGRAM Transaxle Shift Solenoid Valve SL ECM 1 E1 P 8 E6 SL D02260 DI–162 DIAGNOSTICS – AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Measure resistance between terminal SL of ECM and body ground. PREPARATION: Disconnect the connector from ECM. CHECK: Measure resistance between terminal SL of ECM and body ground. OK: Resistance: 11 – 15 Ω SL D05155 OK Check and replace the ECM. NG 2 Check harness and connector between ECM and automatic transaxle solenoid connector. SL PREPARATION: Disconnect the solenoid connector from the transaxle. CHECK: Check the harness and connector between terminal SL of ECM and terminal SL of solenoid connector. OK: There is no open or short circuit. 1 2 SL D05154 NG OK Repair or replace the harness or connector. DI–163 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE Check shift solenoid valve SL. Q07749 PREPARATION: (a) Jack up the vehicle. (b) Remove the oil pan. (c) Disconnect the shift solenoid valve SL connector. (d) Remove the shift solenoid valve SL. CHECK: (a) Measure resistance between terminal SL of shift solenoid valve and solenoid body. (b) Connect positive
lead to terminal of solenoid connector, negative  lead to solenoid body. OK: (a) Resistance: 11 – 15 Ω (b) The shift solenoid valve SL makes operation noise. NG OK Check and replace or repair the solenoid wire. Replace the shift solenoid valve SL. DI–164 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI036–05 DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock–up condition, when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to ECM. Then the ECM cancels operation of the lock–up clutch while braking is in progress. DTC No. P1520 DTC Detecting Condition No stop light switch signal to ECM during driving. (2 trip detection logic) WIRING DIAGRAM See page DI–108. INSPECTION PROCEDURE See page DI–108. Trouble Area
Open or short in stop light switch circuit
Stop light switch
ECM DI–165 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI037–05 DTC P1780 Park/Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. DTC No. P1780 DTC Detection Condition When driving under conditions (a) and (b) for 30 seconds or more, the park/neutral position switch is ON (N position). (2 trip detection logic) (a) Vehicle speed: 80 km/h (50 mph) or more (b) Engine speed: 2,000 – 5,000 rpm Trouble Area
Short in park/neutral position switch circuit
Park/neutral position switch
ECM DI–166 DIAGNOSTICS – AUTOMATIC TRANSAXLE WIRING DIAGRAM Combination Meter 8 R C10 11 2 C10 L ECM R–B 6 C10 O 13 IF1 Y 16 IF1 L–W Park/Neutral Position Switch LL J19 Junction Connector 2 RB P1 D R–L 4 P1 Y 5 IG2 Y J22 Junction Connector E E E 1V 5 Y 19 E4 L L–W 18 E4 2 R–B J22 Junction Connector D 2L 3 L–W 6 P1 IG2 D R–L RL 8 P1 3 IG3 R–B 2 IG2 6 F R–L P1 N GR P 5 P1 F 11 IG2 B–W R–L J24 Junction Connector B–R Instrument Panel J/B 1H 10 1 1B AM1 2 1K W D D C J27 17 C A R R–B J23 J24 E4 R–B Junction Connector B–W B–W B B J22 Junction B B–W Connector Ignition Switch 1 2 4 B–Y I10 I10 1K B+ 6 NSW E7 GAUGE 1 1J B–R 1 F14 2 F14 ALT 1 F9 1 F11 B–G FL B MAIN Battery Instrument Panel J/B Instrument Panel J/B 7 5 W–R I10 1K 5 1B 8 I10 AM2 1 2A STARTER 3 1J Engine Room J/B No.2 B 3 2B Engine Room J/B No.2 J7 J8 Junction Connector C B 10 GR J7 J6 IG2 4 1K Instrument Panel J/B W–R Instrument Panel J/B 4 2L R 11 2J ST Relay MAIN 5 3 1 2 5 2D 9 2K Starter J9 Junction Connector A GR IF D06504 DI–167 DIAGNOSTICS – AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Read PNP, REVERSE, 2ND and LOW signals. When using hand–held tester: PREPARATION: (a) Remove the DLC3 cover. (b) Connect a hand–held tester to the DLC3. (c) Turn the ignition switch to ON and hand–held tester main switch ON. CHECK: Shift the shift lever into the P, R, N, 2 and L positions, and read the PNP, REVERSE, 2ND and LOW signals on the hand–held tester. OK: L NSW (–) (+) 2 R D06387 Shift position Signal 2 2ND OFF → ON L LOW OFF → ON R REVERSE OFF → ON P, N PNP OFF → ON When not using hand–held tester: PREPARATION: Turn the ignition switch to ON. CHECK: Measure voltage between terminals NSW, 2, L and R of ECM and body ground when the shift lever is shifted in the following positions. OK: Position NSW–Body ground R–Body ground 2–Body ground L–Body ground P, N 0V 0V 0V 0V 0V 0V 0V 0V R 9 – 14 V* D 9 – 14 V 0V 2 9 – 14 V 0V L 9 – 14 V 0V 9 – 14 V* 9 – 14 V 0V 0V 9 – 14 V HINT: The voltage will drop slightly due to lighting up of the back up light. OK NG Proceed to next circuit inspection shown on matrix chart (See page DI–148). DI–168 DIAGNOSTICS 2 – AUTOMATIC TRANSAXLE Check park/neutral position switch. PREPARATION: (a) Jack up the vehicle. (b) Remove the park/neutral position switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift Position Terminal No. to continuity Terminal No. to continuity P 4–7 5–6 R 4–8 – N 4 – 10 5–6 D 4–9 – 2 2–4 – L 2–3 – Q07657 OK: Continuity exists. NG Replace the park/neutral position switch. OK 3 Check harness and connector between battery and park/neutral position switch, park/neutral position switch and ECM (See page IN–29). NG OK Check and replace the ECM. Repair or replace the harness and connector. DI–169 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI038–05 O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising overdrive may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. WIRING DIAGRAM Cruise Control ECU ECM B+ OD 14 C16 Y–B 20 OD1 E4 Q05352 DI–170 DIAGNOSTICS – AUTOMATIC TRANSAXLE INSPECTION PROCEDURE 1 Check voltage between terminal OD1 of ECM and body ground. PREPARATION: Turn the ignition switch to ON. CHECK: Measure voltage between terminal OD1 of ECM and body ground. OK: Voltage: 9 – 14 V ON (–) (+) OD1 BE3840 D05153 D05153 OK Proceed to next circuit inspection shown on matrix chart (See page DI–148). NG 2 Check voltage between terminal OD of cruise control ECU harness side connector and body ground. PREPARATION: (a) Disconnect the cruise control ECU connector. (b) Turn the ignition switch to ON. CHECK: Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. OK: Voltage: 9 – 14 V ON (–) (+) OD BE3840 I00143 D00057 OK Check and replace the cruise control ECU. NG 3 Check harness and connector between cruise control ECU and ECM. NG OK Check and replace the ECM. Repair or replace the harness or connector. DI–171 DIAGNOSTICS – AUTOMATIC TRANSAXLE DI1J1–04 O/D Main Switch & O/D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. In O/D main switch in OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. WIRING DIAGRAM Ignition Switch 2 I10 W ECM 4 I10 AM1 IG1 G–O Instrument Panel J/B AM1 Instrument Panel J/B 2 1D IB 1 GAUGE C 7 OD2 E4 C J5 Junction Connector C 1 1K B+ G–O 11 IF1 IK 2 G–O B–R 2 O2 B–R 1 F14 G–O R–L 2 F14 ALT (*) O/D OFF J3 Indicator Light Junction (Combination Meter) Connector 7 12 R–L C12 C10 D D FUSIBLE LINK BLOCK 1 F9 O/D Main Switch 4 O2 W–B A J4 Junction Connector A W–B Battery B–G IE FL MAIN *: O/D Main Switch Contacts go open with switch pushed in contacts go closed with switch pushed once again D05150 DI–172 DIAGNOSTICS – AUTOMATIC TRANSAXLE INSPECTION PROCEDURE O/D OFF indicator light does not light up 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity at each terminal 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Specified condition ON No continuity OFF Continuity Replace the O/D main switch. OK 2 Check and replace combination meter (See page BE–4). NG OK Replace the combination meter. DI–173 DIAGNOSTICS 3 – AUTOMATIC TRANSAXLE Check OVERDRIVE CUT SW2 signal. When using hand–held tester: PREPARATION: (a) Remove the DLC3 cover. (b) Connect hand–held tester to the DLC3. (c) Turn the ignition switch to ON and hand–held tester main switch ON. CHECK: Read the OVRDRIVE CUT SW2 signal on the hand–held tester. OK: O/D main switch condition OVRDRIVE CUT SW2 signal O/D ON (Pushed in) OFF O/D OFF (Pushed once again) ON When not using hand–held tester: PREPARATION: Turn the ignition switch to ON. CHECK: Check voltage between terminal OD2 of ECM and body ground. OK: ON OD2 BE3840 D05151 D06388 O/D main switch condition Voltage O/D ON (Pushed in) 9 – 14 O/D OFF (Pushed once again) Below 1.5 V OK Check and replace the ECM (See page IN–29). NG 4 Check harness and connector between O/D OFF indicator light and ECM (See page IN–29). NG OK Check and replace the ECM (See page IN–29). Repair or replace the harness or connector. DI–174 DIAGNOSTICS – AUTOMATIC TRANSAXLE O/D OFF indicator light remains ON 1 Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity at each terminal 2 and 4 of O/D main switch connector. OK: 2 4 Q07595 NG O/D main switch Specified condition ON No continuity OFF Continuity Replace the O/D main switch. OK 2 Check harness and connector between O/D OFF indicator light and O/D main switch, O/D OFF indicator light and ECM (See page IN–29). NG OK Check and replace the ECM (See page IN–29). Repair or replace the harness or connector. DI–175 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM ANTI–LOCK BRAKE SYSTEM DI03A–03 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. 1 Customer Problem Analysis P. DI–176 2 Check and Clear DTC (Precheck) P. DI–177 Symptom does not occur 3 Problem Symptom Confirmation 4 Symptom Simulation P. IN–19 7 Problem Symptoms Table P. DI–185 Symptom occurs 5 Normal code DTC Check P. DI–177 Malfunction code 6 8 DTC Chart P. DI–181 Circuit Inspection 9 Sensor Check Check for Fluid Leakage P. DI–220 P. DI–186 – DI–218 Identification of Problem 10 11 Repair Confirmation Test End Step 2, 5, 8, 9, 11: Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. Author: Date: 245 DI–176 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03B–02 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s : Name Registration No. Registration Year Customer’s Name / / Frame No. Date Vehicle Brought In / Date Problem First Occurred / Frequency Problem Occurs km miles Odometer Reading / Continuous / Intermittent ( times a day) ABS does not operate. Symptoms ABS does not operate efficiently. ABS Warning Light Abnormal Remains ON Does not Light Up 1st Time Normal Code Malfunction Code (Code ) 2nd Time Normal Code Malfunction Code (Code ) DTC Check DI–177 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03C–04 PRE–CHECK 1. (a) F00047 DIAGNOSIS SYSTEM Check the indicator. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page DI–213). (b) Short Pin Check the DTC. (1) Disconnect the short pin from DLC1. DLC1 F00006 DLC2 Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843 – 18020 (3) Turn the ignition switch ON. (4) Read the DTC from the ABS warning light on the combination meter. (2) DLC1 E1 Tc Tc S−17−1 HINT:
E1 Iei−23−1−A F00041
As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. (5) Codes are explained in the code table on page DI–181. (6) After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st. Normal Code 2 sec. 0.25 sec. 0.25 sec. ON OFF Code 11 and 21 0.5 sec. 1.5 sec. 4 sec. 0.5 sec. 2.5 sec. ON OFF Code 11 If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page DI–216 or DI–213). Code 21 R01346 DI–178 DIAGNOSTICS TOYOTA Hand–held Tester – ANTI–LOCK BRAKE SYSTEM (c) Using TOYOTA hand–held tester, check the DTC. (1) Hook up the TOYOTA hand–held tester to the DLC2. (2) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. (d) Clear the DTC. (1) Using SST, connect terminals Tc and E1 of DLC2 or DLC1 and remove the short pin from DLC1. SST 09843 – 18020 (2) Turn the ignition switch ON. (3) Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 5 seconds. DLC2 H07517 BR3890 (4) Check that the warning light shows the normal code. (5) Remove the SST from the terminals of DLC2 or DLC1. SST 09843 – 18020 (6) Connect the short pin to DLC1. Short Pin DLC1 F00006 TOYOTA Hand–held Tester ECU TOYOTA Break–out–box N09348 (e) Using TOYOTA break–out–box and TOYOTA hand–held tester, measure the ECU terminal values. (1) Hook up the TOYOTA hand–held tester and TOYOTA break–out–box to the vehicle. (2) Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester/TOYOTA break– out–box operator’s manual for further details. DI–179 DIAGNOSTICS 2. (a) DLC1 E1 – SPEED SENSOR SIGNAL Check the speed sensor signal. (1) Turn the ignition switch OFF. (2) Using SST, connect terminals Ts and E1 of DLC1. SST 09843 – 18020 (3) Start the engine. Tc Ts F02201 (4) 0.13 sec. ANTI–LOCK BRAKE SYSTEM 0.13 sec. ON OFF BR3904 Check that the ABS warning light blinks. HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page DI–213). (5) Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. (6) Stop the vehicle. (7) Using SST, connect terminals Tc and E1 of DLC1. SST 09843 – 18020 (8) Read the number of blinks of the ABS warning light. HINT:
See the list of DTC shown on the next page.
If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated).
If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed 1st. Malfunction Code (Example Code 72, 76) 7 2 7 6 ON OFF 0.5 sec. 1.5 sec. 0.5 sec. 0.5 sec. 2.5 sec. 0.5 sec. 4 sec. Repeat BR3893 (9) After doing the check, disconnect the SST from terminals Ts and E1, Tc and E1 of DLC1, and turn ignition switch OFF. SST 09843 – 18020 DI–180 DIAGNOSTICS TOYOTA Hand–held Tester (b) DLC2 – ANTI–LOCK BRAKE SYSTEM Using TOYOTA hand–held tester, check the DTC. (1) Do step 1. – 6. on the previous page. (2) Hook up the TOYOTA hand–held tester to the DLC2. (3) Read the DTC by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. H07517 DTC of speed sensor check function: Code No. Diagnosis Trouble Area 71 Low output voltage of right front speed sensor
Right front speed sensor
Sensor installation
Right front speed sensor rotor 72 Low output voltage of left front speed sensor
Left front speed sensor
Sensor installation
Left front speed sensor rotor 73 Low output voltage of right rear speed sensor
Right rear speed sensor
Sensor installation
Right rear speed sensor rotor 74 Low output voltage of left rear speed sensor
Left rear speed sensor
Sensor installation
Left rear speed sensor rotor 75 Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor 76 Abnormal change in output voltage of left front speed sensor
Left front speed sensor rotor 77 Abnormal change in output voltage of right rear speed sensor
Right rear speed sensor rotor 78 Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor DI–181 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03D–04 DIAGNOSTIC TROUBLE CODE CHART HINT:


Using SST 09843 –18020, connect the terminals Tc and E1, and remove the short pin. If any abnormality is not found when inspection parts, inspect the ECU. If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details of each code, turn to the page referred to under the ”See page” for respective ”DTC No.” in the DTC chart. DTC No. (See Page) Detection Item Trouble Area 11 (DI–186) Open circuit in ABS solenoid relay circuit 12 (DI–186) Short circuit in ABS solenoid relay circuit 13 (DI–191) Open circuit in ABS motor relay circuit 14 (DI–191) Short circuit in ABS motor relay circuit 21 (DI–195) Open or short circuit in 2–position solenoid circuit for right front wheel
ABS actuator
SFRR or SFRH circuit 22 (DI–195) Open or short circuit in 2–position solenoid circuit for left front wheel
ABS actuator
SFLR or SFLH circuit 23 (DI–195) Open or short circuit in 2–position solenoid circuit for right rear wheel
ABS actuator
SRRR or SRRH circuit 24 (DI–195) Open or short circuit in 2–position solenoid circuit for left rear wheel
ABS actuator
SRLR or SRLH circuit 31 (DI–198) Right front wheel speed sensor signal malfunction 32 (DI–198) Left front wheel speed sensor signal malfunction 33 (DI–198) Right rear wheel speed sensor signal malfunction
ABS solenoid relay
ABS solenoid relay circuit
ABS motor relay
ABS motor relay circuit
Right front, left front, right rear and left rear speed sensor
Each E h speed d sensor circuit i it
Speed sensor rotor 34 (DI–198) Left rear wheel speed sensor signal malfunction 33, 34 (DI–203) Rear speed sensor rotor faulty
Rear axle hub
Right rear, left rear speed sensor
Rear speed sensor circuit 41 (DI–204) Power source voltage down
Battery
Charging system
Power source circuit 49 (DI–207) Open circuit in stop light switch circuit
Stop light switch
Stop light switch circuit 51 (DI–209) Pump motor is locked
ABS pump motor Malfunction in ECU
ECU
Battery Always ON (DI–211) DI–182 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03E–04 PARTS LOCATION Sensor Rotor ABS Warning Light ABS ECU DLC 1 Front Speed Sensor ABS Actuator DLC 2 ABS Solenoid Relay ABS Motor Relay Rear Speed Sensor Front Speed Sensor Stop Light Switch Sensor Rotor F01172 DI–183 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI1JL–03 TERMINALS OF ECU A13 A14 3 2 1 13 12 11 10 9 8 7 12 11 10 9 8 7 26 25 24 23 22 21 20 19 18 17 16 15 14 6 5 4 6 5 4 3 2 1 F07155 Symbols (Terminals No.) Wiring Color Condition IG1 (A14 – 13) – GND (A14 – 12, 25) B–R ↔ W–B IG switch ON 10 – 14 R+ (A14 – 26) – SR (A13 – 7) GR–R ↔ GR IG switch ON, ABS warning light OFF 9 – 14 R+ (A14 – 26) – MR (A13 – 1) GR–R ↔ GR–L SFRR (A14 – 1) – GND (A14 – 12, 25) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFRH (A14 – 2) – GND (A14 – 12, 25) R–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLR (A13 – 6) – GND (A14 – 12, 25) W–L ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SFLH (A13 – 5) – GND (A14 – 12, 25) L–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRR (A13 – 12) – GND (A14 – 12, 25) R–G ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRRH (A13 – 11) – GND (A14 – 12, 25) W–R ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLR (A14 – 14) – GND (A14 – 12, 25) LG–B ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 SRLH (A14 – 15) – GND (A14 – 12, 25) G–Y ↔ W–B IG switch ON, ABS warning light OFF 10 – 14 WA (A14 – 11) – GND (A14 – 12, 25) G B ↔ W–B G–B W B IG switch ON, ABS warning light ON Below 2.0 IG switch ON IG switch ON, ABS warning light OFF STD Voltage (V) Below 1.0 10 – 14 Stop light switch OFF Below 1.5 Stop light switch ON 8 – 14 IG switch ON, ABS warning light OFF 10 – 14 STP (A14 – 5) – GND (A14 – 12, 25) G W ↔ W–B G–W W B D/G (A14 – 24) – GND (A14 – 12, 25) R–L ↔ W–B Tc (A14 – 8) – GND (A14 – 12, 25) LG–R ↔ W–B IG switch ON 8 – 14 Ts (A14 – 21) – GND (A14 – 12, 25) R–Y ↔ W–B IG switch ON 8 – 14 FR+ (A13 – 3) – FR– (A13 – 9) W↔B IG switch ON, slowly turn right front wheel AC generation FL+ (A13 – 8) – FL– (A13 – 2) R↔G IG switch ON, slowly turn left front wheel AC generation RR+ (A14 – 10) – RR– (A14 – 23) W↔B IG switch ON, slowly turn right rear wheel AC generation DI–184 DIAGNOSTICS RL+ (A14 – 22) – RL– (A14 – 9) R↔G MT (A13 – 10) – GND (A13 – 12, 25) R–W ↔ W–B – ANTI–LOCK BRAKE SYSTEM IG switch ON, slowly turn left rear wheel IG switch ON AC generation Below 1.5 DI–185 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03G–05 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptom Suspect Area See page ABS does not operate Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS ECU. 2. Check the DTC reconfirming that the normal code is output. 3. IG power source circuit. 4. Speed sensor circuit. 5. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page *DI–536). ABS does not operate efficiently Only when 1. to 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the DTC reconfirming that the normal code is output. 2. Speed sensor circuit 3. Stop light switch circuit 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (See page *DI–536). ABS warning light abnormal 1. ABS warning light circuit 2. ABS ECU DI–213 DI–211 DTC check cannot be done Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit 2. Tc terminal circuit DI–213 DI–216 Speed sensor signal check cannot be done 1. Ts terminal circuit 2. ABS ECU DI–218 DI–211 *See Pub. No. RM654U DI–177 DI–204 DI–198 *BR–50 DI–177 DI–198 DI–207 *BR–50 DI–186 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03H–04 CIRCUIT INSPECTION DTC 11, 12 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. DTC Detecting Condition 11 Condition 1. or 2. continues for 0.2 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and when the solenoid relay is ON.*1 2. With solenoid relay ON driving, when IG1 terminal of ABS ECU is less than 9.5 V.*1 12 Immediately after IG switch has been turned ON, when the solenoid relay is OFF.*2 Trouble Area
ABS solenoid relay
ABS solenoid relay circuit
ECU *1 Solenoid relay contact OFF condition: All of solenoid terminal voltage is half of IG1 terminal voltage or less than. *2 Solenoid relay contact ON condition: All of solenoid terminal voltage is half of IG 1 terminal voltage or more. Fail safe function: If trouble occurs in the ABS solenoid relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DI–187 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WIRING DIAGRAM 1 IJ1 GR–R ABS Solenoid Relay 3 6 4 ABS ECU 26 A14 R+ GR–R Engine Room R/B No.3 GR 3 7 A13 SR DLC1 ABS Actuator 5 3 3 1 3 2 3 ABS 1 2 3 W–L B–G Fusible Link Block 1 F9 1 F10 ALT B–G FL Main W–B 4 A4 1 A5 R–B 11 IJ2 R–B 2 A14 SFRH 5 A5 W–R 12 IJ2 W–R 1 A14 SFRR 3 A5 L–B 5 A13 SFLH 7 A5 W–L 6 A13 SFLR 4 A5 W–R 11 A13 SRRH 8 A5 R–G 12 A13 SRRR 2 A5 G–Y 13 IJ2 G–Y 15 A14 SRLH 6 A5 LG–B 5 IJ2 LG–B 14 A14 SRLR Battery EA F07147 DI–188 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS solenoid relay). (+) PREPARATION: Remove ABS solenoid relay from Engine Room R/B No. 3. CHECK: Measure the voltage between terminals 1 and 2 of Engine Room R/B No. 3 (for ABS solenoid relay). OK: Voltage: 10 – 14 V (–) Engine Room R/B No. 3 123 45 6 F00048 NG Check and repair harness or connector. OK 2 Check continuity between terminal 3 of ABS solenoid relay and terminal SRLR, SRLH, SRRR, SRRH, SFLR, SFLH, SFRR or SFRH of ABS ECU. ABS Solenoid Relay 3 A4 4 A5 ABS Actuator CHECK: Check continuity between terminal 3 of Engine Room R/B No.3 (for ABS solenoid relay) and terminal SRLR, SRLH, SRRR, SRRH, SFLR, SRLH, SFRR or SFRH of ABS ECU. OK: Continuity HINT: Resistance of each solenoid coil SRLR, SRRR, SFLR, SFRR: 4.3 Ω SRLH, SRRH, SFLH, SFRH: 8.8 Ω 1234 5678 4321 8765 A13 ECU SFRH SFRR SFLH SFLR SRLR SRLH SRRH SRRR F07153 NG OK Repair or replace harness or ABS actuator. DI–189 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM Check ABS solenoid relay. 3 2 6 CHECK: Check continuity between each terminal of ABS solenoid relay. OK: 1 5 4 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Open 3 2 1 CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: Continuity Continuity 6 5 4 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Continuity 3 2 1 Open (–) (+) 6 5 4 F00042 NG OK Replace ABS solenoid relay. DI–190 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM Check for open and short circuit in harness and connector between ABS solenoid relay and ABS ECU (See page IN–29). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. DI–191 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03I–04 DTC 13, 14 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor. DTC No. DTC Detecting Condition 13 Condition 1. or 2. continues for 0.2 sec. or more: 1. ABS ECU terminal IG1 voltage is 9.5 V to 18.5 V, and when motor relay is ON in the midst of initial check or in operation of ABS control.*1 2. Motor relay is ON driving in the midst of initial check or in operation of ABS control, ABS ECU terminal IG1 voltage becomes 9.5 V or less.*2 14 Condition below continues for 4 sec. or more: When the motor relay is OFF, there is open circuit in MT terminal of ABS ECU. Trouble Area
ABS motor relay
ABS motor relay circuit
ECU *1 Relay contact OFF condition: MT terminal voltage is below 3.6 V. *2 Relay contact ON condition: MT terminal voltage is 3.6 V or above. Fail safe function: If trouble occurs in the ABS motor relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DI–192 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WIRING DIAGRAM Engine Room R/B No.3 ABS Motor Relay ABS B–G 1 3 1 F10 1 ABS ECU 3 3 GR–R 1 IJ1 GR–R 26 A14 R+ 2 2 3 4 GR–L 3 1 A13 MR Fusible Link Block ALT F9 1 ABS Actuator 3 A4 B–G R–W 10 A13 MT 2 A4 W–R FL Main 1 A4 W–B Battery EA F07146 DI–193 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal 1 of Engine Room R/B No. 3 (for ABS motor relay) and body ground. (–) PREPARATION: Remove ABS motor relay from Engine Room R/B No. 3. CHECK: Measure voltage between terminal 1 of Engine Room R/B No. 3 (for ABS motor relay) and body ground. OK: Voltage: 10 – 14 V (+) 1 Engine Room R/B No. 3 2 3 4 F00049 NG Check and repair harness or connector. OK 2 Check continuity between terminal 2 of ABS motor relay and terminal MT of ABS ECU. 2 ABS Motor Relay 2 A4 2 CHECK: Check continuity between terminal 2 of Engine Room R/B No.3 (for ABS motor relay) and terminal MT of ABS ECU. OK: Continuity HINT: There is a resistance of 4 – 6 Ω between terminals A4 – 2 and A4 – 3 of ABS actuator. A4 ABS Actuator 3 3 A18 ECU MT OK F07154 NG Repair or replace harness or ABS actuator. DI–194 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM Check ABS motor relay. 2 1 4 3 CHECK: Check continuity between each terminal of ABS motor relay. OK: Terminals 3 and 4 Continuity (Reference value 62 Ω) Terminals 1 and 2 Open Open 2 Continuity 1 4 CHECK: (a) Apply battery positive voltage between terminals 3 and 4. (b) Check continuity between terminals of ABS motor relay. 3 Continuity 2 OK: 1 Terminals 1 and 2 (–) 4 Continuity 3 (+) F00044 NG Replace ABS motor relay. OK 4 Check for open and short circuit in harness and connector between ABS motor relay and ABS ECU (See page IN–29). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. DI–195 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03J–04 DTC 21, 22, 23, 24 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. DTC No. DTC Detecting Condition Trouble Area 21 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SFRR or SFRH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SFRR or SFRH circuit 22 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SFLR or SFLH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SFLR or SFLH circuit 23 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SRRR or SRRH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SRRR or SRRH circuit 24 Condition 1. or 2. continues for 0.05 sec. or more: 1. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, there is open or short circuit in actuator solenoid SRLR or SRLH. 2. IG1 terminal voltage of ABS ECU is 9.5 – 18.5 V, and while ABS is control in operation.*1
ABS actuator
SRLR or SRLH circuit *1 Solenoid relay contact ON condition: All of solenoid terminal voltage is half of IG1 terminal voltage or less than. Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DI–196 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WIRING DIAGRAM 1 IJ1 GR–R ABS Solenoid Relay 3 6 4 ABS ECU 26 A14 R+ GR–R Engine Room R/B No.3 GR 3 7 A13 SR DLC1 ABS Actuator 5 3 3 1 3 2 3 ABS 1 2 3 W–L B–G Fusible Link Block 1 F9 1 F10 ALT B–G FL Main W–B 4 A4 1 A5 R–B 11 IJ2 R–B 2 A14 SFRH 5 A5 W–R 12 IJ2 W–R 1 A14 SFRR 3 A5 L–B 5 A13 SFLH 7 A5 W–L 6 A13 SFLR 4 A5 W–R 11 A13 SRRH 8 A5 R–G 12 A13 SRRR 2 A5 G–Y 13 IJ2 G–Y 15 A14 SRLH 6 A5 LG–B 5 IJ2 LG–B 14 A14 SRLR Battery EA F07147 DI–197 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check ABS actuator solenoid. 4 3 8 7 A4 2 1 A5 6 5 4 W00714 PREPARATION: Disconnect the 2 connectors from ABS actuator. CHECK: Check continuity between terminals A4 – 4 and A5 – 1, 2, 3, 4, 5, 6, 7, 8 of ABS actuator connector. OK: Continuity HINT: Resistance of each solenoid coil is 1.2 Ω. NG Replace ABS actuator. OK 2 Check for open and short circuit in harness and connector between ABS ECU and actuator (See page IN–29). NG Repair or replace harness or connector. OK If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. DI–198 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI1JM–03 DTC Speed Sensor Circuit 31, 32, 33, 34 CIRCUIT DESCRIPTION Rotor The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Speed Sensor S Magnet N Coil To ECU Low Speed High Speed +V BR3583 BR3582 –V F00010 DTC No. DTC Detecting Condition 31, 32, 33, 34 Detection of any of conditions from 1. through 4.: 1. Vehicle speed is at 10 km/h (6 mph) or more and the speed sensor signal circuit is open or short circuit continues for 15 sec. or more. 2. Momentary interruption of the speed sensor signal occurs 7 times or more. 3. Vehicle speed is at 20 km/h (12mph) or more and interference on the speed sensor signal continues for 5 sec. or more. 4. Open circuit condition of the speed sensor signal circuit continues for 0.5 sec. or more. Trouble Area
Right front, left front, right rear, left rear speed sensor
Each speed sensor circuit
Speed sensor rotor HINT:



DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor. DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DI–199 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WIRING DIAGRAM ABS ECU W 3 A13 FR+ B 9 A13 FR– 2 Right Front Speed Sensor 1 R 1 IJ2 R 8 A13 FL+ G 6 IJ2 G 2 A13 FL– W 2 IK1 W 10 A14 RR+ B 1 IK1 B 23 A14 RR– R 3 IB1 R 22 A14 RL+ G 9 IB1 G 9 A14 RL– 2 Left Front Speed Sensor 1 1 Right Rear Speed Sensor 2 1 Left Rear Speed Sensor 2 F00116 DI–200 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check speed sensor. 1 2 F08572 1 2 F08573 Front: PREPARATION: (a) Remove the front fender liner. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 0.6 – 2.5 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher Rear: PREPARATION: (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector. OK: Resistance: 1.2 – 2.3 kΩ CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. OK: Resistance: 1 MΩ or higher NG Replace speed sensor. NOTICE: Check the speed sensor signal last (See page DI–177). OK DI–201 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM Check for open and short circuit in harness and connector between each speed sensor and ECU (See page IN–29). NG Repair or replace harness or connector. OK 3 Check speed sensor installation. CHECK: Check the speed sensor installation. OK: The installation bolt is tightened properly and there is no clearance between the sensor and steering knuckle or rear axle carrier. OK NG NG Replace speed sensor. BR3795 NOTICE: Check the speed sensor signal last (See page DI–177). OK 4 Check speed sensor and sensor rotor serrations. Normal Signal Waveform GND 2 m/s / Division 1 V / Division REFERENCE: INSPECTION USING OSCILLOSCOPE PREPARATION: (a) Remove the ABS ECU. (b) Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ABS ECU. CHECK: Drive the vehicle with about 30 km/h (19 mph), and check the signal waveform. W04200 OK NG Check and replace ABS ECU. DI–202 DIAGNOSTICS 5 – ANTI–LOCK BRAKE SYSTEM Check sensor rotor and sensor tip. R00948 R00947 Front: PREPARATION: Remove the front drive shaft (See page SA–6). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See Pub. No. RM654U on page BR–68). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. Rear: PREPARATION: Remove the axle hub (See Pub. No. RM654U on page SA–52). CHECK: Check the sensor rotor serrations. OK: No scratches or missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See Pub. No. RM654U on page BR–68). CHECK: Check the sensor tip. OK: No scratches or foreign objects on the sensor tip. NG Replace sensor rotor or speed sensor. NOTICE: Check the speed sensor signal last (See page DI–177). OK Check and replace ABS ECU. DI–203 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03L–04 DTC 33, 34 Rear Speed Sensor Rotor Faulty CIRCUIT DESCRIPTION DTC No. 33, 34 DTC Detecting Condition Trouble Area The condition that the both rear side wheels’ speed is lower than the front wheels’ speed at 20 km/h (12 mph) or more for 20 sec. or more when the IG switch turns ON and OFF , which is repeated in a sequence more than 8 times.
Rear axle hub
Right rear, left rear speed sensor
Rear speed sensor circuit INSPECTION PROCEDURE 1 Check rear axle hub (See Pub. No. RM654U on page SA–52). NG Replace rear axle hub. OK 2 Check rear speed sensor (See page DI–198). NG Replace rear speed sensor. OK 3 Check for open and short circuit in harness and connector between rear speed sensor and ECU (See page IN–29). NG OK Check and replace ABS ECU. Repair or replace harness and connector. DI–204 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03M–04 DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition 41 Condition 1. or 2. is detected: 1. Vehicle speed is at 3 km/h (1.9 mph) or more and ECU terminal IG1 voltage is 9.5 V or less , which continues for 10 sec. or more. 2. When IG1 terminal voltage is less than 9.5 V, there is open circuit in the motor relay or in the solenoid relay, or the solenoid circuit malfunction. Trouble Area
Battery
Charging system
Power source circuit Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM Ignition Switch B–Y 2 AM1 IG1 4 1 1K 9 1J ABS ECU J/C J12 Instrument Panel J/B B–R B–R C ECU–IG C 13 A14 IG1 W 2 1K Instrument Panel J/B 1 1B AM1 1 F9 B–G FL Block B–R 1 F14 W–B 12 A14 GND1 W–B 25 A14 GND2 ALT A FL MAIN Battery IF J9 Junction Connector Instrument Panel Brace LH F07156 DI–205 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check ECU–IG fuse. PREPARATION: Remove ECU–IG fuse from Instrument Panel J/B. CHECK: Check continuity of ECU–IG fuse. OK: Continuity ECU–IG Instrument Panel J/B NG Check for short circuit in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). NG Check and repair the charging system (See Pub. No. RM654U on page CH–1). F00073 OK 2 Check battery positive voltage. OK: Voltage: 10 – 14 V OK DI–206 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM Check voltage between terminals IG1 and GND of ABS ECU connector. PREPARATION: Remove ABS ECU with connectors still connected. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals IG1 and GND of ABS ECU connector. OK: Voltage: 10 – 14 V ON (–) (+) IG1 GND GND F07151 OK Check and replace ABS ECU. NG 4 Check continuity between terminals GND of ABS ECU connector and body ground. LOCK F07152 GND (+) (–) GND F07216 PREPARATION: Disconnect the connector from the ABS ECU. CHECK: Measure resistance between terminal GND of ABS ECU connector and body ground. OK: Resistance: 1 Ω or less NG Repair or replace harness or connector. OK Check for open circuit in harness and connector between ABS ECU and ECU–IG fuse (See page IN–29). DI–207 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03N–04 DTC 49 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. 49 DTC Detecting Condition Trouble Area ABS ECU terminal IG1 voltage is 9.5 V to 18.5 V and ABS is in non–operation, the open circuit of the stop light switch circuit continues for 0.3 sec. or more.
Stop light switch
Stop light switch circuit WIRING DIAGRAM ABS ECU J/C G–W Instrument Panel J/B Stop Light 1R 5 Switch 4 2 G–W 1R 1S 2 1 W J23 A J24 C G–W 7 R Instrument Panel J/B 7 1C 1 F9 STOP FL Block Light Failure Sensor 1 4 1B 1 B–R F14 ALT B–G MAIN G–W 5 A14 STP G–R 2 G–R G–R 2 R10 2 R8 H8 2 High Right Mounted Stop Stop Light 5 R10 5 R8 H8 1 Light W–B W–B A W–B W–B J/C W–B A J34 W–B Battery BK Under the Left Center Pillar BM Left Stop Light Back Panel Center F00124 INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. NG OK Repair stop light circuit (See Pub. No. RM654U on page BE–37). DI–208 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM Check voltage between terminal STP of ABS ECU and body ground. STP (+) (–) PREPARATION: Remove ABS ECU with connectors still connected. CHECK: Measure voltage between terminal STP of ABS ECU and body ground when brake pedal is depressed. OK: Voltage: 8 – 14 V F07150 OK Check and replace ABS ECU. NG 3 Check for open circuit in harness and connector between ABS ECU and stop light switch (See page IN–29). NG Repair or replace harness or connector. OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–185). DI–209 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI4KW–02 DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition 51 Trouble Area
ABS pump motor ABS actuator pump motor is not operating normally. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. WIRING DIAGRAM Engine Room R/B No.3 ABS Motor Relay ABS B–G 1 3 1 F10 1 ABS ECU 3 3 GR–R 1 IJ1 GR–R 26 A14 R+ 2 2 3 4 GR–L 3 1 A13 MR Fusible Link Block ALT F9 1 ABS Actuator 3 A4 B–G R–W 10 A13 MT 2 A4 W–R FL Main 1 A4 W–B Battery EA F07146 DI–210 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM INSPECTION PROCEDURE 1 Check operation of ABS & TRAC pump motor. A4 1 2 (–) (+) F03291 PREPARATION: Disconnect the ABS actuator connector. CHECK: Connect positive
lead to terminal A4–2 and negative  lead to terminal A4 – 1 of the ABS actuator connector, check that the pump motor is operates. OK: The running sound of the pump motor should be heard. OK NG Replace ABS actuator. Check for open circuit in harness and connector between ABS motor relay, ABS actuator and ABS ECU (See page IN–29). DI–211 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03P–05 DTC Always ON ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. Always ON DTC Detecting Condition ABS ECU internal malfunction is detected. Trouble Area
ECU
Battery Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. INSPECTION PROCEDURE 1 Is DTC output? Check DTC on page DI–177. YES Repair circuit indicated by the code output. YES Check ABS solenoid relay. Check for short circuit in harness and connector between ABS solenoid relay and DLC1 (See page IN–29). YES Check for open or short circuit in harness and connector between ECU–IG fuse and ABS ECU (See page IN–29). NO 2 Is normal code displayed? NO 3 NO Is ABS warning light go off? DI–212 DIAGNOSTICS 4 – ANTI–LOCK BRAKE SYSTEM Check battery positive voltage. CHECK: Check the battery positive voltage. OK: 10 – 14 V NG Check and repair the charging system (See Pub. No. RM654U on page CH–1). OK 5 Check ABS warning light. PREPARATION: (a) Disconnect the connector from the ABS ECU. (b) Turn the ignition switch ON. CHECK: Check the ABS warning light goes off. OK Check and replace ABS ECU. NG Check for short circuit in harness and connector between ABS warning light, DLC1, DLC2, and ABS ECU (See page IN–29). DI–213 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03Q–04 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Engine Room R/B No. 3 Instrument Panel J/B 2 1D ABS Solenoid Relay 1 Battery 6 2 4 5 GAUGE R–L 3 D ABS ECU J/C J3 3 3 R–L 8 IJ2 R–L D R–L 3 3 4 IG3 C12 7 ABS Warning R–L Light 23 C12 4 Short DLC1 ABS ECU Pin R–L 22 12 IF1 G–B 3 W–L 4 A4 ABS Actuator W–B ABS ECU EA 5 IG3 G–B G–B C C J/C J22 G–B 11 A14 WA C F07217 INSPECTION PROCEDURE Troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step 1 ABS warning light remains on Go to step 3 1 Check ABS warning light. See combination meter troubleshooting on page See Pub. No. RM654U on page BE–2. NG OK Repair bulb or combination meter assembly. DI–214 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM Check ABS solenoid relay. 3 2 1 6 5 4 PREPARATION: Remove ABS solenoid relay from Engine Room R/B No. 3. CHECK: Check continuity between each terminal of ABS solenoid relay. OK: Open 3 2 1 Terminals 4 and 6 Continuity (Reference value 80 Ω) Terminals 2 and 3 Continuity Terminals 1 and 3 Open Continuity Continuity CHECK: (a) Apply battery positive voltage between terminals 4 and 6. (b) Check continuity between each terminal of ABS solenoid relay. OK: 65 4 Continuity 3 2 1 Terminals 2 and 3 Open Terminals 1 and 3 Continuity Open (–) 6 5 4 CHECK: Connect the
test lead to terminal 5 and the  lead to terminal 3. Check continuity between the terminals. OK: Continuity If there is no continuity, connect the  test lead to terminal 5 and the
lead to terminal 3. Recheck continuity between terminals. (+) Continuity (–) 3 2 1 (+) 65 4 F00043 NG Replace ABS solenoid relay. OK Check for open circuit in harness and connector between DLC1, ABS solenoid relay and body ground (See page IN–29). DI–215 DIAGNOSTICS 3 – ANTI–LOCK BRAKE SYSTEM Is DTC output? Check DTC on page DI–177. YES Repair circuit indicated by the code output. NO 4 Does ABS warning light go off if short pin is removed? NO Check for short circuit in harness and connector between ABS warning light, DLC1 and ABS ECU (See page IN–29). YES 5 Check ABS solenoid relay (See step 2). NG Replace ABS solenoid relay. OK Check for short circuit in harness and connector between DLC1 and ABS solenoid relay (See page IN–29). DI–216 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03R–04 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and E1 of the DLC1 or the DLC2 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM 6 IG3 BR DLC1 A J20 J/C B J/C C J7 J6 BR BR A 3 E1 Tc J/C J2 DLC2 BR 3 LG–R 11 E1 11 IG3 LG–R Tc B 4 ABS ECU LG–R 8 A14 Tc B B LG–R A BR EC F00113 INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2 or DLC1. DLC2 CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Tc and E1 of DLC2 or DLC1. OK: Voltage: 10 – 14 V DLC1 E1 Tc E1 Tc F02607 F00445 F02612 OK NG If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. DI–217 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM Check for open and short circuit in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–29). NG OK Check and replace ABS ECU. Repair or replace harness or connector. DI–218 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03S–04 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. WIRING DIAGRAM ABS ECU DLC1 BR 3 E1 Ts R–Y 16 8 IG3 R–Y 8 A14 Ts A J20 J/C BR A EC F00172 INSPECTION PROCEDURE 1 Check voltage between terminals Ts and E1 of DLC1. CHECK: (a) Turn the ignition switch ON. (b) Measure voltage between terminals Ts and E1 of DLC1. OK: Voltage: 10 – 14 V ON E1 Ts AB0119 S08096 DLC1 F00446 OK NG If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. DI–219 DIAGNOSTICS 2 – ANTI–LOCK BRAKE SYSTEM Check for open and short circuit in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–29). NG OK Check and replace ABS ECU. Repair or replace harness or connector. DI–220 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM DI03T–04 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F00071 DI–221 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM DI1AX–09 HOW TO PROCEED WITH TROUBLESHOOTING Vehicle Brought to Workshop 1 Item inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations. Customer Problem Analysis DI–222 2 Warning Light Check Remains OFF DI–223 Remains ON 3 4 DTC Check (Read Present DTC) DTC Check (Read Past DTC) DI–223 DI–223 5 DTC Chart DI–229 6 Circuit Inspection Normal 7 DI–234 to DI–313 Malfunction Code Symptom Simulation IN–19 Warning Light Remains OFF Warning Light ON Identification of Problem 8 Repair DTC Check DI–223 9 10 Clear DTC (Present and Past DTC) DI–223 Warning Light Check Remains ON DI–223 Remains OFF 11 DTC Check (Read Past DTC) DI–223 Confirmation Test END Step 3, 4, 6, 8, 9, 11 : Diagnostic steps permitting the use of the TOYOTA hand–held tester. Author: Date: 291 DI–222 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI15Z–09 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s Name Supplemental Restraint System Check Sheet Registration No. Customer’s Name Registration Year / / Frame No. Date Vehicle Brought In / / km Miles Odometer Reading / Date Problem Occurred Weather Fine Temperature Cloudy Rainy Snowy / Other Approx. Starting Vehicle Operation Driving Idling [ Constant speed Other Acceleration Deceleration ] Road Conditions Details Of Problem Vehicle Inspection, Repair History Prior to Occurrence of Malfunction (Including Supplemental Restraint System) Diagnosis System Inspection SRS Warning Light Inspection 1st Time Remains ON Sometimes Light Up Does Not Light Up 2nd Time Remains ON Sometimes Light Up Does Not Light Up 1st Time Normal Code Malfunction Code [ Code. ] 2nd Time Normal Code Malfunction Code [ Code. ] DTC Inspection DI–223 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L1–05 PRE–CHECK 1. (a) (b) SRS WARNING LIGHT CHECK Turn the ignition switch to the ACC or ON position and check that the SRS warning light lights up. Check that the SRS warning light goes out after approx. 6 seconds. HINT:
H10313
2. (a) DLC1 E1 Tc R13006 When the ignition switch is at ACC or ON and the SRS warning light remains on or flashes, the airbag sensor assembly has detected a malfunction code. If, after approx. 6 seconds have elapsed, the SRS warning light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered likely. Proceed to ”SRS warning light circuit malfunction” on page DI–308. DTC CHECK (Using diagnosis check wire) Present troubles codes: Output the DTC. (1) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. (2) Using SST, connect terminals Tc and E1 of the DLC1. SST 09843–18020 NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. (b) Past troubles codes: Output the DTC. (1) Using service wire, connect Terminals Tc and E1 of the DLC1. SST 09843–18020 (2) Turn the ignition switch to the ACC or ON position and wait for approx. 20 seconds. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. DI–224 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM (c) Normal Code 0.25 ON OFF 0.25 Code 11 and 31 0.5 4.0 2.5 ON OFF 1.5 0.5 DTC 11 AT0716 AB0056 Repeat DTC 31 H08231 TOYOTA Hand–Held Tester DLC3 S05331 Read the DTC. Read the 2–digit DTC as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are shown in the illustration.
Normal code indication The light will blink 2 times per second.
Malfunction code indication The first blinking output indicates the first digit of a 2–digit DTC. After a 1.5–second pause, the second blinking output will indicate the second digit. If there are 2 or more codes, there will be a 2.5–second pause between each code. After all the codes have been output, there will be a 4.0–second pause and they will all be repeated. HINT:
In the event of a number of trouble codes, indication will start from the smallest numbered code.
If a DTC is not output or a DTC is output without terminal connection, proceed to the Tc terminal circuit inspection on page DI–313. 3. (a) (b) DTC CHECK (Using TOYOTA hand–held tester) Hook up the TOYOTA hand–held tester to the DLC3. Read the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. 4. DTC CLEARANCE (Not using service wire) When the ignition switch is turned off, the diagnostic trouble code is cleared. HINT: DTC might not be cleared by turning the ignition switch OFF. In this case, proceed to the next step. 5. DTC CLEARANCE (Using service wire) (a) Connect the 2 service wires to terminals Tc and AB of DLC1. (b) Turn the ignition switch to ACC or ON and wait for approx. 6 seconds. DI–225 DIAGNOSTICS (c) – SUPPLEMENTAL RESTRAINT SYSTEM Starting with the Tc terminal, ground alternately terminal Tc and terminal AB twice each in cycles of 1.0 seconds. Make sure that the terminals are grounded. Ensure the terminal Tc remain grounded. HINT: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately ground the other terminal within an interval of 0.2 seconds. If DTCs are not cleared, repeat the above procedure until the codes are cleared. Terminal 1 seconds OFF Tc Tc AB Body Ground 1 seconds (± 0.5 sec.)(± 0.5 sec.) 3 1 5 OFF AB Body Ground 2 4 Several Seconds ON 50 m sec. OFF 50 m sec. H10313 H01461 H10314 TOYOTA Hand–Held Tester (d) Several seconds after doing the clearing procedure, the SRS warning light will blink in a 50 m sec. cycle to indicate the codes which have been cleared. 6. (a) (b) DTC CLEARANCE (Using TOYOTA hand–held tester) Hook up the TOYOTA hand–held tester to the DLC3. Clear the DTCs by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operation’s manual for further details. DLC3 S05331 DI–226 DIAGNOSTICS 7. – SUPPLEMENTAL RESTRAINT SYSTEM RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure as shown in the illustration of the connectors on the next pages, insert paper which has the same thickness as the male terminal, between the terminal and the short spring. CAUTION: Never release the airbag activation prevention mechanism on the steering wheel pad connector. NOTICE:
Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure.
If the inserted paper is too thick the terminal and short spring may be damaged, so always use paper with the same thickness as the male terminal. DI–227 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM 8 Pretensioner (RH) 9 Front Airbag Sensor (RH) 10 4 Front Passenger Airbag Assembly (Squib) 2 Spiral Cable Airbag Sensor Assembly 1 5 7 3 Steering Wheel Pad (Squib) 6 No.1 J/B 11 Front Airbag Sensor (LH) 12 Pretensioner (LH) H02720 DI–228 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Airbag Sensor Assembly Connector 1 3 Short Spring Short Spring 2 Short Spring After Release Before Release Paper Connector 5 6 Connector 4 7 Short Spring Short Spring Before Release After Release Paper Paper H04511 H01356 H01233 AB0130 AB0045 H02249 H02248 AB0046 H11583 DI–229 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1AZ–09 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No. (See Page) Detection Item
Short in D squib circuit ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness ON
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to Ground)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (RH) circuit (to B+)
Seat belt pretensioner RH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Open in D squib circuit B0101/14 (DI–239)
Short in D squib circuit (to Ground) B0102/11 (DI–243)
Short in D squib circuit (to B+) B0103/12 (DI–247) B0106/54 (DI–255) B0107/51 (DI–258) B0108/52 (DI–261) B0130/63 (DI–264) B0131/64 (DI–268) B0132/61 (DI–271) B0133/62 (DI–274) B0135/73 (DI–277) B0136/74 (DI–281) SRS Warning Light
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness B0100/13 (DI–234) B0105/53 (DI–251) Trouble Area
Short in P squib circuit
Open in P squib circuit
Short in P squib circuit (to Ground)
Short in P squib circuit (to B+)
Short in P/T squib (RH) circuit
Open in P/T squib (RH) circuit
Open in P/T squib (LH) circuit DI–230 DIAGNOSTICS DTC No. (See Page) B0137/71 (DI–284) B0138/72 (DI–287) B1100/31 (DI–290) B1156/B1157/ 15 (DI–292) B1158/B1159/ 16 (DI–300) Normall N (DI–305) Detection Item – SUPPLEMENTAL RESTRAINT SYSTEM Trouble Area SRS Warning Light
Short in P/T squib (LH) circuit (to Ground)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Short in P/T squib (LH) circuit (to B+)
Seat belt pretensioner LH (squib)
Airbag sensor assembly
Wire harness Blink
Airbag sensor assembly malfunction
Airbag sensor assembly
Front airbag sensor (RH) malfunction
Front airbag sensor (RH)
Wire harness
Engine room main wire harness
Airbag sensor assembly ON
Front airbag sensor (LH)
Wire harness
Airbag sensor assembly ON
Front airbag sensor (LH) malfunction
System normal
Voltage source drop ON –
Battery
Airbag sensor assembly OFF ON HINT:


When the SRS warning light remains lit up and the DTC is the normal code, this means a voltage source drops. This malfunction is not stored in memory by the airbag sensor assembly and if the power source voltage returns to normal, the SRS warning light will automatically go out. When 2 or more codes are indicated, the codes will be displayed in numeral order starting from the lowest numbered code. If a code not listed on the chart is displayed, the airbag sensor assembly is faulty. DI–231 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B0–10 PARTS LOCATION Steering Wheel Pad (with Airbag) Front Passenger Airbag Assembly Front Airbag Sensor (RH) Airbag Sensor Assembly Combination Meter (Warning Light) Front Airbag Sensor (LH) Seat Belt Pretensioner (RH) Spiral Cable Seat Belt Pretensioner (LH) H10307 DI–232 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B1–15 TERMINALS OF ECU C6 C5 C4 B 6 A 5 4 3 2 1 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 12 11 10 9 8 7 B 6 5 4 3 2 1 17 16 15 14 13 12 12 11 10 9 8 7 28 27 26 A 11 10 A B H01357 No. Symbol A – Electrical Connector Check Mechanism Terminal Name B – Electrical Connector Check Mechanism C5 – 3 LA C5 – 4 GSW C5 – 5 IG2 Power Source (IGN Fuse) C5 – 6 ACC Power Source (CIG Fuse) C5 – 9 SR+ Front Airbag Sensor (RH) C5 – 10 P+ Squib (Passenger) C5 – 11 P– Squib (Passenger) C5 – 12 SIL Diagnosis C5 – 13 D– Squib (Driver) C5 – 14 D+ Squib (Driver) C5 – 15 SL+ Front Airbag Sensor (LH) C5 – 19 Tc C5 – 20 SR– Front Airbag Sensor (RH) C5 – 26 SL– Front Airbag Sensor (LH) C5 – 27 E1 Ground C5 – 28 E2 Ground C4 – 1 PL– Squib (Seat Belt Pretensioner, LH) C4 – 2 PL+ Squib (Seat Belt Pretensioner, LH) C6 – 5 PR+ Squib (Seat Belt Pretensioner, RH) C6 – 6 PR– Squib (Seat Belt Pretensioner, RH) SRS Warning Light EFI ECU Diagnosis DI–233 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI164–25 PROBLEM SYMPTOMS TABLE Proceed with troubleshooting of each circuit in the table below. Symptom
With the ignition switch in ACC or ON position, the SRS warning light sometimes lights up after approx. 6 seconds have elapsed.
SRS warning light is always lit up even when ignition switch is in the LOCK position.
With the ignition switch in ACC or ON position, the SRS warning light does not light up. Suspect Area See page
SRS warning light circuit (Al (Always lights li ht up when h ignition i iti switch it h is i in i LOCK posii tion.) DI 308 DI–308
SRS warning light circuit (Does not light up when ignition switch is turned to ACC or ON.) DI–308
Tc terminal circuit DI–313
DTC is not displayed.
SRS warning light is always lit up at the time of DTC check procedure.
DTC is displayed without Tc and E1 terminal connection. DI–234 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI18Q–15 CIRCUIT INSPECTION DTC B0100/13 Short in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0100/13 is recorded when a short is detected in the D squib circuit. DTC No. B0100/13 DTC Detecting Condition Trouble Area
Short circuit between D+ wire harness and D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly D Squib 1 Y–B 14 C5 D+ 2 Y 13 C5 D– Spiral Cable H01451 DI–235 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check D squib circuit. Spiral Cable Airbag Sensor Assembly D– D+ D Squib (–) H01001 R14286 PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI–223). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher (+) H01134 NG OK Go to step 5. DI–236 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly Spiral Cable D Squib ACC →← ON or DTC B0100/13 DLC1 E1 H01002 AB0118 AB0119 R13006 FI1390 OK – Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. H07478 NG Replace airbag sensor assembly. DI–237 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DTC B0100/13 DLC1 E1 Tc H01003 AB0118 AB0119 R13006 FI1390 H01136 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory (See page DI–223). (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC (See page DI–223). OK: DTC B0100/13 is not output. HINT: Codes other than code B0100/13 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–238 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ D– (–) D+ (+) H01000 R14286 H01137 PREPARATION: (a) Disconnect the connector between the airbag sensor assembly and the spiral cable. (b) Release the airbag activation prevention mechanism of the spiral cable connector on the airbag sensor assembly side (See page DI–223). CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the spiral cable (See page DI–223). CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Spiral Cable D Squib D– (–) D+ (+) NG H01004 R14286 H01138 Repair or replace harness or connector between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–239 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI18R–23 DTC B0101/14 Open in D Squib Circuit CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0101/14 is recorded when an open is detected in the D squib circuit. DTC No. DTC Detecting Condition B0101/14 Trouble Area
Open circuit in D+ wire harness or D– wire harness of squib
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–234. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check D squib circuit. Airbag Sensor Assembly Spiral Cable D Squib D– (–) H01001 R14286 CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω D+ (+) H01139 NG OK Go to step 5. DI–240 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable D Squib Airbag Sensor Assembly →← D– D+ ACC ON or DLC1 E1 H01002 AB0069 AB0118 AB0119 R13006 W02044 DTC B0101/14 Tc H01140 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG OK – Replace airbag sensor assembly. DI–241 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. D Squib Airbag Sensor Assembly Spiral Cable →← ACC ON or DLC1 E1 H01003 AB0118 AB0119 R13006 W02044 DTC B0101/14 Tc H01141 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0101/14 is not output. HINT: Codes other than code B0101/14 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–242 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable D Squib ←→ D– Airbag Sensor Assembly D+ H01000 R14286 H01142 PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib D– (–) H01004 R14286 CHECK: For the connector (on the spiral cable side) between the airbag sensor assembly and the spiral cable, measure the resistance between D+ and D–. OK: Resistance: Below 1 Ω D+ (+) NG Repair or replace harness or connector between airbag sensor assembly and spiral cable. H01143 OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–243 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L2–05 DTC B0102/11 Short in D Squib Circuit (to Ground) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0102/11 is recorded when a ground short is detected in the D squib circuit. DTC No. B0102/11 DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to ground)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–234. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check D squib circuit. Spiral Cable CHECK: For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly D Squib D+ H01001 R14301 H01126 NG OK Go to step 5. DI–244 DIAGNOSTICS 3 D Squib Airbag Sensor Assembly →← D– D+ ACC ON or DLC1 DTC B0102/11 Tc H01002 W01933 AB0069 AB0118 AB0118 R13006 W02042 H01127 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG OK SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Spiral Cable E1 – Replace airbag sensor assembly. DI–245 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DLC1 E1 H01003 AB0118 AB0119 R13006 W02042 DTC B0102/11 Tc H01128 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0102/11 is not output. HINT: Codes other than code B0102/11 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–246 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Airbag Sensor Assembly Spiral Cable D Squib ←→ D+ (–) PREPARATION: Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: For the connector (on the spiral cable side) between the steering wheel pad and the spiral cable, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher (+) H01000 R14301 H01129 NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. Airbag Sensor Assembly Spiral Cable D Squib CHECK: For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the resistance between D+ and body ground. OK: Resistance: 1 MΩ or Higher D+ (–) H01004 R14301 (+) H06304 NG Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–247 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4L3–05 DTC B0103/12 Short in D Squib Circuit (to B+) CIRCUIT DESCRIPTION The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0103/12 is recorded when a B+ short is detected in the D squib circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in D squib wire harness (to B+)
D squib malfunction
Spiral cable malfunction
Airbag sensor assembly malfunction B0103/12
Steering wheel pad (D squib)
Spiral cable
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–234. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check D squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly Spiral Cable D Squib D+ (–) AB0119 H01001 R14288 (+) H04530 NG OK Go to step 5. DI–248 DIAGNOSTICS 3 Spiral Cable D Squib D+ D– Airbag Sensor Assembly ACC ON or DTC B0103/12 DLC1 Tc H01002 AB0069 AB0118 AB0119 R13006 W02043 H01131 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect D+ and D– of the connector (on the spiral cable side) between the spiral cable and the steering wheel pad. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG OK SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← E1 – Replace airbag sensor assembly. DI–249 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check D squib. →← Airbag Sensor Assembly Spiral Cable D Squib ACC ON or DTC B0103/12 DLC1 E1 – Tc H01003 AB0118 AB0019 R13006 W02043 H01132 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the steering wheel pad connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0103/12 is not output. HINT: Codes other than code B0103/12 may be output at this time, but they are not relevant to this check. NG Replace steering wheel pad. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–250 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Check spiral cable. Spiral Cable ←→ D Squib Airbag Sensor Assembly ON D+ (–) (+) H01000 AB0119 R14288 H01133 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect the connector between the airbag sensor assembly and the spiral cable. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and the steering wheel pad, measure the voltage between D+ and body ground. OK: Voltage: 0 V NG Repair or replace spiral cable. OK 6 Check harness between airbag sensor assembly and spiral cable. ON Airbag Sensor Assembly Spiral Cable D Squib CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the spiral cable side) between the spiral cable and airbag sensor assembly, measure the voltage between D+ and body ground. OK: Voltage: 0 V D+ (–) AB0119 H01004 R14288 (+) H08261 NG Repair or replace harness between airbag sensor assembly and spiral cable. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–251 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B6–20 DTC B0105/53 Short in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0105/53 is recorded when a short is detected in the P squib circuit. DTC No. B0105/53 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P Squib 1 Y–R 10 C5 P+ 2 Y–G 11 C5 P– H01454 DI–252 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P squib circuit. PREPARATION: Release airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the front passenger airbag assembly and the airbag sensor assembly (See page DI–223). CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P– (–) R14286 H02142 OK P+ (+) H02251 NG Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–253 DIAGNOSTICS 3 Airbag Sensor Assembly →← ACC ON or DLC1 E1 AB0119 H01077 DTC B0105/53 Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. H07479 NG OK SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib H01023 AB0118 R13006 – Replace airbag sensor assembly. DI–254 DIAGNOSTICS 4 →← ACC Airbag Sensor Assembly ON or DLC1 E1 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib H01024 AB0118 R13006 – DTC B0105/53 Tc AB0119 H01077 H01202 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–223) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC. (See page DI–223) OK: DTC B0105/53 is not output. HINT: Codes other than code B0105/53 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–255 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B7–25 DTC B0106/54 Open in P Squib Circuit CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0106/54 is recorded when an open is detected in the P squib circuit. DTC No. B0106/54 DTC Detecting Condition Trouble Area
Open circuit in P+ wire harness or P– wire harness of squib
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–251. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and P–. OK: Resistance: Below 1 Ω P Squib Airbag Sensor Assembly P– (–) R14286 H02142 OK P+ (+) NG H02251 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–256 DIAGNOSTICS 3 Airbag Sensor Assembly →← ACC ON P+ P– or DLC1 DTC B0106/54 Tc H01023 H02144 AB0118 AB0119 R13006 H01078 H02253 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG OK SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib E1 – Replace airbag sensor assembly. DI–257 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01024 AB0118 AB0119 R13006 H01078 DTC B0106/54 Tc H01205 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0106/54 is not output. HINT: Codes other than code B0106/54 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–258 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B8–17 DTC B0107/51 Short in P Squib Circuit (to Ground) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0107/51 is recorded when a ground short is detected in the P squib circuit. DTC No. B0107/51 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to ground)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–251. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P squib circuit. CHECK: For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the resistance between P+ and body ground. OK: Resistance: 1 MΩ or Higher P Squib Airbag Sensor Assembly P+ (–) H01227 H02145 OK (+) NG H02254 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–259 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P– or DTC B0107/51 DLC1 E1 Tc H01023 H02144 AB0118 AB0118 R13006 H01075 H02255 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG OK Replace airbag sensor assembly. DI–260 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B0107/51 Tc H01024 AB0118 AB0119 R13006 H01075 H01196 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0107/51 is not output. HINT: Codes other than code B0107/51 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–261 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1B9–23 DTC B0108/52 Short in P Squib Circuit (to B+) CIRCUIT DESCRIPTION The P squib circuit consists of the airbag sensor assembly and front passenger airbag assembly. It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0108/52 is recorded when a B+ short is detected in the P squib circuit. DTC No. B0108/52 DTC Detecting Condition Trouble Area
Short circuit in P squib wire harness (to B+)
P squib malfunction
Airbag sensor assembly malfunction
Front passenger airbag assembly (P squib)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–251. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P squib circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly, measure the voltage between the P+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P Squib P+ (–) AB0119 H01022 H02146 OK (+) NG H08262 Repair or replace harness or connector between front passenger airbag assembly and airbag sensor assembly. DI–262 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P Squib Airbag Sensor Assembly →← ACC ON P+ P– or DTC B0108/52 DLC1 E1 Tc H01023 H02144 AB0118 AB0118 R13006 H01076 H02257 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect P+ and P– of the connector (on the front passenger airbag assembly side) between the front passenger airbag assembly and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG OK Replace airbag sensor assembly. DI–263 DIAGNOSTICS 4 SUPPLEMENTAL RESTRAINT SYSTEM Check P squib. P Squib →← ACC Airbag Sensor Assembly ON or DLC1 E1 – DTC B0108/52 Tc H01024 AB0118 AB0119 R13006 H01076 H01199 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front passenger airbag assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0108/52 is not output. HINT: Codes other than code B0108/52 may be output at this time, but they are not relevant to this check. NG Replace front passenger airbag assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–264 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16S–25 DTC B0130/63 Short in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0130/63 is recorded when a short is detected in the P/T squib (RH) circuit. DTC No. B0130/63 DTC Detecting Condition Trouble Area
Short circuit between PR+ wire harness and PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (RH) 1 Y–B 5 C6 PR+ 2 Y 6 C6 PR– H01454 DI–265 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (RH) circuit. Airbag Sensor Assembly P/T Squib (RH) PR+ (+) H01019 H02141 OK PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (RH) (See page DI–223). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: 1 MΩ or Higher PR– (–) NG H02203 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–266 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 DTC B0130/63 E1 H01020 AB0118 AB0119 R13006 H01082 Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. H07485 NG OK – Replace airbag sensor assembly. DI–267 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 DTC B0130/63 E1 H01021 AB0118 AB0119 R13006 H01082 Tc H01214 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory (See page DI–223). (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC (See page DI–223). OK: DTC B0130/63 is not output. HINT: Codes other than code B0130/63 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–268 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BG–20 DTC B0131/64 Open in P/T Squib (RH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (RH) consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0131/64 is recorded when an open is detected in the P/T squib (RH) circuit. DTC No. B0131/64 DTC Detecting Condition Trouble Area
Open circuit in PR+ wire harness or PR– wire harness of squib
P/T squib (RH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–264. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (RH) circuit. P/T Squib (RH) PR+ (+) H01019 H02141 OK CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and PR–. OK: Resistance: Below 1 Ω Airbag Sensor Assembly PR– NG (–) H02205 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–269 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01083 DTC B0131/64 Tc H02206 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG OK – Replace airbag sensor assembly. DI–270 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01083 DTC B0131/64 Tc H01217 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0131/64 is not output. HINT: Codes other than code B0131/64 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–271 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BH–16 DTC B0132/61 Short in P/T Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0132/61 is recorded when a ground short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (RH) wire harness (to ground)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0132/61
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–264. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (RH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the resistance between PR+ and body ground. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly P/T Squib (RH) PR+ (–) (+) NG H01019 H08392 OK H08393 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–272 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 E1 H01020 H02139 AB0118 AB0119 R13006 H01079 DTC B0132/61 Tc H02208 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG OK – Replace airbag sensor assembly. DI–273 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). P/T Squib (RH) Airbag Sensor Assembly →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01079 DTC B0132/61 Tc H01208 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0132/61 is not output. HINT: Codes other than code B0132/61 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–274 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BI–19 DTC B0133/62 Short in P/T Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (RH) circuit consists of the airbag sensor assembly and seat belt pretensioner (RH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0133/62 is recorded when a B+ short is detected in the P/T squib (RH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (RH) wire harness (to B+)
P/T squib (RH) malfunction
Airbag sensor assembly malfunction B0133/62
Seat belt pretensioner (RH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–264. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (RH) circuit. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly, measure the voltage between PR+ and body ground. OK: Voltage: 0 V ON Airbag Sensor Assembly P/T Squib (RH) PR+ (–) (+) NG H01019 AB0119 H08394 OK H08268 Repair or replace harness or connector between seat belt pretensioner (RH) and airbag sensor assembly. DI–275 DIAGNOSTICS 3 Airbag Sensor Assembly →← PR+ PR– ACC ON or DLC1 H01020 H02139 AB0118 AB0119 R13006 H01081 DTC B0133/62 Tc H02210 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PR+ and PR– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (RH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG OK SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (RH) E1 – Replace airbag sensor assembly. DI–276 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (RH). Airbag Sensor Assembly P/T Squib (RH) →← ACC ON or DLC1 E1 H01021 AB0118 AB0119 R13006 H01081 DTC B0133/62 Tc H01211 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (RH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0133/62 is not output. HINT: Codes other than code B0133/62 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (RH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–277 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI16W–25 DTC B0135/73 Short in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0135/73 is recorded when a short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area B0135/73
Short circuit between PL+ wire harness and PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM Airbag Sensor Assembly P/T Squib (LH) 1 2 Y–B Y 2 C4 PL+ 1 C4 PL– H01454 DI–278 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (LH) circuit. Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 OK PREPARATION: Release the airbag activation prevention mechanism of the connector (on the airbag sensor assembly side) between the airbag sensor assembly and the seat belt pretensioner (LH) (See page DI–223). CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: 1 MΩ or Higher PL– (–) NG H02211 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–279 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 E1 H01017 AB0118 AB0119 R13006 H01086 DTC B0135/73 Tc PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. H07487 NG OK – Replace airbag sensor assembly. DI–280 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 E1 H01018 AB0118 AB0119 R13006 H01086 DTC B0135/73 Tc H01229 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to LOOK, and wait at least for 20 second. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Clear DTC stored in memory. (See page DI–223) (d) Turn ignition switch to LOCK, and wait at least for 20 seconds. (e) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (f) Check DTC (See page DI–223). OK: DTC B0135/73 is not output. HINT: Codes other than code B0135/73 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–281 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BJ–21 DTC B0136/74 Open in P/T Squib (LH) Circuit CIRCUIT DESCRIPTION The P/T squib circuit (LH) consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0136/74 is recorded when an open is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Open circuit in PL+ wire harness or PL– wire harness of squib
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0136/74
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–277. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (LH) circuit. Airbag Sensor Assembly P/T Squib (LH) PL+ (+) H01016 H02141 OK CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and PL–. OK: Resistance: Below 1 Ω PL– NG (–) H02213 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–282 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) Airbag Sensor Assembly PL+ PL– ACC ON or DLC1 DTC B0136/74 E1 H01017 H02139 AB0118 AB0119 R13006 H01087 Tc H02214 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG OK – Replace airbag sensor assembly. DI–283 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← ACC Airbag Sensor Assembly ON or DLC1 E1 DTC B0136/74 Tc H01018 AB0118 AB0119 R13006 H01087 H01232 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0136/74 is not output. HINT: Codes other than code B0136/74 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–284 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BK–16 DTC B0137/71 Short in P/T Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0137/71 is recorded when a ground short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in P/T squib (LH) wire harness (to ground)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0137/71
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–277. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (LH) circuit. CHECK: For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the resistance between PL+ and body ground. OK: Resistance: 1 MΩ or Higher P/T Squib (LH) Airbag Sensor Assembly (–) PL+ (+) NG H01016 H08392 OK H08396 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–285 DIAGNOSTICS 3 SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. →← P/T Squib (LH) PL+ PL– Airbag Sensor Assembly ACC ON or DLC1 E1 H01017 H02139 AB0118 AB0119 R13006 H01084 DTC B0137/71 Tc H02216 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG OK – Replace airbag sensor assembly. DI–286 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). →← P/T Squib (LH) ACC Airbag Sensor Assembly ON or DLC1 DTC B0137/71 E1 H01018 AB0118 AB0119 R13006 H01084 Tc H01220 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0137/71 is not output. HINT: Codes other than code B0137/71 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–287 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BL–20 DTC B0138/72 Short in P/T Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The P/T squib (LH) circuit consists of the airbag sensor assembly and seat belt pretensioner (LH). It causes the SRS to deploy when the SRS deployment conditions are satisfied. For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B0138/72 is recorded when a B+ short is detected in the P/T squib (LH) circuit. DTC No. DTC Detecting Condition Trouble Area
Short circuit in seat belt pretensioner (LH) wire harness (to B+)
P/T squib (LH) malfunction
Airbag sensor assembly malfunction B0138/72
Seat belt pretensioner (LH)
Airbag sensor assembly
Wire harness WIRING DIAGRAM See page DI–277. INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check P/T squib (LH) circuit. ON Airbag Sensor Assembly P/T Squib (LH) (–) CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly, measure the voltage between PL+ and body ground. OK: Voltage: 0 V PL+ (+) NG AB0119 H01016 H08394 OK H08269 Repair or replace harness or connector between seat belt pretensioner (LH) and airbag sensor assembly. DI–288 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. P/T Squib (LH) →← Airbag Sensor Assembly PL+ PL– ACC ON or DLC1 E1 H01017 H02139 AB0118 AB0119 R13006 H01085 DTC B0138/72 Tc H02217 PREPARATION: (a) Connect the connector to the airbag sensor assembly. (b) Using a service wire, connect PL+ and PL– of the connector (on the seat belt pretensioner side) between the seat belt pretensioner (LH) and the airbag sensor assembly. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG OK Replace airbag sensor assembly. DI–289 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check P/T squib (LH). P/T Squib (LH) →← Airbag Sensor Assembly ACC ON or DLC1 DTC B0138/72 E1 H01018 AB0118 AB0119 R13006 H01085 Tc H01222 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the seat belt pretensioner (LH) connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B0138/72 is not output. HINT: Codes other than code B0138/72 may be output at this time, but they are not relevant to this check. NG Replace seat belt pretensioner (LH). OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. If the malfunctioning part can not be detected by the simulation method, replace all SRS components including the wire harness. DI–290 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BM–27 DTC B1100/31 Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The airbag sensor assembly consists of a airbag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control, etc. It receives signals from the airbag sensor, judges whether or not the SRS must be activated, and detects diagnosis system malfunction. DTC B1100/31 is recorded when occurrence of a malfunction in the airbag sensor assembly is detected. DTC No. DTC Detecting Condition Trouble Area
Airbag sensor assembly malfunction B1100/31
Airbag sensor assembly INSPECTION PROCEDURE HINT: When a malfunction code other than code B1100/31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code B1100/31. 1 Prepare for inspection. (See step 1 on page DI–305) 2 Check voltage at IG2 and ACC of airbag sensor assembly. ON Airbag Sensor Assembly ACC (–) AB0119 H01298 IG2 (+) CHECK: (a) Turn ignition switch to ON. (b) Measure the voltage between body ground and terminals each of IG2 and ACC of the airbag sensor assembly connector. OK: Voltage: 10 – 14 V H01299 NG OK Check that an abnormality occurs on the battery and charging system. DI–291 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Is DTC B1100/31 output again? ACC ON or DLC1 E1 AB0118 AB0119 R13006 FI1394 DTC B1100/31 Tc PREPARATION: Clear DTC. (See step 5 on page DI–223) CHECK: (a) Turn ignition switch to LOCK, and wait at least for 20 seconds. (b) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (c) Repeat operation in step (a) and (b) at least 5 times. (d) Check DTC. (See page DI–223) HINT: Codes other than code B1100/31 may be output at this time, but they are not relevant to this check. H00022 NO YES Replace airbag sensor assembly. Using simulation method, reproduce malfunction symptoms. (See page IN–19) DI–292 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4LA–04 DTC B1156/B1157/15 Front Airbag Sensor (RH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (RH) circuit consists of the airbag sensor assembly and front airbag sensor (RH). For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B1156/B1157/15 is recorded when malfunction is detected in the front airbag sensor (RH) circuit. DTC No. B1156/B1157/15 DTC Detecting Condition Trouble Area
Front airbag sensor (RH)
Wire harness
Engine room main wire harness
Airbag sensor assembly
Front airbag sensor (RH) malfunction WIRING DIAGRAM Airbag Sensor Assembly Front Airbag Sensor (RH) SR+ SR– B–W 2 II1 B–W 9 C5 BR–W 1 II1 BR–W 20 C5 SR– 2 1 SR+ H02750 DI–293 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (RH) ON (+) H03355 AB0119 H03363 (–) Airbag Sensor Assembly CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the voltage between body ground and each of SR+ and SR–. OK: Voltage: Below 1 V SR+ NG SR– Go to step 8. H03445 OK 3 Check wire harness (to ground). Airbag Sensor Assembly Front Airbag Sensor (RH) (+) (–) H03353 H03361 Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between body ground and each of SR+ and SR–. OK: Resistance: 1 MΩ or Higher SR+ SR– H03443 NG OK Go to step 9. DI–294 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly Airbag Sensor Assembly CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR–. OK: Resistance: 1 MΩ or Higher SR+ (+) (–) SR– H03355 H03356 H09518 NG Go to step 10. OK 5 Check wire harness. Front Airbag Sensor (RH) Airbag Sensor Assembly SR+ SR– (+) (–) H03353 H09521H03356 OK Airbag Sensor Assembly SR+ PREPARATION: Using a service wire, connect SR+ and SR– of the connector (on the front airbag sensor (RH) side) between the airbag sensor assembly and the front airbag sensor (RH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (RH) and the airbag sensor assembly, measure the resistance between SR+ and SR–. OK: Resistance: Below 1 Ω SR– H09523 NG Go to step 11. DI–295 DIAGNOSTICS 6 Airbag Sensor Assembly SR+ OK SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (RH). Front Airbag Sensor (RH) H04504 H01062 – (+) CHECK: For the connector (on the front airbag sensor (RH)), measure the resistance between SR+ and SR–. OK: Resistance: 300 – 1500 Ω SR– (–) H08346 NG Replace front airbag sensor (RH). DI–296 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (RH) Airbag Sensor Assembly →← ACC →← ON or DLC1 DTC B1156/B1157/15 E1 H02757 AB0118 AB0119 R13006H01063 Tc H04014 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (RH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See step 5 on page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B1156/B1157/15 is not output. HINT: Codes other than code B1156/B1157/15 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–297 DIAGNOSTICS 8 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness (to B+). Front Airbag Sensor (RH) ←→ Airbag Sensor Assembly Engine Room Main Wire Harness ON SR+ (–) SR– (+) PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the RH front door wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the voltage between body ground and each of SR+ and SR–. OK: Voltage: Below 1 V NG H03354 AB0119 H06141 H08272 Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. 9 Check engine room main wire harness (to ground). Front Airbag Sensor (RH) Airbag Sensor Assembly Engine Room Main Wire Harness (–) SR+ SR– PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between body ground and each of SR+ and SR–. OK: Resistance: 1 MΩ or Higher (+) NG H03354 H06140 Repair or replace engine room main wire harness. H08258 OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. DI–298 DIAGNOSTICS 10 SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Front Airbag Sensor (RH) Engine Room Main Wire Harness ←→ SR+ H03354 H09519 – (+) Airbag Sensor Assembly SR– (–) H09520 PREPARATION: Disconnect the engine room main wire harness connector on the airbag sensor assembly side. CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SR+ and SR–. OK: Resistance: 1 MΩ or Higher NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. DI–299 DIAGNOSTICS 11 – SUPPLEMENTAL RESTRAINT SYSTEM Check engine room main wire harness. Engine Room Main Wire Harness Front Airbag Sensor (RH) Airbag Sensor Assembly ←→ SR+ SR– SR+ (+) H03352 H09521 H09519 SR– (–) PREPARATION: (a) Disconnect the engine room main wire harness connector on the airbag sensor assembly side. (b) Using a service wire, connect SR+ and SR– of the connector (on the engine room main wire harness side) between the engine room main wire harness and the front airbag sensor (RH). CHECK: For the connector (on the engine room main wire harness side) between the airbag sensor assembly and the engine room main wire harness, measure the resistance between SR+ and SR–. OK: Resistance: Below 1 Ω H09522 NG Repair or replace engine room main wire harness. OK Repair or replace harness or connector between airbag sensor assembly and engine room main wire harness. DI–300 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI4LB–03 DTC B1158/B1159/16 Front Airbag Sensor (LH) Malfunction CIRCUIT DESCRIPTION The front airbag sensor (LH) circuit consists of the airbag sensor assembly and front airbag sensor (LH). For details of the function of each component, see Pub. No. RM654U on page RS–2. DTC B1158/B1159/16 is recorded when malfunction is detected in the front airbag sensor (LH) circuit. DTC No. B1158/B1159/16 DTC Detecting Condition Trouble Area
Front airbag sensor (LH)
Wire harness
Airbag sensor assembly
Front airbag sensor (LH) malfunction WIRING DIAGRAM Front Airbag Sensor (LH) SL+ SL– Airbag Sensor Assembly W–R 15 C5 SL+ BR 26 C5 SL– 2 1 H02751 DI–301 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection (See step 1 on page DI–305). 2 Check wire harness (to B+). Airbag Sensor Assembly Front Airbag Sensor (LH) ON Airbag Sensor Assembly CHECK: (a) Turn ignition switch to ON. (b) For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the voltage between body ground and each of SL+ and SL–. OK: Voltage: Below 1 V SL+ (+) NG H01370 AB0119 H08065 (–) SL– H08066 Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. OK 3 Check wire harness (to ground). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between body ground and each of SL+ and SL–. OK: Resistance: 1 MΩ or Higher Airbag Sensor Assembly Front Airbag Sensor (LH) (+) Airbag Sensor Assembly SL+ NG H01370 H08399 OK (–) SL– H08400 Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. DI–302 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Check wire harness. CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL–. OK: Resistance: 1 MΩ or Higher Front Airbag Sensor (LH) Airbag Sensor Assembly Airbag Sensor Assembly (+) SL+ (–) SL– H01370 H08058 H09524 NG Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. OK 5 Check wire harness. Front Airbag Sensor (LH) Airbag Sensor Assembly SL+ Airbag Sensor Assembly SL– (+) (–) H09526 H09521H08058 OK SL+ SL– H09525 PREPARATION: Using a service wire, connect SL+ and SL– of the connector (on the front airbag sensor (LH) side) between the airbag sensor assembly and the front airbag sensor (LH). CHECK: For the connector (on the airbag sensor assembly side) between the front airbag sensor (LH) and the airbag sensor assembly, measure the resistance between SL+ and SL–. OK: Resistance: Below 1 Ω NG Repair or replace harness or connector between front airbag sensor (LH) and airbag sensor assembly. DI–303 DIAGNOSTICS 6 – SUPPLEMENTAL RESTRAINT SYSTEM Check front airbag sensor (LH). Airbag Sensor Assembly CHECK: For the connector (on the front airbag sensor (LH)), measure the resistance between SL+ and SL–. OK: Resistance: 300 – 1500 Ω Front Airbag Sensor (LH) SL+ H01371 H01009 OK (+) SL– (–) H01155 NG Replace front airbag sensor (LH). DI–304 DIAGNOSTICS 7 – SUPPLEMENTAL RESTRAINT SYSTEM Check airbag sensor assembly. Front Airbag Sensor (LH) Airbag Sensor Assembly →← ACC →← ON or DLC1 E1 H01369 AB0118 AB0119 R13006 H01064 DTC B1158/B1159/16 Tc H01154 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Connect the front airbag sensor (LH) connector and airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. CHECK: (a) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (b) Clear DTC stored in memory (See page DI–223). (c) Turn ignition switch to LOCK, and wait at least for 20 seconds. (d) Turn ignition switch to ACC or ON, and wait at least for 20 seconds. (e) Check DTC (See page DI–223). OK: DTC B1158/B1159/16 is not output. HINT: Codes other than code B1158/B1159/16 may be output at this time, but they are not relevant to this check. NG Replace airbag sensor assembly. OK From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–305 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BN–12 DTC Normal Source Voltage Drop CIRCUIT DESCRIPTION The SRS is equipped with a voltage–increase circuit (DC–DC converter) in the airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage–increase circuit (DC–DC converter) functions to increase the voltage of the SRS to normal voltage. The diagnosis system malfunction display for this circuit is different from other circuits that is when the SRS warning light remains lit up and the DTC is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the airbag sensor assembly, and the source voltage returns to normal, the SRS warning light automatically goes off. DTC No. Diagnosis (Normal) Source voltage drop WIRING DIAGRAM Battery FL MAIN B–G Instrument Panel J/B 40A AM1 2 1 2 1K W Fusible Link Block 1 1 F11 F9 100A ALT 2 F14 Instrument Panel J/B 4 5 W–R 5 W–R 2L 1B 1K Ignition Switch 7 6 B–R 3 1K 2 3 L–R 6 1K Junction Connector A W–B IF 7 1J 30A AM2 5A IGN 15A CIG B B–R 1 1B 1 2A Airbag Sensor Assembly 4 1N B–O 5 C5 IG2 2 1N GR 6 C5 ACC 1 1N W–B 27 C5 E1 Instrument Panel J/B H02288 DI–306 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE 1 Prepare for inspection. LOCK Airbag Sensor Assembly P/T Squib (LH) Front Airbag Sensor (LH) D Squib Spiral Cable P Squib Front Airbag Sensor (RH) P/T Squib (RH) AB0117 H02756 H02774 PREPARATION: (a) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (b) Remove the steering wheel pad (See Pub. No. RM654U on page SR–11). (c) Disconnect the connector of the front passenger airbag assembly (See Pub. No. RM654U on page RS–28). (d) Disconnect the connector of the seat belt pretensioner RH and LH (See Pub. No. RM654U on page BO–126). (e) Disconnect the connectors of the airbag sensor assembly (See Pub. No. RM654U on page RS–59). (f) Disconnect the connector of the front airbag sensor RH and LH (See Pub. No. RM654U on page RS–64). CAUTION: Store the steering wheel pad and front passenger airbag assembly with the front surface facing upward. DI–307 DIAGNOSTICS 2 – SUPPLEMENTAL RESTRAINT SYSTEM Check source voltage. ON Airbag Sensor Assembly ACC (–) AB0119 H01298 IG2 (+) H01299 PREPARATION: Connect negative (–) terminal cable to the battery. CHECK: (a) Turn ignition switch ON. (b) Measure the voltage each of IG2 and ACC on the sensor and operate electric system (defogger, wiper, headlight, heater blower, etc.). OK: Voltage: 10 – 14 V NG Check harness between battery and airbag sensor assembly, and check battery and charging system. OK 3 Does SRS warning light turn off? ON H01249 PREPARATION: (a) Turn ignition switch to LOCK. (b) Connect the steering wheel pad connector. (c) Connect the front passenger airbag assembly connector. (d) Connect the airbag sensor assembly connectors. (e) Connect the seat belt pretensioner connectors. (f) Connect the front airbag sensor connectors. (g) Turn ignition switch to ON. CHECK: Operate electric system (defogger, wiper, headlight, heater blower, etc.) and check that SRS warning light goes off. NO Check for DTCs. If a DTC is output, perform troubleshooting for the DTC. If a normal code is output, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. DI–308 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI64R–01 SRS Warning Light Circuit Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the SRS is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from the LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1 of the DLC1 are connected, the DTC is displayed by blinking the SRS warning light. WIRING DIAGRAM Battery FL MAIN Airbag Sensor Assembly 3 LA C5 Fusible Link Block 1 1 F9 F11 B–G J2 Junction Connector B–Y 1 2A A LG 13 7 2J Instrument Panel J/B SRS Warning Light 2 IE2 LG A B Engine Room J/B No.2 10A ECU–B Short Pin W–R 12 2 1G 3 1W W–R A LG DLC1 7 IG3 LG 5 AB J2 Junction Connector 19 TC C5 P–B B LG–R B 11 IG3 LG–R 11 LG–R B TC DLC2 4 TC H02289 DI–309 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE Always lit up, when ignition switch is in LOCK position 1 Prepare for inspection. (See step 1 on page DI–305) 2 Does SRS warning light turn off? Airbag Sensor Assembly LOCK AB0117 H01293 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Connect negative (–) terminal cable to the battery. CHECK: Check operation of SRS warning light. H01295 NO YES Replace airbag sensor assembly. Check SRS warning light circuit or terminal AB circuit of DLC1. DI–310 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM Does not light up, when ignition switch is turned to ACC or ON 1 Check ECU–B Fuse. Fuse N14677 PREPARATION: Remove ECU–B fuse. CHECK: Check continuity of ECU–B fuse. OK: Continuity HINT:
Fuse may be burnt out even if it appears to be OK during visual inspection.
If fuse is OK, install it. NG Go to step 5. OK 2 Prepare for inspection. (See step 1 on page DI–305) 3 Check SRS warning light circuit. Airbag Sensor Assembly ON (+) LA (–) AB0119 H01300 PREPARATION: (a) Connect negative (–) terminal cable to the battery. (b) Turn ignition switch to ACC or ON. CHECK: Measure the voltage LA terminal of the harness side connector of the airbag sensor assembly. OK: Voltage: 10 – 14 V H01301 NG OK Check SRS warning light bulb or repair SRS warning light circuit. DI–311 DIAGNOSTICS 4 – SUPPLEMENTAL RESTRAINT SYSTEM Does SRS warning light come on? Airbag Sensor Assembly P/T Squib (LH) Front Airbag Sensor (LH) D Squib PREPARATION: (a) Disconnect negative (–) terminal cable from the battery. (b) Connect the airbag sensor assembly connector. (c) Connect negative (–) terminal cable to the battery, and wait at least for 2 seconds. (d) Turn ignition switch to ACC or ON. CHECK: Check operation of SRS warning light. Spiral Cable P Squib Front Airbag Sensor (RH) P/T Squib (RH) ON H02755 AB0119 H10313 H10308 NO Check terminal LA of airbag sensor assembly. If normal, replace airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use simulation method to check. DI–312 DIAGNOSTICS 5 – SUPPLEMENTAL RESTRAINT SYSTEM Is new ECU–B fuse burnt out again? NO YES Check harness between ECU–B fuse and SRS warning light. Using simulation method, reproduce malfunction symptoms. (See page IN–19) DI–313 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM DI1BQ–12 Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode. The DTCs are displayed by blinking the SRS warning light. WIRING DIAGRAM BR 3 E1 Airbag Sensor Assembly J2 Junction Connector DLC1 Tc LG–R 11 11 IG3 LG–R B P–B B 19 C5 Tc A J20 Junction Connector DLC2 A 3 E1 Tc LG–R 4 B BR Junction Connector BR C J6 B J7 BR 6 IG3 J20 Junction Connector BR A A BR EC H08301 EC H10309 DI–314 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE If the DTC is not displayed, do the following troubleshooting. 1 Does SRS warning light up for approx. 6 seconds? LOCK ACC ON PREPARATION: Check operation of the SRS warning light after ignition switch is turned from LOCK position to ACC or ON position. or AB0117 AB0118 H10313 AB0119 H10315 NO Check SRS warning light system. (See page DI–223) YES 2 Check voltage between terminals Tc and E1 of DLC1. ACC ON or E1 (–) AB0118 AB0119 R14305 Tc PREPARATION: Turn ignition switch to ACC or ON. CHECK: Measure the voltage between terminals Tc and E1 of DLC1. OK: Voltage: 10 – 14 V (+) H00030 OK NG Go to step 4. DI–315 DIAGNOSTICS 3 – SUPPLEMENTAL RESTRAINT SYSTEM Check voltage between terminal Tc of DLC1 and body ground. CHECK: Measure the voltage between terminal Tc of DLC1 and body ground. OK: Voltage: 10 – 14 V ON ACC Tc or (–) (+) OK AB0118 AB0119 R14304 H00031 Check harness between terminal E1 of DLC1 and body ground. NG 4 Check airbag sensor assembly. LOCK ACC ON or Airbag Sensor Assembly Tc AB0117 AB0118 AB0119 H01302 H01303 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. (d) Insert service wire into terminal Tc from back side as shown in the illustration. (e) Connect the airbag sensor assembly connector with service wire. (f) Connect negative (–) terminal cable to the battery. (g) Turn ignition switch to ACC or ON and wait at least for 20 seconds. (h) Connect service wire of terminal Tc to body ground. CHECK: Check operation of SRS warning light. OK: SRS waning light comes on. NOTICE: Pay due attention to the terminal connecting position to avoid a malfunction. OK NG Replace airbag sensor assembly. Check harness between the airbag sensor assembly and DLC1. DI–316 DIAGNOSTICS – SUPPLEMENTAL RESTRAINT SYSTEM If the DTC is displayed without a DTC check procedure, perform the following troubleshooting. 1 Check resistance between terminal Tc of airbag sensor assembly and body ground. Airbag Sensor Assembly LOCK Tc (–) AB0119 H01304 (+) H01305 PREPARATION: (a) Turn ignition switch to LOCK. (b) Disconnect negative (–) terminal cable from the battery, and wait at least for 90 seconds. (c) Disconnect the airbag sensor assembly connector. CHECK: Check resistance between terminal Tc of the airbag sensor assembly connector and body ground. OK: Resistance: 1 MΩ or Higher NG OK Replace airbag sensor assembly. Repair or replace harness or connector. DI–317 DIAGNOSTICS – CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM DI08F–12 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following page. Vehicle Brought to Workshop 1 Items inside are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated pages for detailed explanations. Customer Problem Analysis P. DI–318 2 Check and Clear DTC (Precheck) P. DI–319 Symptom does not occur 3 4 Problem Symptom Confirmation Symptom Simulation P. IN–19 Symptom occurs 5 Normal code DTC Check P. DI–319 Malfunction code 6 7 DTC Chart Problem Symptoms Table P. DI–328 P. DI–324 9 8 Circuit Inspection Input Signal Check Parts Inspection P. DI–329 Identification of Problem Repair NG 10 Confirmation Test OK Step 2, 5: Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. End Author: Date: 387 DI–318 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08G–09 CUSTOMER PROBLEM ANALYSIS CHECK CRUISE CONTROL SYSTEM Check Sheet Inspector’s name: Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Brought in / / Date of Problem Occurrence Condition of How Often does Problem Occurrence Problem Occurs / Continuous Symptoms / Intermittent ( Vehicle Speed when Problem Occurred Auto cancel occurs km Mile Odometer Reading Times a day) km Mile
Driving condition  City driving  Freeway  Up hill  Down hill
After cancel occurred, did the driver activate cruise control again?  Yes  No  Cancel does not occur  With brake ON  Except D position shift  At 40 km/h (25 mph) or less  When control SW turns to CANCEL position  Cruise control malfunction  Slip to acceleration side  Slip to deceleration side  Hunting occurs  O/D cut off does not occur  O/D does not return  Switch malfunction   SET  ACCEL  COAST  RESUME  CANCEL  Remains ON  Does not light up 1st Time  Normal Code  Malfunction Code (Code ) 2nd Time  Normal Code  Malfunction Code (Code ) DTC Check  Blinking DI–319 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI1KS–04 PRE–CHECK 1. (a) CRUISE MAIN Indicator Light I00279 HINT: If the indicator check result is not normal, proceed to troubleshooting (See page BE–1) for the combination meter section. (b) Check the DTC. HINT: If a malfunction occurs in the No. 1 vehicle speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a DTC. Indicator light 1.5 sec. DIAGNOSIS SYSTEM Check the indicator. (1) Turn the ignition switch ON. (2) Check that the CRUISE MAIN indicator light comes ON when the cruise control main switch is turned ON, and that the indicator light goes OFF when the main switch is turned OFF. 0.5 sec. ON OFF BE4034 (c) DLC2 Tc E1 I00169 Output of DTC using diagnosis check wire. (1) Turn the ignition switch ON. (2) Using SST, connect terminals Tc and E1 of DLC2. SST 09843–18020 (3) Read the DTC on the CRUISE MAIN indicator light. DI–320 DIAGNOSTICS – CRUISE CONTROL SYSTEM HINT: If the DTC is not output, inspect the diagnosis circuit (See page DI–362). As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. Normal code 0.25 sec. 0.25 sec. ON OFF Malfunction codes 11 and 21 0.5 sec. 4 sec. 0.5 sec. 1.5 sec. 2.5 sec. 1.5 sec. ON OFF Code 11 BE4032 BE4033 Code 21 I00021 2. (a) (b) DLC2 H07517 (b) E1 (d) 5 times within 3 seconds DLC1 TC (c) I08438 USING TOYOTA HAND–HELD TESTER Hook up the TOYOTA hand–held tester to the DLC2. Monitor the ECU data by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” function which records the monitored data. Please refer to the TOYOTA hand–held tester operator’s manual for further details. 3. DTC CLEARANCE (ERASE MODE) HINT: During in the erase mode, diag detection does not work. (a) Stop the vehicle. (b) Using SST, connect terminals Tc and E1 of DLC1. SST 09843–18020 (c) Pull the cruise control switch to CANCEL. (d) On the above metioned condition, turn on the cruise control main switch 5 times within 3 seconds. DI–321 DIAGNOSTICS – CRUISE CONTROL SYSTEM 4. (a) PROBLEM SYMPTOM CHECK (ROAD TEST) Inspect the SET switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Press the control switch to the SET/COAST. (4) After releasing the switch, check that the vehicle cruises at the desired speed. (b) Inspect the ACCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. (4) Momentarily raise the control switch upward to the RES/ACC position and then immediately release it. Check that the vehicle speed increases by approx. 1.5 km/h (Tap–up function). (c) Inspect the COAST switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) Check that the vehicle speed decreases while the control switch is turned to SET/COAST, and the vehicle cruises at the set speed when the switch is released. (4) Momentarily pull the control switch down to SET/ COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap–down function). N17520 N17520 N17520 DI–322 DIAGNOSTICS CRUISE CONTROL SYSTEM (d) Inspect the CANCEL switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations, check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Push the main switch OFF
Pull the cruise control switch to CANCEL (e) Inspect the RESUME switch. (1) Push the main switch ON. (2) Drive at a desired speed (40 km/h (25 mph) or higher). (3) When operating one of the following operations check that the cruise control system is cancelled and that the normal driving mode is reset.
Depress the brake pedal
Shift to except D position
Push the main switch OFF
Pull the cruise control switch to CANCEL (4) After the control switch is turned to RES/ACC at the driving speed of more than 40 km/h (25 mph), check that the vehicle restores the speed prior to the cancellation. N17520 N17520 – DI–323 DIAGNOSTICS (1) (2) (1) No. N17520 – 5. INPUT SIGNAL CHECK HINT: (1): For check No.1 – No.3
Turn ignition switch ON. (2): For check No.4
Jack up the vehicle.
Start the engine.
Shift to D position. (a) Pull the control switch to SET/COAST or RES/ACC position and hold it down or up (1). (b) Push the main switch ON (2). (c) Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. (d) Turn the SET/COAST or RES/ACC switch OFF. (e) Operate each switch as listed in the table below. (f) Read the blinking pattern of the CRUISE MAIN indicator light. (g) After performing the check, turn the main switch OFF. HINT: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed first. CRUISE MAIN Indicator Light Blinking Pattern Operation Method 0.25 sec. 1 Turn SET/COAST switch ON CRUISE CONTROL SYSTEM Light ON 0.25 sec. SET/COAST switch circuit is normal 1sec. OFF ON 2 Turn RES/ACC switch ON Light RES/ACC switch circuit is normal OFF Turn CANCEL switch ON ON Switch ON OFF Turn stop light switch ON Depress brake pedal ON Turn PNP switch OFF (Shift to except D position) Light Drive at about 40 km/h (25 mph)or higher Light Drive at about 40 km/h (25 mph) or below Light OFF 4 CANCEL switch circuit is normal Switch OFF Light 3 Diagnosis Stop light switch circuit is normal Switch ON Switch OFF PNP switch circuit is normal ON OFF ON OFF Vehicle Speed Sensor is normal DI–324 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08I–09 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. DTC No. (See Page) Circuit Inspection Trouble Area Actuator Motor Circuit
Actuator motor
Harness or connector between cruise control ECU and actuator motor
Cruise control ECU 12 (DI–331) Actuator Magnetic Clutch Circuit
STOP Fuse
Stop light switch
Actuator magnetic clutch
Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground
Cruise control ECU 14 (DI–334) Actuator Mechanical Malfunction
Actuator motor (actuator lock: motor, arm)
Cruise control ECU 21 (DI–336) Open in Vehicle Speed Sensor Circuit
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU 23 (DI–339) Vehicle Speed Signal Abnormal
Vehicle speed sensor
Cruise control ECU Control Switch Circuit
Cruise control switch
Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground
Cruise control ECU 41 Cruise control ECU
Cruise control ECU 42 Source voltage drop
Power source Idle Signal Circuit
Throttle position sensor
Harness or connector between ECM and throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU 11, 15 (DI–329) 32 (DI–340) 51 (DI–343) DI–325 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08J–09 PARTS LOCATION Cruise Control Actuator
Actuator Motor
Actuator Magnetic Clutch Stop Light Switch Cruise Control switch
Main Switch
Control Switch Cruise Control ECU Instrument Panel Junction Block No.1
ECU–IG Fuse
STOP Fuse DLC2 Vehicle Speed Sensor Park/Neutral Position Switch I08453 DI–326 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI1KT–07 TERMINALS OF ECU C16 I00293 Symbols (Terminals No.) Wiring Color STP ↔ GND STP– (C16–2 ↔ C16–16) G W ↔ W–B G–W W B D ↔ GND (C16–3 (C16 3 ↔ C16–16) C16 16) B R ↔ W–B B–R W B PI ↔ GND (C16–4 (C16 4 ↔ C16–16) C16 16) TC ↔ GND (C16–5 ↔ C16–16) ECT ↔ GND (C16–6 ↔ C16–16) O ↔ W–B W B LG–R ↔ W–B L B ↔ W–B L–B W B MC ↔ GND (C16–7 ↔ C16–16) R B ↔ W–B R–B W B L ↔ GND (C16–8 ↔ C16–16) G B ↔ W–B G–B W B B ↔ GND (C16–9 ↔ C16–16) B–R ↔ W–B CCS ↔ GND (C16–10 ↔ C16–16) W ↔ W–B Condition STD Voltage (V) Depress brake pedal 10 – 16 V Release brake pedal Below 1 V Shift to positions except D Below 1 V Shift to D position 10 – 16 V Ignition switch ON Cruise control main switch ON Below 1.2 V Ignition switch ON Cruise control main switch OFF 10 – 16 V Ignition switch ON 10 – 16 V Ignition switch ON Connect terminals Tc and E1 of diagnostic check connector Below 1 V During driving Gear position 3rd 10 – 16 V During driving Gear position O/D Below 1 V During cruise control driving COAST switch held ON 9 – 15 V During cruise control driving ACC switch held ON Below 1 V During cruise control driving 9 – 15 V Except during cruise control driving Below 1 V Ignition switch ON 10 – 16 V Ignition switch ON 10 – 16 V Ignition switch ON CANCEL switch held ON 4.2 – 8.8 V Ignition switch ON SET/COAST switch held ON 2.5 – 6.3 V Ignition switch ON RES/ACC switch held ON 0.8 – 3.7 V DI–327 DIAGNOSTICS Symbols (Terminals No.) W L ↔ W–B W–L W B SPD ↔ GND (C16 12 ↔ C16–16) (C16–12 C16 16) V–W V W↔W W–B B OD ↔ GND (C16–14 ↔ C16–16) CRUISE CONTROL SYSTEM Wiring Color CMS ↔ GND (C16–11 ↔ C16–16) IDL ↔ GND (C16–13 ↔ C16–16) – Condition Ignition switch ON Main switch OFF 10 – 16 V Ignition switch ON Main switch ON Below 0.5 V Engine start Car stoppage. During driving (Pulse generated). L R ↔ W–B L–R W B Y B ↔ W–B Y–B W B MO ↔ GND (C16–15 ↔ C16–16) R G ↔ W–B R–G W B GND ↔ Body Ground (C16–16 ↔ Body Ground) W–B ↔ Body Ground STD Voltage (V) Below 1.5 V or 4.7 – 16 V 3–7V Ignition switch ON Throttle valve fully opened. 10 – 16 V Ignition switch ON Throttle valve fully closed. Below 1.5 V During cruise control driving OD switch ON. 10 – 16 V During cruise control driving OD switch OFF (3rd driving) Below 1 V During cruise control driving ACC switch hold ON 9 – 15 V During cruise control driving COAST switch hold ON Below 1 V Constant Below 1 V DI–328 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08L–14 PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page SET not occourring or CANCEL occurring. (DTC is Normal) 1. Main Switch Circuit (Cruise control switch) 2. Vehicle Speed Sensor 3. Control Switch Circuit (Cruise control switch) 4. Stop Light Switch Circuit 5. Park/Neutral Position Switch Circuit 6. Actuator Motor Circuit 7. Cruise Control Cable 8. Cruise Control ECU SET not occurring or CANCEL occurring. (DTC dose not output) 1. ECU Power Source Circuit 2. Cruise Control ECU DI–355 IN–29 DI–364 DI–339 Actual vehicle speed deviates above or below the set speed. 1. Cruise Control Cable 2. Vehicle Speed Signal Abnormal 3. Electronically Controlled Transmission Communication Circuit 4. Actuator Motor Circuit 5. Idle Signal Circuit (Main throttle position sensor) 6. Cruise Control ECU DI–358 DI–336 DI–340 DI–346 DI–352 DI–329 DI–364 IN–29 DI–349 DI–329 DI–343 IN–29 Gear shifting frequent between 3rd O/D when driving on uphill road. (Hurting) 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU DI–349 IN–29 Cruise control not cancelled, even when brake pedal is depressed. 1. 2. 3. 4. Cruise Control Cable Stop Light Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–364 DI–346 DI–329 IN–29 Cruise control not cancelled, even when transmission is shifted to ”N” postion. 1. 2. 3. 4. Cruise Control Cable Park/Neutral Position Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–364 DI–352 DI–329 IN–29 Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) 1. 2. 3. 4. Cruise Control Cable Control Switch Circuit Actuator Motor Circuit Cruise Control ECU DI–364 DI–340 DI–329 IN–29 SET possible at 40 km/h (25 mph) or less, or CANCEL does not operate at 40 km/h (25 mph) or less. 1. 2. 3. 4. Cruise Control Cable Vehicle Speed Signal Abnormal Actuator Motor Circuit Cruise Control ECU DI–364 DI–339 DI–329 IN–29 Poor response is in ACCEL and RESUME modes. 1. Cruise Control Cable 2. Electronically Controlled Transmission Communication Circuit 3. Actuator Motor Circuit 4. Cruise Control ECU O/D does not resume, even though the road is not uphill. 1. Electronically Controlled Transmission Communication Circuit 2. Cruise Control ECU DI–349 IN–29 DTC memory is erased. 1. Cruise Control ECU IN–29 DTC is not output, or is output when should not be. 1. Diagnosis Circuit 2. Cruise Control ECU DI–362 IN–29 Cruise MAIN indicator light remains ON or falls to light up. 1. Cruise MAIN Indicator Light Switch Circuit DI–360 DI–364 DI–349 DI–329 IN–29 DI–329 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08M–13 CIRCUIT INSPECTION DTC 11, 15 Actuator Motor Circuit CIRCUIT DESCRIPTION The actuator motor is operated by signals from the ECU. Acceleration and deceleration signals are transmitted according to changes in the Duty Ratio (See below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity. A A Duty Ratio = A+B DTC No. ON x 100 (%) B 1 cycle OFF DTC Detecting Condition Trouble Area 11 Short in actuator motor circuit.  Actuator motor  Harness or connector between cruise control ECU and actuator motor  Cruise control ECU 15 Open in actuator motor circuit.  Actuator motor WIRING DIAGRAM Cruise Control ECU Cruise Control Actuator
Actuator Motor 1 C3 15 R–G 2 C3 C16 MO 7 R–B C16 MC N21216 DI–330 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check resistance between terminals MO and MC of actuator motor. ON 2 1 I00004 I00151 PREPARATION: (a) Turn ignition switch ON. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 1 and 2. HINT: If control plate is in fully opened or fully closed positions, resistance can not be measured. OK: Resistance: more than 4.2 Ω NG Replace cruise control actuator. OK 2 Check for open and short in harness and connectors between cruise control ECU and actuator motor (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–331 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08N–13 DTC 12 Actuator Magnetic Clutch Circuit CIRCUIT DESCRIPTION This circuit turns on the magnetic clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control operation, the rotor shaft between the motor and control plate is released. When the brake pedal is depressed, the stop light switch turns on, supplying electrical power to the stop light. Power supply to the magnetic clutch is mechanically cut and the magnetic clutch is turned OFF. When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the safety magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph), cruise control at the set speed is resumed. DTC No. DTC Detecting Condition Trouble Area  STOP Fuse  Stop light switch  Actuator magnetic clutch  Harness or connector between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground  Cruise control ECU Short in actuator magnetic clutch circuit. Open (0.8 sec.) in actuator magnetic clutch circuit. 12 WIRING DIAGRAM Cruise Control ECU A J6 J/C Cruise Control Actuator
Actuator Magnetic Clutch A J6 4 W–B 3 R–Y Stop Light Switch 4 3 1 2 8 C16 G–B L W–B 8 1J Instrument Panel J/B 7 1J Stop Lights STOP Fuse W–B A J9 J/C IF I00281 DI–332 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check STOP fuse. Instrument panel junction block No.1: STOP Fuse PREPARATION: (a) Turn ignition switch OFF. (b) Remove the STOP fuse from instrument panel junction block No.1. CHECK: Check fuse continuity. OK: There is continuity. I00157 NG Replace STOP fuse. OK 2 Check stop light switch. 2 4 1 PREPARATION: Disconnect the stop light switch connector. CHECK: Check continuity between terminals. 3 I00133 NG OK Switch position Continuity Switch pin free (Brake pedal depressed) 1–2 Switch pin pushed in (Brake pedal released) 3–4 Replace stop light switch. DI–333 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check resistance between terminals L and GND of actuator magnetic clutch. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Measure resistance between terminals 3 and 4. OK: Resistance: 34.65 – 42.35 Ω 4 3 I00311 NG Replace cruise control actuator. OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch, actuator magnetic clutch and body ground (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–334 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08O–13 DTC 14 Actuator Mechanical Malfunction CIRCUIT DESCRIPTION The circuit detects the rotation position of the actuator control plate and sends a signal to the ECU. DTC No. 14 DTC Detecting Condition Trouble Area Cruise control actuator mechanical malfunction.
Actuator lock: (motor, arm)
Actuator motor
Cruise control ECU WIRING DIAGRAM See page DI–329. INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation 4 (+) (–) 3 I00055 PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to the terminal 3 of actuator and the negative (–) lead to terminal 4. NOTICE: Do not connect the high tension cables to the wrong battery terminal. The cruise control actuator will be damaged. Move the control plate by hand. OK: Control plate doesn’t move. NG OK Replace cruise control actuator. DI–335 DIAGNOSTICS 2 – CRUISE CONTROL SYSTEM Check cruise control actuator operation. PREPARATION: (a) Turn ignition switch OFF. (b) Disconnect the actuator connector. CHECK: Connect the positive (+) lead from the battery to terminals 1 and 3 of actuator, connect the negative (–) lead to terminals 2 and 4 of actuator. OK: Control arm moves to fully open side Fully open side 4 1 3 2 Control plate CHECK: Connect the positive (+) lead from the battery to terminals 2 and 3 of actuator, connect the negative (–) lead to terminals 1 and 4 of actuator. OK: Control arm moves to fully colsed side Fully Closed side 4 1 3 2 Control plate I08437 NG Replace cruise control actuator. OK 3 Check harness and connector between cruise control ECU and cruise control actuator (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–336 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08P–13 DTC 21 Open in Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The signal from the vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. The rotor shaft is driven by the gear of the transmission. For each rotation of the shaft, the vehicle speed sensor sends a 4–pulse signal through the combination meter to the cruise control ECU (See the following installation). This signal is converted inside the combination meter and sent as a 4–pulse signal to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. 4 pulses/ 4 pulses/ 1 rotation 1 rotation of rotor shaft of rotor shaft Vehicle Speed Sensor Combination Meter ECU DTC No. 21 Cruise Control ECU DTC Detecting Condition I00292 Trouble Area Speed signal is not input to the cruise control ECU while cruise control is set.
Combination meter
Harness or connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor
Vehicle speed sensor
Cruise control ECU WIRING DIAGRAM Cruise Control ECU Combination Meter 15 C11 L P 7 2 IH1 14 3 C11 IF1 V–W B V–W 12 B C16 V–W SPD 6 IH1 L 3 SI C12 Speedo –meter J15 J/C P 2 SE Speed Sensor IG+ 1 to GAUGE Fuse R–L I00282 DI–337 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Input Signal Indicator Light Blinking Pattern Drive at about 40 km/h (25 mph) or below Light Drive at about 40 km/h (25 mph) or higher Light ON OFF ON OFF CHECK: (a) See input signal check on page DI–319. (b) Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph). OK: Vehicle speed above 40 km/h (25 mph): Indicator light blinks Vehicle speed below 40 km/h (25 mph): Indicator light stays on OK Check and replace cruise control ECU (See page IN–29). NG 2 Check speedometer circuit (See Combination meter troubleshooting on page BE–1). NG Repair or replace harness, connector or combination meter assembly. OK 3 Check harness and connector between cruise control ECU and combination meter, combination meter and vehicle speed sensor (See page IN–29). NG OK Repair or replace harness or connector. DI–338 DIAGNOSTICS 4 – CRUISE CONTROL SYSTEM Check vehicle speed sensor (See Pub. No. RM654U on page BE–47). NG OK Check and replace cruise control ECU (See page IN–29). Replace vehicle speed sensor. DI–339 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08Q–11 DTC 23 Vehicle Speed Signal Abnormal CIRCUIT DESCRIPTION See page DI–336. DTC No. 23 DTC Detecting Condition Trouble Area
Vehicle speed sensor
Cruise control ECU Vehicle speed sensor pulse is abnormal. WIRING DIAGRAM See page DI–336. INSPECTION PROCEDURE 1 Check vehicle speed sensor (See Pub. No. RM654U on page BE–47). NG OK Check and replace cruise control ECU (See page IN–29). Replace vehicle speed sensor. DI–340 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08R–13 DTC 32 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. DTC No. 32 DTC Detecting Condition Trouble Area  Cruise control switch  Harness or connector between cruise control ECU and cruise control switch, cruise control switch and body ground  Cruise control ECU Short in control switch circuit. WIRING DIAGRAM Cruise Control Switch
Main Switch
Control Switch MAIN Cruise Control ECU 11 CMS 5 C16 W–L CANCEL CMS SET/COAST RES/ACC 3 EP 10 CCS 4 C16 W A J6 W–B J9 J/C Instrument Panel J/B A W–B 7 8 1J 1J A J/C CCS A J7 16 C16 W–B GND J6 W–B IF I00283 DI–341 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Input signal check. Indicator Light Blinking Pattern Input Signal SET/COAST switch 2 Pulses ON OFF RESUME/ACCEL switch OFF ON CANCEL switch 3 Pulses ON SW OFF OFF SW ON PREPARATION: See input signal check on page DI–319. CHECK: Check the indicator light operation when each of the SET/ COAST, RESUME/ACCEL and CANCEL is turned on. OK: SET/COAST, RESUME/ACCEL switch The signals shown in the table on the left should be output when each switch is ON. The signal should disappear when the switch is turned OFF. CANCEL switch The indicator light goes off when the cancel switch is turned ON. OK Wait and see. NG 2 Check voltage between terminals CCS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals 18 of ECU connector and body ground, when each of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON. ON CCS (–) (+) AB0119 I00168 I00171 OK NG Switch position Resistance (V) Neutral 10 – 16 V RES/ACC 0.8 – 3.7 V SET/COAST 2.5 – 6.3 V CANCEL 4.2 – 8.8 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). DI–342 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check control switch. 4 PREPARATION: (a) Remove steering wheel center pad. (b) Disconnect the control switch connector. CHECK: Measure resistance between terminals 3 and 4 of control switch connector when control switch is operated. 3 N16045 NG Switch position Resistance (Ω) Neutral ∞ (No continuity) RES/ACC 50 – 80 SET/COAST 180 – 220 CANCEL 400 – 440 Replace control switch. OK 4 Check harness and connector between cruise control ECU and cruise control switch, cruise control switch and body ground (See page IN–29). NG Repair or replace harness or connector. OK Wait and see. OK 5 Input signal check (See step 1). NG Check and replace cruise control ECU (See page IN–29). DI–343 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08S–11 DTC 51 Idle Signal Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. DTC No. 51 DTC Detecting Condition Trouble Area
Harness or connector between ECM and throttle position sensor
Throttle position sensor
Harness or connector between cruise control ECU and ECM
Cruise control ECU Short in idle signal circuit. WIRING DIAGRAM Cruise Control ECU ECM IDLO 3 E4 L–R 13 C16 IDL N21220 DI–344 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminal IDL of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Disconnect the ECM connector. (c) Turn ignition switch ON. CHECK: Measure voltage between terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened. OK: ON IDL (–) AB0119 I00167 (+) I00172 OK Throttle valve position Voltage Fully opened 10 – 14 V Fully closed Below 2 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). NG 2 Check harness and connector between ECM and throttle position sensor (See page IN–29). NG Repair or replace harness or connector. OK 3 Check throttle position sensor circuit (See page DI–39). NG OK Replace throttle position sensor. DI–345 DIAGNOSTICS 4 – CRUISE CONTROL SYSTEM Check throttle position sensor. PREPARATION: Disconnect the throttle position sensor connector. CHECK: Measure resistance between terminals 3 and 4 of throttle position sensor connector when the throttle valve is fully closed and fully opened. OK: Throttle Position Sensor 3 4 I00052 NG Throttle valve position Resistance Fully opened 1 MΩ or higher Fully closed Below 2.3 kΩ Replace throttle position sensor. OK 5 Check for open and short in harness and connector between cruise control ECU and ECM (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–346 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08T–12 Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is depressed, the stop light switch sends a signal to the ECU. When the ECU receives this signal, it cancels the cruise control. A fail–safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. The cancel conditions are: Battery positive voltage at terminal STP– When the brake is ON, battery positive voltage normally is applied through the STOP fuse and stop light switch to terminal STP– of the ECU, and the ECU turns the cruise control OFF. If the harness connected to terminal STP– has an open circuit, terminal STP– will have battery positive voltage and the cruise control will be turned OFF. Also, when the brake is ON, the magnetic clutch circuit is cut mechanically by the stop light switch, turning the cruise control OFF. (See page DI–331 for operation of the magnetic clutch) WIRING DIAGRAM Cruise Control ECU Stop Light Switch Instrument Panel J/B 2 1 G–W 3 4 1R 5 1R J23 J/C A G–W A G–W 2 C16 STP– 4 R–Y 8 W C16 G–B Instrument Panel J/B 7 1C STOP 1 F9 ALT Cruise Control Actuator 3 4 4 1B B–R FL BLOCK W–B A J6 1 F14 B–G FL MAIN J/C A J6 Instrument Panel J/B J9 J/C A W–B Battery L 7 1J W–B 8 1J IF I08461 DI–347 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of stop light. CHECK: Check that stop light comes ON when brake pedal is depressed, and turns OFF when brake pedal is released. NG Check stop light system (See page BE–1). OK 2 Input signal check. Input Signal Stop Light switch ON Indicator Light Blinking Pattern OFF Light ON SW OFF SW ON CHECK: (a) See input signal check on DI–319. (b) Check the indicator light when the brake pedal is depressed. OK: The indicator light goes OFF when the brake pedal is depressed. OK NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). DI–348 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal STP– of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connectors still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal STP– of cruise control ECU connector and body ground, when the brake pedal is depressed and released. OK: ON STP– (–) (+) OK AB0119 I00142 – Depressed 10 – 14 V Released Below 1 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). I00173 NG 4 Check for open in harness and connectors between terminal STP– of cruise control ECU and stop light switch (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–349 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08U–12 Electronically Controlled Transmission Communication Circuit CIRCUIT DESCRIPTION When driving uphill under the cruise control, in order to reduce shifting due to ON–OFF overdrive operation and to provide smooth driving, when down shifting in the electronically controlled transmission occurs, a signal to prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the electronically controlled transmission. Terminal ECT of the cruise control ECU detects the shift change signal (output to electronically controlled transmission No. 2 solenoid) from the ECM. If the vehicle speeds down, also when terminal ECT of the cruise control ECU receives down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gear shifts are reduced and gear shift points in the electronically controlled transmission are changed. WIRING DIAGRAM Cruise Control ECU ECM OD1 S2 20 E4 6 E6 14 OD C16 Y–B J19 J/C L–B L–B B B L–B 7 IG2 L–B 6 ECT C16 ECT No.2 Solenoid I08462 DI–350 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check operation of overdrive. PREPARATION: Test drive after engine warms up. CHECK: Check that overdrive ON ↔ OFF occurs by operation of OD switch ON–OFF. NG Check and repair electronically controlled transmission (See page DI–133). OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. (c) Disconnect the ECU connector. CHECK: Measure voltage between terminal OD of harness side connector of ECU and body ground. OK: Voltage: 10 – 14 V ON O/D (–) (+) AB0119 I00143 I00174 NG OK Go to step 5. DI–351 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). (–) (+) ECT PREPARATION: (a) Connect the ECU connector. (b) Test drive after engine warms up. CHECK: Check voltage between terminal ECT of ECU connector and body ground when OD switch is ON and OFF. OK: I00141 OK OD switch position Voltage ON 8 – 14 V OFF Below 0.5 V Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transmission solenoid (See page IN–29). NG Repair or replace harness or connector. OK Check and replace cruise control ECU. 5 Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–352 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08V–12 Park/Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Cruise Control ECU J19 J/C PNP Switch 10 2 D D 9 IG2 B–R R–L J22 J/C A A B–R B–R 3 C16 D R–L Instrument Panel J/B 2 IG2 F J24 R–L J/C F J24 1 1J R–L GAUGE 1 1K B–Y Instrument Panel J/B 1 1B Ignition Switch 2 1K AM1 2 AM1 IG1 4 W B–R FL BLOCK 1 F14 ALT 1 F9 FL MAIN B–G Battery I08463 DI–353 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check starter operation. CHECK: Check that the starter operates normally and that the engine starts. NG Proceed to engine troubleshooting (See Pub. No. RM654U on page ST–1). OK 2 Input signal check. Input Signal Indicator Light Blinking Pattern Turn PNP switch ON SW ON OFF (Shift to posi- Light SW OFF tions except D ) OFF PREPARATION: See input signal check on page DI–319. CHECK: Check the indicator light when shifting into positions except D. OK: The indicator light goes off when shifting into positions except D. OK NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). DI–354 DIAGNOSTICS 3 CRUISE CONTROL SYSTEM Check voltage between terminal D of cruise control ECU connector and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal D of ECU connector and body ground when shifting into D position and other positions. OK: ON D (–) AB0119 I00139 – Shift Position Voltage D position 10 – 14 V Other positions Below 1 V (+) I00175 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). NG 4 Check harness and connector between cruise control ECU and park/neutral position switch (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–355 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08X–12 ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc, when terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Cruise Control ECU Instrument Panel J/B Ignition Switch 2 AM1 IG1 4 B–Y 1 1K 9 1J ECU–IG J12 J/C C C B–R B–R 9 C16 B W Instrument Panel J/B FL BLOCK 1 F9 1 F14 B–R 1 1B AM1 2 1K B–G J9 J/C FL MAIN Battery A W–B Instrument Panel J/B 7 8 1J 1J W–B A J/C A J7 J6 W–B 16 C16 GND IF I08464 DI–356 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check ECU–IG fuse. Instrument panel junction block No.1: ECU–IG Fuse PREPARATION: Remove the ECU–IG fuse from instrument panel junction block No.1. CHECK: Check continuity of ECU–IG fuse. OK: Continuity I00157 NG Check for short in all the harness and components connected to ECU–IG fuse. OK 2 Check voltage between terminals B and GND of cruise control ECU connector. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals B and GND of ECU connector. OK: Voltage: 10 – 14 V ON B GND (–) (+) AB0119 I00147 I00176 OK NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). DI–357 DIAGNOSTICS 3 – CRUISE CONTROL SYSTEM Check resistance between terminal GND of cruise control ECU connector and body ground. CHECK: Measure resistance between terminal GND of ECU connector and body ground. OK: Resistance: Below 1 Ω GND I00140 NG OK Check and repair harness and connector between cruise control ECU and battery (See page IN–29). Repair or replace harness or connector. DI–358 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI08Z–17 Main Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION When the cruise control main switch is turned OFF, the cruise control does not operate. WIRING DIAGRAM See page DI–340. INSPECTION PROCEDURE 1 Check voltage between terminal CMS of cruise control ECU connector and body ground. PREPARATION: (a) Remove the ECU with connector still connected. (b) Turn ignition switch ON. CHECK: Measure voltage between terminal CMS of cruise control ECU connector when main switch is held ON and OFF. OK: ON CMS (–) (+) Main switch Voltage OFF 10 – 14 V ON Below 0.5 V AB0119 I00145 I00177 OK NG Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). DI–359 DIAGNOSTICS 2 – CRUISE CONTROL SYSTEM Check main switch continuity. 3 PREPARATION: (a) Remove steering wheel pad (See Pub. No. RM654U on page SR–11). (b) Disconnect the control switch connector. CHECK: Check continuity between terminals 3 and 5 of control switch connector when main switch is held ON and OFF. OK: 5 N15969 Switch position Tester connection Specified condition OFF 3–5 No continuity Hold ON 3–5 Continuity NG Replace control switch. OK 3 Check harness and connector between cruise control ECU and main switch (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–360 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI090–20 CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON, CRUISE MAIN indicator light lights up. WIRING DIAGRAM CRUISE MAIN Indicator Light J3 (in Combination Meter) J/C 7 10 D D C12 C12 O R–L Cruise Control ECU J1 J/C 5 IE2 4 D D O O PI C16 R–L Instrument Panel J/B 2 1D GAUGE 1 1K Ignition Switch 4 IG1 B–G ALT W Instrument Panel J/B FL BLOCK 1 F9 AM1 2 B–Y 1 F14 B–R 1 1B AM1 2 1K FL MAIN Battery I08465 DI–361 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals PI and GND of cruise control ECU connector. PREPARATION: Tun ignition switch ON. CHECK: Measure voltage between terminals PI and GND of cruise control ECU connector when main switch is ON and OFF. OK: ON PI (–) AB0119 I00144 Switch position Voltage OFF 10 – 16 V ON Below 1.2 V (+) I00178 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). NG 2 Check combination meter (See page BE–1). NG OK Check and replace cruise control ECU (See page IN–29). Replace combination meter. DI–362 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI091–12 Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that outputs DTC. WIRING DIAGRAM Cruise Control ECU J1 J/C D 4 D C16 PI O O 10 D2 DLC2 J2 J/C 4 D2 B 5 B C16 LG–R LG–R TC B LG–R 11 IG3 DLC1 11 D1 LG–R I00291 DI–363 DIAGNOSTICS – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE 1 Check voltage between terminals Tc and E1 of DLC2. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminals Tc and E1 of DLC2. OK: Voltage: 10 – 14 V ON AB0119 I00169 TC E1 I00179 OK Proceed to next circuit inspection shown on problem symptoms table (See page DI–328). NG 2 Check harness and connector between cruise control ECU and DLC2, DLC2 and body ground (See page IN–29). NG OK Check and replace cruise control ECU (See page IN–29). Repair or replace harness or connector. DI–364 DIAGNOSTICS – CRUISE CONTROL SYSTEM DI092–08 Actuator Control Cable INSPECTION PROCEDURE 1 Actuator control cable inspection OK: (a) Check that the actuator and control cable throttle link are properly installed and that the cable and link are connected correctly. (b) Check that the actuator and bell crank operate smoothly. (c) Check that the cable is not loose or too tight. OK: Freeplay: less than 10 mm HINT:
If the control cable is very loose, the vehicle’s loss of speed going uphill will be large.
If the control cable is too tight, the idle RPM will become high. CL–1 CLUTCH – TROUBLESHOOTING TROUBLESHOOTING CL034–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page Clutch grabs/chatters 1. Engine mounting (Loosen) 2. Clutch disc (Runout is excessive) 3. Clutch disc (Oily) 4. Clutch disc (Worn out) 5. Clutch disc torsion rubber (Damaged) 6. Clutch disc (Glazed) 7. Diaphragm spring (Out of tip alignment) – CL–17 CL–17 CL–17 CL–17 CL 17 CL–17 CL 17 CL–19 Clutch pedal edal spongy s ongy 1. Clutch line (Air in line) 2. Master cylinder cup cu (Damaged) 3. Release cylinder cup (Damaged) – CL–4 CL 4 CL–9 Clutch noisy 1. Release bearing (Worn, 1 (Worn dirty, dirty or damaged) 2 Clutch 2. Cl h disc di torsion i rubber bb (Damaged) (D d) CL–19 CL 19 CL 17 CL–17 Cl t h slips Clutch li 1. Clutch pedal edal (Free (Freeplay lay out of adjustment) 2. Clutch disc (Oily) 3. Clutch disc (Worn out) 4. Dia Diaphragm hragm sspring ring (Damaged) 5. Pressure plate late (Distortion) 6. Flywheel (Distortion) CL–2 CL–17 CL–17 CL 17 CL–17 CL 17 CL–17 CL 17 – Cl t h does Clutch d nott disengage di 1. Clutch pedal (Freeplay out of adjustment) 1 2 Clutch line (Air in line) 2. 3 Master cylinder cup (Damaged) 3. 4 Release cylinder cup (Damaged) 4. 5 Clutch disc (out of true) 5. 6 Clutch 6. Cl tch disc (Runout (R no t is excessive) e cessi e) 7 Cl 7. Clutch t h di disc (Li (Lining i b broken) k ) 8 Clutch 8. Cl t h disc di (Dirty (Di t or burned) b d) 9. Cl Clutch h di disc (Oil (Oily)) 10. Clutch disc (Lack of spline grease) 11. Diaphragm g spring g ((Damaged) g ) 12. Diaphragm g spring g (Out ( of tip alignment) g ) 13. Pressure plate (Distortion) CL–2 – CL 4 CL–4 CL 9 CL–9 CL 17 CL–17 CL 17 CL–17 CL 17 CL–17 CL 17 CL–17 CL CL–17 CL–19 CL–17 CL–19 CL–17 Author: Date: 1780 CL–2 CLUTCH – CLUTCH PEDAL CLUTCH PEDAL CL035–01 INSPECTION 1. Pedal Height Adjust Point Push Rod Play and Freeplay Adjust Point Push Rod Play Pedal Height Q10088 CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: 1MZ–FE: 161.8 – 171.8 mm (6.370 – 6.764 in.) 5S–FE: 156.8 – 166.8 mm (6.173 – 6.567 in.) 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resistance is felt. Pedal freeplay: 5.0 – 15.0 mm (0.197 – 0.591 in.) Gently push the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 – 5.0 mm (0.039 – 0.197 in.) 4. (a) Pedal Freeplay (b) (c) (d) IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct. Tighten the lock nut. After adjusting the pedal freeplay, check the pedal height. Connect the air duct and install the lower finish panel. CL0042 5. (a) (b) (c) 25 mm (0.98 in. ) or more Release Point Full Stroke End Position CL0512 INSPECT CLUTCH RELEASE POINT Pull the parking brake lever and install wheel stopper. Start the engine and idle the engine. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. (d) Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance not as specified, do the following operation.
Inspect pedal height.
Inspect push rod play and pedal freeplay.
Bleed the clutch line.
Inspect the clutch cover and disc. Author: Date: 1781 CL–3 CLUTCH – CLUTCH PEDAL 6. (a) CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch. Clutch Start Switch Q00307 5.0 ± 0.5 mm (0.197 ± 0.020 in.) 7. INSPECT CONTINUITY OF CLUTCH START SWITCH Check the continuity between terminals when the switch is ON and OFF. Switch position Condition ON (pushed) Continuity OFF (free) No continuity CL0477 Author: Date: 1782 CL–4 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER CL036–01 COMPONENTS Filler Cap Clip Float Reservoir Tank
Grommet Clevis Pin Boot Slotted Spring Pin Washer Master Cylinder Body Clevis Piston Lock Nut Clutch Line Snap Ring 15 (155, 11) Push Rod Spring 12 (120, 9)
Non–reusable part N·m (kgf·cm, ft·lbf) : Specified torque Q10085 Author: Date: 1783 CL–5 CLUTCH – CLUTCH MASTER CYLINDER CL037–01 REMOVAL SST Q10094 1. DRAW OUT FLUID WITH SYRINGE 2. DISCONNECT CLUTCH LINE Using SST, disconnect the clutch line. Use a container to catch the fluid. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 3. REMOVE CLIP AND CLEVIS PIN 4. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Author: Date: 1784 CL–6 CLUTCH – CLUTCH MASTER CYLINDER CL038–01 DISASSEMBLY 1. (a) (b) REMOVE RESERVOIR TANK Using a pin punch and hammer, drive out the slotted spring pin. Remove the reservoir tank and grommet. Q10083 2. REMOVE PUSH ROD Pull back the boot, and using snap ring pliers, remove the snap ring. 3. REMOVE PISTON Q05039 Author: Date: 1785 CL–7 CLUTCH – CLUTCH MASTER CYLINDER CL039–01 REASSEMBLY 1. 2. 3. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSERT PISTON INTO CYLINDER INSTALL PUSH ROD ASSEMBLY WITH SNAP RING CL0528 4. (a) (b) INSTALL RESERVOIR TANK Install the reservoir tank and a new grommet. Using a pin punch and hammer, drive in the slotted spring pin. Protrusion 1.5 – 3.5 mm (0.059 – 0.138 in.) Q10081 Author: Date: 1786 CL–8 CLUTCH – CLUTCH MASTER CYLINDER CL03A–01 INSTALLATION Installation is in the reverse order of removal (See page CL–5). HINT: After installation, bleed system and adjust clutch pedal (See page CL–2). Author: Date: 1787 CL–9 CLUTCH – CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CL03B–01 COMPONENTS Clutch Line 15 (155, 11) Release Cylinder Body 12 (120, 9) Piston Boot Bleeder Plug 8.4 (85, 74 in.·lbf) Spring Push Rod N·m (kgf·cm, ft·lbf) : Specified torque Q10016 Author: Date: 1788 CL–10 CLUTCH – CLUTCH RELEASE CYLINDER CL03C–01 REMOVAL SST Q10077 1. DISCONNECT CLUTCH LINE Using SST, disconnect the line. Use a container to catch the fluid. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Author: Date: 1789 CL–11 CLUTCH – CLUTCH RELEASE CYLINDER CL03D–01 DISASSEMBLY 1. REMOVE BLEEDER PLUG 2. PULL OUT BOOT WITH PUSH ROD 3. REMOVE PISTON Blow compressed air into the release cylinder and remove the piston with spring. Q05878 Author: Date: 1790 CL–12 CLUTCH – CLUTCH RELEASE CYLINDER CL03E–01 REASSEMBLY 1. 2. 3. 4. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER INSTALL BLEEDER PLUG Torque: 8.4 N·m (85 kgf·cm, 74 in.·lbf) Q06048 Author: Date: 1791 CL–13 CLUTCH – CLUTCH RELEASE CYLINDER CL03F–01 INSTALLATION Installation is in the reverse order of removal (See page CL–10). HINT: After installation, bleed clutch system. Author: Date: 1792 CL–14 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CLUTCH ACCUMULATOR (1MZ–FE) CL03G–01 COMPONENTS w/ Cruise Control System : Starter 39 (400, 29) Cruise Control Actuator 21 (210, 15) Battery 27 (270, 20) 13 (130, 9) 13 (130, 9) Clutch Accumulator Bracket 15 (155, 11) N·m (kgf·cm, ft·lbf) : Specified torque Q10092 Author: Date: 1793 CL–15 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CL03H–01 REMOVAL 1. (a) (b) w/ Cruise Control System: REMOVE CRUISE CONTROL ACTUATOR Remove the battery. Remove the 3 bolts and cruise control actuator with bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Q10074 2. (a) (b) REMOVE STARTER Remove the nut and disconnect the connectors. Remove the 2 bolt and clamp. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 3. (a) REMOVE CLUTCH ACCUMULATOR WITH BRACKET Using SST, disconnect the clutch lines from the clutch accumulator. Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) SST 09023–00100 Remove the 2 bolts and nut. Torque: Bolt: 21 N·m (210 kgf·cm, 15 ft·lbf) Nut: 27 N·m (270 kgf·cm, 20 ft·lbf) Q10078 SST Q10076 (b) Author: Date: 1794 CL–16 CLUTCH – CLUTCH ACCUMULATOR (1MZ–FE) CL03I–01 INSTALLATION Installation is in the reverse order of removal (See page CL–15). Author: Date: 1795 CL–17 CLUTCH – CLUTCH UNIT CLUTCH UNIT CL03J–01 COMPONENTS 5S–FE : Release Fork Flywheel 39 (400, 29) 19 (195, 14) x6 Release Bearing and Hub Release Fork 47 (480, 35) 5S–FE : Clutch Disc Clutch Cover Clutch Disc Boot N·m (kgf·cm, ft·lbf) : Specified torque Q10017 Author: Date: 1796 CL–18 CLUTCH – CLUTCH UNIT CL03K–01 REMOVAL 1. Matchmarks Q10161 REMOVE TRANSAXLE FROM ENGINE (See page E153 MX–4, S51 MX–4) 2. REMOVE CLUTCH COVER AND DISC (a) Place matchmarks on the flywheel and clutch cover. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc. 3. 1MZ–FE: (a) (b) REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing together with the fork and then separate them. Remove the boot. 5S–FE: Z19000 Author: Date: 1797 CL–19 CLUTCH – CLUTCH UNIT CL03L–01 INSPECTION 1MZ–FE: 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc. 5S–FE: Q10090 2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc. CL0373 3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.1 mm (0.004 in.) If necessary, replace the flywheel. CL0372 A 4. INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers, measure the diaphragm spring for depth and width of wear. Maximum: Depth A: 0.6 mm (0.024 in.) Width B: 5.0 mm (0.197 in.) If necessary, replace the clutch cover. B Z09915 Author: Date: 1798 CL–20 CLUTCH – CLUTCH UNIT 5. INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the bearing. N00414 Author: Date: 1799 CL–21 CLUTCH – CLUTCH UNIT CL03M–02 INSTALLATION 1MZ–FE: 1. (a) (b) SST INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL 1MZ–FE: Insert SST in the clutch disc, and then set them. SST 09301–00220 5S–FE: Insert SST in the clutch disc, and then set them. SST 09301–00210 Flywheel Side 5S–FE: SST Q10089 3 5 (c) (d) SST 1 Align the matchmarks on the clutch cover and flywheel. Torque the bolts on the clutch cover in the order shown. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: Temporarily tighten the No.3 bolt. 6 4 2 Matchmarks Q10084 2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum non–alignment: 0.5 mm (0.020 in.) If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment. SST 09333–00013 SST Q10072 Author: Date: 1800 CL–22 CLUTCH 3. 1MZ–FE Engine: (a) (b) – CLUTCH UNIT APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) Apply release hub grease to these parts:
Release fork and hub contact point
Release fork and push rod contact point
Release fork pivot point Apply clutch spline grease:
Clutch disc spline HINT: Recommended grease part number 08887–01706 (100 g). 4. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE Install the bearing to the release fork, and then install them to the transaxle. 5. INSTALL TRANSAXLE TO ENGINE (See page E153 MX–9, S51 MX–8) 5S–FE Engine: Q10091 Author: Date: 1801 BE–1 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM BE09Y–01 PRECAUTION Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts. 1. HEADLIGHT SYSTEM
Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM)
The CAMRY is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 3. AUDIO SYSTEM
If the negative (–) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so make sure to note the stations and reset them after the negative (–) terminal cable is reconnected to the battery.
If the negative (–) terminal cable is disconnected from the battery, the ”ANTI–THEFT SYSTEM” will operate when the cable is reconnected, but the radio, tape player and CD player will not operate. Be sure to input the correct ID number so that the radio, tape player and CD player can be operated again. 4. MOBILE COMMUNICATION SYSTEM
If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. Author: Date: 2221 BE–2 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BE09Z–03 PROBLEM SYMPTOMS TABLE POWER OUTLET Symptom Electric power source cannot be taken out of the power outlet Suspect Area See page 11.Battery 12.POWER OUTLET Fuse (I/P J/B No.1) 13.Wire Harness – – – HEADLIGHT AND TAILLIGHT SYSTEM (USA) Symptom Suspect Area See page Headlight does not light. (Taillight is normal) 1. HEAD–(LH, RH) Fuse (E/G Room J/B No.2) 2. Headlight Bulb 3. Wire Harness Headlight does not light. (Taillight does not light up) 1. 2. 3. 4. Only one side light does not light. 1. HEAD–(LH, RH) Fuse (E/G Room J/B No.2) 2. Headlight Bulb 3. Wire Harness ”Lo–Beam” does not light. 1. Headlight Bulb 2. Light Control Switch 3. Wire Harness – BE–24 – ”Hi–Beam” does not light. 1. Headlight Dimmer Switch 2. Light Control Switch 3. Wire Harness BE–24 BE–24 – ”Flash” does not light. 1. Headlight Dimmer Switch 2. Wire Harness BE–24 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. 5. 6. – – BE–14 BE–24 BE–14 – Taillight does not light. (Headlight does not light) 1. Light Control Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness BE–24 BE–14 – Taillight does not light. (Headlight is normal) 1. 2. 3. 4. 5. – BE–24 BE–24 BE–14 – Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Bulb 2. Light Failure Sensor 3. Wire Harness – BE–37 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. – BE–14 BE–32 – HEAD–(LH, RH) Fuse (E/G Room J/B No.2) Headlight Control Relay (E/G Room J/B No.2) Headlight Bulb Wire Harness GAUGE Fuse (I/P J/B No.1) DOME Fuse (E/G Room J/B No.2) Integration Relay (I/P J/B No.2) Door Courtesy Switch (Driver’s) Ignition Switch Wire Harness TAIL Fuse (I/P J/B No.1) Taillight Control Relay (I/P J/B No.1) Light Control Switch Integration Relay (I/P J/B No.1) Wire Harness – – – – BE–24 – – – – – – – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Door Courtesy Switch (Driver’s) Wire Harness Author: Date: 2222 BE–3 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM (CANADA) Symptom Suspect Area See page Headlight does not light. (Taillight is normal) 1. Wire Harness – Headlight does not light. (Taillight does not light up) 1. Wire Harness – Only one side light does not light. 1. Headlight Bulb 2. HEAD LO (LH, RH) Fuse (E/G Room R/B No.2) 3. Wire Harness – – – ”Lo–Beam” does not light. 1. 2. 3. 4. 5. 6. Headlight Bulb HEAD LO (LH, RH) Fuse (E/G Room R/B No.2) Headlight Control Relay (E/G Room J/B No.2) Integration Relay (I/P J/B No.1) Light Control Switch Wire Harness – – BE–24 BE–14 BE–24 – 1. 2. 3. 4. 5. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) DRL Fuse (E/G Room R/B No.2) Daytime Running Light Relay No.2 (E/G Room R/B No.2) 6. Daytime Running Light Relay No.3 (E/G Room R/B No.2) 7. Daytime Running Light Relay No.4 (E/G Room R/B No.2) 8. Daytime Running Light Relay (Main) 9. Headlight Dimmer Switch 10.Wire Harness – – – – – BE–24 – BE–24 – BE–24 BE–24 BE–24 – 1. 2. 3. 4. 5. ”Flash” does not light. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) DRL Fuse (E/G Room R/B No.2) Daytime Running Light Relay No.2 (E/G Room R/B No.2) 6. Daytime Running Light Relay No.3 (E/G Room R/B No.2) 7. Daytime Running Light Relay No.4 (E/G Room R/B No.2) 8. Daytime Running Light Relay (Main) 9. Headlight Dimmer Switch 10.Wire Harness – – – – – BE–24 – BE–24 – BE–24 BE–24 BE–24 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. 5. 6. GAUGE Fuse (I/P J/B No.1) DOME Fuse (E/G Room J/B No.2) Integration Relay (I/P J/B No.2) Door Courtesy Switch (Driver’s) Ignition Switch Wire Harness – – BE–14 BE–24 BE–14 – Headlight does not light with engine running and light control SW OFF. 1. 2. 3. 4. 5. 6. 7. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) GAUGE Fuse (I/P J/B No.1) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) Daytime Running Light Relay (Main) Wire Harness Other Parts* – – – – BE–24 – – ”Hi–Beam” does not light. Author: Date: 2223 BE–4 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM Taillight does not light. (Headlight does not light) 1. Integration Relay (I/P J/B No.1) 2. Light Control Switch 3. Wire Harness BE–14 BE–24 – Taillight does not light. (Headlight is normal) 1. 2. 3. 4. 5. – BE–24 BE–14 BE–24 – Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Bulb 2. Light Failure Sensor 3. Wire Harness – BE–37 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. – BE–14 BE–24 – TAIL Fuse (I/P J/B No.1) Taillight Control Relay (I/P J/B No.1) Integration Relay (I/P J/B No.1) Light Control Switch Wire Harness – – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Door Courtesy Switch (Driver’s) Wire Harness *Terminal L of generator and parking brake switch TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspect Area See page ”Hazard” and ”Turn” do not light up. 1. Hazard Warning Switch 2. Turn Signal Flasher 3. Wire Harness BE–30 BE–30 – The flashing frequency is abnormal. 1. Bulb 2. Turn Signal Switch 3. Wire Harness – BE–30 – Hazard warning light does not light up. (Turn is normal.) 1. HORN Fuse (E/G Room J/B No.2) 2. Wire Harness Hazard warning light does not light up in one direction. 1. Hazard Warning Switch 2. Wire Harness BE–30 – *1Turn signal does not light up. 1. 2. 3. 4. Ignition Switch TURN Fuse (I/P J/B No.1) Turn Signal Switch Wire Harness BE–14 – BE–30 – *2Turn signal does not light up. 1. TURN Fuse (I/P J/B No.1) 2. Turn Signal Switch 3. Wire Harness – BE–30 – Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness BE–30 – Only one bulb does not light up. 1. Bulb 2. Wire Harness – – – – *1: Combination meter, wiper and washer do not operate. *2: Combination meter, wiper and washer are normal. INTERIOR LIGHT SYSTEM Symptom Suspect Area See page ”Illuminated Entry System” does not operate. 1. Door Courtesy Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness Only one interior light does not light up. 1. Bulb 2. Wire Harness – – Interior light does not light up (All). 1. DOME Fuse (E/G Room J/B No.2) 2. Wire Harness – – Author: BE–32 BE–14 – Date: 2224 BE–5 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM Dome light does not light up. 1. Bulb 2. Dome Light 3. Wire Harness – BE–32 – Map Light does not light up. 1. Bulb 2. Map Light 3. Wire Harness – BE–32 – Luggage compartment light does not light up. 1. Bulb 2. Luggage compartment door courtesy switch 3. Wire Harness – BE–32 – BACK–UP LIGHT SYSTEM Symptom Back–Up Light does not light up. Back–Up Light remains always ON. Only one light does not light up. Suspect Area 1. 2. 3. 4. See page GAUGE Fuse (I/P J/B No.1) Ignition Switch Wire Harness Bulb 1. Back–Up Light Switch (M/T) 2. Park/Neutral Position Switch (A/T) – BE–14 – – 3. Wire Harness BE–35 DI–424 DI–479 – 1. Bulb 2. Wire Harness – – (A140E) (A541E) STOP LIGHT SYSTEM Symptom Suspect Area See page Stop light does not light up. 1. STOP Fuse (I/P J/B No.1) 2. Stop Light Switch 3. Wire Harness – BE–37 – Only one light always lights up. 1. Wire Harness – Only one light does not light. 1. Bulb 2. Wire Harness – – WIPER AND WASHER SYSTEM *1: Inspect wiper arm and blade set position Symptom Suspect Area See page Wiper and washers do not operate. 1. 2. 3. 4. WIPER Fuse (I/P J/B No.1) Wiper Switch Wiper Motor Wire Harness Wipers do not operate in LO or HI. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–40 BE–40 – Wipers do not operate in INT. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–40 BE–40 – Washer motor does not operate. 1. Washer Switch 2. Washer Motor 3. Wire Harness BE–40 BE–40 – Wipers do not operate when washer switch in ON. 1. Washer Motor 2. Wire Harness BE–40 – Author: – BE–40 BE–40 – Date: 2225 BE–6 BODY ELECTRICAL Washer fluid does not operate.
In wiper switch HI position, the wiper blade is in contact with the body.
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong. – BODY ELECTRICAL SYSTEM 1. Washer Hose and Nozzle – *1Wiper 1. Switch 2. Wire Harness BE–40 – COMBINATION METER METER, GAUGES AND ILLUMINATION: Symptom Suspect Area See page Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–46 – Speedometer does not operate. 1. No.1 Vehicle Speed Sensor 2. Meter Circuit Plate 3. Wire Harness BE–47 BE–46 – 1. Igniter 2. Meter Circuit Plate 3. Wire Harness IG–1 IG–1 BE–46 – Fuel Gauge does not operate or abnormal operation. 1. 2. 3. 4. Fuel Receiver Gauge Fuel Sender Gauge Meter Circuit Plate Wire Harness BE–47 BE–47 BE–46 – Engine Coolant Temperature Gauge does not operate or abnormal operation 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness BE–47 BE–47 BE–46 – All illumination lights do not light up. 1. TAIL Fuse (I/P J/B No.1) 2. Light Control Rheostat 3. Wire Harness Brightness does not change even when rheostat turned. 1. Bulb 2. Wire Harness – – Only one illumination light does not light up. 1. Bulb 2. Wire Harness – – Tachometer does not operate. (5S–FE) (1MZ–FE) – BE–47 – COMBINATION METER WARNING LIGHTS: Symptom Suspect Area See page Warning lights do not light up. (Except Discharge, Open Door and SRS) 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–46 – Low Oil Pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – Fuel Level warning light does not light up. 1. 2. 3. 4. Bulb Fuel Level Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – ABS warning light does not light up. 1. Bulb 2. ABS ECU 3. Wire Harness – IN–31 – Author: Date: 2226 BE–7 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. 2. 3. 4. Bulb Seat Belt Buckle Switch Integration Relay (I/P J/B No.1) Wire Harness – BE–47 BE–47 – 1. 2. 3. 4. IGN Fuse (I/P J/B No.1) Bulb Wire Harness Generator – – – CH–1 CH–1 Light Failure warning light does not light up. 1. 2. 3. 4. 5. Bulb Light Failure Sensor Bulb Check Relay Wire Harness Taillight system – BE–37 BE–47 – BE–24 Brake warning light does not light up. 1. 2. 3. 4. 5. 6. Bulb Parking Brake Switch Brake Fluid Level Warning Switch Bulb Check Relay Meter Circuit Plate Wire Harness – BE–47 BE–47 BE–47 BE–46 – SRS Warning light does not light up. 1. 2. 3. 4. 5. ECU–B Fuse (E/G Room J/B No.2) Bulb Airbag Sensor Assembly Meter Circuit Plate Wire Harness – – DI–626 BE–46 – Open Door warning light does not light up. 1. 2. 3. 4. 5. DOME Fuse (E/G Room J/B No.2) Bulb Door Courtesy Switch Meter Circuit Plate Wire Harness – – BE–32 BE–46 – Washer Level warning light does not light up. 1. 2. 3. 4. Bulb Washer Fluid Level Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – Seat Belt warning light does not light up. Discharge warning light does not light up. (5S–FE) (1MZ–FE) COMBINATION METER INDICATOR LIGHTS: Symptom Suspect Area 1. Bulb 2. O/D OFF Switch See page 3. Meter Circuit Plate 4. Wire Harness – DI–431 DI–487 BE–46 – Cruise Control indicator light does not light up. 1. 2. 3. 4. Bulb Cruise Control ECU Meter Circuit Plate Wire Harness – IN–31 BE–46 – High beam indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Headlight System – BE–46 – BE–22 Turn indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Turn Signal and Hazard Warning System – BE–46 – BE–29 O/D OFF indicator light does not light up. Author: (A140E) (A541E) Date: 2227 BE–8 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 4. Wire Harness – BE–46 DI–424 DI–479 – Only one shift indicator does not light up. 1. Bulb 2. Meter Circuit Plate – BE–46 Malfunction indicator light does not light up. 1. 2. 3. 4. Bulb ECM Meter Circuit Plate Wire Harness – – BE–46 – SLIP indicator light does not light up. 1. 2. 3. 4. Bulb Traction ECU Meter Circuit Plate Wire Harness – – BE–46 – TRAC OFF indicator light does not light up. 1. 2. 3. 4. Bulb Traction ECU Meter Circuit Plate Wire Harness – – BE–46 – Security indicator light does not light up. 1. 2. 3. 4. Bulb Security ECU Meter Circuit Plate Wire Harness – – BE–46 – Indicator lights do not light up. (Except Turn, Hi–beam and security) 1. GAUGE Fuse (I/P J/B No.1) 2. Wire Harness Shift indicator lights do not light up. 1. Bulb 2. Meter Circuit Plate 3. Park/Neutral Position Switch (A140E) (A541E) – – DEFOGGER SYSTEM Symptom Suspect Area See page All defogger systems do not operate. 1. 2. 3. 4. 5. DEFOG M–Fuse (I/P J/B No.1) HTR Fuse (I/P J/B No.1) Defogger Relay (I/P J/B No.1) Defogger Switch Wire Harness – – BE–56 BE–56 – Rear window defogger does not operate. 1. Defogger Wire 2. Choke Coil 3. Wire Harness BE–56 – – Mirror defogger does not operate. 1. MIR/HTR Fuse (I/P J/B No.1) 2. Mirror Defogger 3. Wire Harness – BE–56 – POWER WINDOW CONTROL SYSTEM Symptom Suspect Area See page Power window does not operate (ALL). (Power Door Lock does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Power Main Relay (I/P J/B No.1) 3. Wire Harness – BE–60 – Power window does not operate (ALL). (Power Door Lock is normal) 1. Ignition Switch 2. Power Window Master Switch 3. Wire Harness BE–14 BE–60 – ”One Touch Power Window System” does not operate. 1. Power Window Master Switch BE–60 Only one window glass does not move. 1. 2. 3. 4. Power Window Master Switch Power Window Switch Power Window Motor Wire Harness BE–60 BE–60 BE–60 – ”Window Lock System” does not operate. 1. Power Window Master Switch BE–60 Author: Date: 2228 BE–9 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM ”Window Lock Illumination” does not light up. 1. Power Window Master Switch BE–60 Key–off power window does not operate. 1. 2. 3. 4. 5. – BE–60 BE–14 BE–32 – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Ignition Switch Door Courtesy Switch Wire Harness POWER DOOR LOCK CONTROL SYSTEM Symptom Suspect Area See page ”Door lock system” does not operate at all. 1. 2. 3. 4. 5. POWER M–Fuse (I/P J/B No.1) CIG Fuse (I/P J/B No.1) DOOR Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Wire Harness – – – BE–70 – Door lock system does not operate by manual switch. 1. 2. 3. 4. Power Window Master Switch Door Lock Manual Switch Integration Relay (I/P J/B No.1) Wire Harness BE–60 BE–70 BE–70 – Door lock system does not operate by door key. 1. 2. 3. 4. Door Key Lock and Unlock Switch Integration Relay (I/P J/B No.1) Wire Harness Door Lock Link Disconnected BE–70 BE–70 – – Fault in 2–Operation unlock function of Driver’s side door key lock and unlock switch. 1. Door Key Lock and Unlock Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness BE–70 BE–70 – Fault in key confine prevention operate. 1. 2. 3. 4. BE–70 BE–14 BE–32 – Only one door lock does not operate. 1. Door Lock Motor 2. Wire Harness Integration Relay (I/P J/B No.1) Key Unlock Warning Switch Door Courtesy Switch Wire Harness BE–70 – SLIDING ROOF SYSTEM Symptom Suspect Area See page Sliding roof system does not operate. (Door Lock does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Power Main Relay (I/P J/B No.1) 3. Wire Harness – BE–60 – Sliding roof system does not operate. (Door Lock is normal) 1. 2. 3. 4. Ignition Switch Sliding Roof Control Relay and Switch Sliding Roof Motor and Limit Switch Wire Harness BE–14 BE–74 BE–74 – Sliding roof system operates abnormally. 1. Sliding Roof Control Relay and Switch 2. Sliding Roof Motor and Limit Switch 3. Wire Harness BE–74 BE–74 – Sliding roof system stops operation half way. (Stones of foreign material trapped in motor assembly) 1. Sliding Roof Control Relay and Switch 2. Sliding Roof Motor and Limit Switch 3. Wire Harness BE–74 BE–74 – ”Key–off Sliding Roof” operation does not operate. 1. 2. 3. 4. 5. – – BE–14 BE–14 – DOME Fuse (E/G Room J/B No.2) GAUGE Fuse (I/P J/B No.1) Ignition Switch Integration Relay (I/P J/B No.1) Wire Harness Author: Date: 2229 BE–10 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM POWER SEAT CONTROL SYSTEM Symptom Suspect Area See page Power seat does not operate. (Door lock system does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Wire Harness – – Power seat does not operate. (Door lock system is normal) 1. Power Seat Swtich (D,P) 2. Wire Harness BE–78 – ”Slide operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Slide Motor (D, P) BE–78 – BE–78 ”Lifter Operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Lifter Motor (D, P) BE–78 – BE–78 ”Reclining Operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Reclining Motor (D, P) BE–78 – BE–78 (D): Driver’s seat (P): Passenger’s seat POWER MIRROR CONTROL SYSTEM Symptom Suspect Area Mirror does not operate. 1. 2. 3. 4. Mirror operates abnormally. 1. Mirror Switch 2. Mirror Motor 3. Wire Harness See page CIG Fuse (I/P J/B No.1) Mirror Switch Mirror Motor Wire Harness – BE–83 BE–83 – BE–83 BE–83 – Author: Date: 2230 BE–11 BODY ELECTRICAL – POWER SOURCE POWER SOURCE BE0A0–03 LOCATION Engine Room Relay Block No.1 Engine Room Junction Block No.2 Engine Room Relay Block No.2 Instrument Panel Junction Block No.1 Turn Signal Flasher Z19043 Author: Date: 2231 BE–12 BODY ELECTRICAL – POWER OUTLET POWER OUTLET BE0A1–03 LOCATION Power Outlet Instrument Panel J/B No.1
PWR OUTLET Fuse N20688 Author: Date: 2232 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–13 IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A2–03 LOCATION Key Unlock Warning Switch Instrument Panel J/B No.1
Integration Relay Ignition Switch N20687 Author: Date: 2233 BE–14 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A3–02 INSPECTION 1. ACC ON LOCK 4 3 2 1 8 7 6 5 START N14824 INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK – ACC 2–3 Continuity ON 2–3–4 6–7 Continuity START 1–2–4 6–7–8 Continuity No continuity If continuity is not as specified, replace the switch. 2. OFF ON 2 1 INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY Switch position Tester connection OFF (Key removed) – ON (Key set) 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. N20125 3. 10 6 5 1 (a) (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE A) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzer sounds. N20126 (d) 10 6 5 (e) 1 Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. N20127 Author: Date: 2234 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–15 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20128 4. 10 6 5 1 (a) (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE B) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzerr sounds. N20129 (d) 10 6 5 (e) 1 Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. N20130 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20131 5. 10 6 5 (a) 1 (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE C) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzerr sounds. N20132 Author: Date: 2235 BE–16 BODY ELECTRICAL (d) (e) 10 6 5 – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. 1 N20133 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20134 6. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE A) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Tester connection Condition Specified condition 2 – Ground 4 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity 2 – Ground 4 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF No continuity 6 – Ground Driver’s door courtesy switch ON Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage Author: Date: 2236 BODY ELECTRICAL (b) Wire harness side: – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–17 Disconnect the connector from the integration relay and inspect the connector on the wire harness side. 1 23 4 N20136 Tester connection Condition Specified condition 1 – Ground Light control switch OFF No continuity 1 – Ground Light control switch HEAD or TAIL Continuity 4 – Ground Light control switch OFF or TAIL No continuity 4 – Ground Light control switch HEAD Continuity 2 – Ground 3 – Ground Constant Battery positive voltage If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 7. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE B) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Tester connection Condition Specified condition 2 – Ground All door courtesy switches OFF (Except Driver’s Door/ Door closed) No continuity 2 – Ground One of the door courtesy switches ON (Except Driver’s Door/ Door opened) Continuity 4 – Ground Door courtesy switches except that of the driver’s door OFF (Door closed) No continuity 4 – Ground One of the door courtesy switches except that of the driver’s door ON (Door opened) Continuity Author: Date: 2237 BE–18 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF (Door closed) No continuity 6 – Ground Driver’s door courtesy switch ON (Door opened) Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage 11 – Ground Ignition switch LOCK No voltage 11 – Ground Ignition switch ACC or ON Battery positive voltage (b) Wire harness side: 1 – 2 3 4 5 6 Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Connector ”A” Wire harness side: 1 2 3 eh–25–1 h–4–1 4 Connector ”B” N20137 Tester connection Condition Specified condition A3 – Ground Constant Continuity A5 – Ground Driver’s door unlock detection switch OFF (Door locked) No continuity A5 – Ground Driver’s door unlock detection switch ON (Door unlocked) Continuity A6 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity Author: Date: 2238 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH A6 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity A7 – Ground Passenger’s door unlock detection switch OFF (Door locked) No continuity A7 – Ground Passenger’s door unlock detection switch ON (Door unlocked) Continuity A9 – Ground Rear door unlock detection switch OFF (Door locked) No continuity A9 – Ground Rear door unlock detection switch ON (Door unlocked) Continuity Constant Continuity A16 – Ground Door lock manual switch OFF or UNLOCK No continuity A16 – Ground Door lock manual switch LOCK Continuity A17 – Ground Door lock manual switch OFF or LOCK No continuity A17 – Ground Door lock manual switch UNLOCK Continuity A18 – Ground Driver’s and passenger’s door key lock and unlock switch OFF or UNLOCK No continuity A18 – Ground Driver’s or passenger’s door key lock and unlock switch LOCK Continuity A19 – Ground Driver’s door key lock and unlock switch OFF or LOCK No continuity A19 – Ground Driver’s door key lock and unlock switch UNLOCK Continuity A20 – Ground Passenger’s door key lock and unlock switch OFF or LOCK No continuity A20 – Ground Passenger’s door key lock and unlock switch UNLOCK Continuity A1 – Ground Constant Battery positive voltage B1 – Ground Light control switch OFF No voltage B1 – Ground Light control switch TAIL or HEAD Battery positive voltage B4 – Ground Light control switch OFF or TAIL No voltage B4 – Ground Light control switch HEAD Battery positive voltage B2 – Ground B3 – Ground Constant Battery positive voltage A11 – A12 A12 – A25 BE–19 If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 8. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE C) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Author: Date: 2239 BE–20 BODY ELECTRICAL Tester connection – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Condition Specified condition 2 – Ground All door courtesy switches OFF (Except Driver’s Door/ Door closed) No continuity 2 – Ground One of the door courtesy switches ON (Except Driver’s Door/ Door opened) Continuity 4 – Ground Door courtesy switches except that of the driver’s door OFF (Door closed) No continuity 4 – Ground One of the door courtesy switches except that of the driver’s door ON (Door opened) Continuity 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF (Door closed) No continuity 6 – Ground Driver’s door courtesy switch ON (Door opened) Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage 11 – Ground Ignition switch LOCK No voltage 11 – Ground Ignition switch ACC or ON Battery positive voltage (b) Wire harness side: Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 1 2 3 4 5 6 7 8 9 10 11 12 13 Connector ”A” Wire harness side: 1 2 3 4 Connector ”B” N20138 Author: Date: 2240 BODY ELECTRICAL Tester connection – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Condition Specified condition A1 – Ground Door lock manual switch OFF or UNLOCK No continuity A1 – Ground Door lock manual switch LOCK Continuity A2 – Ground Door lock manual switch OFF or LOCK No continuity A2 – Ground Door lock manual switch UNLOCK Continuity A3 – Ground Driver’s and passenger’s door key lock and unlock switch OFF or UNLOCK No continuity A3 – Ground Driver’s or passenger’s door key lock and unlock switch LOCK Continuity A4 – Ground Driver’s door key lock and unlock switch OFF or LOCK No continuity A4 – Ground Driver’s door key lock and unlock switch UNLOCK Continuity A5 – Ground Passenger’s door key lock and unlock switch OFF or LOCK No continuity A5 – Ground Passenger’s door key lock and unlock switch UNLOCK Continuity Constant Continuity A8 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity A8 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity A9 – Ground Driver’s door unlock detection switch OFF (Door closed) No continuity A9 – Ground Driver’s door unlock detection switch ON (Door opened) Continuity A10 – Ground Passenger’s door unlock detection switch OFF (Door closed) No continuity A10 – Ground Passenger’s door unlock detection switch ON (Door opened) Continuity A11 – Ground Rear door unlock detection switch OFF (Door closed) No continuity A11 – Ground Rear door unlock detection switch ON (Door opened) Continuity A12 – Ground Constant Continuity A13 – Ground Constant Battery positive voltage B1 – Ground Light control switch OFF No voltage B1 – Ground Light control switch TAIL or HEAD Battery positive voltage B4 – Ground Light control switch OFF or TAIL No voltage B4 – Ground Light control switch HEAD Battery positive voltage B2 – Ground B3 – Ground Constant Battery positive voltage A6 – A7 BE–21 If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2241 BE–22 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE0A4–02 LOCATION E/G Room J/B No.2
HEAD LH Fuse (USA)
HEAD RH Fuse (USA)
HEAD LH (UPR) Fuse (CANADA)
HEAD RH (UPR) Fuse (CANADA)
DOME Fuse
ECU–B Fuse
Headlight Control Relay Daytime Resister E/G Room R/B No.2 (CANADA)
HEAD LH (LWR) Fuse
HEAD RH (LWR) Fuse
DRL No.2 Fuse
Daytime Running Light Relay No.4 Automatic Light Control Sensor Headlight Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
Taillight Control Relay
Integration Relay Ignition Switch Combination Switch
Light Control Switch
Headlight Dimmer Switch Daytime Running Light Relay Door Courtesy Switch Light Failure Sensor Taillight I08436 Author: Date: 2242 BE–23 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A5–02 COMPONENTS Combination Switch
Light Control Switch
Headlight Dimmer Switch Switch Body Spiral Cable Combination Switch
Wiper and Washer Switch N18012 Author: Date: 2243 BE–24 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE10D–01 INSPECTION 1. Hi beam HEAD TAIL OFF Flash INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition OFF – TAIL 14 – 16 Continuity HEAD 13 – 14 – 16 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY 8 7 Switch position Tester connection Specified condition Low beam 16 – 17 Continuity High beam 7 – 16 Continuity Flash 7 – 8 – 16 Continuity If continuity is not as specified, replace the switch. 17 16 14 13 N20149 3. 1 2 4 2 1 4 3 3 INSPECT HEADLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–4 Continuity If continuity is not as specified, replace the relay. Z08521 4. 2 1 3 5 5 2 1 3 INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 5. 2 4 1 3 2 4 1 INSPECT HEADLIGHT DIMMER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 – 4, 2 – 4 Continuity Apply B+ between terminals 2 and 4. 3–4 Continuity If continuity is not as specified, replace the relay. 3 Z08523 Author: Date: 2244 BE–25 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM 6. INSPECT DAYTIME RUNNING LIGHT RELAY (MAIN) CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. Wire harness side: I08219 Tester connection Condition Specified condition 2 – Ground Light control switch position OFF or TAIL No continuity 2 – Ground Light control switch position HEAD Continuity 3 – Ground Headlight dimmer switch position Low beam No continuity 3 – Ground Headlight dimmer switch position High beam of Flash Continuity 4 – Ground Brake fluid level warning position OFF No continuity 4 – Ground Brake fluid level warning position ON Continuity 12 – Ground Constant Continuity 14 – Ground Parking brake switch position OFF (Parking brake lever released) No continuity 14 – Ground Parking brake switch position ON (Parking brake lever pulled up) Continuity 17 – Ground Light control switch position OFF or HEAD No voltage 17 – Ground Light control switch position TAIL Continuity 20 – Ground Constant Continuity 21 – Ground Constant Continuity 13 – Ground Engine Stop No voltage 13 – Ground Engine Running Battery positive voltage 16 – Ground Constant Battery positive voltage 18 – Ground Ground terminal 19 Battery positive voltage 19 – Ground Constant Battery positive voltage 22 – Ground Constant Battery positive voltage 23 – Ground Ignition switch position LOCK or ACC No voltage 23 – Ground Ignition switch position ON or START Battery positive voltage If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2245 BE–26 BODY ELECTRICAL 7. 2 3 1 4 2 1 3 4 – HEADLIGHT AND TAILLIGHT SYSTEM INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY Condition Tester connection Specified condition Constant 3–4 Continuity Apply B+ between terminals 3 and 4. 1–2 Continuity If continuity is not as specified, replace the relay. Z08559 8. 2 1 INSPECT DAYTIME RUNNING LIGHT RESISTER CONTINUITY Condition Tester connection Specified condition Constant 1–2 Approx. 250mΩ If continuity is not as specified, replace the resistor. 9. INSPECT LIGHT AUTO TURN OFF SYSTEM (See Integration relay circuit on page BE–14) N20139 10. (a) (b) (c) (d) (e) INSPECT AUTOMATIC LIGHT CONTROL Turn the ignition switch ON. Turn the light control switch to OFF. Parking brake lever released. Gradually cover the top of the sensor. Verify that the lights should turn ON the accessory lights and the headlights. 11. (a) (b) INSPECT AUTOMATIC LIGHT CONTROL Gradually expose the sensor. Verify that the lights should turn OFF the headlights and the accessory lights. INSPECT LIGHT–OFF CONDITION Turn the ignition switch ON. Gradually cover the top of the sensor. Lights auto ON: INSPECT LIGHTS–ON CONDITION Open the driver’s door while the ignition switch is OFF. Turn the light control switch to OFF leaving the door open and cover the top of the sensor, and verify that the lights go on when the ignition switch is turned ON. I08422 12. (a) (b) I08423 13. (a) (b) Author: Date: 2246 BE–27 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM 14. INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Connector disconnected: Disconnect the connector from the sensor and inspect the connector on the wire harness side, as shown in the table. Wire harness side: 1234 I01254 Tester connection Condition Specified condition 3 – Ground Constant Constant 1 – Ground Ignition switch LOCK or ACC No voltage 1 – Ground Ignition switch ON Battery positive voltage 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON 5.2 – 9.0 v If circuit is as specified, perform the inspection on the following page. If the circuit is not as specified, inspect the circuit connected to other parts. 15. 4 3 1 2 I01255 INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Connector disconnected: Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side, as shown. HINT:
Ignition switch ON.
Light control switch OFF.
Vehicle’s surroundings are bright. Tester connection Condition Specified condition 3 – Ground Constant Continuity 1 – Ground Ignition switch LOCK or ACC No voltage 1 – Ground Ignition switch ON 9.5 V or more Vehicle under the direct sun light. (Sensor is not covered) Taillight and Headlight are ON. If circuit is as specified, try replacing the sensor with a new one. If the circuit is not as specified, inspect the circuit connected to other parts. Author: Date: 2247 BE–28 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A7–02 ADJUSTMENT 1. ADJUST HEADLIGHT AIMING For Adjustment in Vertical Direction For Adjustment in Horizontal Direction N20156 2. ADJUST SPIRAL CABLE (See page SR–16) Author: Date: 2248 BE–29 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A8–03 LOCATION E/G Room J/B No.2
HORN Fuse Hazard Warning Switch Ignition Switch Turn Signal Light Instrument Panel J/B No.1
TURN Fuse Turn Signal Flasher Combination Switch
Turn Signal Switch Turn Signal Light Z19045 Author: Date: 2249 BE–30 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A9–02 INSPECTION Right 1. Left INSPECT TURN SIGNAL SWITCH CONTINUITY Switch position Tester connection Left turn 1–2 Neutral – Right turn 2–3 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 3 2 1 N20150 2. (a) 3 2 (b) 1 Turn Signal Light Bulbs (21 W) 4 3 BE1843 INSPECT TURN SIGNAL FLASHER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3. Connect the 2 turn signal light bulbs in parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT: The turn signal lights should flash 60 to 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashes will be more than 140 per minute. If operation is not as specified, replace the flasher. 3. INSPECT HAZARD WARNING SWITCH CONTINUITY Switch position Tester connection Switch OFF 7 – 10 Continuity Switch ON 5–6–9 7–8 Continuity Illumination circuit 2–3 Continuity 2 1 10 9 8 7 6 5 Specified condition If continuity is not as specified, replace the switch. N20140 Author: Date: 2250 BE–31 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE0AA–03 LOCATION E/G Room J/B No.2
DOME Fuse Instrument Panel J/B No.1
Integration Relay Map Light Dome Light Door Courtesy Switch Door Courtesy Switch Luggage Compartment Door Courtesy Switch Z19046 Author: Date: 2251 BE–32 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM BE0AB–03 INSPECTION w/ Sliding roof: 2 1 1. INSPECT MAP LIGHT SWITCH CONTINUITY Switch position Tester connection OFF – ON 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the light assembly or bulb. w/o Sliding roof: 1 2 N21873 2. (a) (b) 2 Ohmmeter INSPECT DOME LAMP SWITCH Disconnect the connector from the dome lamp. Turn the dome lamp switch ON, check that continuity exists between terminal 2 and body ground. N20157 (c) Turn the dome lamp switch DOOR, check that there is continuity exists between terminal 1 and 2. If operation is not as specified, replace the switch. 2 Ohmmeter 1 N20158 3. (a) ON Ohmmeter OFF INSPECT DOOR COURTESY SWITCH CONTINUITY Check that continuity exists between terminal and the switch body with the switch ON (switch pin released: opened door). (b) Check that no continuity exists between terminal and the switch body with the switch OFF (switch pin pushed in: closed doors). If operation is not as specified, replace the switch. N20159 Author: Date: 2252 BE–33 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM 4. ON OFF I01447 INSPECT LUGGAGE COMPARTMENT DOOR COURTESY SWITCH CONTINUITY (a) Check that continuity exists between terminal and switch body with the switch ON (switch pin released: opened door). (b) Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. 5. INSPECT ILLUMINATED ENTRY SYSTEM (See Integration relay circuit on page BE–14) Author: Date: 2253 BE–34 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BACK–UP LIGHT SYSTEM BE0AC–02 LOCATION Instrument Panel J/B No.1
GAUGE Fuse Ignition Switch Back–up Light 1MZ–FE engine: 5S–FE engine: Back–up Light Switch Back–up Light Switch PNP Switch Z19047 Author: Date: 2254 BE–35 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BE0AD–02 INSPECTION INSPECT BACK–UP LIGHT SWITCH CONTINUITY Tester connection Free – Push 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. Push Free Condition N14065 Author: Date: 2255 BE–36 BODY ELECTRICAL – STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE0AE–02 LOCATION Stop Light Switch Instrument Panel J/B No.1
STOP Fuse Hi–Mounted Stop Light Stop Light Light Failure Sensor Z19048 Author: Date: 2256 BE–37 BODY ELECTRICAL – STOP LIGHT SYSTEM BE0AF–02 INSPECTION w/o Cruise control: Free 1. Pushed in 2 1 w/ Cruise control: Free Switch position Tester connection Specified condition Switch pin free 1–2 Continuity Switch pin pushed in 1–2 No continuity If continuity is not as specified, replace the switch. 2. w/ Cruise control: INSPECT STOP LIGHT SWITCH CONTINUITY Pushed in 1 2 w/o Cruise control: INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition Switch pin free 1–2 Continuity Switch pin pushed in 1–2 No continuity Switch pin free 3–4 No continuity Switch pin pushed in 3–4 Continuity If continuity is not as specified, replace the switch. 3 4 N18026 3. 1 INSPECT HI–MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter, check that continuity exists between terminals. If continuity is not as specified, replace the bulb or light assembly. 2 N20208 Author: Date: 2257 BE–38 BODY ELECTRICAL STOP LIGHT SYSTEM 4. INSPECT LIGHT FAILURE RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown. Wire harness side: 5 4 – 3 2 1 12 11 10 9 8 7 6 e–12–2–B N20209 Tester connection Condition Specified condition 1 – Ground Constant Continuity* 2 – Ground Constant Continuity* 9 – Ground Constant Continuity* 11 – Ground Constant Continuity 3 – Ground Light control switch OFF No voltage 3 – Ground Light control switch TAIL or HEAD Battery positive voltage 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON Battery positive voltage 7 – Ground Stop light switch OFF No voltage 7 – Ground Stop light switch ON Battery positive voltage 8 – Ground Ignition switch LOCK or ACC No voltage 8 – Ground Ignition switch ON Battery positive voltage *: There is resistance because this circuit is grounded through the bulb. If the circuit is as specified, replace the relay. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2258 BE–39 BODY ELECTRICAL – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE0AG–03 LOCATION Wiper Motor Washer Tank Washer Motor Wiper and Washer Switch Instrument Panel J/B No.1
WIPER Fuse Z19049 Author: Date: 2259 BE–40 BODY ELECTRICAL – WIPER AND WASHER SYSTEM BE0AH–03 w/o Timer OFF INT LO HI INSPECTION 1. INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection OFF 7 – 16 Continuity INT 7 – 16 Continuity LO 7 – 17 Continuity HI 8 – 17 Continuity Washer ON 2 – 11 Continuity Washer ON w/ Timer OFF INT LO HI Specified condition If continuity is not as specified, replace the switch. Washer ON 8 7 17 2 11 16 N20218 2. (a) (b) (c) 2 7 (d) 16 INSPECT INTERMITTENT OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2, check that the meter needle indicates battery positive voltage. N20210 (e) 7 2 After connecting terminal 16 to terminal 17, connect it to terminal 2, check the voltage rises from 0 volts to battery positive voltage within the time, as shown in the table. 17 INT time control switch position 16 Voltage Approx. 2 sec. Battery positive voltage FAST N20211 0V 10.7 ± 5 sec. Battery positive voltage SLOW 0V 3.3 ± 1 sec. Non variable type Battery positive voltage 0V If operation is not as specified, replace the wiper and washer switch. Author: Date: 2260 BE–41 BODY ELECTRICAL 3. (a) 2 7 (b) (c) 16 – WIPER AND WASHER SYSTEM INSPECT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2. Push in the washer switch, and check that the voltage changes as shown in the chart. Washer Switch ON N20210 OFF Less than 1 sec. Approx. 3 sec. Battery positive Voltage 0V N11301 If operation is not as specified, replace the wiper and washer switch. 4. Low speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (–) lead to terminal 4, check that the motor operates at low speed. If operation is not as specified, replace the motor. 5 4 N20151 Author: Date: 2261 BE–42 BODY ELECTRICAL – WIPER AND WASHER SYSTEM 5. High speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 4, check that the motor operates at high speed. If operation is not as specified, replace the motor. 3 4 N20152 6. (a) Stopping in stop position: INSPECT FRONT WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except in the stop position by disconnecting positive (+) lead from terminal 5. 5 4 N20153 Author: Date: 2262 BE–43 BODY ELECTRICAL – WIPER AND WASHER SYSTEM (b) (c) 3 Connect terminals 3 and 5. Connect the positive (+) lead from the battery to terminal 2 and negative (–) lead to terminal 4, check that the motor stops running in the stop position after the motor operates again. If operation is not as specified, replace the motor. 2 5 4 N20154 7. INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. 2 1 2 1 N20155 Author: Date: 2263 BE–44 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE0AI–03 LOCATION Brake Fluid Level Warning Switch E/G Room J/B No.2
ECU–B Fuse
DOME Fuse Washer Fluid Level Warning Switch Combination Meter
Bulb Check Relay ECM ABS ECU Light Control Rheostat Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
IGN Fuse
Integration Relay Z19050 Author: Date: 2264 BE–45 BODY ELECTRICAL PKB Switch – COMBINATION METER Door Courtesy Switch Seat Belt Buckle Switch Door Courtesy Switch Fuel Sender Gauge
Fuel Level Warning Switch Light Failure Sensor 5S–FE engine: 1MZ–FE engine: Low Oil Pressure Warning Switch Engine Coolant Temperature Gauge Engine Coolant Temperature Gauge Low Oil Pressure Warning Switch Park/Neutral Position Switch Park/Neutral Position Switch Z19055 Author: Date: 2265 BE–46 BODY ELECTRICAL – COMBINATION METER BE0AJ–03 CIRCUIT Connector ”A” 1 2 3 4 5 6 Connector ”B” 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 Connector ”C” 9 10 11 12 13 14 15 16 J–13–1–A C7 E T 7 8 9 10 11 1213 J–16–1 B3 C5 A2 A1 C8 F 1 2 3 4 5 6 Connector ”C” Connector ”B” J–13–1 Connector ”A” B15 C6 S B14 ODOMETER Fuel Level Warning Seat Belt Warning ABS Warning Low Oil Pressure Warning Cruise Control Indicator Malfunction Indicator O/D OFF Indicator Light Failure Warning Brake Warning SLIP Indicator TRAC Indicator Washer Level Warning Discharge Warning A13 B2 C1 B1 C9 A6 A11 A7 A10 A8 A9 Bulb Check Relay Right Turn Indicator Left Turn Indicator Security Indicator L 2 D N R P Illumination C13 B8 B11 B12 Hi–Beam Indicator Open Door Warning SRS Warning B6 A4 C4 B5 C10 C2 A12 A3 B7 C3 A5 C11 B4 No. A B16 B C12 B9 B10 B13 C F : Fuel Gauge E : Engine Coolant Temperature Gauge T : Tachometer S : Speedometer 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 Wire Harness Side Engine coolant temperature sender gauge Ground Light failure sensor Integration relay Traction ECU Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) O/D OFF switch (A/T) IGN fuse Turn signal switch ST relay Fuel sender gauge Generator Oil pressure switch Fuel sender gauge Parking brake switch and brake fluid level warning switch Headlight dimmer switch Headlight dimmer switch Door courtesy switch DOME fuse ECU–B fuse Airbag sensor assembly ECM No.1 Vehicle speed sensor Ground Turn signal switch ECM Traction ECU ABS ECU Ground No.1 Vehicle speed sensor GAUGE fuse Igniter Security ECU Cruise control ECU Washer fluid level warning switch Light control rheostat TAIL fuse N20107 N20108 Z18937 Author: Date: 2266 BE–47 BODY ELECTRICAL – COMBINATION METER BE0AK–03 INSPECTION 1. INSPECT SPEEDOMETER ON–VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. USA (mph) CANADA (km/h) Standard indication Allowable range Standard indication Allowable range 20 18 – 24 20 40 38 – 44 40 38 – 46 60 56 – 66 60 57.5 – 67 80 78 – 88 80 77 – 88 100 98 – 110 100 96 – 109 120 118 – 132 120 115 – 130 140 134 – 151.5 160 153 – 173 2. (a) 3 (b) 1 (c) (d) 2 N02332 17 – 24 INSPECT VEHICLE SPEED SENSOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2. Connect the positive (+) lead from the tester to terminal 3 and the negative (–) lead to terminal 2. Rotate the shaft. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. 3. INSPECT TACHOMETER ON–VEHICLE (a) Connect a tune–up test tachometer, and start the engine. NOTICE:
Reversing the connection of the tachometer will damage the transistors and diodes inside.
When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. Author: Date: 2267 BE–48 BODY ELECTRICAL (b) Ignition Switch – COMBINATION METER Compare the tester with tachometer indications. DC 13.5 V 25°C at (77 °F) Standard indication Allowable range 700 630 – 770 1,000 900 – 1,100 2,000 1,850 – 2,150 3,000 2,800 – 3,200 4,000 3,800 – 4,200 5,000 4,800 – 5,200 6,000 5,750 – 6,250 7,000 6,700 – 7,300 4. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 and 3 on the wire harness side connector through a 3.4–W test bulb. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. Fuel Gauge Battery N20160 Ignition Switch (d) Fuel Gauge Battery 1 2 4 BE1206 Ie–5–1–A 3 5 Z05727 HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 5. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. A B C Tester connection Resistance (Ω) A–B Approx. 126.2 A–C Approx. 280.5 B–C Approx. 154.3 If resistance value is not as specified, replace the receiver gauge. N20212 Author: Date: 2268 BE–49 BODY ELECTRICAL – COMBINATION METER 6. INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3 for each float position. F 1/2 E 3 1 2 N20161 Float position mm (in.) Resistance (Ω) F: Approx. –91.1 (–3.587) Approx. 3.0 1/2: Approx. –34.2 (–1.346) Approx. 31.7 E: Approx. 30.8 (1.213) Approx. 110.0 If resistance value is not as specified, replace the sender gauge. 7. (a) (b) INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 1 and 3 on the wire harness side connector. (c) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Battery 2 1 4 3 5 Z05730 BE1217 Ie–5–1–A 3 1 8. (a) INSPECT FUEL LEVEL WARNING SWITCH Apply battery positive voltage between terminals 1 and 3 through a 3.4–W test bulb, check that the bulb lights up. HINT: It takes a short time for the bulb to light up. N20213 1 3 (b) Submerge the switch in fuel, check that the bulb goes out. If operation is not as specified, replace the sender gauge. N20214 9. Engine coolant temperature gauge Ignition Switch Battery (a) (b) Sender Gauge INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. N20215 Author: Date: 2269 BE–50 BODY ELECTRICAL Battery COMBINATION METER (c) Ground terminal on the wire harness side connector through a 3.4–W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. Engine coolant temperature gauge Ignition Switch – Test Bulb (3.4 W) Wire Harness Side Z15788 10. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. C B A N20216 Tester connection Resistance (Ω) * A–B Approx. 175.7 A–C Approx. 54.0 B–C Approx. 229.7 *: This circuit includes the diode. HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. If resistance value is not as specified, replace the receiver gauge. 11. INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Measure the resistance between the terminal and gauge body. Temperature °C (°F) Resistance (Ω) 50 (122.0) 274 120 (248.0) 26.4 If resistance value is not as specified, replace the engine coolant temperature sender gauge. N21646 12. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery 1 Z14205 Author: Date: 2270 BE–51 BODY ELECTRICAL 13. (a) (b) (c) N06640 – COMBINATION METER INSPECT LOW OIL PRESSURE SWITCH Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2, 3.55 psi). If operation is not as specified, replace the switch. 14. (a) Warning Light Ignition Switch Battery BE1217 INSPECT BRAKE SYSTEM WARNING LIGHT Disconnect the connector from the brake fluid warning switch. (b) Release the parking brake pedal. (c) Connect the terminals on the wire harness side of the level warning switch connector. (d) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. 15. (a) (b) (c) OFF ON 2 1 N02346 INSPECT BRAKE FLUID LEVEL WARNING SWITCH Remove the reservoir tank cap and strainer. Disconnect the connector. Check that no continuity exists between the terminals with the switch OFF (float up). (d) Use syphon, etc. to take fluid out of the reservoir tank. (e) Check that continuity exists between the terminals with the switch ON (float down). (f) Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. 16. INSPECT PARKING BRAKE SWITCH (a) Check that continuity exists between the terminal and switch body with the switch ON (switch pin released). (b) Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. N01212 17. (a) INSPECT WASHER FLUID LEVEL WARNING LIGHT Disconnect the connectors from the level warning switch and parking brake switch. (b) Connect terminals on the wire harness side connector of the level warning switch connector. (c) Remove the GAUGE fuse and turn the ignition switch ON, and check that the warning light comes on. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery BE1217 Author: Date: 2271 BE–52 BODY ELECTRICAL Ohmmeter OFF ON – COMBINATION METER 18. (a) INSPECT WASHER FLUID LEVEL WARNING SWITCH Check that no continuity exists between terminals with the switch OFF (float up). (b) Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. N20217 19. INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch and ground terminal 1 on the wire harness side, and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. Warning Light Ignition Switch Battery 1 Z05732 20. (a) Warning Light Ignition Switch Battery BE0044 INSPECT SEAT BELT WARNING LIGHT Remove the integration relay from the instrument panel junction block. (b) Ground terminal 2 on the integration relay with the connectors still connected. (c) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 21. 1 2 OFF ON w/o Power seat: INSPECT BUCKLE SWITCH CONTINUITY (a) Check that continuity exists between the terminals on the switch side connector with the switch ON (belt fastened). (b) Check that no continuity exists between the terminals on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. Z16167 OFF 1 2 ON N02354 22. w/ Power seat: INSPECT BUCKLE SWITCH CONTINUITY (a) Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). (b) Check that no continuity exists between terminals 1 and 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. Author: Date: 2272 BE–53 BODY ELECTRICAL 23. Type A: 1 7 (a) 9 10 (b) (c) (d) Type B and C: 1 (e) 7 9 – COMBINATION METER INSPECT INTEGRATION RELAY OF SEAT BELT WARNING SYSTEM OPERATION Connect the positive (+) lead from the battery to terminals 1 and 7. Connect the terminal 7 to terminal 9 through the 3.4–W test bulb. Connect the negative (–) lead from the battery to terminal 10. Check that the bulb lights and the buzzer sounds for 4 – 8 seconds. Return to step (a) and operate the chime again. 10 N20219 (f) Type A: 1 7 Connect the negative (–) lead from the battery to terminal 8. Check that the buzzer stops sounding. (g) HINT: Check the buzzer within a period of 4 to 8 seconds. If operation is not as specified, replace the relay. 24. INSPECT INTEGRATION RELAY CIRCUIT See page BE–14 8 9 10 Type B and C: 1 7 8 9 10 N20220 Author: Date: 2273 BE–54 BODY ELECTRICAL 25. (a) (b) (c) – COMBINATION METER INSPECT LIGHT CONTROL RHEOSTAT Connect the positive (+) lead from the battery to terminal 1 and negative lead (–) to terminal 3. Connect the positive (+) lead from the voltmeter to terminal 2 and negative lead to terminal 3. Turn the rheostat knob and check that the voltage changes. 270° 2 3 1 N08958 (a) B A C (b) B A C 26. (a) INSPECT BULB CHECK RELAY OPERATION Connect the positive (+) lead from the battery to terminal C through a 1.4–W test bulb and the negative (–) lead to terminal B, check that the test bulb does not light up. (b) Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Z09972 Author: Date: 2274 BE–55 BODY ELECTRICAL – DEFOGGER SYSTEM DEFOGGER SYSTEM BE0AL–03 LOCATION Defogger Switch Instrument Panel J/B No.1
DEFOG M–Fuse
HTR Fuse
MIR–HTR Fuse
Defogger Relay Mirror Defogger Defogger Wire Z19051 Author: Date: 2275 BE–56 BODY ELECTRICAL – DEFOGGER SYSTEM BE0AM–03 INSPECTION Switch side: 2 1. INSPECT DEFOGGER SWITCH CONTINUITY Check that is continuity exists between terminals 2 and 6. If continuity is not as specified, check the bulb. 1 6 5 4 3 N20315 2. (a) 5 ON 4 3 N20314 INSPECT DEFOGGER TIMER OPERATION Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 3. (b) Connect the positive (+) lead from the battery to terminal 5 through a 3.4–W tester bulb. (c) Push the defogger switch ON, check that the indicator light and test bulb light up for 12 to 18 minutes, then the indicator light and test bulb light goes out. If operation is not as specified, replace the switch. 3. INSPECT DEFOGGER TIMER CIRCUIT Disconnect the connector from the switch and inspect the connector on the wire harness side, as shown in the table. Wire harness side: 1 2 3 4 5 6 S–6–1 Z08467 Tester connection Condition Specified condition 3 – Ground Constant Continuity 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON Battery positive voltage 5 – Ground Ignition switch LOCK or ACC No voltage 5 – Ground Ignition switch ON Battery positive voltage Connect terminals 3 and 5. Defogger system operation is normal – If the circuit is not as specified, replace the switch. 4. 1 2 3 5 1 5 2 3 INSPECT DEFOGGER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 Author: Date: 2276 BE–57 BODY ELECTRICAL 5. (a) 6 4 – DEFOGGER SYSTEM w/ Heater: INSPECT MIRROR DEFOGGER Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 6. Check that the mirror becomes warm. (b) HINT: It takes short time for the mirror to become warm. N21371 Tester Probe Heat Wire Tin Foil BE4029 At Center 6. INSPECT DEFOGGER WIRE NOTICE:
When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires.
Do not use detergents or glass cleaners with abrasive ingredients.
When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown. (a) Turn the ignition switch ON. (b) Turn the defogger switch ON. (c) Inspect the voltage at the center of each heat wire, as shown. Voltage Criteria Approx. 5V Okay (No break in wire) Approx.10V or 0V Broken wire BE0123 Several 0 Volt Volts Broken Wire BE0124 HINT: If there is approximately 10 V, the wire is broken between the center of the wire and the positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. (d) Place the voltmeter positive (+) lead against the defogger positive (+) terminal. (e) Place the voltmeter negative (–) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (–) terminal end. (f) The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. Author: Date: 2277 BE–58 BODY ELECTRICAL 7. (a) Repair Point (b) Broken Wire (c) Masking Tape – DEFOGGER SYSTEM IF NECESSARY, REPAIR DEFOGGER WIRE Clean the broken wire tips with grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817). BE0150 (d) (e) (f) (g) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. BE0151 Author: Date: 2278 BE–59 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE0AN–03 LOCATION Ignition Switch Instrument Panel J/B No.1
POWER M–Fuse
GAUGE Fuse
Power Main Relay
Integration Relay Door Courtesy Switch Power Window Switch Power Window Switch Power Window Switch Power Window Master Switch Power Window Regulator Assembly
Power Window Motor Door Courtesy Switch Power Window Regulator Assembly
Power Window Motor Power Window Regulator Assembly
Power Window Motor Z19052 Author: Date: 2279 BE–60 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM BE0AO–02 INSPECTION 1. (a) 6 5 4 3 2 1 141312 1110 9 8 7 INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Inspect the front driver’s switch. Window unlock: Switch position Tester connection Specified condition UP 3–8–9 4–5–6 Continuity OFF 3–4–5 4–5–6 Continuity DOWN 6–8–9 3–4–5 Continuity Window lock: Switch position Tester connection UP 3–8–9 4–5–6 Continuity OFF 3–4–5 4–5–6 Continuity DOWN 6–8–9 3–4–5 Continuity N20559 (b) Specified condition Inspect the front passenger’s switch. Window unlock: Switch position Tester connection Specified condition UP 8 – 9 – 11 4 – 5 – 13 Continuity OFF 4 – 5 – 11 4 – 5 – 13 Continuity DOWN 8 – 9 – 13 4 – 5 – 11 Continuity Window lock: (c) Switch position Tester connection Specified condition UP 8 – 9 – 11 Continuity OFF 11 – 13 Continuity DOWN 8 – 9 – 13 Continuity Inspect the rear left switch. Window unlock: Switch position Tester connection UP 8 – 9 – 10 4 – 5 – 12 Continuity OFF 4 – 5 – 10 4 – 5 – 12 Continuity DOWN 8 – 9 – 12 4 – 5 – 10 Continuity Author: MH Specified condition Date: 3/7/02 2280 BE–61 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Window lock: (d) Switch position Tester connection UP 8 – 9 – 10 Continuity Specified condition OFF 10 – 12 Continuity DOWN 8 – 9 – 12 Continuity Inspect the rear right switch. Window unlock: Switch position Tester connection Specified condition UP 7–8–9 4 – 5 – 14 Continuity OFF 4–5–7 4 – 5 – 14 Continuity DOWN 8 – 9 – 14 4–5–7 Continuity Window lock: Switch position Tester connection Specified condition UP 7–8–9 Continuity OFF 7 – 14 Continuity DOWN 8 – 9 – 14 Continuity If continuity is not as specified, replace the master switch. 2. Unlock (a) (b) 4 8 INSPECT POWER WINDOW MASTER SWITCH ILLUMINATION Set the window lock switch to the unlock position. Connect the positive (+) lead from the battery to terminal 8 and the negative (–) lead to terminal 4, and check that all the illuminations light up. N02358 (c) Set the window lock switch to the lock position, check that all the passenger’s power window switch illuminations go out. If operation is not as specified, replace the master switch. Lock 4 8 N02359 Author: Date: 2281 BE–62 BODY ELECTRICAL 3 3. 6 (a) (b) (c) Z05738 (d) 3 (e) 6 – POWER WINDOW CONTROL SYSTEM Using an ammeter: INSPECT ONE–TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 3 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 6 on the wire harness side connector. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Z05739 4. 8 (a) (b) (c) Z05740 8 (d) (e) Using an ammeter with a current – measuring probe: INSPECT ONE–TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Remove the master switch with connector connected. Attach a current–measuring probe to terminal 8 of the wire harness. Turn the ignition switch ON and set the power window switch in the down position. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Z05741 Author: MH Date: 3/7/02 2282 BE–63 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM 5. INSPECT POWER WINDOW MASTER SWITCH CIRCUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side, as shown in the following page. Wire harness side: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 e–14–1–A Z05742 Tester connection Condition Specified condition 4 – Ground Constant Continuity 8 – Ground Ignition switch position LOCK or ACC *No voltage 8 – Ground Ignition switch position ON Battery positive voltage *Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or a passenger’s door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, inspect the circuits connected to other parts. 6. 5 4321 Front passenger’s door: INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 – 2, 3 – 4 Continuity OFF 1 – 2, 3 – 5 Continuity DOWN 1 – 4, 3 – 5 Continuity If continuity is not as specified, replace the switch. N20560 7. 5 432 1 Rear door: INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 – 3, 4 – 5 Continuity OFF 1 – 2, 4 – 5 Continuity DOWN 1 – 2, 3 – 5 Continuity If continuity is not as specified, replace the switch. N20561 8. 1 2 3 5 5 1 2 3 INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 Author: Date: 2283 BE–64 BODY ELECTRICAL 9. TMMK made: (a) 2 – POWER WINDOW CONTROL SYSTEM Left side door: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. 1 TMC made: N20555 (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. TMMK made: 2 1 TMC made: N20556 Author: MH Date: 3/7/02 2284 BE–65 BODY ELECTRICAL 10. TMMK made: (a) 2 – POWER WINDOW CONTROL SYSTEM Right side door: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. 1 TMC made: N20557 (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. TMMK made: 2 1 TMC made: N20558 Author: Date: 2285 BE–66 BODY ELECTRICAL 11. 1 2 (a) (b) (c) I21314 (d) (e) – POWER WINDOW CONTROL SYSTEM Driver’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 2 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector, and raise the window to the fully position. Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, and check that the window begins to descend. If operation is not as specified, replace the motor. 2 1 I21315 12. 2 1 (a) (b) (c) I21312 (d) (e) Passenger ’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the power window switch. Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. Disconnect the leads from the terminals. Author: MH Date: 3/7/02 2286 BE–67 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the window begins to descend. If operation is not as specified, replace the motor. 2 1 I21313 13. 2 1 I12561 2 1 Rear Door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION (a) Disconnect the connector from the power window switch. (b) Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. (d) Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, and check that the window begins to descend. If operation is not as specified, replace the motor. I12560 14. Type B: (b) Close (c) Open A3 N20564 Key–off power window signal: INSPECT INTEGRATION RELAY (TYPE B) OPERATION HINT: When the relay circuit is as specified, inspect the key–off power window signal. (a) Connect the positive (+) lead from the voltmeter to terminal A3 and the negative (–) lead to body ground. (b) Close the door with ignition switch turned to LOCK or ACC, and check that the meter needle indicates battery positive voltage. (c) Open the door and check that the meter needle indicates 0 V. Author: Date: 2287 BE–68 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM (d) Turn the ignition switch ON and check that the meter needle indicates battery positive voltage again. If operation is not as specified, replace the relay. Type B: A3 N20565 Type C: 15. (b) Close (c) Open A12 N20566 Key–off power window signal: INSPECT INTEGRATION RELAY (TYPE C) OPERATION HINT: When the relay circuit is as specified, inspect the key–off power window signal. (a) Connect the positive (+) lead from the voltmeter to terminal A12 and the negative (–) lead to body ground. (b) Close the door with ignition switch turned to LOCK or ACC, and check that the meter needle indicates battery positive voltage. (c) Open the door and check that the meter needle indicates 0 V. (d) Turn the ignition switch ON and check that the meter needle indicates battery positive voltage again. If operation is not as specified, replace the relay. 16. INSPECT INTEGRATION RELAY CIRCUIT (See page XX–XXX) Type C: A12 N20567 Author: MH Date: 3/7/02 2288 BE–69 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE0AP–02 LOCATION Instrument Panel J/B No.1
POWER M–Fuse
CIG Fuse
DOOR Fuse
Integration Relay Door Key Lock and Unlock Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Power Window Master Switch
Door Lock Control Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Door Lock Control Switch Z19053 Author: Date: 2289 BE–70 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM BE0AQ–02 INSPECTION 1. N21181 Master switch: INSPECT DRIVER’S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection LOCK 2–4 OFF – UNLOCK 4–7 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER’S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection LOCK 3–6 OFF – UNLOCK 3–5 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N20568 3. OFF UNLOCK LOCK 1 2 3 w/ Theft deterrent system: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 2–1 OFF – UNLOCK 3–1 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N20569 4. Lock Unlock w/o Theft deterrent system: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 2–1 OFF – UNLOCK 3–1 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N21580 4 5. 1 Lock Unlock INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) – ON (Door Lock set to UNLOCK) 1–4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. N20673 Author: Date: 2290 BE–71 BODY ELECTRICAL 3 2 3 – POWER DOOR LOCK CONTROL SYSTEM 6. (a) INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Remove the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. 2 N20570 7. Front door Rear door (a) (b) Using an ammeter: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 3. Connect the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to battery negative (–) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. N20571 Front door (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. Rear door N20572 Front door 8. Rear door (a) (b) Using an ammeter with a current–measuring probe: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2. Attach a current–measuring probe to either the positive (+) lead or the negative (–) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. N20573 Front door (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. Rear door N20572 Author: Date: 2291 BE–72 BODY ELECTRICAL Type B: 9. Lock A25 A12 N20574 Type B: Unlock A25 A12 – POWER DOOR LOCK CONTROL SYSTEM Door lock signal: INSPECT INTEGRATION RELAY (Type B) OPERATION HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the positive (+) lead from the voltmeter to terminal A12 and the negative (–) lead to terminal A25. (b) Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. (c) Reverse the polarity of the voltmeter leads. (d) Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. N20575 Type C: 10. Lock A7 A6 N20576 Type C: Unlock A7 A6 Door lock signal: INSPECT INTEGRATION RELAY (Type C) OPERATION HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the positive (+) lead from the voltmeter to terminal A6 and the negative (–) lead to terminal A7. (b) Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. (c) Reverse the polarity of the voltmeter leads. (d) Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. 11. INSPECT INTEGRATION RELAY CIRCUIT (See page BE–14) N20577 Author: Date: 2292 BE–73 BODY ELECTRICAL – SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE0AR–02 LOCATION E/G Room J/B No.2
DOME Fuse Ignition Switch Instrument Panel J/B No.1
POWER Fuse
GAUGE Fuse
Power Main Relay
Integration Relay Sliding Control Relay and Switch Sliding Roof Motor
Limit Switch Z19490 Author: Date: 2293 BE–74 BODY ELECTRICAL – SLIDING ROOF SYSTEM BE0AS–02 INSPECTION Wire harness side: 1. 1 2 INSPECT SLIDING ROOF CONTROL RELAY AND SWITCH CIRCUIT Disconnect the connector from the relay and switch and inspect the connector on the wire harness side, as shown in the table. 3 4 5 6 7 8 s–8–1 N21643 TMMK made: Tester connection Condition Specified condition 1–5 Constant Continuity 2 – Ground Constant Continuity 3 – Ground Limit switch No.1 is OFF (Sliding roof is in a closed position) No continuity 3 – Ground Limit switch No.1 is ON (Sliding roof is in an open position) Continuity 7 – Ground Limit switch No.2 is OFF (Sliding roof is in a tilt up position) No continuity 7 – Ground Limit switch No.2 is ON (Sliding roof is in the open position) Continuity 8 – Ground Limit switch No.3 is OFF (Sliding roof is in a closed position) No continuity 8 – Ground Limit switch No.3 is ON (Sliding roof is in an open position) Continuity 4 – Ground Ignition switch is in a LOCK or ACC position * No voltage 4 – Ground Ignition switch is in an ON position Battery positive voltage TMC made: Tester connection Condition Specified condition 1–5 Constant Continuity 2 – Ground Constant Continuity 3 – Ground No.1 limit switch OFF (Sliding roof closed) No continuity 3 – Ground No.1 limit switch ON (Sliding roof opened) Continuity 7 – Ground No.2 limit switch OFF (Sliding roof tilted up open approx. 200 mm (7.87 in.) No continuity 7 – Ground No.2 limit switch ON (Except for conditions mentioned above) Continuity 4 – Ground Ignition switch LOCK or ACC * No voltage 4 – Ground Ignition switch ON Battery positive voltage *: Exceptions: For 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or passenger door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, replace the relay and switch. Author: Date: 2294 BE–75 BODY ELECTRICAL Webasto type: 2 1 2. (a) – SLIDING ROOF SYSTEM INSPECT SLIDING ROOF MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise (moves to the close and up side). DENSO type: 1 2 N21182 (b) Webasto type: 2 1 Reverse the polarity, check that the motor turns clockwise (moves to the open and down side). If operation is not as specified, replace the motor. DENSO type: 1 2 N21183 3. (a) INSPECT CIRCUIT BREAKER OPERATION With the sliding roof in the fully opened position, hold the sliding roof switch in ”OPEN” position and check that is a circuit breaker operation noise is heard within 10 to 60 seconds. Within 10 to 60 seconds N21644 Author: Date: 2295 BE–76 BODY ELECTRICAL – SLIDING ROOF SYSTEM (b) With the sliding roof in fully opened position, hold the sliding roof switch in ”TILT UP” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. within 60 seconds N21645 4. No.3 Limit Switch ON OFF Switch position Tester connection No.1 Limit Switch No.1 limit switch OFF (SW pin released) 3–5 No continuity No.2 Limit Switch No.1 limit switch ON (SW pin pushed in) 3–5 Continuity No.2 limit switch OFF (SW pin released) 3–6 No continuity No.2 limit switch ON (SW pin pushed in) 3–6 Continuity No.3 limit switch OFF (SW pin released) 3–4 No continuity No.3 limit switch ON (SW pin pushed in) 3–4 Continuity N21872 5. ON OFF TMMK made: INSPECT SLIDING ROOF LIMIT SWITCH CIRCUIT No.1 Limit Switch No.2 Limit Switch 4 1 5 2 6 3 N21180 Specified condition TMC made: INSPECT SLIDING ROOF LIMIT SWITCH CIRCUIT Switch position Tester connection Specified condition No.1 limit switch OFF (SW pin released) 4–5 No continuity No.1 limit switch ON (SW pin pushed in) 4–5 Continuity No.2 limit switch OFF (SW pin released) 4–6 No continuity No.2 limit switch ON (SW pin pushed in) 4–6 Continuity If continuity is not as specified, replace the switch. 6. INSPECT KEY–OFF SLIDING ROOF OPERATION (See integration relay circuit on page BE–14) Author: Date: 2296 BE–77 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM BE0AT–02 LOCATION Instrument Panel J/B No.1
CIG Fuse Lifter Motor Reclining Motor Power Seat Switch Lifter Motor Sliding Motor Power Seat Switch Z19504 Author: Date: 2297 BE–78 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM BE0AU–02 INSPECTION Lifter Up 1. (a) Down Reclining Forward Rear (b) Front Rear Slide (c) 5 4 3 21 121110 9 8 7 6 I01932 TMC made: INSPECT DRIVER’S SEAT SWITCH CONTINUITY Inspect the slide switch. Switch position Tester connection FRONT 4 – 6, 8 – 11 Continuity Specified condition OFF 4 – 6, 6 – 8 Continuity BACK 6 – 8, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 11, 3 – 6 Continuity OFF 3 – 6, 2 – 6 Continuity DOWN 2 – 6, 3 – 11 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 1 – 11, 5 – 6 Continuity OFF 1 – 6, 5 – 6 Continuity REAR 1 – 6, 5 – 11 Continuity If continuity is not as specified, replace the switch. 2. TMMK made: INSPECT DRIVER’S SEAT SWITCH CONTINUITY (a) Inspect the slide switch. (b) (c) Switch position Tester connection Specified condition FRONT 2 – 11, 4 – 7 Continuity OFF 4 – 11, 4 – 7 Continuity BACK 2 – 7, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 5, 4 – 8 Continuity OFF 4 – 5, 4 – 8 Continuity DOWN 2 – 8, 4 – 5 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 2 – 12, 4 – 6 Continuity OFF 4 – 12, 4 – 6 Continuity REAR 2 – 6, 4 – 12 Continuity If continuity is not as specified, replace the switch. Author: Date: 2298 BE–79 BODY ELECTRICAL 3. Lifter Up (a) Down Reclining Forward Front Rear (b) Rear Slide (c) 5 4 3 21 121110 9 8 7 6 I01932 – POWER SEAT CONTROL SYSTEM TMC made: INSPECT PASSENGER’S SEAT CONTINUITY Inspect the slide switch. Switch position Tester connection Specified condition FRONT 4 – 6, 8 – 11 Continuity OFF 4 – 6, 6 – 8 Continuity BACK 6 – 8, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 6, 3 – 11 Continuity OFF 3 – 6, 2 – 6 Continuity DOWN 3 – 6, 2 – 11 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 5 – 6, 1 – 11 Continuity OFF 1 – 6, 5 – 6 Continuity REAR 1 – 6, 5 – 11 Continuity If continuity is not as specified, replace the switch. 4. TMMK made: INSPECT PASSENGER’S SEAT CONTINUITY (a) Inspect the slide switch. (b) (c) Switch position Tester connection Specified condition FRONT 2 – 11, 4 – 7 Continuity OFF 4 – 11, 4 – 7 Continuity BACK 2 – 7, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 8, 4 – 5 Continuity OFF 4 – 5, 4 – 8 Continuity DOWN 2 – 5, 4 – 8 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 2 – 12, 4 – 6 Continuity OFF 4 – 12, 4 – 6 Continuity REAR 2 – 6, 4 – 12 Continuity If continuity is not as specified, replace the switch. (a) 5. (a) INSPECT SLIDE MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 2 1 N21865 Author: Date: 2299 BE–80 BODY ELECTRICAL 2 6. 1 (a) (b) – POWER SEAT CONTROL SYSTEM INSPECT SLIDE MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to the battery negative (–) terminal, then move the seat cushion to the front position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. N21866 2 (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to move backwards. If operation is not as specified, replace the seat adjuster. 1 N21867 (a) 7. (a) INSPECT LIFTER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 1 2 N21865 2 8. (a) 1 (b) INSPECT LIFTER PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to the battery negative (–) terminal, then move the seat cushion to the highest position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. N21868 2 (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to fall down. If operation is not as specified, replace the seat adjuster. 1 N21869 Author: Date: 2300 BE–81 BODY ELECTRICAL (a) 1 POWER SEAT CONTROL SYSTEM 9. (a) INSPECT RECLINING MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 – 1 2 N21865 2 10. 1 (a) (b) INSPECT RECLINING MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative (–) lead to the battery negative (–) terminal, then recline the seat back to the most forward position. Continue to apply voltage, check that the current change to less than 1 ampere within 4 to 90 seconds. N21870 2 (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the seat back starts to fall backward. If operation is not as specified, replace the seat adjuster. 1 N21871 Author: Date: 2301 BE–82 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM BE0AV–03 LOCATION Mirror Control Switch Instrument Panel J/B No.1
CIG Fuse LH Mirror
Mirror Motor RH Mirror
Mirror Motor Z19488 Author: Date: 2302 BE–83 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM BE0AW–03 INSPECTION R L 1. MIRROR OFF RIGHT SIDE LEFT SIDE UP LEFT OFF Switch position Tester connection Specified condition OFF – UP 1 – 9, 6 – 10 Continuity DOWN 1 – 10, 6 – 9 Continuity LEFT 5 – 9, 6 – 10 Continuity RIGHT 5 – 10, 6 – 9 Continuity No continuity If continuity is not as specified, replace the switch. 2. Master switch right side: INSPECT MIRROR CONTROL SWITCH CONTINUITY RIGHT DOWN 4 3 10 9 8 Master switch left side: INSPECT MIRROR CONTROL SWITCH CONTINUITY 2 1 7 6 5 BE2357 h–10–2 Z16591 Switch position Tester connection Specified condition OFF – UP 6 – 10, 7 – 9 Continuity DOWN 6 – 9, 7 – 10 Continuity LEFT 6 – 10, 8 – 9 Continuity RIGHT 6 – 9, 8 – 10 Continuity No continuity If continuity is not as specified, replace the switch. 3. (a) TMMK made (w/o Heater) 1 (b) 2 TMC made (w/o Heater) 3 2 TMMK made (w/ Heater) 3 2 (c) INSPECT MIRROR MOTOR TMMK made (w/o Heater): Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the mirror turns to left side. TMC made (w/o Heater): Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns to left side. TMMK made (w/ Heater): Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns to left side. N21184 Author: Date: 2303 BE–84 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM (d) Reverse the polarity and check that the mirror turns to right side. (e) TMMK made (w/o Heater): Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMC made (w/o Heater): Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMMK made (w/ Heater): Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMMK made (w/o Heater) TMC made (w/o Heater) – TMMK made (w/ Heater) N21185 TMMK made (w/o Heater) (f) (g) TMC made (w/o Heater) TMMK made (w/ Heater) N21186 Author: Date: 2304 BE–85 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM (h) TMMK made (w/o Heater) TMC made (w/o Heater) Reverse the polarity, check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. TMMK made (w/ Heater) N21187 Author: Date: 2305 BE–86 BODY ELECTRICAL – AUDIO SYSTEM AUDIO SYSTEM BE0AX–03 DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: 30 kHz Frequency Designation 3 MHz 300 kHz LF Modulation method 300 MHz VHF HF MF AM Radio wave 30 MHz FM Amplitude modulation Frequency modulation LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. SERVICE AREA There are great differences in the size of the service area for AM and FM monaural. Sometimes FM stereo broadcasts cannot be received even through AM comes in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference (”noise”) easily. FM (Stereo) FM (Monaural) AM BE2818 3. RECEPTION PROBLEMS Besides the problem of static, there are also the problems called ”fading”, ”multipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading
Ionosphere Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 Author: Date: 2306 BE–87 BODY ELECTRICAL Multipath – AUDIO SYSTEM
Multipath One type of interference caused by bouncing of radio waves off obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is received directly.
Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mountains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstructions. This is called ”fade out”. BE2820 Fade Out BE2821 4. NOISE PROBLEMS (a) Questionnaire for noise: It is very important for noise troubleshooting to have good understanding of the claims from the customers, so that make the best use of following quenstionnaire and diagnose the problem accurately. AM FM Noise occurs at a specific place. Strong possibility of foreign noise. Noise occurs when listening to faint broadcasting. There is a case that the same program is broadcasted from each local station and that may be the case you are listening to different station if the program is the same. Noise occurs only at night. Strong possibility of the beat from a distant broadcasting. Noise occurs while driving and at a specific place. Strong possibility of multipath noise and fading noise caused by the changes of FM waves. HINT: In the case that the noise occurrence condition does not meet any of the above quenstionnaire, check based on the ”Trouble Phenomenon”. Refer to previous page for multipath and fading. Author: Date: 2307 BE–88 BODY ELECTRICAL Noise Glass Printed Antenna Noise Matlers that require attention when checking:
Noise coming into the radio usually has no harm for practical use as the noise protection is taken and it is hardly thinkable for an extremely loud noise to come in. When extremely loud noise comes into the radio, check if the grounding is normal where the antenna is installed.
Check if all the regular noise prevention parts are properly installed and if there is any installation of non–authorized parts and non–authorized wiring.
If you leave the radio out of tune (not tuning), it is easy to diagnose the phenomenon as noise occurs frequently. (c) Antenna and noise: Electronic signal received by the antenna will reach to the radio transmitting through the core wire of the coaxial cable. Any noise wave other than radio wave is mixed into this core wire, that naturally causes noise in the radio and poor sound quality. In order to prevent these noises from mixing into the radio, the core wire inside the coaxial cable is covered with a mesh wire called shield wire. This shield wire shelters the noise and transmits it to the ground, thus preventing noise from mixing in. If this shield wire has grounding failure, that causes noise. (d) Choke coil and noise: The choke coil is connected in the rear window defogger circuit. This is conneted so to prevent noise from mixing into the radio by making the noise current included in the power source of the rear window defogger flow to the ground. Signal Radio Noise N21545 to Radio Battery Choke Coil AUDIO SYSTEM (b) Noise Noise – Noise N21546 Author: Date: 2308 BE–89 BODY ELECTRICAL Plug (Main) Antenna Terminal (Main) (1) (2) (3) (4) Plug (Sub) Antenna Terminal (Sub) I00399 5. – AUDIO SYSTEM Glass printed antenna: GROUNDING FOR THE ANTENNA CORD AND CHOKE COIL HINT: During troubleshooting, in case that the antenna code continuity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustration. Terminal connection Normal condition (1) ↔ (2) Continuity (3) ↔ (4) Continuity Ground point: Antenna Cord Center Brace Pillar (RH) Choke Coil N21548 I00402 I00403 Pillar (LH) I00407 Author: Date: 2309 BE–90 BODY ELECTRICAL 6. Antenna Terminal Plug (1) (2) I00400 – AUDIO SYSTEM Fixed mast antenna: GROUNDING FOR THE ANTENNA CORD AND CHOKE COIL HINT: During troubleshooting, in case that the antenna code continuity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustrations. Terminal connection Normal condition (1) ↔ (2) Continuity Ground point: Antenna Cord Center Brace Luggage Room (RH side) Noise Filter I00427 I00428 I00429 Pillar (LH) I00408 Author: Date: 2310 BE–91 BODY ELECTRICAL – AUDIO SYSTEM BE0AY–05 TROUBLESHOOTING NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement part (spare part). HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and connectors, etc.). Always inspect the trouble taking the following items into consideration.  Open or short circuit of the wire harness  Connector or terminal connection fault Problem Radio Tape Player CD Player Noise No. Radio not operating when power switch turned ’ON’. 1 Display indicates when power switch turned ’ON’, but no sound (including ’noise’) is produced. 2 Noise present, but AM – FM not operating. 3 Any speaker does not work. 4 Either AM or FM does not work, reception poor (volume faint), Fewer station presets. 5 Poor reception. 6 Sound quality poor. 7 Preset memory disappears. 8 Cassette tape cannot be inserted. 9 Cassette tape is inserted, but no power. 10 Power coming in, but tape player not operating. 11 Either speaker does not work. 12 Sound quality poor. (volume faint) 13 Tape jammed, malfunction with tape speed or auto–reverse. 14 Cassette tape will not be ejected. 15 CD cannot be inserted. 16 CD inserted, but no power. 17 Power coming in, but CD player not operating. 18 Sound jumps. 19 Sound quality poor (Volume faint). 20 Either speaker does not work. 21 CD will not be ejected. 22 Noise occurs. 23 Noise produced by vibration or shock while driving. 24 Noise produced when engine starts. 25 The term ”AM” includes LW, MW and SW, and the term ”FM” includes UKW. Author: Date: 2311 BE–92 BODY ELECTRICAL 1 Radio – AUDIO SYSTEM RADIO NOT OPERATING WHEN POWER SWITCH TURNED ’ON’
Radio–CD Plater Unit (Built–in Power Amplifier)
Radio–Tape Plater Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio assembly faulty. No NG Replace fuse. Check that RAD No.1 fuse is OK? OK No ACC wire harness faulty. Is ACC applied to radio? Yes NG Replace fuse. Check that RAD No.2 fuse is OK? OK No Is +B applied to radio? Yes Check that GND (wire harness side) to radio is OK? +B wire harness faulty. NG GND faulty. OK Radio assembly faulty. Author: Date: 2312 BE–93 BODY ELECTRICAL – AUDIO SYSTEM
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Yes Does tape or CD player operate normally? Radio assembly faulty. No NG Replace fuse. Check that RAD No.1 fuse is OK? OK Is ACC applied to power amplifier? No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK Is ACC applied to radio assembly? No Power amplifier or wire harness faulty. Yes No Is +B applied to radio assembly? Power amplifier or wire harness faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG GND faulty. OK Radio assembly faulty. I03349 Author: Date: 2313 BE–94 BODY ELECTRICAL 2 – AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED ’ON’, BUT NO SOUND (INCLUDING ’NOISE’) IS PRODUCED Radio
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to radio? No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to radio? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio is OK? NG GND faulty. OK Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Yes Speaker faulty. No Radio faulty. I03350 Author: Date: 2314 BE–95 BODY ELECTRICAL – AUDIO SYSTEM
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to power amplifier. No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier. No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK No Is ACC applied to radio assembly? Power amplifier faulty. Yes Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG GND faulty. OK Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Yes Temporarily install another speaker. Functions OK? Speaker faulty. No No Hiss noise from speaker? Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. V08239 Author: Date: 2315 BE–96 BODY ELECTRICAL 3 Radio – AUDIO SYSTEM NOISE PRESENT, BUT AM–FM NOT OPERATING Yes Does tape player operate normally? Radio assembly faulty. No Yes Separate amplifier? No Hiss noise from speaker? Power amplifier faulty. Yes No Radio assembly faulty. 4 Radio ANY SPEAKER DOSE NOT WORK
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker? Yes Radio assembly Recheck system after repair. No Does continuity exist in speaker wire harness? Yes Temporarily install another speaker. Functions OK? No Yes Speaker wire harness faulty. Speaker faulty. No Power amplifier faulty. Recheck system after repair. I03351 Author: Date: 2316 BE–97 BODY ELECTRICAL 5 Radio – AUDIO SYSTEM EITHER AM OR FM DOES NOT WORK, RECEPTION POOR (VOLUME FAINT), FEWER STATION PRESETS
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Problem with radio wave signals or location? Yes Poor signals, poor location. No Are both AM or FM defective? No Radio assembly faulty. Yes Is power for the antenna being output from the radio assembly? No Yes Go to No.15 Does tape player operate normally? Yes Radio assembly faulty. No Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Problem with radio wave signals or location? Yes Poor signals, poor location. No Are both AM and FM defective? No Radio assembly faulty. Yes Is power for the antenna being output from the radio assembly? No Yes Go to No.15 Does tape player operate normally? Yes Radio assembly faulty. No Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Hiss noise from speaker? No Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. V08242 I03352 Author: Date: 2317 BE–98 BODY ELECTRICAL 6 Radio – AUDIO SYSTEM POOR RECEPTION Is the condition bad in comparison with other vehicle? Yes An electric wave environment. No Yes Is there any additional installation parts? (Sun shade film, telephone antenna etc.). Does the condition get better if removing them? Yes No No Check if there is any scratch and breaking in a wire on the glass antenna and the defogger pattern. (See page BE–115) Influence of additional installation parts. Yes Repair No Is the contact of the plug jack of the radio OK? No Check for contact. Yes No Does the condition get better by using the outer antenna? (Such as pillar antenna) Check the radio. Yes No Is the contact of the antenna terminal on the glass surface and the defogger terminal? Measure for contact. Yes No Is the continuity of the antenna cord OK? Exchange the antenna cord. Yes NG Check the grounding of the antenna, antenna cord, choke coil and noise filter. Grounding failure. OK Yes Does the condition get better by exchanging the choke coil? Exchange the choke coil. No Yes Does the condition get better by exchanging the antenna cord? Exchange the antenna cord. No Exchange the glass. I01472 Author: Date: 2318 BE–99 BODY ELECTRICAL 7 Radio – AUDIO SYSTEM SOUND QUALITY POOR
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) No Is sound quality always bad? Yes Is sound quality bad in certain area only. Poor signals, poor location. No Yes Radio assembly faulty. Yes Does tape player operate normally? Radio assembly faulty. No No Installed properly. Is speaker properly installed? Yes Yes Speaker faulty. Temporarily install another speaker. Functions OK? No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power amplifier)
Radio–Tape CD Unit (Separate Power Amplifier) Is sound quality always bad? No Yes Is sound quality bad only in certain areas? Poor signals, poor location. No Yes Does tape player operate normally? Yes No Radio assembly or power amplifier faulty. Does tape player operate normally? Radio assembly faulty. Yes Radio assembly faulty. No Is speaker properly installed? No Installe properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly or power amplifier faulty. Recheck system after repair. I03353 Author: Date: 2319 BE–100 BODY ELECTRICAL 8 – AUDIO SYSTEM PRESET MEMORY DISAPPEARS Radio
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Can cassette tape be inserted in tape player? Yes Radio assembly faulty. No Replace fuse. NG Check that RAD No.1 fuse is OK? OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio? NG GND faulty. OK Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Can cassette tape be inserted in tape player? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier? NG GND faulty. OK Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly? NG Power amplifier faulty. OK Radio assembly faulty. I03354 Author: Date: 2320 BE–101 BODY ELECTRICAL 9 Tape Player – AUDIO SYSTEM CASSETTE TAPE CANNOT BE INSERTED
Radio–Tape Player Unit (Built–in Power Amplifier) Is there a foreign object inside tape player? Yes Remove foreign object. No Does auto search button of radio operate normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio assembly? NG GND faulty. OK Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Is there a foreign object inside tape player? Yes Remove foreign object. No Yes Does auto search button radio operate normally? Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG Power amplifier faulty. OK Radio assembly faulty. V08246 Author: Date: 2321 BE–102 BODY ELECTRICAL 10 Tape Player – AUDIO SYSTEM CASSETTE TAPE IS INSERTED, BUT NO POWER
Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to radio assembly? No ACC wire harness faulty. Yes Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does radio operate normal? Yes Radio assembly faulty. No Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is ACC applied to power amplifier? No ACC wire harness faulty. Yes Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Is ACC applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. V08247 Author: Date: 2322 BE–103 BODY ELECTRICAL 11 Tape Player – AUDIO SYSTEM POWER COMING IN, BUT TAPE PLAYER NOT OPERATING
Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Does radio operate normally? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Function OK if different cassette tape inserted? Yes Cassette tape faulty. No Does radio operate normally? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Hissing sound from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. V08248 Author: Date: 2323 BE–104 BODY ELECTRICAL 12 Tape Player – AUDIO SYSTEM EITHER SPEAKER DOES NOT WORK
Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Is hiss noise produces by non–functioning speaker. Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker. Yes No Does continuity exist in speaker wire harness? No Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Radio assembly or power amplifier faulty. V08249 Author: Date: 2324 BE–105 BODY ELECTRICAL 13 Tape Player – AUDIO SYSTEM SOUND QUALITY POOR (VOLUME FAINT)
Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Yes Operates normally after cleaning the heads? Head dirty. No Does radio operate normally? Yes Radio assembly faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Yes Operates normally after cleaning the heads? Head dirty. No Does radio operate normally? Yes Radio assembly faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty or power amplifier faulty. V08250 Author: Date: 2325 BE–106 BODY ELECTRICAL 14 Tape Player – AUDIO SYSTEM TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR AUTO–REVERSE Function OK if different tape (less than 120 mints.) inserted? Yes Cassette tape faulty. No Yes Is there a foreign object inside tape player? Remove foreign object. No Operates normally after cleaning the heads? Yes Head dirty. No Radio assembly faulty. 15 Tape Player CASSETTE TAPE WILL NOT BE EJECTED
Radio–Tape Player Unit (Built–in Power Amplifier) No Does tape player operate normally? Cassette tape jammed. Yes Is auto search button of radio operating normally? Yes Radio assembly faulty. No NG Check that RAD No.1 fuse is OK? Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? No Cassette tape jammed. Yes Is auto search button of radio operating normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Is +B applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. V08251 Author: Date: 2326 BE–107 BODY ELECTRICAL 16 CD Player – AUDIO SYSTEM CD CANNOT BE INSERTED
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Is CD already inserted? Eject CD. No Yes Is auto search button of radio operating normally? No Is +B applied to CD player? Radio assembly faulty. Yes NG Check that GND wire harness side to CD player is OK? No OK CD player faulty. NG Check that RAD No.1 fuse is OK? Replace fuse. OK No Is +B applied to power amplifier? +B wire harness faulty. Yes NG Check that GND (wire harness side) to radio assembly is OK? OK Radio assembly faulty. 17 CD Player CD INSERTED, BUT NO POWER
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Does radio operate normally? Yes Is ACC applied to CD player? No Radio assembly faulty. Yes No Check that RAD No.1 and No.2 fuse is OK? CD player faulty. NG Replace fuse. OK Is ACC and +B, +B2 applied to power amplifier? No ACC and +B, +B2 wire harness faulty. I03355 Yes Is ACC and +B, +B2 applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. I03355 Author: Date: 2327 BE–108 BODY ELECTRICAL 18 CD Player – AUDIO SYSTEM POWER COMING IN, BUT CD PLAYER NOT OPERATING
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) No Is CD inserted with correct side up? Insert correctly. Yes Yes Function OK if different CD inserted? CD faulty. No Yes Does radio operate normally? Is temperature inside cabin hot? Protective circuit in operation. No No Has sudden temperature change occurred inside cabin? Yes Yes Formation of condensation due to temp. changes. No CD player faulty. Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Hissing sound from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. I03356 Author: Date: 2328 BE–109 BODY ELECTRICAL 19 CD Player – AUDIO SYSTEM SOUND JUMPS
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Does sound jump only during strong vibration? Jumping caused by vibration. No Is CD player properly installed? No Installed properly. Yes Functions OK if different CD inserted? Yes CD faulty. No Has sudden temperature change occurred inside cabin? Yes No Formation of condensation due to temp. changes. CD player faulty. 20 CD Player SOUND QUALITY POOR (VOLUME FAINT)
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Functions OK if different CD inserted? CD faulty. No Does radio operate normally? Yes CD player faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly or CD player or Power amplifier faulty. I03357 Author: Date: 2329 BE–110 BODY ELECTRICAL 21 CD Player – AUDIO SYSTEM EITHER SPEAKER DOES NOT WORK
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Does radio operate normally? CD player. No Yes Is hiss noise produced by non–functioning speaker? Radio assembly faulty. Recheck system after repair. No No Does continuity exist in speaker wire harness? Speaker wire harness faulty. Yes Yes Temporarily install another speaker. Function OK. Speaker faulty. No Power amplifier faulty. Recheck system after repair. 22 CD Player CD WILL NOT BE EJECTED
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Is auto search button of radio operating normally? Yes Is +B applied to CD player? No Radio assembly faulty. Yes No Check that RAD No.1 fuse is OK? CD player faulty. NG Replace fuse. OK Is +B and +B2 applied to power amplifier? No +B wire harness faulty. Yes Is +B and +B2 applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. I03358 Author: Date: 2330 BE–111 BODY ELECTRICAL 23 Noise – AUDIO SYSTEM NOISE OCCURS No Does the noise occur only in the radio? It occurs in the cassette CD. (Go to step 13 or 20) Yes Yes Does the noise occur in a particular place? An electric environment. No Yes Is there any additional installation part around the glass printed antenna? (Sunshade film, telephone antenna, etc.) Does the noise stop by removing it? Yes No No Influence of the film of the noise radiation of additional installation part. Does the noise occur even pulling out the antenna cord from the radio? Yes Check the radio. No Yes Does the noise occur even pulling out the antenna terminal on the glass surface? Mixing into the antenna cable. No Yes Is there any adhesive stuck on the bases of the antenna terminal, defogger terminal and bus bar? Failure of glass installation. Must plane the butyl rubber. No Yes Does the noise occur even pulling out the defogger terminal? Interfering noise from the defogger line and choke coil. Does the condition get better by exchanging the choke coil? No Exchange the choke coil. Check the grounding of the antenna, antenna cord, choke coil and noise filter. NG OK Grounding failure. Yes Does the condition get better by exchanging the antenna cord? Exchange the antenna cord. No Radiates directly to the antenna from the generation source. I01473 Author: Date: 2331 BE–112 BODY ELECTRICAL 24 Noise – AUDIO SYSTEM NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING Is speaker properly installed? No Installed properly. Yes No Is speaker properly installed? Yes With vehicle stationary lightly tap each system. Is noise produced? Yes Each system faulty. No Noise produced by static electricity accumulated in the vehicle body. I01474 Author: Date: 2332 BE–113 BODY ELECTRICAL 25 Noise – AUDIO SYSTEM NOISE PRODUCED WHEN ENGINE STARTS Whistling noise which becomes high–pitched when accelerator strongly depressed, disappears shortly after engine stops. Yes Generator noise. No Whining noise occurs when A/C is operating. Yes A/C noise. No Scratching noise occurs during sudden acceleration, driving on rough roads or when ignition switch is turned on. Yes Fuel gauge noise. No Clicking sound heard when horn button is pressed, then released. Whirring/ grating sound when pressed continuously. Yes Horn noise. No Murmuring sound stops when engine stops. Yes Ignition noise. No Tick–tock noise occurs in co–ordination with blinking of flasher. Yes Turn signal noise. No Noise occurs during window washer operation. Yes Washer noise. No Yes Scratching noise occurs while engine is running and continues for a while even after engine stops. Engine coolant temp. gauge noise. No Scraping noise in time with wiper beat. Yes Wiper noise. No Other type of noise. I01475 Author: Date: 2333 BE–114 BODY ELECTRICAL – AUDIO SYSTEM BE0AZ–05 LOCATION Tweeter Speaker Tweeter Speaker AMP Instrument Panel J/B No.1
RADIO Fuse
DOME Fuse Glass Printed Antenna (MAIN) Front Speaker Diversity Only (SUB) Rear Speaker Z19489 Author: Date: 2334 BE–115 BODY ELECTRICAL – AUDIO SYSTEM BE0B0–06 INSPECTION 1. GLASS PRINTED ANTENNA INSPECTION PROCEDURE NOTICE:
When cleaning the glass, use soft dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires.
Do not use detergents or glass cleaners with abrasive ingredients. NOTICE: In order not to damage the glass printed antenna, wrap up the tip of the tester stick with aluminum foil as shown in the illustration and check by holding the aluminum foil with a finger. Tester Probe Aluminum Foil BE4029 By placing and moving the tester stick along the glass printed antenna, check if continuity exists. I00430 HINT: Matching module is built in the bus bar of the glass printed antenna (main terminal side) of CAMRY and no continuity exists between the terminal and the antenna. Therefore, for the continuity checking of the glass printed antenna on the main antenna side of CAMRY, place one probe of the tester on the position beside the bus bar (position shown in the illustration) and check by making the other probe of the tester move along. Matching module I00459 2. (a) Repair Point (b) Broken Wire (c) GLASS PRINTED ANTENNA REPAIR PROCEDURE Clean the broken wire tips with grease, wax and silicone remover. Place the masking tape along both sides of the wire for repair. Thoroughly mix the repair agent (Dupont paste No. 4817). Masking Tape BE0150 Author: Date: 2335 BE–116 BODY ELECTRICAL (d) (e) – AUDIO SYSTEM Using a fine tip brush, apply a small amount of the agent to the wire. After a few minutes, remove the masking tape. BE0151 Author: Date: 2336 BE–117 BODY ELECTRICAL – CLOCK CLOCK BE0B1–02 TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Clock will not operate 1 Clock loses or gains time 2 ± 1.5 seconds / day Ground E Connector (Clock Side) Power Source (Illumination) ILL B Power Source (System Operation) ACC Power Source (Display Operation) 4 3 2 1 (Wire Harness Side) 1 2 3 4 Z04388 BE1847 e–4–2–D e–4–1–D 1 CLOCK WILL NOT OPERATE (a) Check that the battery positive voltage is 10 – 16 V. (Wire Harness Side) (Clock Side) If voltage is not as specified, replace the battery. (b) Check that the DOME fuse is not blown. If the fuse is blown, replace the fuse and check for short circuit. (c) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. B+ GND e–4–2–D e–4–1–D Is there battery positive voltage between terminal B+ and body ground? No Open or short circuit in wire harness between terminal GND and body ground. No Open circuit in wire harness between terminal GND and body ground. Yes Does continuity exist between terminal GND and body ground. Yes Replace clock. V04421 Author: Date: 2337 BE–118 BODY ELECTRICAL 2 – CLOCK CLOCK LOSES OR GAINS TIME (Clock Side) (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Inspect the error of the clock. Allowable error (per day): ± 1.5 seconds (Wire Harness Side) If the error exceeds the allowable error, replace the clock. (c) Check that the clock adjusting button is caught in position, and does not return. If the button is not returned, repair or replace the clock. (d) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. e–4–2–D e–4–1–D B+ GND Is there 10 – 16 V between terminal B+ and body ground? Below 10 V Locate cause and repair, or recharge battery. Yes Adjust or replace clock. V04422 Author: Date: 2338 BE–119 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM BE0B2–06 REGISTRATION PROCEDURE 1. KEY REGISTRATION IN AUTOMATIC REGISTRATION MODE (a) Registration of a new transponder key. HINT:
This must be done when you have installed a new ECM.
The new ECM is in the automatic key code registration mode. The already fixed number of key codes for this ECM can be registered. On this type of vehicle, up to 4 key codes can be registered.
In the automatic registration mode, the last key registered becomes sub–key. START Security indicator blinks until the first key is inserted. The indicator lights up after the key registration. Insert the key in the key cylinder. Security Indicator ON Under registration Security OFF Indicator Registration completion Remove the key. Yes Security Indicator ON (After the last key (sub–key) has been registered, the indicator goes off.) Will you register the next key? No END Author: Date: 2339 BE–120 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM HINT:


When a key is not inserted in the key cylinder in the automatic registration mode, the security indicator always lights on. When the immobiliser system operations normally and the key is pull out, the security indicator blinks. When key code registration could not be performed in the automatic registration mode, code 2–1 is output from the security indicator and when inserting the already registered key, code 2–2 is output. Blinks 1.2 Sec. 0.8 Sec. (b) Code 2–1 0.25 Sec. 1 Sec. 0.25 Sec. 0.5 Sec. Code2–2 0.25 Sec. 1 Sec. 0.25 Sec.0.5 Sec. Automatic registration mode completion If completing the mode forcibly when more than 1 key code have been registered in the automatic registration mode, perform the following procedures. After 1 more key code have been registered with master key, perform step (1) or (2) without pulling the key out or inserting the already registered key. (1) Depress and release brake pedal 5 times or more within 15sec. (2) With the TOYOTA hand–held tester, require automatic registration mode completion. Author: Date: 2340 BE–121 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 2. REGISTRATION OF ADDITIONAL MASTER KEY There are 2 ways for registration of additional master key, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. HINT:
It is possible to register up to 7 master key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 5 times. Depress and release the brake pedal 6 times, and remove the master key. Within 15 sec. Within 20 sec. Within 10 sec. Insert key to be registered in key cylinder. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec. additional master key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2341 BE–122 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select master key registration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec., additional master key is registered. (Security indicator OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2342 BE–123 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 3. REGISTRATION ADDITIONAL OF SUB–KEY There are 2 ways for registration of additional sub–key, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. HINT:
It is possible top register up to 3 sub–key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 4 times. Depress and release the brake pedal 5 times, and remove the master key. Within 15 sec. Within 20 sec. Within 10 sec. Insert key to be registered in key cylinder. Within 10 sec. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 sec. After 60 sec. additional sub–key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2343 BE–124 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select sub–key registration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec., additional master key is registered. (Security indicator OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2344 BE–125 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 4. ERASURE OF TRANSPONDER KEY CODE There are 2 ways for erasure of transponder key code, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. NOTICE: All other master and sub–key codes are deleted leaving the master key code to use the operation. When using the key which was used before deleting, it is necessary to register the code again. HINT:
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: 1. Insert master key in the key cylinder. Within 15 sec. 2. Depress and release the acceleration pedal 6 times. Within 20 sec. 3. Depress and release the brake pedal 7 times. (Security indicator blinks) Within 10 sec. 4. Remove the master key. (Security indicator blinks) END (Key code erasured) HINT: When the key cannot be pulled out in the step 4, key code deletion is canceled. (Security indicator is OFF) Author: Date: 2345 BE–126 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: 1. Insert master key in the key cylinder. Within 120 sec. 2. Require key code deletion from hand–held tester. (Security indicator blinks) Within 10 sec. 3. Remove the master key. END (Key code erasured) HINT: When the key cannot be pulled out in the step 3, key code deletion is canceled. (Security indicator is OFF) Author: Date: 2346 BE–127 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B3–06 LOCATION Engine Room J/B No.2
EFI Fuse Transponder Key Amplifier Transponder Key Coil ECM Instrument Panel J/B
IGN Fuse I02682 Author: Date: 2347 BE–128 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B4–05 INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminal 1 and 2. If continuity is not as specified, replace the coil. I03099 Author: Date: 2348 BE–1 BODY ELECTRICAL – TROUBLESHOOTING TROUBLESHOOTING BE16T–01 PROBLEM SYMPTOMS TABLE COMBINATION METER METER, GAUGES AND ILLUMINATION: Symptom Suspect Area See page Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–4 – Fuel Gauge does not operate or abnormal operation. 1. 2. 3. 4. 5. 6. 7. 8. Fuel Receiver Gauge Fuel Temperature Sensor (For Delivery Pipe) Fuel Temperature Sensor (For Fuel Tank) Fuel Pressure Sensor (For Delivery Pipe) Fuel Pressure Sensor (For Fuel Pipe) ECM Meter Circuit Plate Wire Harness BE–5 SF–36 SF–40 SF–42 SF–45 – BE–4 – Engine Coolant Temperature Gauge does not operate or abnormal operation 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness BE–5 BE–5 BE–4 – All illumination lights do not light up. 1. TAIL Fuse (I/P J/B No.1) 2. Light Control Rheostat 3. Wire Harness Only one illumination light does not light up. 1. Bulb 2. Wire Harness – BE–54* – – – COMBINATION METER WARNING LIGHTS: Symptom Suspect Area See page Warning lights do not light up. (Except Discharge, Open Door and SRS) 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–4 – Low Oil Pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness – BE–5 BE–4 – Fuel Level warning light does not light up. 1. 2. 3. 4. 5. 6. 7. 8. Bulb Fuel Temperature Sensor (For Delivery Pipe) Fuel Temperature Sensor (For Fuel Tank) Fuel Pressure Sensor (For Delivery Pipe) Fuel Pressure Sensor (For Fuel Pipe) ECM Meter Circuit Plate Wire Harness – SF–36 SF–40 SF–42 SF–45 – BE–4 – *: See Pub. No. RM654U Author: Date: 533 BE–2 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE0AI–04 LOCATION Brake Fluid Level Warning Switch E/G Room J/B No.2
ECU–B Fuse
DOME Fuse Washer Fluid Level Warning Switch Combination Meter
Bulb Check Relay ECM ABS ECU Light Control Rheostat Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
IGN Fuse
Integration Relay I08447 Author: Date: 534 BE–3 BODY ELECTRICAL – COMBINATION METER Door Courtesy Switch PKB Switch Seat Belt Buckle Switch Door Courtesy Switch Light Failure Sensor Low Oil Pressure Warning Switch Engine Coolant Temperature Sender Gauge Park/Neutral Position Switch I08448 Author: Date: 535 BE–4 BODY ELECTRICAL – COMBINATION METER BE0AJ–04 CIRCUIT Connector ”A” 1 2 3 4 5 6 Connector ”B” 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 9 10 11 12 13 14 15 16 J–13–1–A C7 E T 1 2 3 4 5 6 7 8 9 10 11 1213 J–16–1 B3 C5 A2 A1 C8 F Connector ”C” Connector ”C” Connector ”B” J–13–1 Connector ”A” B15 C6 S B14 ODOMETER Fuel Level Warning Seat Belt Warning ABS Warning Low Oil Pressure Warning Cruise Control Indicator Malfunction Indicator O/D OFF Indicator Light Failure Warning Brake Warning SLIP Indicator TRAC Indicator Washer Level Warning Discharge Warning A13 B2 C1 B1 C9 A6 A11 A7 A10 A8 A9 Bulb Check Relay Right Turn Indicator Left Turn Indicator Security Indicator L 2 D N R P Illumination C13 B8 B11 B12 Hi–Beam Indicator Open Door Warning SRS Warning B6 A4 C4 B5 C10 C2 A12 A3 B7 C3 A5 C11 B4 No. A B16 B C12 B9 B10 B13 C F : Fuel Gauge E : Engine Coolant Temperature Sender Gauge T : Tachometer S : Speedometer N20107 N20108 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 Wire Harness Side Engine coolant temperature sender gauge Ground Light failure sensor Integration relay Traction ECU Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) O/D OFF switch (A/T) IGN fuse Turn signal switch ST relay ECM Generator Oil pressure switch ECM Parking brake switch and brake fluid level warning switch Headlight dimmer switch Headlight dimmer switch Door courtesy switch DOME fuse ECU–B fuse Airbag sensor assembly ECM No.1 Vehicle speed sensor Ground Turn signal switch ECM Traction ECU ABS ECU Ground No.1 Vehicle speed sensor GAUGE fuse Igniter Security ECU Cruise control ECU Washer fluid level warning switch Light control rheostat TAIL fuse Z18937 BE–5 BODY ELECTRICAL – COMBINATION METER BE16U–01 INSPECTION Ignition Switch Fuel Gauge 1. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the ECM. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 on the wire harness side connector through a 3.4–W test bulb. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. ECM Battery I12031 Fuel Gauge (d) Ignition Switch Wire Harness Side Battery I12029 HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 2. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. A B C N20212 Ignition Switch Wire Harness Side Battery I12030 Resistance (Ω) A–B Approx. 270.1 A–C Approx. 141.3 B–C Approx. 128.8 If resistance value is not as specified, replace the receiver gauge. 3. INSPECT FUEL SENDER GAUGE RESISTANCE (See page SF–36) 4. (a) (b) (c) Warning Light Tester connection INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 8 on the wire harness side connector. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. 5. INSPECT FUEL LEVEL WARNING SWITCH (See page SF–40) BE–6 BODY ELECTRICAL 6. Engine coolant temperature gauge (a) (b) Ignition Switch Sender Gauge Battery – COMBINATION METER INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. N20215 (c) Ground terminal on the wire harness side connector through a 3.4–W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. Engine coolant temperature gauge Ignition Switch Battery Test Bulb (3.4 W) Wire Harness Side Z15788 7. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. C B A N20216 Tester connection Resistance (Ω) * A–B Approx. 175.7 A–C Approx. 54.0 B–C Approx. 229.7 *: This circuit includes the diode. HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. If resistance value is not as specified, replace the receiver gauge. BE–7 BODY ELECTRICAL – COMBINATION METER 8. 35.63 ± 0.1 Ω 35.63 ± Slide rheostat 0.1 Ω INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate ”0” using the slide rheostat, then read the rheostat indication. Temperature °C (°F) Resistance (Ω) 50 (122.0) 160 – 240 120 (248.0) 17.1 – 21.2 If resistance value is not as specified, replace the engine coolant temperature sender gauge. I07709 9. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery 1 Z14205 10. (a) (b) (c) N06640 INSPECT LOW OIL PRESSURE SWITCH Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2, 3.55 psi). If operation is not as specified, replace the switch. SF–1 SFI (5S–FE) – SFI SYSTEM SFI SYSTEM SF0D6–04 PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (–) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (–) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON THE FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection to battery terminals, etc. (2) After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Precautions when handling the oxygen sensor. (1) Do not allow oxygen sensor to drop or hit against an object. (2) Do not allow the sensor to come into contact with water. 5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. 7. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery. Author: Date: 1434 SF–2 SFI (5S–FE) (b) (c) (d) (e) (f) (g) (h) – SFI SYSTEM When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (–) cables. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting as there are numerous transistor circuit, and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. (i) Use SST for inspection or test of the injector or its wiring connector. SST 09842–30070 8. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch OFF. SST FI2553 Fuel Pump Connector S04600 (3) (4) (5) (6) (7) Plug Put a container under the connection. Slowly loosen the connection. Disconnect the connection. Plug the connection with a rubber plug. Reconnect the fuel pump connector. S05326 Author: Date: 1435 SF–3 SFI (5S–FE) (b) – SFI SYSTEM When connecting the union bolt on the high pressure pipe union, observe these procedures: (1) Always use 2 new gaskets. (2) Tighten the union bolt by hand. (3) Tighten the union bolt to the specified torque. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) New Gasket S05523 (c) SST Fulcrum Length 30 cm FI1654 O–Ring When connecting the flare nut on the high pressure pipe union, observe these procedures: (1) Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. (2) Using SST, tighten the flare nut to specified torque. SST 09631–22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) for using SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (d) CORRECT Injector Delivery Pipe Grommet WRONG Observe these precautions when removing and installing the injectors. (1) Never reuse the O–ring. (2) When placing a new O–ring on the injector, take care not to damage it in any way. (3) Coat a new O–ring with spindle oil or gasoline before installing–never use engine, gear or brake oil. FI0420 Author: Date: 1436 SF–4 SFI (5S–FE) (e) California O–Ring Insulator Grommet O–Ring (f) Injector Except California – SFI SYSTEM Install the injector to the delivery pipe and cylinder head, as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O–ring of the injector. Observe these precautions when disconnecting the fuel tube connector (quick type): (1) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. (2) Be sure to disconnect with hands. O–Ring Insulator Grommet Injector Z11336 (3) Pull (4) When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. S04583 (5) Vinyl Bag Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag. S05040 (g) Retainer Observe these precautions when connecting the fuel tube connector (quick type): (1) Do not reuse the retainer removed from the pipe. (2) Must use hands without using tools when to remove the retainer from the pipe. (3) Check if there is any damage or foreign objects on the connected part of the pipe. S05382 Author: Date: 1437 SF–5 SFI (5S–FE) – SFI SYSTEM (4) Click Sound S05050 (h) Match the axis of the connector with axis of the pipe, and push in the connector until the retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. (5) After having finished the connection, check if the pipe and the connector are securely connected by pulling them. (6) Check if there is any fuel leakage. Observe these precautions when handling nylon tube. (1) Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them. (2) Pay attention not to kink the nylon tube. (3) Do not remove the EPDM protector on the outside of the nylon tube. (4) Must not close the piping with the nylon tube by bending it. (i) S05331 Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the TOYOTA hand– held tester. (4) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (5) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (6) Check that there are no leaks from any part of the fuel system. (7) Turn the ignition switch OFF. (8) Disconnect the TOYOTA hand–held tester from the DLC3. Author: Date: 1438 SF–6 SFI (5S–FE) – FUEL PUMP FUEL PUMP SF0D7–03 ON–VEHICLE INSPECTION 1. (a) (b) S05331 CHECK FUEL PUMP OPERATION Connect a TOYOTA hand–held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. NOTICE: Do not start the engine. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (d) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (e) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See step 7) (f) Fuel Inlet Hose S05327 Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the fusible link, fuses, EFI main relay, fuel pump, ECM and wiring connections. (g) Turn the ignition switch OFF. (h) Disconnect the TOYOTA hand–held tester from the DLC3. 2. CHECK FUEL PRESSURE (a) Check the battery positive voltage is above 12 V. (b) Disconnect the negative (–) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet. CAUTION:
Put a shop towel under the fuel filter.
Slowly loosen the union bolt. S05522 Author: Date: 1439 SF–7 SFI (5S–FE) Fuel Inlet Hose Gasket S05328 Ohmmeter 4 FUEL PUMP (d) SST (Union Bolt) SST (Gauge) Gasket Gasket SST (Union) – 5 Install the fuel inlet hose and SST (pressure gauge) to the fuel filter outlet with the 3 gaskets and SST (union bolt). SST 09268–45014 (09268–41190, 90405–06167) Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) (e) Wipe off any splattered gasoline. (f) Reconnect the negative (–) terminal cable to the battery. (g) Connect a TOYOTA hand–held tester to the DLC3. (See step 1 in check fuel pump operation (a) to (e)) (h) Measure the fuel pressure. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the fuel hoses, fuel hose connections, fuel pump, fuel filter and fuel pressure regulator. (i) Disconnect the TOYOTA hand–held tester from the DLC3. (j) Start the engine. (k) Measure the fuel pressure at idle. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) (l) Stop the engine. (m) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (n) After checking fuel pressure, disconnect the negative (–) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268–45014 (o) Reconnect the fuel inlet hose with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) (p) Reconnect the negative (–) terminal cable to the battery. (q) Check for fuel leaks. (See page SF–1) 3. REMOVE REAR SEAT CUSHION 4. REMOVE FLOOR SERVICE HOLE COVER 5. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 6. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 – 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. S04508 Author: Date: 1440 SF–8 SFI (5S–FE) 4 Battery 5 S04509 – FUEL PUMP 7. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil burning out.
Keep the fuel pump as far away from the battery as possible.
Always do the switching at the battery side. If operation is not as specified, replace the fuel pump or lead wire. 8. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 9. REINSTALL FLOOR SERVICE HOLE COVER 10. REINSTALL REAR SEAT CUSHION Author: Date: 1441 SF–9 SFI (5S–FE) – FUEL PUMP SF0D8–02 COMPONENTS Type A Rear Seat Cushion Floor Service Hole Cover x8 4 (40, 35 in.·lbf) Fuel Pump & Sender Gauge Connector No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Hose Fuel Pump Assembly Fuel Pump Connector Fuel Pump
Gasket Fuel Pump Filter
Clip Rubber Cushion N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19025 Author: Date: 1442 SF–10 SFI (5S–FE) – FUEL PUMP Type B Rear Seat Cushion Floor Service Hole Cover Fuel Pump & Sender Gauge Connector Fuel Sender Gauge Connector x8 Fuel Sender Gauge 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Pump Flange Fuel Tank Vent Tube Set Plate
O–Ring Fuel Filter Ground Plate Fuel Pump Fuel Pump Assembly Fuel Pump Lead Wire Housing
Gasket Fuel Pump Filter
Clip Rubber Cushion ”C” Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part S06038 Author: Date: 1443 SF–11 SFI (5S–FE) – FUEL PUMP SF0D9–03 REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE REAR SEAT CUSHION 2. REMOVE FLOOR SERVICE HOLE COVER (a) Take out the floor carpet. (b) Remove the service hole cover. HINT: At the time of installation, please refer to the following items. Check for fuel leakage. 3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 4. REMOVE NO.1 FUEL TANK PROTECTOR Remove the 2 bolts and No.1 fuel tank protector. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) 5. S04583 DISCONNECT FUEL TUBE (FUEL TUBE CONNECTOR) CAUTION:
Perform disconnecting and connecting operations of the fuel tube connector (quick type) after observing the precautions.
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the vehicle compartment. 6. (a) Vinyl Bag S04592 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK Remove the 6 bolts and fuel tank vent tube set plate. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) (b) Pull out the fuel pump assembly. (c) Remove the gasket from the pump assembly. NOTICE:
Do not damage the fuel pump filter.
Be careful that the arm of the sender gauge should not bent. HINT: At the time of installation, please refer to the following items. Install a new gasket to the pump assembly. Author: Date: 1444 SF–12 SFI (5S–FE) – FUEL PUMP SF0DA–02 DISASSEMBLY Type B 1. 2. 3. DISCONNECT FUEL PUMP CONNECTOR Type B: DISCONNECT GROUND PLATE Type B: DISCONNECT FUEL SENDER GAUGE CONNECTOR S06028 4. Type A (a) (b) (c) Pull Type A: REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull off the lower side of the fuel pump from the pump bracket. Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump. S04603 5. Type B: REMOVE FUEL SENDER GAUGE. Push down the portion of A with a finger, and push up the sender gauge. NOTICE: Be careful that the arm of the sender gauge should not bent. Type B A Push S06033 6. Type B S06050 (a) (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) 7. Type B: REMOVE FUEL PUMP FLANGE Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring of the fuel pump. Type B (2) Type B: REMOVE FUEL FILTER Remove the screw, and pull out the fuel filter. Remove the O–ring from the fuel filter. (3) (1) S06030 Author: Date: 1445 SF–13 SFI (5S–FE) 8. Type B – FUEL PUMP Type B: REMOVE FUEL PUMP LEAD WIRE. S06027 9. Type B (3) (1) (2) Type B: REMOVE ”C” BRACKET, RUBBER CUSHION AND FUEL PUMP Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. S06029 10. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. FI6376 Author: Date: 1446 SF–14 SFI (5S–FE) – FUEL PUMP SF0DB–01 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page SF–12) Author: Date: 1447 SF–15 SFI (5S–FE) – FUEL PUMP SF0DC–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–11) Author: Date: 1448 SF–16 SFI (5S–FE) – FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR SF0DD–02 COMPONENTS Type A Rear Seat Cushion Floor Service Hole Cover x8 Fuel Pump & Sender Gauge Connector 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Assembly
Gasket Fuel Pressure Regulator
O–Ring
O–Ring Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19026 Author: Date: 1449 SF–17 SFI (5S–FE) – FUEL PRESSURE REGULATOR Type B Rear Seat Cushion Floor Service Hole Cover x8 Fuel Pump and Sender Gauge Connector 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Assembly
Gasket Fuel Pressure Regulator
O–Ring
O–Ring Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part S06037 Author: Date: 1450 SF–18 SFI (5S–FE) – FUEL PRESSURE REGULATOR SF0DE–03 REMOVAL 1. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (See page SF–11) 2. REMOVE FUEL FILTER (a) Remove the screw, and pull out the fuel filter. (b) Remove the O–ring from the fuel filter. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) S04591 3. (a) REMOVE FUEL PRESSURE REGULATOR Remove the screw, and pull out the pressure regulator. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remove the O–ring from the pressure regulator. (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator. S04590 Author: Date: 1451 SF–19 SFI (5S–FE) – FUEL PRESSURE REGULATOR SF0DF–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–18) Author: Date: 1452 SF–20 SFI (5S–FE) – INJECTOR INJECTOR SF0DG–03 ON–VEHICLE INSPECTION 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is a normal operating noise in proportion to engine speed. Sound Scope S05304 (b) If you have no sound scope, you can check the injector transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. S05305 2. (a) (b) INSPECT INJECTOR RESISTANCE Disconnect the injector connector. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 – 14.2 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (c) Reconnect the injector connector. Ohmmeter S05306 Author: Date: 1453 SF–21 SFI (5S–FE) – INJECTOR SF0DH–03 COMPONENTS High–Tension Cord 44 (450, 33) Grommet Cylinder Head Cover PCV Hose PCV Hose Gasket Injector (Except California) Injector (California) 13 (130, 9) Injector Connector Delivery Pipe
Insulator
Insulator
O–Ring
O–Ring
Grommet Engine Wire Clamp Spacer Spacer N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part S05925 Author: Date: 1454 SF–22 SFI (5S–FE) – INJECTOR SF0DI–03 REMOVAL 1. (a) (b) REMOVE CYLINDER HEAD COVER Disconnect the 4 high–tension cords from the clamps on the cylinder head cover. Disconnect the 4 high–tension cords from the spark plugs. (c) (d) (e) Disconnect the PCV hose from the intake manifold. Disconnect the PCV hose from the cylinder head cover. Disconnect the engine wire clamp from the mounting bolt of the No.2 timing belt cover. (f) Remove the cylinder head cover. (See page EM–33) NOTICE: Cover the cylinder head with a clean cloth to prevent dirt, etc. getting into the cylinder head. (c) (e) (d) S05289 2. (a) (b) REMOVE DELIVERY PIPE AND INJECTORS Disconnect the 4 injector connectors. Remove the 2 bolts holding the delivery pipe to the cylinder head. B06353 B06354 (c) Disconnect the delivery pipe from the 4 injectors. (d) Pull out the 4 injectors. NOTICE: Be careful not to drop the injectors. (e) Remove the 4 insulators (Except California) and 2 spacers from the cylinder head. (f) California: Remove the 2 O–rings, insulator and grommet from each injector. (g) Except California: Remove the O–ring and grommet from each injector. Author: Date: 1455 SF–23 SFI (5S–FE) – INJECTOR SF0DJ–03 SST (Hose) INSPECTION Union Bolt SST (Union) Fuel Filter (On Vehicle) SST (Clamp) SST (Union) Injector 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. S05525 (a) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet. (b) Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolts. SST 09268–41047 (90405–09015) Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) S05522 Union Bolt SST (Union) Gasket SST (Hose) S05524 SST (Hose) SST (Union) O–Ring SST (Clamp) Vinyl Tube (c) (d) Install the grommet and O–ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41047 (09268–41100, 09268–41110) (e) Put the injector into the graduated cylinder. CAUTION: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. P01078 (f) (g) (h) S05331 Connect a TOYOTA hand–held tester to the DLC3. Connect the battery negative (–) cable to the battery. Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. NOTICE: Do not start the engine. (i) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (j) Please refer to the TOYOTA hand–held tester operator’s manual for further details. Author: Date: 1456 SF–24 SFI (5S–FE) (k) – INJECTOR If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (l) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 51 – 63 cm3 (3.2 – 3.8 cu in.) per 15 seconds Difference between each injector: 12 cm3 (0.7 cu in.) or less If the injection volume is not as specified, replace the injector. SST (Wire) Connect P01077 California Except California 2. (a) (b) (c) Z09211 (d) (e) (f) INSPECT LEAKAGE In the condition above, disconnect the tester probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: 1 drop or less per 3 minutes Turn the ignition switch OFF. Disconnect the negative (–) terminal cable from the battery. Remove the SST. SST 09268–41047, 09842–30070 Disconnect the TOYOTA hand–held tester from the DLC3. Reconnect the fuel inlet hose to the fuel filter outlet with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) S05522 Author: Date: 1457 SF–25 SFI (5S–FE) – INJECTOR SF0Z8–01 INSTALLATION California New Insulator 1. (a) New O–Ring New O–Ring (b) (c) New Grommet (d) Except California INSTALL INJECTORS AND DELIVERY PIPE California: Install new insulator and grommet to each injector. Except California: Install a new grommet to each injector. California: Apply a light coat of gasoline onto 2 new O–rings, and install them to each injector. Except California: Apply a light coat of gasoline onto a new O–ring, and install it to each injector. New O–Ring New Grommet Z09141 (e) Install the 2 spacers and 4 new insulators to the cylinder head. (f) While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors. Position the injector connector upward. Spacer New Insulator Spacer S05980 Upward (g) Connector Turn Push S05978 Author: Date: 1458 SF–26 SFI (5S–FE) (h) (i) – INJECTOR Attach the 4 injectors and delivery pipe assembly to the cylinder head. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. B06352 (j) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (k) Position the injector connector upward. (l) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Upward Connector Turn S05976 No.1 (m) Connect the 4 injector connectors. HINT: The No.1 and No.3 injector connectors are brown, and the No.2 and No.4 injector connectors are gray. Gray No.2 No.3 Brown No.4 B06351 2. (a) (b) (c) (d) (b) (d) (e) (f) (c) S05289 3. INSTALL CYLINDER HEAD COVER Install the cylinder head cover. (See page EM–53) Connect the PCV hose to the intake manifold. Connect the PCV hose to the cylinder head cover. Install the engine wire clamp to the mounting bolt of the No.2 timing belt cover. Connect the 4 high–tension cords to the spark plugs. Install the 4 high–tension cords to the clamps on the cylinder head cover. CHECK FOR FUEL LEAKS (See page SF–1) Author: Date: 1459 SF–27 SFI (5S–FE) – FUEL TANK AND LINE FUEL TANK AND LINE SF0DL–03 COMPONENTS CAUTION:  Always use new gaskets when replacing the fuel tank or component parts.  Apply the proper torque to all parts tightened Location of Fuel Tank Cushion No.1 Fuel Tank Protector x8 Fuel Tank Vent Tube Set Plate Fuel Pump Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted, remove the heated oxygen sensor and reinstall it. Charcoal Canister Fuel Inlet Pipe Shield Fuel Tank Cap Vent Line Hose  Gasket Fuel Outlet Tube  Gasket EVAP Line Hose Fuel Inlet Pipe Fuel Inlet Hose Fuel Tank Fuel Inlet Pipe Protector 39 (400, 29)  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) Fuel Tank Band Heat Insulator 44 (450, 33) 56 (570, 41)  Gasket Center Exhaust Pipe 56 (570, 41) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part B06469 Author: Date: 1460 SF–28 SFI (5S–FE) – FUEL TANK AND LINE SF0DM–03 INSPECTION Crack Leakage Deformation BO0919 SST Use SST 28 N·m (285 kgf·cm, 21ft·lbf) SST: 09631–22020 INSPECT FUEL TANK AND LINE (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Fulcrum Length 30 cm (11.81 in.) Z10162 2 – 7 mm (0.08 – 0.28 in.) Hose Pipe Clip 0 – 3 mm (0 – 0.12 in.) FU0041 Author: Date: 1461 SF–29 SFI (5S–FE) – THROTTLE BODY THROTTLE BODY SF0DN–03 ON–VEHICLE INSPECTION Move 1. (a) INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port.
Start the engine.
Check the vacuum with your finger. B01277 P Port name R E At idle Other than idle Mark E Vacuum Vacuum Mark P No vacuum Vacuum Mark R No vacuum No vacuum B00525 2. (a) (b) (c) INSPECT THROTTLE POSITION SENSOR Disconnect the sensor connector. Disconnect the vacuum hose from the throttle opener. Apply vacuum to the throttle opener. (d) Using an ohmmeter, measure the resistance between each terminal. Disconnect Vacuum B01278 VTA E2 VC Ohmmeter B01282 (e) (f) 3. (a) Clearance between lever and stop screw Between terminals Resistance 0 mm (0 in.) VTA – E2 0.2 – 5.7 kΩ Throttle valve fully open VTA – E2 2.0 – 10.2 kΩ – VC – E2 2.5 – 5.9 kΩ Reconnect the vacuum hose to the throttle opener. Reconnect the sensor connector. INSPECT THROTTLE OPENER Allow the engine to warm up to normal operating temperature. Author: Date: 1462 SF–30 SFI (5S–FE) (b) (c) S05331 (d) Plug Disconnect – THROTTLE BODY Connect a TOYOTA hand–held tester or OBDII scan tool. (1) Remove the fuse cover on the instrument panel. (2) Connect a TOYOTA hand–held tester or OBDII scan tool to the DLC3. (3) Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. Check the idle speed. Idle speed: 700 ± 50 rpm Check and adjust the throttle opener setting speed. (1) Disconnect the vacuum hose from the throttle opener, and plug the hose end. (2) Maintain the engine speed at 2,500 rpm. (3) Release the throttle valve. (4) Check that the throttle opener is set. Throttle opener setting speed: 1,300 – 1,500 rpm (w/ Cooling fan OFF) B01279 (5) 2.5 mm Hexagon Wrench (e) Using a 2.5 mm hexagon wrench, loosen the lock nut and adjust the throttle opener setting speed by turning the throttle opener adjusting screw. Tighten the lock nut. (6) Reconnect the vacuum hose to the throttle opener. Disconnect the TOYOTA hand–held tester or OBDII scan tool. B01280 Author: Date: 1463 SF–31 SFI (5S–FE) – THROTTLE BODY SF0DO–03 COMPONENTS Vacuum Hose 19 (195, 14)
Gasket Accelerator Cable Throttle Cable (A/T) Throttle Position Sensor Connector Throttle Body IAC Valve Connector Water Bypass Hose Air Hose (California) EVAP Hose EVAP Hose Air Cleaner Hose EVAP Hose PCV Hose IAT Sensor Connector Air Cleaner Cap VSV Connector for EVAP N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B00526 Author: Date: 1464 SF–32 SFI (5S–FE) – THROTTLE BODY SF0DP–03 REMOVAL 1. 2. 3. 5. (a) (b) (c) DRAIN ENGINE COOLANT REMOVE AIR CLEANER CAP (See page EM–69) DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY REMOVE THROTTLE BODY Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the 2 vacuum hoses from the throttle body. (d) (e) (f) Remove the 3 bolts. Disconnect the throttle body from the intake manifold. Remove the gasket. (g) Disconnect the air hose for air assist system (California) and the 2 water bypass hoses from the throttle body, and remove the throttle body. 4. B01283 Water Bypass Hose Air Hose Water Bypass Hose S05534 Author: Date: 1465 SF–33 SFI (5S–FE) – THROTTLE BODY SF0DQ–03 INSPECTION 1. (a) B00527 Throttle Lever Stop Screw 2. (a) (b) (c) No Clearance Disconnect Vacuum CLEAN THROTTLE BODY Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor and throttle opener. (d) B01284 3. INSPECT THROTTLE BODY Disconnect the throttle opener vacuum hose from the throttle body. Apply vacuum to the throttle opener. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. Reconnect the throttle opener vacuum hose to the throttle body. INSPECT THROTTLE POSITION SENSOR (See page SF–29) Author: Date: 1466 SF–34 SFI (5S–FE) – THROTTLE BODY SF0DR–03 INSTALLATION 1. (a) (a) (b) (c) (c) (b) S05534 (d) (e) (f) (g) 2. 3. B01283 4. 5. INSTALL THROTTLE BODY Connect the water bypass hose (from the water bypass pipe) to the throttle body. Connect the water bypass hose (from the water outlet) to the throttle body. California: Connect the air hose (from the intake manifold) for air assist system to the throttle body. Install a new gasket and the throttle body with the 3 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Connect the 2 vacuum hoses to the throttle body. Connect the throttle position sensor connector. Connect the IAC valve connector. CONNECT ACCELERATOR CABLE TO THROTTLE BODY A/T: CONNECT THROTTLE CABLE TO THROTTLE BODY INSTALL AIR CLEANER CAP (See page EM–75) FILL WITH ENGINE COOLANT Author: Date: 1467 SF–35 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE IDLE AIR CONTROL (IAC) VALVE SF0DS–03 ON–VEHICLE INSPECTION 1. (a) TE1 INSPECT IAC VALVE OPERATION Initial conditions:
Engine at normal operating temperature
Idle speed set correctly
Transmission in neutral position (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (c) After the engine speed is kept at 900 – 1,300 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST from the DLC1. SST 09843–18020 E1 SST A07370 Ohmmeter +B ISCC ISCO B01281 2. INSPECT IAC VALVE RESISTANCE NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (ISCC, ISCO). Resistance: Cold 17.0 – 24.5 Ω Hot 21.5 – 28.5 Ω If the resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. Author: Date: 1468 SF–36 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DT–03 COMPONENTS Vacuum Hose
Gasket Accelerator Cable Throttle Cable (A/T) Throttle Position Sensor Connector Throttle Body Water Bypass Hose Air Hose (California) IAC Valve Connector 19 (195, 14) EVAP Hose EVAP Hose Air Cleaner Hose EVAP Hose Throttle Body PCV Hose IAT Sensor Connector
Gasket IAC Valve Air Cleaner Cap VSV Connector for EVAP N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B01285 Author: Date: 1469 SF–37 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DU–03 REMOVAL 1. Except California REMOVE THROTTLE BODY (See page SF–32) 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. B01276 Author: Date: 1470 SF–38 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DV–03 INSPECTION INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal ISCC, and check that the valve is closed. Battery ISCC Closed +B S01477 (b) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal ISCO, and check that the valve is open. If operation is not as specified, replace the IAC valve. Battery Open +B ISCO S01478 Author: Date: 1471 SF–39 SFI (5S–FE) – IDLE AIR CONTROL (IAC) VALVE SF0DW–03 INSTALLATION 1. (a) (b) 2. INSTALL IAC VALVE Place a new gasket on the throttle body. Install the IAC valve with the 4 screws. INSTALL THROTTLE BODY (See page SF–34) New Gasket B01275 Author: Date: 1472 SF–40 SFI (5S–FE) – EFI MAIN RELAY EFI MAIN RELAY SF0DX–03 INSPECTION EFI Main Relay 1. 2. REMOVE RELAY BOX COVER REMOVE EFI MAIN RELAY (Marking: EFI) S05392 3. (a) Continuity Ohmmeter Ohmmeter 2 1 5 3 No Continuity INSPECT EFI MAIN RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. S04970 (b) 2 Ohmmeter 1 5 3 Battery Continuity Inspect the relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL EFI MAIN RELAY 5. REINSTALL RELAY BOX COVER S04969 Author: Date: 1473 SF–41 SFI (5S–FE) Circuit Opening Relay – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY SF0DY–03 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) S05389 Continuity Ohmmeter Ohmmeter 2 1 5 3 No Continuity 3. (a) INSPECT CIRCUIT OPENING RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. S04970 (b) 2 Ohmmeter 1 5 3 Battery Continuity Inspect the relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL CIRCUIT OPENING RELAY 5. REINSTALL RELAY BOX COVER S04969 Author: Date: 1474 SF–42 SFI (5S–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF0DZ–03 COMPONENTS VSV Connector for EGR Vacuum Hose VSV for EGR B06348 Author: Date: 1475 SF–43 SFI (5S–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF0E0–03 INSPECTION 1. Ohmmeter REMOVE VSV 2. (a) INSPECT VSV Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S05259 Ohmmeter (b) Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity S05260 (c) Air Inspect the VSV operation. (1) Check that air flows from ports E to G. E G S05261 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from port E to filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Air Battery E Filter S05262 Author: Date: 1476 SF–44 SFI (5S–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) VSV FOR EVAPORATIVE EMISSION (EVAP) SF0E1–03 COMPONENTS VSV for EVAP VSV Connector for EVAP EVAP Hose S05276 Author: Date: 1477 SF–45 SFI (5S–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) SF0E2–03 INSPECTION 1. REMOVE VSV 2. (a) INSPECT VSV Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 – 34 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Ohmmeter Continuity S05263 (b) Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. Ohmmeter No Continuity S05264 (c) Inspect the VSV operation. (1) Check that air dose not flow from ports E to F. NOTICE: Never apply more than 93 kPa (0.95 kgf/cm2, 13.5 psi) of pressure compressed air to the VSV. Air E F S05265 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Air E F Battery S05266 Author: Date: 1478 SF–46 SFI (5S–FE) – VSV FOR VAPOR PRESSURE SENSOR VSV FOR VAPOR PRESSURE SENSOR SF0E3–03 COMPONENTS VSV for Vapor Pressure Sensor Connector VSV for Vapor Pressure Sensor Vacuum Hose Charcoal Canister B06550 Author: Date: 1479 SF–47 SFI (5S–FE) – VSV FOR VAPOR PRESSURE SENSOR SF0E4–04 INSPECTION 1. REMOVE VSV 2. (a) INSPECT VSV Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Ohmmeter Continuity B01273 (b) Ohmmeter No Continuity Inspect the VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. B00798 (c) Air Inspect the VSV operation. (1) Check that air flows from ports E to G. E G B00799 (2) Apply battery positive voltage across the terminals. (3) Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 3. REINSTALL VSV Air E F Battery B00800 Author: Date: 1480 SF–48 SFI (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF0E5–03 COMPONENTS ECT Sensor Connector ECT Sensor
Gasket
Non–reusable part B06361 Author: Date: 1481 SF–49 SFI (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF0E6–03 INSPECTION 1. 2. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR 5. REFILL WITH ENGINE COOLANT Ohmmeter 30 20 Resistance kΩ 10 5 3 2 DRAIN ENGINE COOLANT REMOVE ECT SENSOR Acceptable 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (68) (104) (140) (176) (212) S01196 S01699 Temperature °C (°F) Z17274 Author: Date: 1482 SF–50 SFI (5S–FE) – INTAKE AIR TEMPERATURE (IAT) SENSOR INTAKE AIR TEMPERATURE (IAT) SENSOR SF0E7–03 COMPONENTS Grommet IAT Sensor IAT Sensor Connector S05277 Author: Date: 1483 SF–51 SFI (5S–FE) – INTAKE AIR TEMPERATURE (IAT) SENSOR SF0E8–03 INSPECTION 1. 2. INSPECT IAT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the sensor. 3. REINSTALL IAT SENSOR Resistance kΩ Ohmmeter 30 20 10 5 3 2 REMOVE IAT SENSOR Acceptable 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4)(32)(68)(104)(140)(176)(212) Temperature °C (°F) Z17273 Author: Date: 1484 SF–52 SFI (5S–FE) – MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SF0E9–03 COMPONENTS MAP Sensor and Bracket Assembly MAP Sensor Vacuum Hose MAP Sensor Connector Wire Clamp B00528 Author: Date: 1485 SF–53 SFI (5S–FE) – MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SF0EA–03 Ohmmeter INSPECTION 1. (a) (b) (c) Disconnect E2 VC S05545 2. (a) (b) (c) Disconnect (d) Vacuum w/o Immobilizer ECM (d) (e) PIM (e) INSPECT POWER SOURCE VOLTAGE OF MAP SENSOR Disconnect the MAP sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn the ignition switch OFF. Reconnect the MAP sensor connector. INSPECT POWER OUTPUT OF MAP SENSOR Turn the ignition switch ON. Disconnect the vacuum hose from the MAP sensor. Connect a voltmeter to terminals PIM and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69 in.Hg). Measure the voltage drop from step (c) above for each segment. Voltage Drop: Voltmeter Applied Vacuum kPa mmHg in.Hg E2 Voltage drop V w/ Immobiliser ECM PIM (+) A03009 (f) (g) E2 (–) 13.3 26.7 40.0 53.5 66.7 100 3.94 200 7.87 300 11.81 400 15.75 500 19.69 0.3 – 0.5 0.7 – 0.9 1.1 – 1.3 1.5 – 1.7 1.9 – 2.1 Turn the ignition switch OFF. Reconnect the vacuum hose to the MAP sensor. B01912 Author: Date: 1486 SF–54 SFI (5S–FE) – VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR SF0EF–04 COMPONENTS Vapor Pressure Sensor (Type B) Vapor Pressure Sensor (Type A) Vapor Pressure Sensor Connector Vacuum hose Charcoal Canister B06554 Author: Date: 1487 SF–55 SFI (5S–FE) – VAPOR PRESSURE SENSOR SF0EG–03 INSPECTION Voltmeter 1. (a) (b) (c) Disconnect VC E2 B06551 (d) (e) 2. Type A (a) (b) Pressure Vacuum (c) Disconnect Type B Disconnect Pressure P Vacuum w/o Immobiliser ECM PTNK E2 (d) (e) Voltmeter w/ Immobiliser PTNK (+) ECM B06552 B06553 S05603 A03018 INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Disconnect the vapor pressure sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn the ignition switch OFF. Reconnect the vapor pressure sensor connector. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR Turn the ignition switch ON. Disconnect the vacuum hose from the vapor pressure sensor. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: (1) Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 – 2.1 V (2) Release the vacuum from the vapor pressure sensor. Voltage: 3.0 – 3.6 V (3) Apply pressure (1.5 kPa (15 gf/cm2, 0.22 psi)) to the vapor pressure sensor. Voltage: 4.2 – 4.8 V Turn the ignition switch OFF. Reconnect the vacuum hose to the vapor pressure sensor. E2 (–) B06570 Author: Date: 1488 SF–56 SFI (5S–FE) – KNOCK SENSOR KNOCK SENSOR SF0ED–03 COMPONENTS Knock sensor 1 Knock Sensor 1 Connector B06349 Author: Date: 1489 SF–57 SFI (5S–FE) – KNOCK SENSOR SF0EE–03 INSPECTION 1. (a) (b) SST Ohmmeter REMOVE KNOCK SENSOR 1 Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09816–30010 B06350 No Continuity P01630 2. INSPECT KNOCK SENSOR 1 Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 3. REINSTALL KNOCK SENSOR 1 (a) Using SST, install the knock sensor. SST 09816–30010 Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (b) Connect the knock sensor connector. Author: Date: 1490 SF–58 SFI (5S–FE) – AIR–FUEL RATIO (A/F) SENSOR (California) AIR–FUEL RATIO (A/F) SENSOR (California) SF0EB–03 COMPONENTS No.3 Exhaust Manifold Heat Insulator A/F Sensor Connector Clamp A/F Sensor 44 (450, 32) N·m (kgf·cm, ft·lbf) : Specified torque B06358 Author: Date: 1491 SF–59 SFI (5S–FE) – AIR–FUEL RATIO (A/F) SENSOR (California) SF0EC–04 INSPECTION +B Ohmmeter HT B06365 1. (a) (b) INSPECT HEATER RESISTANCE OF A/F SENSOR Disconnect the A/F sensor connector. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: 0.8 – 1.4 Ω at 20°C (68°F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) Reconnect the A/F sensor connector. 2. INSPECT OPERATION OF A/F SENSOR (See page DI–152) Author: Date: 1492 SF–60 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.) HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.) SF0EH–03 COMPONENTS Heated Oxygen Sensor (Bank 1 Sensor 1) Connector Clamp Heated Oxygen Sensor (Bank 1 Sensor 1) 44 (450, 32) N·m (kgf·cm, ft·lbf) : Specified torque B06359 Author: Date: 1493 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 1/Except Calif.) SF–61 SF0EI–03 INSPECTION +B 1. Ohmmeter HT B06363 INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (a) Disconnect the oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: 11 – 16 Ω at 20°C (68°F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSOR (See page DI–66) Author: Date: 1494 SF–62 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 2) HEATED OXYGEN SENSOR (Bank 1 Sensor 2) SF0EJ–03 COMPONENTS Passenger’s Seat 37 (375, 27) Connector for Seat Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 32) Clamp Heated Oxygen Sensor Connector (Bank 1 Sensor 2) Grommet N·m (kgf·cm, ft·lbf) : Specified torque Z19284 Author: Date: 1495 SF–63 SFI (5S–FE) – HEATED OXYGEN SENSOR (Bank 1 Sensor 2) SF0EK–03 Ohmmeter INSPECTION 1. +B HT S05303 INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (a) Disconnect the oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: 11 – 16 Ω at 20°C (68°F) If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) Reconnect the oxygen sensor connector. 2. INSPECT OPERATION OF HEATED OXYGEN SENSOR (See page DI–75) Author: Date: 1496 SF–64 SFI (5S–FE) – ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) SF0EL–03 COMPONENTS No.2 Instrument Lower Panel ECM ECM Connector Under Cover Cowl Side Trim Front Door Inside Scuff Plate S06018 Author: Date: 1497 SF–65 SFI (5S–FE) – ENGINE CONTROL MODULE (ECM) SF0EM–03 INSPECTION 1. 2. 3. REMOVE ECM INSPECT ECM (See page DI–22) REINSTALL ECM Author: Date: 1498 SF–66 SFI (5S–FE) – FUEL CUT RPM FUEL CUT RPM SF0EN–03 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. (a) (b) (c) CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Remove the fuse cover on the instrument panel. Connect a TOYOTA hand–held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. S05331 3. (a) (b) (c) Sound Scope S05304 INSPECT FUEL CUT RPM OPERATION Increase the engine speed to at least 2,500 rpm. Check for injector operating noise. Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return speed: 1,500 rpm 4. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Author: Date: 1499 SF–1 SFI (1MZ–FE) – SFI SYSTEM SFI SYSTEM SF078–03 PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (–) terminal cable is removed from the battery. Therefore, if necessary, read the diagnosis before removing the negative (–) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. MAINTENANCE PRECAUTIONS (a) In event of engine misfire, these precautions should be taken. (1) Check proper connection to battery terminals, etc. (2) After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. (3) When cleaning the engine compartment, be especially careful to protect the electrical system from water. (b) Precautions when handling the oxygen sensor. (1) Do not allow the oxygen sensor to drop or hit against an object. (2) Do not allow the sensor to come into contact with water. 5. IF VEHICLE IS EQUIPPED WITH A MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. 6. AIR INDUCTION SYSTEM (a) Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. (b) Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. 7. ELECTRONIC CONTROL SYSTEM (a) Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery. Author: Date: 1500 SF–2 SFI (1MZ–FE) (b) (c) (d) (e) (f) (g) (h) – SFI SYSTEM When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (–) cables. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. Be careful during troubleshooting as there are numerous transistor circuit, and even slight terminal contact can cause further troubles. Do not open the ECM cover. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the SFI parts and wiring connectors. Parts should be replaced as an assembly. Care should be taken when pulling out and inserting wiring connectors. (1) Release the lock and pull out the connector, pulling on the connectors. (2) Fully insert the connector and check that it is locked. (i) Use SST for inspection or test of the injector or its wiring connector. SST 09842–30070 8. (a) FUEL SYSTEM When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe these procedures: (1) Disconnect the fuel pump connector. (2) Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK. SST FI2553 Fuel Pump Connector S04600 (3) (4) (5) (6) Plug Put a container under the connection. Slowly loosen the connection. Disconnect the connection. Plug the connection with a rubber plug. S05039 Author: Date: 1501 SF–3 SFI (1MZ–FE) (b) – SFI SYSTEM When connecting the union bolt on the high pressure pipe union, observe these procedures: (1) Always use 2 new gaskets. (2) Tighten the union bolt by hand. (3) Tighten the union bolt to the specified torque. Torque: 32.5 N·m (330 kgf·cm, 24 ft·lbf) New Gasket S05054 (c) Fulcrum Length 30 cm SST FI1654 New O–Ring CORRECT Grommet Injector WRONG When connecting the flare nut on the high pressure pipe union, observe these procedures: (1) Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. (2) Using SST, tighten the flare nut to specified torque. SST 09631–22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N·m (285 kgf·cm, 21 ft·lbf) for using SST HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (d) Observe these precautions when removing and installing the injectors. (1) Never reuse the O–ring. (2) When placing a new O–ring on the injector, take care not to damage it in any way. (3) Coat a new O–ring with spindle oil or gasoline before installing–never use engine, gear or brake oil. FI6372 FI6372 Author: Date: 1502 SF–4 SFI (1MZ–FE) California A/T Delivery Pipe – SFI SYSTEM (e) Install the injector to the delivery pipe and intake manifold, as shown in the illustration. Before installing the injector, must apply spindle oil or gasoline on the place where a delivery pipe or an intake manifold touches an O–ring of the injector. (f) Observe these precautions when disconnecting the fuel tube connector (quick type). (1) Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away. (2) Be sure to disconnect with hands. O–Ring Insulator Grommet Spacer O–Ring Except California A/T Delivery Pipe O–Ring Insulator Grommet Spacer O–Ring B00630 (3) (4) When the connector and the pipe are stuck, pinch the retainer between the hands, push and pull the connector to free to disconnect and pull it out. Do not use any tool at this time. Inspect if there is any dirt or the likes on the seal surface of the disconnected pipe and clean it away. S04583 (5) Vinyl Bag Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag. S05040 Author: Date: 1503 SF–5 SFI (1MZ–FE) (g) Retainer – SFI SYSTEM Observe these precautions when connecting the fuel tube connector (quick type). (1) Do not reuse the retainer removed from the pipe. (2) Must use hands without using tools when to remove the retainer from the pipe. (3) Check if there is any damage or foreign objects on the connected part of the pipe. S05382 (4) Click Sound (5) (6) S05050 (h) TOYOTA Hand–Held Tester S05358 Match the axis of the connector with axis of the pipe, and push in the connector until the retainer makes a ”click” sound. In case that the connections is tight, apply little amount of new engine oil on the tip of the pipe. After having finished the connection, check if the pipe and the connector are securely connected by pulling them. Check if there is any fuel leakage. Observe these precautions when handling nylon tube. (1) Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them. (2) Pay attention not to kink the nylon tube. (3) Do not remove the EPDM protector on the outside of the nylon tube. (4) Must not close the piping with the nylon tube by bending it. (i) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Turn the ignition switch ON and push the TOYOTA hand–held tester main switch ON. NOTICE: Do not start the engine. (3) Select the active test mode on the TOYOTA hand– held tester. (4) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (5) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) (6) Check that there are no leaks from any part of the fuel system. (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand–held tester from the DLC3. Author: Date: 1504 SF–6 SFI (1MZ–FE) TOYOTA Hand Held Tester – FUEL PUMP FUEL PUMP SF079–04 ON–VEHICLE INSPECTION 1. (a) (b) S05358 CHECK FUEL PUMP OPERATION Connect a TOYOTA hand–held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. NOTICE: Do not start the engine. (c) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (d) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (e) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See step 7) (f) S05353 HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check these parts: Fusible link Fuses EFI main relay Fuel pump ECM Wiring connections (g) Turn the ignition switch OFF. (h) Disconnect the TOYOTA hand–held tester from the DLC3. 2. (a) (b) Fuel Tube Connector Check that there is pressure in the fuel inlet hose from the fuel filter. (c) CHECK FUEL PRESSURE Check the battery positive voltage is above 12 V. Disconnect the negative (–) terminal cable from the battery. Purchase the new No.1 fuel pipe and take out the fuel tube connector from its pipe. Part No. 23801–20041 S05359 Author: Date: 1505 SF–7 SFI (1MZ–FE) (d) – FUEL PUMP Remove the fuel hose clamp. Fuel Hose Clamp S06086 (e) S05352 Disconnect the No.1 fuel pipe (fuel tube connector) from the fuel filter outlet. CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1)
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (f) SST (Hose) SST Retainer No.1 Fuel Pipe SST Fuel Tube Connector SST (Hose) S05364 Install SST (pressure gauge) as shown in the illustration by using SST and fuel tube connector. SST 09268–41047, 09268–41250, 09268–45012 (g) Wipe off any splattered gasoline. (h) Reconnect the negative (–) terminal cable to the battery. (i) Connect the TOYOTA hand held tester to the DLC3. (See step 1. check fuel pump operation (a) to (e)) (j) Measure the fuel pressure. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check these parts: Fuel hoses and connections Fuel pump Fuel filter Fuel pressure regulator (k) Disconnect the TOYOTA hand–held tester from the DLC3. (l) Start the engine. (m) Measure the fuel pressure at idle. Fuel pressure: 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) (n) Stop the engine. (o) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. Author: Date: 1506 SF–8 SFI (1MZ–FE) (p) – FUEL PUMP After checking fuel pressure, disconnect the negative (–) terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing. SST 09268–41047, 09268–41250, 09268–45012 (q) Reconnect the No.1 fuel pipe (fuel tube connector). CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) S05351 (r) Fuel Hose Clamp S06086 Ohmmeter 5 4 Surely install the fuel hose clamp to the fuel filter with ”click” sound. (s) After installing the clamp, check that the clamp is fixed by pulling up the clamp. (t) Reconnect the negative (–) terminal cable to the battery. (u) Check for fuel leaks. 3. REMOVE REAR SEAT CUSHION 4. REMOVE FLOOR SERVICE HOLE COVER 5. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 6. INSPECT FUEL PUMP RESISTANCE Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2 – 3.0 Ω at 20°C (68°F) If the resistance is not as specified, replace the fuel pump. S04508 5 Battery 4 S04509 7. INSPECT FUEL PUMP OPERATION Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE:
These tests must be done quickly (within 10 seconds) to prevent the coil burning out.
Keep the fuel pump as far away from the battery as possible.
Always do the switching at the battery side. Author: Date: 1507 SF–9 SFI (1MZ–FE) – FUEL PUMP If operation is not as specified, replace the fuel pump or lead wire. 8. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 9. REINSTALL FLOOR SERVICE HOLE COVER 10. REINSTALL REAR SEAT CUSHION Author: Date: 1508 SF–10 SFI (1MZ–FE) – FUEL PUMP SF07A–02 COMPONENTS Type A Rear Seat Cushion Floor Service Hole Cover x8 Fuel Pump and Sender Gauge Connector 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Hose Fuel Pump Connector Fuel Pump Assembly Fuel Pump
Gasket Fuel Pump Filter
Clip Rubber Cushion N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06401 Author: Date: 1509 SF–11 SFI (1MZ–FE) – FUEL PUMP Type B Rear Seat Cushion Floor Service Hole Cover Fuel Pump and Sender Gauge Connector x8 4 (40, 35 in.·lbf) Fuel Sender Gauge No.1 Fuel Tank Protector Fuel Pump Flange Fuel Tank Vent Tube Set Plate
O–Ring Fuel Filter Fuel Pump Assembly Fuel Pump
Gasket Lead Wire Housing Fuel Pump Filter
Clip Rubber Cushion ”C” Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06394 Author: Date: 1510 SF–12 SFI (1MZ–FE) – FUEL PUMP SF07B–04 REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. REMOVE REAR SEAT CUSHION 2. REMOVE FLOOR SERVICE HOLE COVER (a) Take out the floor carpet. (b) Remove the service hole cover. HINT: At the time of installation, plaese refer to the following items. Check for fuel leakage. 3. DISCONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 4. REMOVE NO.1 FUEL TANK PROTECTOR Remove the 2 bolts and No.1 fuel tank protector. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) 5. S04583 DISCONNECT FUEL TUBE (FUEL TUBE CONNECTOR) CAUTION:
Perform disconnecting and connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1)
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the vehicle compartment. 6. (a) Vinyl Bag S04592 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK Remove the 6 bolts and fuel tank vent tube set plate. Torque: 4 N·m (40 kgf·cm, 35 in.·lbf) (b) Pull out the fuel pump assembly. (c) Remove the gasket from the pump assembly. NOTICE:
Do not damage the fuel pump filter.
Be careful that the arm of the sender gauge should not bent. HINT: At the time of installation, plaese refer to the following items. Install a new gasket to the pump assembly. Author: Date: 1511 SF–13 SFI (1MZ–FE) – FUEL PUMP SF07C–03 DISASSEMBLY Type B 1. 2. 3. DISCONNECT FUEL PUMP CONNECTOR TYPE B: DISCONNECT GROUND PLATE TYPE B: DISCONNECT FUEL SENDER GAUGE CONNECTOR S06028 4. Type A (a) (b) (c) Pull Type A: REMOVE FUEL PUMP FROM FUEL PUMP BRACKET Pull off the lower side of the fuel pump from the pump bracket. Disconnect the fuel hose from the fuel pump, and remove the fuel pump. Remove the rubber cushion from the fuel pump. S04603 5. Type B: REMOVE FUEL SENDER GAUGE Push down the portion of A with a finger, and push up the sender gauge. NOTICE: Be careful that the arm of the sender gauge should not bent. Type B A Push S06033 6. Type B Type B: REMOVE FUEL FILTER Remove the screw, and pull out the fuel filter. Remove the O–ring from the fuel filter. (a) (b) HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. S06050 7. TYPE B: REMOVE FUEL PUMP FLANGE Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. Type B (2) (3) (1) S06030 Author: Date: 1512 SF–14 SFI (1MZ–FE) 8. Type B – FUEL PUMP Type B: REMOVE FUEL PUMP LEAD WIRE S06027 9. Type B (3) (1) (2) Type B: REMOVE ”C” BRACKET, RUBBER CUSHION AND FUEL PUMP Using a screwdriver, remove the snap fit portion in the order of 1, 2 and 3 as shown in the illustration. S06029 10. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. HINT: At the time of installation, please refer to the following items. Install the pump filter with a new clip. FI6376 Author: Date: 1513 SF–15 SFI (1MZ–FE) – FUEL PUMP SF07D–01 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page SF–13) Author: Date: 1514 SF–16 SFI (1MZ–FE) – FUEL PUMP SF07E–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–12) Author: Date: 1515 SF–17 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR FUEL PRESSURE REGULATOR SF07F–03 COMPONENTS Type A Rear Seat Cushion Floor Service Hole Cover x8 Fuel Pump and Sender Gauge Connector 4 (40,35 in.·lbf) No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Assembly
Gasket
O–Ring Fuel Pressure Regulator
O–Ring Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06392 Author: Date: 1516 SF–18 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR Type B Rear Seat Cushion Floor Service Hole Cover x8 Fuel Pump and Sender Gauge Connector 4 (40, 35 in.·lbf) No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Assembly
Gasket Fuel Pressure Regulator
O–Ring
O–Ring Fuel Filter N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06393 Author: Date: 1517 SF–19 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR SF07G–03 REMOVAL 1. REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK (See page SF–12) 2. (a) REMOVE FUEL FILTER Remove the screw, and pull out the fuel filter. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remove the O–ring from the fuel filter. (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the fuel filter. S04591 3. (a) REMOVE FUEL PRESSURE REGULATOR Remove the screw, and pull out the pressure regulator. Torque: 2.0 N·m (20 kgf·cm, 17 in.·lbf) Remove the O–ring from the pressure regulator. (b) HINT: At the time of installation, please refer to the following items. Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator. S04590 Author: Date: 1518 SF–20 SFI (1MZ–FE) – FUEL PRESSURE REGULATOR SF07H–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–19) Author: Date: 1519 SF–21 SFI (1MZ–FE) – INJECTOR INJECTOR SF07I–03 ON–VEHICLE INSPECTION 5 mm Hexagon Wrench 1. (a) (b) Clip REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts. Disconnect the 2 clips, and remove the V–bank cover. S04528 California A/T 2. INSPECT INJECTOR OPERATION Check operation sound from each injector. (1) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (2) If you have no sound scope, you can check the injector operating vibration with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. Sound Scope Except California A/T Sound Scope B00623 3. (a) (b) INSPECT INJECTOR RESISTANCE Disconnect the injector connector. Using an ohmmeter, measure the resistance between the terminals. Resistance: 13.4 – 14.2 Ω at 20°C (68°F) If the resistance is not as specified, replace the injector. (c) Reconnect the injector connector. 4. REINSTALL V–BANK COVER HINT: For fixing the V–bank cover, push on the cover until a ”click” is felt. California A/T Ohmmeter Except California A/T Ohmmeter B00624 Author: Date: 1520 SF–22 SFI (1MZ–FE) – INJECTOR SF07J–03 COMPONENTS Air Intake Chamber Stay 19.5 (200, 14) 12 (120, 9) 39 (400, 29) PS Pressure Tube
Gasket No.2 EGR Pipe Throttle Position Sensor Connector
Gasket EGR Valve Position Brake Booster Sensor Connector No.1 Engine Hanger 43 (440, 32) VSV Connector for EGR Engine Wire V–Bank Cover Accelerator Cable Vacuum Hose IAC Valve Connector Throttle Cable VSV Connector for EVAP Ground Cable Air Cleaner Hose Ground Strap Purge Hose DLC1 PCV Hose Air Intake Chamber Assembly
Gasket EGR Gas Temperature Sensor Connector Vacuum Hose Water Bypass Hose VSV Connector for ACIS Air Assist Hose and Pipe 19.5 (200, 14) 10 (100, 7)
Retainer Spacer Injector Connector
O–Ring California A/T Injector
Grommet Injector
Insulator
O–Ring High–Tension Cord Set N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06391 Author: Date: 1521 SF–23 SFI (1MZ–FE) – INJECTOR SF07K–04 REMOVAL 1. 2. REMOVE AIR CLEANER HOSE REMOVE AIR INTAKE CHAMBER ASSEMBLY (See page EM–32) 3. DISCONNECT INJECTOR CONNECTORS 4. (a) (b) REMOVE AIR ASSIST HOSES AND PIPE Disconnect the air assist pipe from the bracket on the No.1 fuel pipe. Remove the air assist hoses from the intake manifold. 5. (a) DISCONNECT NO.1 FUEL PIPE Remove the fuel hose clamp. S04505 S04498 Fuel Hose Clamp S06086 (b) S05352 Disconnect the No.1 fuel pipe (fuel tube connector) from the fuel filter outlet. CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1)
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. Author: Date: 1522 SF–24 SFI (1MZ–FE) B01020 – INJECTOR 6. REMOVE DELIVERY PIPES AND INJECTORS NOTICE:
Be careful not to drop the injectors when removing the delivery pipes.
Pay attention to put any hung load on the injector to and from the side direction. (a) Remove the 5 bolts and delivery pipes together with the 6 injectors and No.1 fuel pipe. (b) Remove the 4 spacers from the intake manifold. (c) Pull out the 6 injectors from the delivery pipes. (d) Remove the 2 O–rings and 2 grommets from each injector. Author: Date: 1523 SF–25 SFI (1MZ–FE) – INJECTOR SF07L–04 INSPECTION California A/T Fuel Tube Connector SST (Hose) SST (Union) SST (Clamp) Injector 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. Fuel Filter (On Vehicle) Except California A/T Fuel Tube Connector SST (Hose) SST (Union) SST (Clamp) Injector Fuel Filter (On Vehicle) B01919 (a) Fuel Tube Connector Purchase the new No.1 fuel pipe and take out the fuel tube connector from its pipe. Part No. 23801–20041 S05359 (b) Fuel Tube Connector SST (Hose) Fuel Filter S05357 Connect SST (hose ) and fuel tube connector to the fuel filter outlet. SST 09268–41047 CAUTION: Preform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) HINT: Use the vehicle fuel filter. Author: Date: 1524 SF–26 SFI (1MZ–FE) California A/T SST (Hose) (c) (d) SST (Union) O–Ring SST (Clamp) – INJECTOR Install the grommet and O–Ring to the injector. Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41047 Put the injector into a graduated cylinder. (e) HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. Vinyl Tube Except California A/T SST (Hose) SST (Union) O–Ring SST (Clamp) Vinyl Tube B01914 TOYOTA Hand–Held Tester S05358 (f) (g) Connect a TOYOTA hand–held tester to the DLC3. Turn the ignition switch ON and push the TOYOTA hand– held tester main switch ON. NOTICE: Do not start the engine. (h) Select the ACTIVE TEST mode on the TOYOTA hand– held tester. (i) Please refer to the TOYOTA hand–held tester operator’s manual for further details. (j) If you have no TOYOTA hand–held tester, connect the positive (+) and negative (–) leads from the battery to the fuel pump connector. (See page SF–6) Author: Date: 1525 SF–27 SFI (1MZ–FE) – INJECTOR (k) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 60 – 73 cm3 (3.4 – 4.5 cu in.) per 15 sec. Difference between each injector: 13 cm3 (0.8 cu in.) or less If the injection volume is not as specified, replace the injector. California A/T SST (Wire) Battery Except California A/T SST (Wire) Battery California A/T B01913 2. (a) Except California A/T B00628 INSPECT LEAKAGE In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: 1 drop or less per 12 minutes (b) Turn the ignition switch OFF. (c) Disconnect the negative (–) terminal cable from the battery. (d) Remove the SST and fuel tube connector. SST 09268–41047, 09842–30070 CAUTION:
Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1)
As there is retained pressure in the fuel pipe line, prevent it from splashing inside the engine compartment. (e) Disconnect the TOYOTA hand–held tester from the DLC3. Author: Date: 1526 SF–28 SFI (1MZ–FE) – INJECTOR SF07M–04 California A/T INSTALLATION New Insulator New O–Ring New O–Ring 1. (a) (b) INSTALL INJECTORS AND DELIVERY PIPES Install new insulator and grommet to each injector. Apply a light coat of spindle oil or gasoline to 2 new O– rings and install them to each injector. (c) (e) Apply a light coat of spindle oil or gasoline on the place where a delivery pipe touches an O–ring of the injector. While turning the injector clockwise and counterclockwise, push it to the delivery pipes. Install the 6 injectors. Position the injector connector outward. (f) Place the 4 spacers in position on the intake manifold. New Grommet Except California A/T New Insulator New O–Ring New O–Ring New Grommet B00629 California A/T (d) Turn Push Connector Except California A/T Turn Push Connector B00625 Spacer Spacer S04510 Author: Date: 1527 SF–29 SFI (1MZ–FE) (g) (h) (i) (j) – INJECTOR Apply a light coat of spindle oil or gasoline on the place where a intake manifold touches an O–ring of the injector. Place the delivery pipes and fuel pipe together with the 6 injectors in position on the intake manifold. Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold. B01021 (k) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (l) Position the injector connector outward. Rotate Outward S04728 (m) (n) Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Tighten the bolt holding the No.1 fuel pipe to the intake manifold. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) B01020 2. (a) CONNECT NO.1 FUEL PIPE Align the alignment marks (white paint) on the No.1 fuel pipe. Align S06525 (b) Connect the No.1 fuel pipe (fuel tube connector) to the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precaution. (See page SF–1) S05351 Author: Date: 1528 SF–30 SFI (1MZ–FE) (c) Fuel Hose Clamp (d) – INJECTOR Surely install the fuel hose clamp to the fuel filter with ”click” sound. After installing the clamp, check that the clamp is fixed by pulling up the clamp. S06086 3. (a) (b) 4. 5. S04498 6. 7. INSTALL AIR ASSIST HOSES AND PIPE Connect the air assist hoses to the intake manifold. Install the air assist pipe to the bracket on the No.1 fuel pipe. CONNECT INJECTOR CONNECTORS INSTALL AIR INTAKE CHAMBER ASSEMBLY (See page EM–57) INSTALL AIR CLEANER HOSE CHECK FOR FUEL LEAKS Author: Date: 1529 SF–31 SFI (1MZ–FE) – FUEL TANK AND LINE FUEL TANK AND LINE SF07N–03 COMPONENTS CAUTION:  Always use new gaskets when replacing the fuel tank or component parts.  Apply the proper torque to all parts tightened. x8 No.1 Fuel Tank Protector Fuel Tank Vent Tube Set Plate Fuel Pump Heated Oxygen Sensor (Bank 1 Sensor 2) Location of Fuel Tank Cushion HINT:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the heated oxygen sensor, check that the sensor wire is not twisted, if it is twisted, remove the heated oxygen sensor and reinstall it. Charcoal Canister Fuel Inlet Pipe Shield Fuel Tank Cap Vent Line Hose  Gasket Fuel Outlet Tube  Gasket EVAP Line Hose Fuel Inlet Hose Fuel Inlet Pipe Fuel Inlet Pipe Protector Fuel Tank 39 (400, 29)  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) Fuel Tank Band Heat Insulator 44 (450, 33) 56 (570, 41)  Gasket Center Exhaust Pipe 56 (570, 41) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part B06469 Author: Date: 1530 SF–32 SFI (1MZ–FE) – FUEL TANK AND LINE SF07O–03 INSPECTION Crack Leakage Deformation BO0919 SST Use SST 28 N·m (285 kgf·cm, 21 ft·lbf) INSPECT FUEL TANK AND LINE (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Fulcrum Length 30 cm (11.81 in.) SST: 09631–22020 Z10162 2 – 7 mm (0.08 – 0.28 in.) Hose Pipe Clip 0 – 3 mm (0 – 0.12 in.) FU0041 Author: Date: 1531 SF–33 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER MASS AIR FLOW (MAF) METER SF07P–04 COMPONENTS MAF Meter Connector MAF Meter
Gasket
Non–reusable part S04539 Author: Date: 1532 SF–34 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07Q–03 REMOVAL REMOVE MAF METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts, MAF meter and gasket. HINT: At the time of installation, please refer to the following items. Install a new gasket to the MAF meter. S04755 Author: Date: 1533 SF–35 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07R–03 Ohmmeter INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. Resistance: THA E2 S04526 Terminals Resistance Temperature THA – E2 14.6 – 17.8 kΩ –20°C (–4°F) THA – E2 2.21 – 2.69 kΩ 20°C (68°F) THA – E2 0.29 – 0.35 kΩ 60°C (140°F) If the resistance is not as specified, replace the MAF meter. 2. (a) (b) (c) E2G VG Air Voltmeter S04756 INSPECT MAF METER OPERATION Connect the MAF meter connector. Turn the ignition switch ON. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (–) tester probe to terminal E2G. (d) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (e) Turn the ignition switch OFF. (f) Disconnect the MAF meter connector. Author: Date: 1534 SF–36 SFI (1MZ–FE) – MASS AIR FLOW (MAF) METER SF07S–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–34) Author: Date: 1535 SF–37 SFI (1MZ–FE) – THROTTLE BODY THROTTLE BODY SF07T–03 ON–VEHICLE INSPECTION 1. INSPECT THROTTLE BODY Check that the throttle linkage moves smoothly. S04593 Vacuum Ohmmeter 2. (a) (b) (c) (d) VTA E2 VC S04536 (e) (f) 3. (a) (b) INSPECT THROTTLE POSITION SENSOR Disconnect the sensor connector. Disconnect the vacuum hose from the throttle body. Apply vacuum to the throttle opener. Using an ohmmeter, measure the resistance between each terminal. Resistance: Throttle valve condition Between terminals Resistance Fully closed VTA – E2 0.2 – 6.3 kΩ Fully open VTA – E2 2.0 – 10.2 kΩ – VC – E2 2.5 – 5.9 kΩ Reconnect the vacuum hose to the throttle body. Reconnect the sensor connector. INSPECT THROTTLE OPENER Allow the engine to warm up to normal operating temperature. Check idle speed. Idle speed: 700 ± 50 rpm (c) Plug Disconnect S04604 Disconnect the vacuum hose from the throttle opener, and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 900 – 1,950 rpm If the throttle opener setting is not as specified, replace the throttle body. (e) Stop the engine. (f) Reconnect the vacuum hose to the throttle opener. (g) Start the engine and check that the idle speed returns to the correct speed. Author: Date: 1536 SF–38 SFI (1MZ–FE) – THROTTLE BODY SF07U–03 COMPONENTS
Gasket 19.5 (200, 14) Throttle Body Throttle Position Sensor Connector EGR Gas Temperature Sensor Bracket IAC Valve Connector Water Bypass Hose Air Assist Hose Accelerator Cable Throttle Cable (A/T) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Water Bypass Hose Air Cleaner Hose Author: S04741 Date: 1537 SF–39 SFI (1MZ–FE) – THROTTLE BODY SF07V–03 REMOVAL 1. 2. 3. 4. (a) (b) S04506 (a) (e) (c) (b) 5. (a) (b) (c) (d) (d) (e) DRAIN ENGINE COOLANT DISCONNECT ACCELERATOR CABLE A/T: DISCONNECT THROTTLE CABLE REMOVE AIR CLEANER HOSE Disconnect the PCV hose. Loosen the 2 hose clamps, and remove the air cleaner hose. REMOVE THROTTLE BODY Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the water bypass hose (from the intake manifold). Disconnect the water bypass hose (from the water inlet housing). Disconnect the air assist hose. S06123 (f) EGR Gas Temperature Sensor Bracket Remove the 2 bolts, 2 nuts, EGR gas temperature sensor bracket, throttle body and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the air intake chamber. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) S04527 Author: Date: 1538 SF–40 SFI (1MZ–FE) – THROTTLE BODY SF07W–03 INSPECTION 1. (a) S04582 Throttle Stop Screw CLEAN THROTTLE BODY Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor and IAC valve. 2. (a) (b) Vacuum 3. No Clearance Throttle Lever INSPECT THROTTLE VALVE Apply vacuum to the throttle opener. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. INSPECT THROTTLE POSITION SENSOR (See page SF–37) S04595 Author: Date: 1539 SF–41 SFI (1MZ–FE) – THROTTLE BODY SF07X–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–39) Author: Date: 1540 SF–42 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE IDLE AIR CONTROL (IAC) VALVE SF07Y–03 ON–VEHICLE INSPECTION 1. (a) E1 INSPECT IAC VALVE OPERATION Initial conditions:
Engine at normal operating temperature
Idle speed checked correctly
Transmission in neutral position
A/C switch OFF (b) DLC1 SST TE1 DLC1 S04529 RSC +B RSO Ohmmeter S04533 Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (c) After engine speed is kept at approx. 1,000 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST from the DLC1. SST 09843–18020 2. INSPECT IAC VALVE RESISTANCE NOTICE: ”Cold” and ”Hot” in the following sentences express the temperature of the coils themselves. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold 17.0 – 25.0 Ω Hot 21.5 – 29.5 Ω If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM (a) Initial conditions:
Engine at normal operating temperature
Idle speed checked correctly
Transmission in neutral position
A/C switch OFF Author: Date: 1541 SF–43 SFI (1MZ–FE) E1 (b) DLC1 SST (c) (d) – IDLE AIR CONTROL (IAC) VALVE Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 After engine speed is kept at 900 – 1,300 rpm for 10 seconds, check that it returns to idle speed. Stop the engine. TE1 DLC1 S04529 Plug Disconnect Plug S04531 (e) Disconnect the air assist hose from the air pipe, and block off the IAC valve exit and the entry to the pipe. (f) Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air assist hoses, pipe and injectors. (g) Remove the SST from the DLC1. SST 09843–18020 (h) Reconnect the air assist hose to the air pipe. Author: Date: 1542 SF–44 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF07Z–03 COMPONENTS
Gasket 19.5 (200, 14) Throttle Body Throttle Position Sensor Connector Throttle Body EGR Gas Temperature Sensor Bracket IAC Valve Connector
Gasket IAC Valve Water Bypass Hose Air Assist Hose Water Bypass Hose Accelerator Cable) Throttle Cable (A/T) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Air Cleaner Hose Author: S04742 Date: 1543 SF–45 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF080–03 REMOVAL 1. REMOVE THROTTLE BODY (See page SF–39) 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. HINT: At the time of installation, please refer to the following items. Place a new gasket on the throttle body. P14340 Author: Date: 1544 SF–46 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF081–03 INSPECTION RSC +B INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal RSC, and check that the valve is closed. Battery Closed P14290 (b) +B RSC Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. Battery Open P14289 Author: Date: 1545 SF–47 SFI (1MZ–FE) – IDLE AIR CONTROL (IAC) VALVE SF082–01 INSTALLATION Installation is in the reverse order of removal. (See page SF–45) Author: Date: 1546 SF–48 SFI (1MZ–FE) Vacuum Gage – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF083–03 ON–VEHICLE INSPECTION S05036 Approx. 27.6 kPa INSPECT INTAKE AIR CONTROL VALVE (a) Using a 3–way connector, connect vacuum gauge to the actuator hose. (b) Start the engine. (c) While the engine is idling, check that the vacuum gauge needle does not move. (d) Rapidly depress the accelerator pedal to fully open position and check that the vacuum gauge needle momentarily fluctuates up to approx. 26.7 kPa (200 mmHg, 7.9 in.Hg). (The actuator rod is pulled out.) S05037 Author: Date: 1547 SF–49 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF084–03 COMPONENTS
Gasket Intake Air Control Valve 14.5 (145, 10) DLC1 Bracket DLC1 Actuator Vacuum Hose Ground Strap Ground Cable N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06467 Author: Date: 1548 SF–50 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF085–02 REMOVAL (2) 1. 2. DISCONNECT ACTUATOR VACUUM HOSE DISCONNECT DLC1 FROM DLC1 BRACKET 3. (a) REMOVE INTAKE AIR CONTROL VALVE Remove the 4 nuts and DLC1 bracket, and disconnect the ground strap and cable. Remove the intake air control valve by prying a screwdriver between the intake air control valve and air intake chamber. Remove the gasket. (1) B06470 (b) (c) B06471 Author: Date: 1549 SF–51 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF086–03 INSPECTION 1. (a) INSPECT INTAKE AIR CONTROL VALVE With 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum in (a), check that the actuator rod does not return. If the operation is not as specified, replace the intake air control valve. Vacuum S05041 Air 2. INSPECT VACUUM TANK LOCATION: The LH side member under the battery tray. (a) Check that air flows from port B to port A. (b) Check that air does not flow from port A to port B. Air S05689 Vacuum (c) Plug port B with your finger, and apply 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum to port A, and check that there is no change is vacuum after one minute. If the operation is not as specified, replace the vacuum tank. 3. INSPECT VSV (See page SF–60) S05688 Author: Date: 1550 SF–52 SFI (1MZ–FE) – ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF087–03 INSTALLATION New Gasket 1. (a) INSTALL INTAKE AIR CONTROL VALVE Install a new gasket to the air intake chamber. (b) (c) Apply a light coat of engine oil to the rubber portions. Apply seal packing to the positions of the intake air control valve shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Install the intake air control valve, DLC1 bracket, ground strap and cable with the 4 nuts. Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf) CONNECT DLC1 CONNECT ACTUATOR VACUUM HOSE B06468 Seal Packing Seal Packing (d) Rubber S05052 2. 3. Author: Date: 1551 SF–53 SFI (1MZ–FE) – EFI MAIN RELAY EFI MAIN RELAY SF088–03 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE EFI MAIN RELAY (Marking: EFI) EFI Main Relay S05392 Continuity Ohmmeter Ohmmeter 2 1 5 3 3. (a) INSPECT EFI MAIN RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04970 2 Ohmmeter 1 5 3 4. (a) (b) INSPECT EFI MAIN RELAY OPERATION Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL EFI MAIN RELAY 6. REINSTALL RELAY BOX COVER Battery Continuity S04969 Author: Date: 1552 SF–54 SFI (1MZ–FE) Circuit Opening Relay – CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY SF089–03 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE CIRCUIT OPENING RELAY (Marking: CIR OPN) S05389 3. (a) Continuity Ohmmeter Ohmmeter 2 1 5 3 INSPECT CIRCUIT OPENING RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04970 2 Ohmmeter 1 5 3 4. (a) (b) INSPECT CIRCUIT OPENING RELAY OPERATION Apply battery positive voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL RELAY BOX COVER Battery Continuity S04969 Author: Date: 1553 SF–55 SFI (1MZ–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF08A–03 COMPONENTS Vacuum Hose V–Bank Cover VSV for EGR Emission Control Valve Set High–Tension Cord Cover VSV Connector for EVAP VSV Connector for EGR VSV Connector for ACIS S04762 Author: Date: 1554 SF–56 SFI (1MZ–FE) – VSV FOR EXHAUST GAS RECIRCULATION (EGR) SF08B–03 INSPECTION 1. 2. (a) (b) Ohmmeter REMOVE V–BANK COVER, HIGH–TENSION CORD COVER AND EMISSION CONTROL VALVE SET REMOVE VSV Disconnect the 3 vacuum hoses from the VSV. Remove the screw and VSV. 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27 – 33 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S04514 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. Ohmmeter No Continuity S04513 5. (a) Air INSPECT VSV OPERATION Check that air flows from port E to port G. E G S04515 Air Battery S04512 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 3 vacuum hoses to the VSV. 7. REINSTALL EMISSION CONTROL VALVE SET 8. REINSTALL HIGH–TENSION CORD COVER 9. REINSTALL V–BANK COVER Author: Date: 1555 SF–57 SFI (1MZ–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) VSV FOR EVAPORATIVE EMISSION (EVAP) SF08C–03 COMPONENTS V–Bank Cover EVAP Hose VSV for EVAP Emission Control Valve Set High–Tension Cord Cover VSV Connector for EVAP VSV for ACIS VSV Connector for ACIS VSV Connector for EGR S04761 Author: Date: 1556 SF–58 SFI (1MZ–FE) – VSV FOR EVAPORATIVE EMISSION (EVAP) SF08D–03 INSPECTION 1. 2. (a) (b) Ohmmeter REMOVE V–BANK COVER, HIGH–TENSION CORD COVER AND EMISSION CONTROL VALVE SET REMOVE VSV Disconnect the 2 EVAP hoses from the VSV. Remove the screw and VSV. 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 27 – 33 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S04522 Ohmmeter 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity S04521 5. (a) Air F INSPECT VSV OPERATION Check that air flows with difficulty from port E to port F. E P18857 Air E F Battery S04520 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 EVAP hoses to the VSV. 7. REINSTALL EMISSION CONTROL VALVE SET 8. REINSTALL HIGH–TENSION CORD COVER 9. REINSTALL V–BANK COVER Author: Date: 1557 SFI (1MZ–FE) – VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF–59 VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF08E–03 COMPONENTS Emission Control Valve Set High–Tension Cord Cover VSV Connector for EVAP VSV Connector for EGR VSV Connector for ACIS Vacuum Hose VSV for ACIS S04760 Author: Date: 1558 SF–60 SFI (1MZ–FE) – VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) SF08F–04 INSPECTION 1. 2. (a) (b) Ohmmeter REMOVE V–BANK COVER, HIGH–TENSION CORD COVER AND EMISSION CONTROL VALVE SET REMOVE VSV Disconnect the 2 vacuum hoses from the VSV. Remove the screw and VSV. 3. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between each terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Continuity S04525 Ohmmeter 4. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. No Continuity S04524 5. (a) Air INSPECT VSV OPERATION Check that air flows from port E to the filter. E Filter FI6393 Air E F Battery S04523 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the VSV. 6. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 vacuum to the VSV. 7. REINSTALL EMISSION CONTROL VALVE SET 8. REINSTALL HIGH–TENSION CORD COVER 9. REINSTALL V–BANK COVER Author: Date: 1559 SF–61 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR VSV FOR VAPOR PRESSURE SENSOR SF08G–03 COMPONENTS VSV for Vapor Pressure Sensor Connector VSV for Vapor Pressure Sensor Vacuum Hose Charcoal Canister B06550 Author: Date: 1560 SF–62 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR SF08H–03 INSPECTION 1. REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Ohmmeter Continuity B01273 Ohmmeter No Continuity 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. B00798 4. (a) Air INSPECT VSV OPERATION Check that air flows from ports E to G. E G B00799 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 5. REINSTALL VSV Air E F Battery B00800 Author: Date: 1561 SF–63 SFI (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF08I–03 INSPECTION 19 mm Deep Socket Wrench ECT Switch Gasket DRAIN ENGINE COOLANT 2. (a) (b) REMOVE ECT SENSOR Disconnect the ECT sensor connector. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. S04759 Ohmmeter 30 20 10 Resistance kΩ 1. 5 3 2 Acceptable 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (c) Connect the ECT sensor connector. 5. REFILL WITH ENGINE COOLANT 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (68) (104) (140) (176) (212) S01196 S01699 Temperature °C (°F) Z17274 Author: Date: 1562 SF–64 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR SF0Z9–01 COMPONENTS Vapor Pressure Sensor (Type B) Vapor Pressure Sensor (Type A) Vapor Pressure Sensor Connector Vacuum hose Charcoal Canister B06554 Author: Date: 1563 SF–62 SFI (1MZ–FE) – VSV FOR VAPOR PRESSURE SENSOR SF08H–03 INSPECTION 1. REMOVE VSV 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. Ohmmeter Continuity B01273 Ohmmeter No Continuity 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. B00798 4. (a) Air INSPECT VSV OPERATION Check that air flows from ports E to G. E G B00799 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from ports E to F. If operation is not as specified, replace the VSV. 5. REINSTALL VSV Air E F Battery B00800 Author: Date: 1561 SF–63 SFI (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SENSOR ENGINE COOLANT TEMPERATURE (ECT) SENSOR SF08I–03 INSPECTION 19 mm Deep Socket Wrench ECT Switch Gasket DRAIN ENGINE COOLANT 2. (a) (b) REMOVE ECT SENSOR Disconnect the ECT sensor connector. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. S04759 Ohmmeter 30 20 10 Resistance kΩ 1. 5 3 2 Acceptable 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (c) Connect the ECT sensor connector. 5. REFILL WITH ENGINE COOLANT 1 0.5 0.3 0.2 0.1 –20 0 20 40 60 80 100 (–4) (32) (68) (104) (140) (176) (212) S01196 S01699 Temperature °C (°F) Z17274 Author: Date: 1562 SF–64 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR SF0Z9–01 COMPONENTS Vapor Pressure Sensor (Type B) Vapor Pressure Sensor (Type A) Vapor Pressure Sensor Connector Vacuum hose Charcoal Canister B06554 Author: Date: 1563 SF–65 SFI (1MZ–FE) – VAPOR PRESSURE SENSOR SF08J–04 Voltmeter INSPECTION 1. (a) (b) (c) Disconnect VC E2 B00801 (d) (e) 2. Type A (a) (b) (c) Air Vacuum Disconnect Type B Disconnect Air Vacuum (d) (e) INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR Disconnect the vapor pressure sensor connector. Turn the ignition switch ON. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 – 5.5 V Turn the ignition switch OFF. Reconnect the vapor pressure sensor connector. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR Turn the ignition switch ON. Disconnect the vacuum hose from the vapor pressure sensor. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: (1) Apply vacuum (2.0 kPa (15 mmHg, 0.59 in.Hg)) to the vapor pressure sensor. Voltage: 1.3 – 2.1 V (2) Release the vacuum from the vapor pressure sensor. Voltage: 3.0 – 3.6 V (3) Apply pressure (1.5 kPa (15 gf/cm2, 0.22 psi)) to the vapor pressure sensor. Voltage: 4.2 – 4.8 V Turn the ignition switch OFF. Reconnect the vacuum hose to the vapor pressure sensor. ECM PTNK E2 B06389 Author: Date: 1564 SF–66 SFI (1MZ–FE) – KNOCK SENSOR KNOCK SENSOR SF08K–03 COMPONENTS Air Intake Chamber Stay 19.5 (200, 14) V–Bank Cover 12 (120, 19) 39 (400, 19) PS Pressure Tube
Gasket No.2 EGR Pipe Throttle Position Sensor Connector No.1 Engine Hanger 43 (440, 32) VSV Connector for EGR Engine Wire Brake Booster EGR Valve Position Vacuum Hose Sensor Connector Accelerator Cable
Gasket IAC Valve Connector VSV Connector for EVAP Ground Cable Throttle Cable Air Cleaner Hose Ground Starp DLC1 PCV Hose Air Intake Chamber Assembly
Gasket VSV Connector for ACIS Engine Coolant 15 (150, 11) ECT Sender Reservoir Hose Gauge Connector Upper Radiator x9 Hose ECT Sensor Engine Connector Wire Band Grand Strap Connector Purge Hose EGR Gas Temperature Sensor Connector Water Bypass Hose Vacuum Hose Air Assist Hose Water Bypass Hose
Retainer Fuel Inlet Hose Heater Hose Intake Manifold Assembly 15 (150, 11) Injector Connector Water Outlet
Gasket
Gasket Knock Sensor Connector High–Tension Cord Set Knock Sensor 39 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06390 Author: Date: 1565 SF–67 SFI (1MZ–FE) – KNOCK SENSOR SF08L–03 INSPECTION Knock Sensor 1 SST 1. 2. 3. REMOVE AIR CLEANER HOSE REMOVE RH ENGINE MOUNTING STAY REMOVE INTAKE MANIFOLD ASSEMBLY AND WATER OUTLET (Seepage EM–32) 4. (a) (b) REMOVE KNOCK SENSORS Disconnect the knock sensor connector. Using SST, remove the knock sensor. SST 09817–16011 Knock Sensor 2 P20115 Ohmmeter No Continuity P01630 5. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 6. REINSTALL KNOCK SENSORS (a) Using SST, install the knock sensor. SST 09817–16011 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Connect the knock sensor connector. 7. REINSTALL WATER OUTLET AND INTAKE MANIFOLD ASSEMBLY (See page EM–57) 8. REINSTALL RH ENGINE MOUNTING STAY 9. REINSTALL AIR CLEANER HOSE Author: Date: 1566 SF–68 SFI (1MZ–FE) Bank 1 Sensor 1 +B Ohmmeter HT – AIR–FUEL RATIO (A/F) SENSOR (California A/T) AIR–FUEL RATIO (A/F) SENSOR (California A/T) SF08M–06 INSPECTION INSPECT HEATER RESISTANCE OF A/F SENSORS (Bank 1 sensor 1, Bank 2 Sensor 1) (a) Disconnect the A/F sensor connector. (b) Using an ohmmeter measure the resistance between terminals +B and HT. Resistance: Bank 2 Sensor 1 Ohmmeter +B HT At 20°C (68°F) 0.8 – 1.4 Ω At 800°C (1,472°F) 1.8 – 3.2 Ω If the resistance is not as specified, replace the sensor. Torque: 44 N·m (440 kgf·cm, 31 ft·lbf) (c) Reconnect the A/F sensor connector. S05042 Author: Date: 1567 SFI (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF–69 EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF08N–03 COMPONENTS
Gasket 19.5 (200, 14) Throttle Body Throttle Position Sensor Connector EGR Gas Temperature Sensor Accelerator Cable (A/T) Throttle Cable IAC Valve Connector Water Bypass Hose Air Assist Hose Water Bypass Hose EGR Gas Temperature Sensor Bracket EGR Gas Temperature Sensor Connector N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Air Cleaner Hose Author: S04740 Date: 1568 SF–70 SFI (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) GAS TEMPERATURE SENSOR SF08O–04 INSPECTION 1. REMOVE THROTTLE BODY (See page SF–39) 2. REMOVE EGR GAS TEMPERATURE SENSOR S04504 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Oil Ohmmeter P03193 At 50°C (122°F) 64 – 97 kΩ At 100°C (212°F) 11 – 16 kΩ At 150°C (302°F) 2 – 4 kΩ If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL THROTTLE BODY (See page SF–41) Author: Date: 1569 SF–71 SFI (1MZ–FE) Bank 1 Sensor 1 +B Ohmmeter HT – HEATED OXYGEN SENSOR (Bank 1,2 Sensor 1) HEATED OXYGEN SENSOR (Bank 1,2 Sensor 1) SF08P–04 INSPECTION Except California A/T: INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (Bank 1 Sensor 1, Bank 2 Sensor 1) (a) Disconnect the oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: Bank 2 Sensor 1 Ohmmeter +B HT At 20°C (68°F) 11 – 16 Ω At 800°C (1,472°F) 23 – 32 Ω If the resistance is not as specified, replace the sensor. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (c) Reconnect the oxygen sensor connector. S05042 Author: Date: 1570 SF–72 SFI (1MZ–FE) Ohmmeter +B – HEATED OXYGEN SENSOR (Bank 1 Sensor 2) HEATED OXYGEN SENSOR (Bank 1 Sensor 2) HT SF08Q–03 INSPECTION S05163 INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR (Bank 1 Sensor 2) (a) Remove the driver’s seat. (b) Take out the floor carpet. (c) Disconnect the oxygen sensor connector. (d) Using an ohmmeter, measure the resistance between the terminals +B and HT. Resistance: At 20°C (68°F) 11 – 16 Ω At 800°C (1,472°F) 23 – 32 Ω If the resistance is not as specified, replace the sensor. (e) Reconnect the oxygen sensor connector. Torque: 44 N·m (450 kgf·cm, 32 ft·lbf) (f) Reinstall the floor carpet. (g) Reinstall the driver’s seat. Author: Date: 1571 SF–73 SFI (1MZ–FE) – ENGINE CONTROL MODULE (ECM) ENGINE CONTROL MODULE (ECM) SF08R–03 COMPONENTS ECM ECM Connector No.2 Instrument Lower Panel Under Cover Front Door Inside Scuff Plate Cowl Side Trim S05450 Author: Date: 1572 SF–74 SFI (1MZ–FE) – ENGINE CONTROL MODULE (ECM) SF08S–01 INSPECTION 1. 2. 3. REMOVE ECM INSPECT ECM (See page DI–218) REINSTALL ECM Author: Date: 1573 SF–75 SFI (1MZ–FE) – FUEL CUT RPM FUEL CUT RPM SF08T–03 INSPECTION 5 mm Hexagon Wrench 1. REMOVE V–BANK COVER (a) Using a 5 mm hexagon wrench, remove the 2 cap nuts. (b) Disconnect the 2 clips, and remove the V–bank cover. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. Clip S04528 TOYOTA Hand–Held Tester 3. (a) (b) CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Connect the TOYOTA hand–held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. S05358 California A/T 4. (a) (b) (c) Sound Scope INSPECT FUEL CUT OFF PRM Increase the engine speed to at least 3,500 rpm. Use a sound scope to check for injector operating noise. Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,200 rpm 5. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL 6. REINSTALL V–BANK COVER HINT: For fixing the V–bank cover, push on the cover until a ”click” is felt. Except California A/T Sound Scope B00623 Author: Date: 1574 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002–0W To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The


procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the back of AX section, for quick reference. IN–3 INTRODUCTION – HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS:


CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English system. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) IN–4 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1. 2. 3. 4. 5. 6. IN022–07 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (–) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminal posts and cable terminals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non–reusable parts (a) Always replace cotter pins, gaskets, O–rings and oil seals etc. with new ones. (b) Non–reusable parts are indicated in the component illustrations by the ”” symbol. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply IN–5 INTRODUCTION 7. 8. 9. – GENERAL REPAIR INSTRUCTIONS the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the preparation of AX section. 10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. 11. To pull apart electrical connectors, pull on the connector itself, not the wires. 12. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. IN–6 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS IN016–02 This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage BARO Barometric Pressure CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position – DFI Direct Fuel Injection (Diesel) DI Distributor Ignition DLC1 Data Link Connector 1 1: Check Connector DLC2 Data Link Connector 2 2: Toyota Diagnosis Communication Link (TDCL) DLC3 Data Link Connector 3 3: OBD@@@@@: [g 2] Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory – +B, Battery Voltage – – Direct Injection (DI) – – – Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Toyota Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control FEEPROM – Flash Electrically Erasable Programmable – Read Only Memory FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IN–7 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure – Indirect Injection Manifold Pressure Intake Vacuum Electric Bleed Air Control Valve (EBCV) MC Mixture Control Mixture Control Valve (MCV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Light MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer RAM Random Access Memory RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass SFI Sequential Multiport Fuel Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body TBI Throttle Body Fuel Injection TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU (Electronic Control Unit) TP Throttle Position Throttle Position TR Transmission Range Electric Air Control Valve (EACV) – Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) Random Access Memory (RAM) – – Electronic Fuel Injection (EFI), Sequential Injection Throttle Body Single Point Injection Central Fuel Injection (Ci) – IN–8 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetallic Vacuum Switching Valve (BVSV) TVV Thermal Vacuum Valve TWC Three–Way Catalytic Converter TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter WU–TWC Warm Up Three–Way Catalytic Converter 3GR Third Gear – 4GR Fourth Gear – Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) CCRO – Manifold Converter IN–9 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL IN01H–0R ATF Automatic Transaxle Fluid B0 Overdrive Brake B1 Second coast Brake B2 Second Brake B3 First and Reverse Brake C0 Overdrive Direct Clutch C1 Forward Clutch C2 Direct Clutch D Disc F Flange F0 O/D One–way Clutch F1 No.1 One–way Clutch F2 No.2 One–way Clutch MP Multipurpose O/D Overdirve P Plate SSM Special Service Materials SST Special Service Tools IN–10 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS IN008–02 IN–11 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS AX–12 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS AT06P–0C SERVICE DATE Oil Pump Body clearance STD Maximum Tip clearance STD Maximum Side clearance STD Maximum Pump body bushing inside diameter Maximum 0.07 – 0.15 mm 0.0028 – 0.0059 in. 0.3 mm 0.012 in. 0.11 – 0.14 mm 0.0043 – 0.0055 in. 0.3 mm 0.012 in. 0.02 – 0.05 mm 0.0008 – 0.0020 in. 0.1 mm 0.004 in. 38.18 mm 1.5031 in. Stator shaft bushing inside diameter Front side Maximum 21.57 mm 0.8492 in. Rear side Maximum 27.07 mm 1.0657 in. Direct Clutch Clutch drum bushing inside diameter Direct clutch piston stroke Maximum 47.07 mm 1.8531 in. 1.11 – 1.44 mm 0.0437 – 0.0567 in. 2.60 mm Flange thickness 0.1024 in. 3.00 mm 0.1181 in. Forward Clutch Piston stroke 1.41 – 1.82 mm 0.0555 – 0.0717 in. 2.8 mm 0.110 in. 3.0 mm Flange thickness 0.118 in. 3.2 mm 0.126 in. 3.4 mm 0.134 in. 3.6 mm 0.142 in. Front Planetary Gear AX–13 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Ring gear bushing inside diameter Standard Planetary pinion gear thrust clearance Standard 19.025 – 19.050 mm 0.7490 – 0.7500 in. 0.20 – 0.50 mm 0.0079 – 0.0197 in. Rear Planetary Gear Planetary pinion gear thrust clearance Standard 0.20 – 0.50 mm 0.0079 – 0.0197 in. Overdrive Unit 1.21 – 1.91 mm Overdrive direct clutch piston stroke Overdrive direct clutch bushing inside diameter 0.0476 – 0.0752 in. Maximam 0.8697 in. 9 – 15 N Counter drive gear preload Planetary pinion gear thrust clearance 22.09 mm 920 – 1,530 gf Standard 2.0 – 3.4 lbf 0.20 – 0.50 mm 0.0079 – 0.0197 in. AX–14 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Valve Body Spring Free length and Coil outer Spring diameter Total No. of coils and Color mm (in.) Upper valve body 21.7 (0.854) Throttle modulator valve 9.5 (0.374) 9.5 None 28.1 (0.105) Accumulator control valve 10.6 (0.417) 13.0 Yellow 21.6 (0.850) Low coast modulator valve 7.9 (0.311) 11.5 None 29.8 (1.172) Down shift plug 8.7 (0.344) 13.5 Yellow 30.7 (1.209) Throttle valve 9.2 (0.362) 9.5 None 20.9 (0.824) Second coast modulator valve 8.5 (0.336) 10.0 Light Green 21.8 (0.858) Cut–back valve 6.0 (0.236) 13.5 None 26.6 (1.046) Lock–up relay valve 10.2 (0.402) 11.5 Green Lower valve body 11.2 (0.441) Pressure relief valve 6.4 (0.252) 7.5 None 29.3 (1.152) 1 – 2 shift valve 9.7 (0.382) 10.5 None 29.3 (1.152) 2 – 3 shift valve 9.7 (0.382) 10.5 None 29.3 (1.152) 3 – 4 shift valve 9.7 (0.382) 10.5 None 66.7 (2.453) Primary regulator valve 18.6 (0.732) 12.5 None 43.6 (1.717) Secondary regulator valve 10.9 (0.429) 11.5 None 30.0 (1.181) Lock–up signal valve 8.2 (0.323) 11.5 None 19.9 (0.784) Cooler By–pass valve 11.0 (0.433) 8.5 None Valve Body Retainer Height Width Thickness mm (in.) mm (in.) mm (in.) Throttle Modulator valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Accumulator control valve 11.5 (0.453) 5.0 (0.197) 3.2 (0.126) Cut–back valve 9.2 (0.591) 5.0 (0.197) 3.2 (0.126) Lock–up relay valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126) Second coast modulator valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126) 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Reteiner Upper valve body Lower valve body Primary regulator valve AX–15 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 1 – 2 shift valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) 2 – 3 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) 3 – 4 shift valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) Lock–up signal valve 15.0 (0.591) 5.0 (0.197) 3.2 (0.126) Accumulator Spring Spring Free length mm (in.) Color C1 57.64 (2.2693) Red, Purple B2 69.39 (2.7323) Green, White C2 70.21 (2.7641) Purple AX–16 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Differential 1.0 – 1.6 N·m Drive pinion preload (at starting) New bearing 10 – 16 kgf·cm Reused bearing 8.7 – 13.9 in.·lbf 0.5 – 0.8 N·m 5 – 8 kgf·cm 4.3 – 6.9 in.·lbf Add drive pinion preload Total preload (at starting) 0.3 – 0.4 N·m New bearing 2.9 – 4.0 kgf·cm 1.5 – 2.0 kgf·cm Pinion to side gear backlash 2.5 – 3.5 in.·lbf 0.1 – 0.2 N·m Reused bearing 1.3 – 1.7 in.·lbf 0.05 – 0.20 mm 0.0020 – 0.0079 in. 0.95 mm 0.0374 in. 1.00 mm 0.0394 in. 1.05 mm Side gear thrust washer thickness 0.0413 in. 1.10 mm 0.0433 in. 1.20 mm 0.0427 in. AX–17 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 1.90 mm 0.0748 in. 1.95 mm 0.0768 in. 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in. 2.20 mm 0.0866 in. 2.25 mm 0.0886 in. 2.30 mm 0.0906 in. Side bearing adjusting shim thickness 2.35 mm 0.0925 in. 2.40 mm 0.0945 in. 2.45 mm 0.0965 in. 2.50 mm 0.0984 in. 2.55 mm 0.1004 in. 2.60 mm 0.1024 in. 2.65 mm 0.1043 in. 2.70 mm 0.1063 in. 2.75 mm 0.1083 in. 2.80 mm 0.1103 in. AX–18 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS AT06Q–0C TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Stator shaft x Oil pump body 10 100 7 Upper valve body x Lower valve body 5.4 55 48 Ring gear x Differential case 97 985 71 Side bearing cap x Transaxle case 72 730 53 Bearing retainer x Transaxle case 19 195 14 Counter drive gear x Drive pinion 172 1,750 127 Carrier cover x Transaxle case 25 250 18 Parking lock pawl bracket 7.4 75 65 in.·lbf Overdrive case x Transaxle case 25 260 19 Oil pump x Transaxle case 22 220 16 Valve body x Transaxle case 10 100 7 Manual valve body x Transaxle case 10 100 7 Detent spring x Valve body 10 100 7 Oil tube bracket x Transaxle case 10 100 7 Oil strainer x Valve body 10 100 7 Oil pan x Transaxle case 4.9 50 43 in.·lbf Park/Neutral position switch 6.9 70 61 in.·lbf Park/Neutral position switch adjusting bolt 5.4 55 48 in.·lbf Union 27 275 20 AX–1 AUTOMATIC TRANSAXLE – GENERAL DESCRIPTION GENERAL DESCRIPTION AX0EP–02 The A140E automatic transaxle described in this AX section is a 4–speed lock–up automatic transaxle developed exclusively for use with a transversely–mounted engine. AX–2 AUTOMATIC TRANSAXLE – GENERAL DESCRIPTION General Specifications Type of Transaxle A140E Type of Engine 5S–FE Torque Converter Clutch Stall Torque Ratio 2.0 : 1 Lock–up Mechanism Gear Ratio Number of Discs and Plates Equipped 1st Gear 2.810 2nd Gear 1.549 3rd Gear 1.000 O/D Gear 0.706 Reverse Gear 2.296 O/D Direct Clutch (C0) 2/1 Forward Clutch (C1) 4/4 Direct Clutch (C2) 3/3 Second Brake (B2) 3/3 First and Reverse Brake (B3) 6/5 O/D Brake (B0) B1 Band Width mm (in.) ATF DEXRON ® @@@@@: [g 2] ATF Type Capacity 2/3 25 mm (0.98 in.) liter (US qts, Imp. qts) Transaxle 5.6 (5.9, 4.9) Differential 1.6 (1.7, 1.4) AX–3 AUTOMATIC TRANSAXLE – OPERATION OPERATION AX0SW–01 OPERATION AX–4 AUTOMATIC TRANSAXLE 1. – OPERATION FUNCTION OF COMPONENTS FUNCTION O/D Direct Clutch (C0) O/D Brake (B0) O/D One–way Clutch (F0) OPERATION Connects overdrive sun gear and overdrive carrier Prevents overdrive sun gear from turning either clockwise or counterclockwise When transmission is being driven by engine, connects overdrive sun gear and overdrive carrier. Front Clutch (C1) Connects input shaft and intermediate shaft Rear Clutch (C2) Connects input shaft and front and rear planetary sun gears No.1 Brake (B1) No.2 Brake (B2) No.3 Brake (B3) No.1 One–way Clutch (F1) No.2 One–way Clutch (F2) Prevents front and rear planetary sun gears from turning either clockwise or counterclockwise Prevents outer race of F1 from turning either clockwise or counterclockwise, thus previnting front and rear planetary sun gears from turning counterclockwise Prevents front planetary carrier from turning either clockwise or counterclockwise When B2 is operating prevents front and rear planetary sun gears from turning counterclockwise Prevents front planetary carrier from turning counterclockwise AX–5 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit. Shift change is carried out by altering the combination of clutch and brake operation. Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle opening angle and vehicle speed, and shift change automatically occurs. The conditions of operation for each gear position are shown on the following illustrations: AX–6 AUTOMATIC TRANSAXLE 2. – OPERATION HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes, and the governor valve as well as the fluid passages which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the vehicle driving conditions. There are three solenoid valves on the valve body. The No.1 and No.2 solenoid valves are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position. The No.3 solenoid valve is operated by signals from the ECM to engage or disengage the lock–up clutch of the torque converter. AX–7 AUTOMATIC TRANSAXLE 2. – OPERATION ELECTRONIC CONTROL SYSTEM The electronic control system for controlling the shift timing and the operation of the lock–up clutch is composed of the following 3 parts: (a) Sensors: These sense the vehicle speed and throttle position and send this data to the ECM in the form of electronic signals. (b) ECM: This determines the shift and lock–up timing based upon the signals from the sensors. (c) Actuators: Solenoid valves divert hydraulic pressure from one circuit of the hydraulic control unit to another, thus controlling shifting and lock–up timing. AX–8 AUTOMATIC TRANSAXLE – PREPARATION PREPARATION AX0EQ–02 SST (SPECIAL SERVICE TOOLS) 09240–00020 Wire Gauge Set 09330–00021 Companion Flange Holding Tool 09350–32014 TOYOTA Automatic Transmission Tool Set 09308–10010 Oil Seal Puller (09351–32020) Stator Stopper (09351–32032) Counter Driven Gear Holding Tool (09351–32040) No.1 Piston Spring Compressor (09351–32050) Snap Ring Expander (09351–32061) Oil Pump Puller (09351–32070) No.2 Piston Spring Compressor (09351–32080) Lock Nut Wrench (09351–32090) Oil Seal Remover & Replacer (09351–32100) Drive Pinion Bearing Replacer AX–9 AUTOMATIC TRANSAXLE – PREPARATION (09351–32111) Side Bearing Race Replacer (09351–32120) Overdrive Bearing Replacer (09351–32130) Handle (09351–32140) Oil Seal Replacer (09351–32150) Oil Seal Replacer (09351–32190) Measure Terminal (09351–32200) No.3 Piston Spring Compressor 09502–10012 Differential Side Bearing Puller
09564–32011 Differential Preload Adaptor 09710–28020 Front Suspension Bushing Tool Set
(09710–08040) 09950–00020 Bushing Replacer
Bearing Remover AX0ER–02 RECOMMENDED TOOL 09031–00030 Pin Punch . AX–10 AUTOMATIC TRANSAXLE – PREPARATION AX0ES–02 EQUIPMENT Feeler gauge Vernier calipers Dial indicator or dial indicator with magnetic base Straight edge Torque wrench AX0ET–02 LUBRICANT Liters Item US qts Imp qts Automatic Transaxle Fluid (w/o Differential Fluid) 5.6 Dry Fill 5.9 4.9 ATF DEXRON ® @@@@@: [g 2] 2.5 Drain and Refill 2.6 Differential Fluid Clacification 2.2 1.6 1.7 1.4 ATF DEXRON ® @@@@@: [g 2] AX0EU–02 SSM (SPECIAL SERVICE MATERIALS) 08826–00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent AX–11 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL AX0GS–02 COMPONENTS AX–12 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–13 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–14 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–15 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0EW–02 SEPARATE BASIC SUBASSEMBLY 1. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the manual shift lever. (b) Pry off the lock washer and remove the manual valve shaft nut. (c) Remove the 2 bolts and pull out the park/neutral position switch. 2. REMOVE UNION AND ELBOW (a) Using the open end wrench, remove the union and elbow. (b) Remove the O–rings from the union and elbow. 3. REMOVE SL SOLENOID (a) Disconnect the connector. (b) Remove the 2 bolts and SL solenoid. 4. 5. REMOVE THROTTLE CABLE RETAINING PLATE REMOVE SOLENOID WIRE RETAINING BOLT 6. REMOVE COVER (a) Remove the 2 bolts and cover bracket. AX–16 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the cover. 7. REMOVE OIL PAN AND GASKET (a) Remove the 15 bolts. (b) Remove the oil pan by lifting transaxle case. NOTICE: Do not turn the transaxle over as this will contaminate the valve body with the foreign materials in the bottom of the oil pan. (c) Place the transaxle on wooden blocks to prevent damage to the tube bracket. 8. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the oil pan and on the magnets to anticipate what type of wear you will find in the transmission: Steel (magnetic): bearing, gear and plate wear Brass (non–magnetic): bushing wear 9. DISCONNECT NO.1 AND NO.2 SOLENOID CONNECTORS 10. REMOVE TUBE BRACKET AND OIL STRAINER AX–17 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 11. REMOVE OIL TUBES Pry up both tube ends with a large screwdriver and remove the 4 tubes. 12. REMOVE MANUAL DETENT SPRING 13. REMOVE MANUAL VALVE AND MANUAL VALVE BODY 14. REMOVE VALVE BODY (a) Remove the 12 bolts. 15. REMOVE THROTTLE CABLE AND SOLENOID WIRING FROM CASE 16. REMOVE SECOND BRAKE APPLY GASKET AX–18 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 17. REMOVE ACCUMULATOR PISTON AND SPRINGS (a) Loosen the 5 bolts one turn at a time until the spring tension is released. (b) Remove the cover and gasket. (c) Remove the piston and spring for C1 and C2. (d) Remove the O–rings. (e) Pop out piston C1 into a rag, using low–pressure compressed air 98 kPa (1 kgf/cm2, 14 psi). (f) Remove the 2 O–rings from the B2 piston. 18. MEASURE PISTON STROKE OF SECOND COAST BRAKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. (b) Using SST, measure the piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm2, 57 – 114 psi). SST 09240–00020 Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in.) If the piston stroke exceeds the limit, replace the piston rod or brake band. AX–19 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 19. REMOVE SECOND COAST BRAKE PISTON (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Remove the cover. (c) Remove the piston and outer return spring. (d) Remove the O–ring from the cover. 20. REMOVE OIL PUMP AND DIRECT CLUTCH NOTICE: Before removing the oil pump, remove the second coast brake piston. (a) Remove the 7 bolts. (b) Using SST, pull out the oil pump from the transaxle case. SST 09350–32014 (09351–32061) 21. REMOVE OIL PUMP AND DIRECT CLUTCH While holding the input shaft, grasp the pump stator shaft and pull the oil pump and direct clutch together out of the transaxle case. NOTICE: Push the second coast brake band into the case, being careful not to catch it on the direct clutch drum. AX–20 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 22. REMOVE DIRECT CLUTCH FROM OIL PUMP 23. BE CAREFUL WHEN REMOVING RACE BEHIND OIL PUMP 24. REMOVE CLUTCH DRUM THRUST WASHER 25. REMOVE FORWARD CLUTCH 26. REMOVE BEARINGS AND RACES FROM FORWARD CLUTCH 27. REMOVE SECOND COAST BRAKE BAND (a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting. (b) Remove the brake band. 28. REMOVE FRONT PLANETARY RING GEAR AX–21 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 29. REMOVE BEARING RACES FROM FRONT PLANETARY RING GEAR 30. REMOVE PLANETARY GEAR 31. REMOVE RACES AND BEARINGS FROM PLANETARY GEAR 32. REMOVE SUN GEAR, SUN GEAR INPUT DRUM, SECOND BRAKE HUB AND NO.1 ONE–WAY CLUTCH 33. STAND TRANSMISSION CASE UP AND REMOVE SECOND COAST BRAKE BAND GUIDE AX–22 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 34. REMOVE SNAP RING HOLDING SECOND BRAKE DRUM TO CASE 35. REMOVE SECOND BRAKE DRUM If the brake drum is difficult to remove, lightly tap it with a wooden block. 36. REMOVE SECOND BRAKE PISTON RETURN SPRING 37. REMOVE PLATES, DISCS AND FLANGE 38. REMOVE SECOND BRAKE DRUM GASKET AX–23 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 39. REMOVE SNAP RING HOLDING NO.2 ONE–WAY CLUTCH OUTER RACE TO CASE 40. REMOVE NO.2 ONE–WAY CLUTCH AND REAR PLANETARY GEAR 41. BE CAREFUL WHEN REMOVING THRUST WASHERS FROM BOTH SIDES OF PLANETARY CARRIER 42. REMOVE REAR PLANETARY RING GEAR 43. REMOVE BEARINGS AND RACES AX–24 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 44. CHECK OPERATION OF FIRST AND REVERSE BRAKE PISTON Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassemble and inspect. 45. REMOVE SNAP RING HOLDING FLANGE TO CASE 46. REMOVE FLANGES, PLATES AND DISCS 47. TURN TRANSAXLE CASE AROUND 48. REMOVE 11 BOLTS HOLDING OVERDRIVE UNIT TO TRANSAXLE CASE 49. REMOVE OVERDRIVE UNIT WITH ALL PARTS (a) Tap on the overdrive case circumference with a plastic hammer to remove the unit from the transaxle case. (b) Remove the overdrive planetary gear and counter gear if they remained in the transaxle. HINT: The overdrive unit is heavy, so be careful not to drop it. AX–25 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS REMOVAL Remove the overdrive brake drum from the transaxle case. (d) Remove the overdrive planetary gear and counter gear if they remain in the transaxle. 50. REMOVE OVERDRIVE CLUTCH APPLY GASKET AND OVERDRIVE BRAKEAPPLY GASKET 51. REMOVE PISTON RETURN SPRING (a) Place SST, and compress the return springs evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040) (b) Using snap ring pliers, remove the snap ring. (c) Remove SST. (d) Remove the return spring from the case. AX–26 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 52. REMOVE FIRST AND REVERSE BRAKE PISTON (a) Apply compressed air into the passage of the case to remove the piston. HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole. (b) If the piston does not pop out with compressed air, use needle–nose pliers to remove it. (c) Remove the 2 O–rings from the piston. 53. REMOVE PARKING LOCK PAWL BRACKET 54. REMOVE PARKING LOCK ROD AX–27 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 55. REMOVE PIN, SPRING AND PARKING LOCK PAWL 56. REMOVE MANUAL VALVE SHAFT (a) Remove the retaining spring. (b) Using a hammer and chisel, pry and turn the collar. (c) Using a hammer and punch, drive out the pin. (d) Slide out the shaft and remove the manual valve lever from the case. 57. REMOVE MANUAL SHAFT OIL SEAL Remove the oil seal with a screwdriver. AX–28 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0EX–02 DISASSEMBLY OF DIFFERENTIAL 1. REMOVE CARRIER COVER 2. MEASURE TOTAL PRELOAD Using a torque meter, measure the total preload, and note the measurement value. 3. MEASURE BACKLASH OF SIDE GEAR Measure each side gear backlash while holding one pinion toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) 4. (a) (b) (c) REMOVE LH BEARING RETAINER Remove the 6 bolts. Tap the retainer with a plastic hammer to remove it. Remove the O–ring from the retainer. 5. REMOVE RH SIDE BEARING CAP Remove the 2 bolts and the side bearing cap. AX–29 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 6. REMOVE DIFFERENTIAL CASE, OUTER RACE AND ADJUSTING SHIM Remove the differential case, the outer race and the adjusting shim from the case. 7. MEASURE DRIVE PINION PRELOAD Using a torque meter, measure the drive pinion preload. Preload (at starting): Reused bearing 0.5 – 0.8 N·m (5 – 8 kgf·cm, 4.3 – 6.9 in.·lbf) The total preload measured in step 2 minus the drive pinion preload equals 0.1 – 0.2 N·m (1.5 – 2.0 kgf·cm, 1.3 – 1.7in.·lbf). If the result is not within this specification, the side bearing preload is bad. 8. REMOVE DRIVE PINION CAP (a) Remove the drive pinion cap installation bolt. (b) Using a screwdriver, push out the drive pinion cap. 9. REMOVE COUNTER DRIVEN GEAR (a) Using a chisel, loosen the staked part of the nut. AX–30 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Install SST onto the gear. SST 09350–32014 (09351–32032) (c) Using SST to hold the gear, remove the nut. SST 09330–00021 (d) Using SST, remove the gear and bearing. SST 09350–32014 (09351–32061) 10. REMOVE OUTER RACE FROM CASE Using SST, remove the outer race. SST 09350–32014 (09308–10010) 11. REMOVE OIL SLINGER 12. REMOVE SPACER AX–31 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 13. REMOVE ROTOR SENSOR 14. REMOVE DRIVE PINION (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Install a brass bar into case hole to tap out the drive pinion. (c) Tap the drive pinion and remove the bearing cage from the bore. 15. REMOVE BEARING CAGE FROM DRIVE PINION 16. REMOVE O–RING FROM BEARING CAGE AX–32 AUTOMATIC TRANSAXLE – COMPONENT PARTS COMPONENT PARTS AX0EY–02 GENERAL NOTES The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar–looking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups. Recommended fluid for the automatic transaxle: DEXRON ® @@@@@: [g 2] GENERAL CLEANING NOTES: 1. All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air. 2. When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transmission fluid or kerosene in your face. 3. The recommended automatic transaxle fluid or kerosene should be used for cleaning. PARTS ARRANGEMENT: 1. After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly. 2. When disassembling a valve body, be sure to keep each valve together with the corresponding spring. 3. New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least 15 minutes before assembly. GENERAL ASSEMBLY: 1. All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly. 2. All gaskets and rubber O–rings should be replaced. 3. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. 4. If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced. 5. Check thrust bearings and races for wear or damage. Replace if necessary. 6. Use petroleum jelly to keep parts in place. AX–33 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE SECOND COAST BRAKE AX0EZ–02 COMPONENTS SECOND COAST BRAKE PISTON DISASSEMBLY 1. AX0F0–02 REMOVE OIL SEAL RING Remove the oil seal ring from the piston. 2. REMOVE PISTON ROD (a) Remove the E–ring while pushing the piston with needle– nose pliers. AX–34 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Remove the spring, washer and piston rod. AX0F1–02 SECOND COAST BRAKE INSPECTION INSPECT BRAKE BAND If the lining of the brake band is peeling off or discolored, or even if a part of the printed numbers are defaced, replace the brake band. AX0F2–02 SECOND COAST BRAKE PISTON ASSEMBLY 1. SELECT PISTON ROD If the band is OK, but the piston stroke is not within the standard value, select a new piston rod. Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in.) There are 2 lengths of piston rod. Piston rod length: 72.9 mm (2.870 in.) 71.4 mm (2.811 in.) 2. INSTALL PISTON ROD (a) Install the washer and spring to the piston rod. (b) Install an E–ring while pushing the piston. AX–35 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE 3. INSTALL OIL SEAL RING (a) Apply ATF to the oil seal ring. (b) Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary. AX–36 AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP AX0F3–02 COMPONENTS OIL PUMP DISASSEMBLY AX0F4–02 1. REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the stator shaft back side. 2. REMOVE THRUST WASHER FROM STATOR SHAFT BACK SIDE AX–37 AUTOMATIC TRANSAXLE – OIL PUMP 3. REMOVE STATOR SHAFT Remove the 11 bolts and stator shaft. Keep the gears in assembly order. 4. REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AX0F5–02 OIL PUMP BUSHING INSPECTION 1. CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: 0.07 – 0.15 mm (0.0028 – 0.0059 in.) Maximum body clearance: 0.3 mm (0.012 in.) 2. If the body clearance is greater than the maximum, replace the oil pump body subassembly. CHECK TIP CLEARANCE OF DRIVEN GEAR Measure between the driven gear teeth and the crescent–shaped part of the pump body. Standard tip clearance: 0.11 – 0.14 mm (0.0043 – 0.0055 in.) Maximum tip clearance: 0.3 mm (0.012 in.) If the tip clearance is greater than the maximum, replace the oil pump body subassembly. 3. CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and a feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.02 – 0.05 mm (0.0008 – 0.0020 in.) Maximum side clearance: 0.1 mm (0.004 in.) There are 3 different thicknesses for drive and driven gears. AX–38 AUTOMATIC TRANSAXLE – OIL PUMP Drive and driven gear thickness Mark Thickness mm (in.) A 9.440 – 9.456 (0.3717 – 0.3723) B 9.456 – 9.474 (0.3723 – 0.3730) C 9.474 – 9.490 (0.3730 – 0.3736) If the thickest gear cannot make the side clearance within standard specification, replace the oil pump body subassembly. 4. CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 38.18 mm (1.5031 in.) If the inside diameter is greater than the maximum, replace the oil pump body subassembly. 5. CHECK STATOR SHAFT BUSHINGS Using a dial indicator, measure the inside diameter of the stator shaft bushings. Maximum inside diameter: Front side 21.57 mm (0.8492 in.) Rear side 27.07 mm (1.0657 in.) If the inside diameter is greater than the maximum, replace the stator shaft. OIL PUMP ASSEMBLY AX0F6–02 1. INSTALL FRONT OIL SEAL Using SST and a hammer, install a new oil seal. The seal end should be flush with the outer edge of the pump body. SST 09350–32014 (09351–32140) 2. INSTALL DRIVEN GEAR AND DRIVE GEAR Make sure the top of the gears are facing upward. AX–39 AUTOMATIC TRANSAXLE 3. 4. – OIL PUMP INSTALL STATOR SHAFT ONTO PUMP BODY Align the stator shaft with each bolt hole. TIGHTEN 11 STATOR SHAFT BOLTS Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 5. INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollow of the pump body. 6. INSTALL 2 OIL SEAL RINGS ON OIL PUMP Install 2 oil seal rings to the stator shaft groove, then snug them down by squeezing their ends together. NOTICE: Do not spread the ring ends too much. HINT: After installing the oil seal rings, check that they move smoothly. 7. CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with screwdrivers and make sure that it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip. AX–40 AUTOMATIC TRANSAXLE – DIRECT CLUTCH DIRECT CLUTCH AX0GT–02 COMPONENTS DIRECT CLUTCH DISASSEMBLY AX0F7–02 1. CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Set a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/ cm2, 57 – 114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.11 – 1.44 mm (0.0437 – 0.0567 in.) If the piston stroke is greater than the maximum inspect each component. AX–41 AUTOMATIC TRANSAXLE 2. 3. – DIRECT CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES 4. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a shop press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with the snap ring pliers. (c) Remove the piston return spring. 5. REMOVE CLUTCH PISTON (a) Install the direct clutch onto the oil pump. (b) Apply compressed air to the oil pump to remove the piston. (if the piston does not come out completely, use needle–nose pliers to remove it). (c) Remove the direct clutch from the oil pump. (d) Remove the 2 O–rings from the piston. AX–42 AUTOMATIC TRANSAXLE – DIRECT CLUTCH AX0F8–02 DIRECT CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying lowpressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the direct clutch bushing. Maximum inside diameter: 47.07 mm (1.8531 in.) If the inside diameter is greater than the maximum, replace the direct clutch. DIRECT CLUTCH ASSEMBLY AX0F9–02 1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM (a) Install new O–rings to the piston. Coat the O–rings with ATF. (b) Being careful not to damage the O–rings, press the piston into the drum with the cup side up. 2. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring onto the piston. (b) Place SST on the spring retainer, and compress the return spring with a shop press. SST 09350–32014 (09351–32070) (c) Install the snap ring with the snap ring pliers. Be sure the end gap of snap ring is not aligned with the spring retainer claw. AX–43 AUTOMATIC TRANSAXLE – DIRECT CLUTCH 3. INSTALL PLATES, DISCS AND FLANGE (a) Install plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 4. INSTALL SNAP RING Check that the end gap of the snap ring is not aligned with one of the cutouts. 5. RECHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Set a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/ cm2, 57 – 114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.11 – 1.44 mm (0.0437 – 0.0567 in.) If the piston stroke is non–standard, select another flange. HINT: There are 2 different flange thickness. Flange thickness: 2.60 mm (0.1024 in.) 3.00 mm (0.1181 in.) AX–44 AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH AX0FA–02 COMPONENTS FORWARD CLUTCH DISASSEMBLY 1. AX0FB–02 CHECK PISTON STROKE OF FORWARD CLUTCH Set a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm2, 57 – 114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.41 – 1.82 mm (0.0555 – 0.0717 in.) If the piston stroke is greater than the maximum inspect the each component. AX–45 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. REMOVE SNAP RING FROM CLUTCH DRUM 3. REMOVE FLANGE, DISCS AND PLATES 4. REMOVE RETURN SPRINGS (a) Place SST on the spring retainer and compress the springs with a shop press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with the snap ring pliers. (c) Remove the piston return spring. 5. REMOVE CLUTCH PISTON (a) Apply compressed air into the oil passage to remove the piston. If the piston does not come out, use needle–nose pliers to remove it. AX–46 AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Remove the 2 O–rings from the piston. 6. IF NECESSARY, REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the shaft. AX0FC–02 FORWARD CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying lowpressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX0FD–02 FORWARD CLUTCH ASSEMBLY 1. INSTALL OIL SEAL RINGS Install the 2 oil seal rings to the shaft. NOTICE: Do not spread the ring ends more than necessary. HINT: After installing the oil seal rings, check that they move smoothly. AX–47 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. INSTALL CLUTCH PISTON TO CLUTCH DRUM (a) Install the 2 new O–rings to the piston. (b) Coat the O–rings with ATF. (c) Press the piston into the drum with the cup side up, being careful not to damage the O–rings. 3. INSTALL PISTON RETURN SPRINGS (a) Place the piston return spring and snap ring onto the piston. (b) Place SST on the piston return spring, and compress the springs with a shop press. SST 09350–32014 (09351–32070) (c) Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. 4. INSTALL PLATES, DISCS AND FLANGE (a) Install the plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 5. INSTALL SNAP RING Check that the end gap of snap ring is not aligned with one of the cutouts. AX–48 AUTOMATIC TRANSAXLE 6. – FORWARD CLUTCH RECHECK PISTON STROKE OF FORWARD CLUTCH Set a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm2, 57 – 114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.41 – 1.82 mm (0.0555 – 0.0717 in.) If the piston stroke is less than the limit, parts may be misassembled and reinstall them. If the piston stroke is non–standard, select another flange. HINT: There are 5 different flange thickness. Flange thickness: 2.8 mm (0.110 in.) 3.0 mm (0.118 in.) 3.2 mm (0.126 in.) 3.4 mm (0.134 in.) 3.6 mm (0.142 in.) AX–49 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR FRONT PLANETARY GEAR AX0FE–02 COMPONENTS ONE–WAY CLUTCH AND SUN GEAR DISASSEMBLY AX0FF–02 1. CHECK OPERATION OF ONE–WAY CLUTCH Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock counterclockwise. 2. REMOVE SECOND BRAKE HUB AND ONE–WAY CLUTCH FRONT SUN GEAR While turning the hub clockwise, remove the one–way clutch from the sun gear. AX–50 AUTOMATIC TRANSAXLE 3. – FRONT PLANETARY GEAR REMOVE THRUST WASHER FROM SUN GEAR INPUT DRUM 4. REMOVE SUN GEAR FROM DRUM (a) Using snap ring pliers, remove the snap ring from the drum. (b) Remove the sun gear from the drum. 5. REMOVE SHAFT SNAP RING Using snap ring pliers, remove the shaft snap ring from the sun gear. ONE–WAY CLUTCH AND SUN GEAR ASSEMBLY AX0FG–02 1. 2. (a) (b) INSTALL SHAFT SNAP RING TO SUN GEAR INSTALL SUN GEAR TO DRUM Install the sun gear to the drum. Using snap ring pliers, install the snap ring to the drum. 3. INSTALL THRUST WASHER TO SUN GEAR INPUT DRUM AX–51 AUTOMATIC TRANSAXLE 4. 5. – FRONT PLANETARY GEAR INSTALL ONE–WAY CLUTCH AND SECOND BRAKE HUB ON SUN GEAR While turning the hub clockwise, slide the one–way clutch onto the sun gear. RECHECK OPERATION OF ONE–WAY CLUTCH AX0FH–02 PLANETARY RING GEAR INSPECTION 1. INSPECT RING GEAR FLANGE BUSHING Using a dial indicator, measure the inside diameter of the flange bushing. Standard inside diameter: 19.025 – 19.050 mm (0.7490 – 0.7500 in.) If the inside diameter is greater than the maximum, replace the flange. 2. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 3. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. AX–52 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR AX0FJ–02 FRONT PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.20 – 0.50 mm (0.0079 – 0.0197 in.) AX–53 AUTOMATIC TRANSAXLE – SECOND BRAKE SECOND BRAKE AX0FK–02 COMPONENTS AX0FL–02 SECOND BRAKE PISTON DISASSEMBLY REMOVE SECOND BRAKE PISTON (a) Apply compressed air to the oil hole to remove the piston. (b) Remove the 2 O–rings from the piston. AX–54 AUTOMATIC TRANSAXLE – SECOND BRAKE AX0FM–02 SECOND BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surface of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX0FN–02 SECOND BRAKE PISTON ASSEMBLY INSTALL PISTON (a) Coat a new O–ring with ATF. (b) Install the 2 O–rings on the piston. (c) Press the piston into the drum, being careful not to damage the O–rings. AX–55 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REAR PLANETARY GEAR AX0FP–02 COMPONENTS ONE–WAY CLUTCH DISASSEMBLY AX0FQ–02 1. CHECK OPERATION OF ONE–WAY CLUTCH Hold the outer race and turn the hub. The hub should turn freely counterclockwise and should lock clockwise. 2. SEPARATE ONE–WAY CLUTCH AND PLANETARY GEAR REMOVE THRUST WASHERS Remove the 2 thrust washers from both sides of the planetary gear. 3. AX–56 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR 4. REMOVE ONE–WAY CLUTCH FROM OUTER RACE (a) Remove the 2 snap rings and retainers from both sides. (b) Remove the one–way clutch from the outer race. AX0FR–02 REAR PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.20 – 0.50 mm (0.0079 – 0.0197 in.) AX0FS–02 ONE–WAY CLUTCH ASSEMBLY 1. INSTALL ONE–WAY CLUTCH (a) Install the one–way clutch into the outer race, facing the flanged side of the one–way clutch toward the shiny side of the outer race. (b) Install the 2 retainers and snap rings to both sides. 2. INSTALL PLANETARY GEAR INTO ONE–WAY CLUTCH Install the planetary gear into the one–way clutch, facing the inner race of the planetary gear toward the black side of the one–way clutch outer race. AX–57 AUTOMATIC TRANSAXLE 3. – REAR PLANETARY GEAR CHECK OPERATION OF ONE–WAY CLUTCH 4. INSTALL THRUST WASHERS (a) Coat the 2 thrust washers with petroleum jelly. (b) Align the tab of the washers with the hollow of the carrier. AX0FT–02 RING GEAR FLANGE REPLACEMENT 1. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 2. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. AX–58 AUTOMATIC TRANSAXLE – FIRST AND REVERSE BRAKE FIRST AND REVERSE BRAKE AX0FU–02 COMPONENTS AX0FV–02 FIRST AND REVERSE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembly new discs, soak them in ATF for at least 15 minutes. AX–59 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT OVERDRIVE UNIT AX0FW–02 COMPONENTS AX–60 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0FX–02 OVERDRIVE BRAKE DISASSEMBLY 1. REMOVE PISTON RETURN SPRING (a) While pushing the return spring, remove the snap ring with a screwdriver. (b) Remove the piston return spring. 2. REMOVE CUSHION PLATE, PLATES, DISCS AND FLANGE 3. REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston. HINT: Blow with the gun slightly away from the oil hole, and be careful that the piston does not tilt. 4. REMOVE O–RINGS Remove the inner and outer O–rings from the piston. AX–61 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0FY–02 OVERDRIVE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX0FZ–02 OVERDRIVE DIRECT CLUTCH DISASSEMBLY 1. CHECK PISTON STROKE OF DIRECT CLUTCH Using a dial indicator, measure the piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm2, 57– 114 psi). Piston stroke: 1.21 – 1.91 mm (0.0476 – 0.0752 in.) If the piston stroke is greater than the maximum, inspect the each component. 2. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE AX–62 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 3. REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE 4. REMOVE SNAP RING WITH SCREWDRIVER 5. REMOVE FLANGES, DISCS AND PLATES 6. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the spring with a shop press. SST 09350–32014 (09351–32070, 09351–32200) (b) Remove the snap ring. (c) Remove the piston return spring. AX–63 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 7. REMOVE PISTON FROM CLUTCH DRUM (a) Install the clutch drum of the case. (b) Apply compressed air to the pressure apply hole of the case. (c) Remove the piston from the clutch drum. If the piston does not come out completely, use needle– nose pliers to remove it. (d) Remove the clutch drum from the case. 8. REMOVE O–RINGS Remove the 2 O–rings from the piston. AX0G0–02 OVERDRIVE DIRECT CLUTCH INSPECTION 1. INSPECT OVERDRIVE DIRECT CLUTCH (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying lowpressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGES Check that the sliding surfaces of discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the two direct clutch bushings. Maximum inside diameter: 22.09 mm (0.8697 in.) If the inside diameter is greater than the maximum, replace the direct clutch drum. AX–64 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G1–02 OVERDRIVE DIRECT CLUTCH ASSEMBLY 1. INSTALL CLUTCH PISTON (a) Install new O–rings to the piston. Coat the O–rings with ATF. (b) Press the piston into the drum with the cup side up, being careful not to damage the O–ring. 2. INSTALL PISTON RETURN SPRING (a) Install the return spring and set snap ring in place. (b) Place SST on the spring retainer, and compress the spring with a shop press. SST 09350–32014 (09351–32070, 09351–32200) (c) Install the snap ring with a screwdriver. Be sure end gap of snap ring is aligned with the groove of the clutch drum. 3. INSTALL PLATES, DISCS AND FLANGE Install in order: P=Plate D=Disc Flange – D – P – D – Flange AX–65 AUTOMATIC TRANSAXLE 4. – OVERDRIVE UNIT INSTALL SNAP RING Be sure end gap of the snap ring is not aligned with the groove of the clutch drum. 5. INSTALL BEARING AND RACE (a) Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum. Bearing: Outer diameter 46.3 mm (1.823 in.) Inner diameter 26.2 mm (1.031 in.) (b) Coat the race with petroleum jelly and install it to thecase. Race: Outer diameter 43.0 mm (1.693 in.) Inner diameter 24.5 mm (0.965 in.) 6. INSTALL DIRECT CLUTCH ON CASE 7. RECHECK PISTON STROKE OF DIRECT CLUTCH Using a dial indicator, measure the piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf/cm2, 57– 114 psi). Piston stroke: 1.21 – 1.91 mm (0.0476 – 0.0752 in.) AX–66 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G2–02 COUNTER DRIVE GEAR DISASSEMBLY 1. CHECK OPERATION OF ONE–WAY CLUTCH (a) While turning the overdrive gear clockwise, install the overdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise. (c) Remove the overdrive direct clutch. 2. CHECK COUNTER DRIVE GEAR PRELOAD (a) Hold the intermediate shaft in a vise with soft jaws. (b) Using a tension gauge, measure the preload. Preload (at starting): 9 – 15 N (920 – 1,530 gf, 2.0 – 3.4 lbf) HINT: Turn the counter drive gear right and left several times before measuring the preload. 3. REMOVE RETAINING PLATE (a) Remove the snap ring with a screwdriver. (b) Remove the retaining plate. 4. REMOVE ONE–WAY CLUTCH AND OUTER RACE AX–67 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 5. REMOVE NO.3 OVERDRIVE PLANETARY THRUST WASHER 6. REMOVE ONE–WAY CLUTCH FROM OUTER RACE Note the direction of the one–way clutch. 7. REMOVE PLUGS FROM PLANETARY GEAR Remove the 4 plugs with a magnetic finger. HINT: Be careful not to lose them. 8. REMOVE ADJUSTING NUT AND WASHER (a) Pry off the locking washer with chisel. (b) Using SST, loosen the adjusting nut. SST 09350–32014 (09351–32080) (c) Remove the adjusting nut and washer. AX–68 AUTOMATIC TRANSAXLE 9. – OVERDRIVE UNIT REMOVE INTERMEDIATE SHAFT BEARING Using SST, press out the bearing from the shaft. SST 09950–00020 10. REMOVE COUNTER DRIVE GEAR AND FRONT BEARING Press out the gear and bearing together. 11. REMOVE REAR BEARING Using SST, press out the bearing. SST 09950–00020 12. REMOVE OVERDRIVE PLANETARY RING GEAR FROM COUNTER DRIVEGEAR (a) While pulling up the ring gear, compress the snap ring with needle–nose pliers and remove it from the groove. (b) Remove the ring gear from the counter drive gear. 13. REMOVE OUTER RACES FROM COUNTER DRIVE GEAR Drive out the 2 races with a brass bar and hammer. AX–69 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 14. REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring. AX0G3–02 OVERDRIVE PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.20 – 0.50 mm (0.0079 – 0.0197 in.) AX0GU–02 COUNTER DRIVE GEAR ASSEMBLY 1. INSTALL SNAP RING INTO COUNTER GEAR Install the snap ring with a screwdriver. 2. INSTALL OUTER RACES INTO COUNTER DRIVE GEAR Using SST, press in the 2 outer races to the gear both side. SST 09350–32014 (09351–32120, 09351–32150) HINT: Press in the 2 outer races until they touch the snap ring. Tap the races in straight, so that they do not tilt. 3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO COUNTER DRIVEGEAR While pushing down the ring gear, squeeze the snap ring end with a needle–nose pliers, and install it into the groove. HINT: When the snap ring is fully seated, the end will be free. AX–70 AUTOMATIC TRANSAXLE 4. – OVERDRIVE UNIT INSTALL REAR BEARING Using SST, press in the bearing onto the shaft. SST 09350–32014 (09351–32120) HINT: Press in the bearing until the side surface of the inner race touches the shaft. 5. INSTALL COUNTER DRIVE GEAR AND FRONT BEARING (a) Install the gear onto the shaft, and mesh the ring gear with the planetary pinions. (b) Place the front bearing onto the shaft. HINT: Hold the ring gear to prevent it from falling. (c) Using SST, press in the bearing until there is slight play between the bearings. SST 09350–32014 (09351–32120) 6. INSTALL INTERMEDIATE SHAFT BEARING Using SST, press in the bearing until it slightly touches the front bearing of the counter drive gear. SST 09350–32014 (09351–32120) HINT: The counter drive gear can be turned lightly. 7. PLACE NEW LOCKING WASHER AND ADJUSTING NUT ONTO INTERMEDIATE SHAFT AX–71 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 8. ADJUST PRELOAD OF COUNTER DRIVE GEAR (a) Place SST onto the adjusting nut and hold the shaft in a vise with soft jaws. SST 09350–32014 (09351–32080) (b) Tighten the adjusting nut until the following gear starting load occurs with a tension gauge. Preload (at starting): 9 – 15 N (920 – 1,530 gf, 2.0 – 3.4 lbf) (c) 9. HINT: Turn the counter drive gear right and left several times before measuring the preload. Lock the adjusting nut with one tab on locking washer. Bend the locking washer tab until it is even with the adjusting nut groove. INSTALL PINION SHAFT PLUGS Install the 4 plugs into the pinion shaft. 10. INSTALL NO.3 OVERDRIVE PLANETARY THRUST WASHER Install the thrust washer, facing the groove toward the overdrive case. 11. ASSEMBLE OVERDRIVE ONE–WAY CLUTCH (a) Install the one–way clutch into the outer race. (b) Install a retainer on both sides of the one–way clutch. AX–72 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 12. INSTALL OVERDRIVE ONE–WAY CLUTCH INTO HUB Be sure that the one–way clutch is installed in the correct direction. 13. INSTALL RETAINING PLATE (a) Place the retaining plate into the hub. (b) Install the snap ring with a screwdriver. 14. CHECK OPERATION OF ONE–WAY CLUTCH (a) While turning the overdrive gear clockwise, install the overdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft. The shafts should turn freely clockwise and should lock counterclockwise. (c) Remove the overdrive direct clutch. AX–73 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G4–02 OVERDRIVE CASE DISASSEMBLY 1. REMOVE C0 ACCUMULATOR PISTON FROM OVERDRIVE CASE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retaining plate and two springs. (c) Remove the accumulator piston. (d) Remove the O–ring from the piston. 2. REMOVE OIL SEAL RINGS Spread the 2 rings apart and remove them. OVERDRIVE CASE INSPECTION INSPECT OVERDRIVE CASE BEARING Check that the bearing turns smoothly with your finger. AX–74 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX0G5–02 OVERDRIVE CASE ASSEMBLY 1. INSTALL OIL SEAL RINGS ON OVERDRIVE CASE Install the oil seal rings to the O/D case groove, then snug them down by squeezing their ends together. HINT: After installing the oil seal rings, check that they move smoothly. INSTALL C0 ACCUMULATOR PISTON OF OVERDRIVE CLUTCH (a) Install a new O–ring to the accumulator piston. Coat the O–ring with ATF. (b) Install the accumulator piston, 2 springs and plate. (c) Install the snap ring with snap ring pliers. 2. AX0G6–02 OVERDRIVE BRAKE ASSEMBLY 1. INSTALL PISTON INTO DRUM (a) Install the new O–rings to the piston. Coat the O–rings with ATF. (b) Press the piston into the drum, being careful not to damage the O–rings. 2. INSTALL FLANGE, DISCS AND PLATES (a) Install the flange, facing the flat end upward. AX–75 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (b) Install the discs and plates. Install in order: P=Plate D=Disc Flange – D – P – P – D – P HINT: There are 2 different thickness plates, as shown in the illustration. (c) Install the cushion plate facing the rounded end upward. 3. INSTALL PISTON RETURN SPRING 4. INSTALL SNAP RING INTO CASE Be sure the end gap of the snap ring is not aligned with one of the cutouts. 5. INSTALL OVERDRIVE GEAR ASSEMBLY ONTO CASE While turning the overdrive gear clockwise, install the overdrive gear assembly to the case. If the overdrive gear assembly is properly installed to the overdrive case, the clearance between them will be about 24 mm (0.94 in.). AX–76 AUTOMATIC TRANSAXLE – VALVE BODY VALVE BODY AX0G7–02 COMPONENTS VALVE BODY DISASSEMBLY 1. AX0G8–02 NOTE THE NUMBERS OF ADJUSTING RINGS HINT: Count the number of adjusting rings before disassembly of the valve body because the throttle pressure is changed according to the number. (Some of the valve bodies do not have any adjusting rings). 2. REMOVE SOLENOIDS (a) Remove the No.1 and No.2 solenoids. (b) Remove the O–rings from the solenoids. AX–77 AUTOMATIC TRANSAXLE 3. – VALVE BODY REMOVE UPPER VALVE BODY COVER Remove the 9 bolts and upper valve body cover. 4. REMOVE STRAINER GASKETS, PLATE AND SLEEVE STOPPER FROM UPPER VALVE BODY (a) Remove the strainer, 2 gaskets and plate. (b) Remove the sleeve stopper. 5. REMOVE BOLTS FROM UPPER VALVE BODY Remove the 3 bolts from the upper valve body. 6. REMOVE LOWER VALVE BODY COVER (a) Remove the 10 bolts. (b) Remove the lower valve body cover and gasket. AX–78 AUTOMATIC TRANSAXLE – VALVE BODY 7. REMOVE BOLTS FROM LOWER VALVE BODY Remove the 3 bolts from lower valve body. 8. LIFT OFF LOWER VALVE BODY AND PLATE AS SINGLE UNIT Hold the plate to the lower valve body and lift off the lower valve body. HINT: Be careful that the check balls do not fall out. REMOVE PLATE AND GASKETS 9. AX0G9–02 VALVE BODY ASSEMBLY 1. POSITION PLATE AND NEW GASKETS ON LOWER VALVE BODY Position the new No.2 gasket, the plate and then the new No.1 gasket on the lower valve body. HINT: Since No.1 gasket and No.2 gasket are similar use the illustration below to discriminate between them. AX–79 AUTOMATIC TRANSAXLE – VALVE BODY 2. PLACE LOWER VALVE BODY WITH PLATE AND GASKETS ON UPPER VALVE BODY HINT: Hold the lower valve body, gaskets and plate securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate. 3. INSTALL AND FINGER TIGHTEN BOLTS IN LOWER VALVE BODY TO SECURE UPPER VALVE BODY Install and finger tighten the 3 bolts. HINT: Each bolt length (mm, in.) is indicated in the illustration. 4. INSTALL LOWER VALVE BODY COVER (a) Install the lower valve body cover over the new gasket. (b) Install and finger tighten the 10 bolts. HINT: Each bolt length (mm, in.) is indicated in the illustration. 5. INSTALL AND FINGER TIGHTEN BOLTS IN UPPER VALVE BODY Install and finger tighten the 3 bolts. HINT: Each bolt length (mm, in.) is indicated in the illustration. 6. INSTALL SLEEVE STOPPER AX–80 AUTOMATIC TRANSAXLE – VALVE BODY 7. INSTALL UPPER VALVE BODY COVER GASKETS, PLATE AND THROTTLE MODULATOR OIL STRAINER (a) Position a new gasket and plate and then another new gasket. HINT: The gaskets are not identical, but can be installed in any order. (b) Install the oil strainer onto the gasket. 8. INSTALL UPPER VALVE BODY COVER (a) Position the upper valve body cover. (b) Install and finger tighten the 9 bolts. HINT: Each bolt length (mm, in.) is indicated in the illustration. 9. (a) (b) (c) INSTALL SOLENOIDS Install the new O–rings on the solenoids. Install the No.1 and No.2 solenoids. Install and finger tighten the 3 bolts. HINT: Each bolt length (mm, in.) is indicated in the illustration. 10. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES (a) Tighten the 16 bolts in the lower valve body. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Tighten the 12 bolts in the upper valve body. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) AX–81 AUTOMATIC TRANSAXLE – UPPER VALVE BODY UPPER VALVE BODY AX0GA–02 COMPONENTS AX–82 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GB–02 VALVE BODY SPRINGS SPECIFICATIONS HINT: During re–assembly please refer to the spring specifications below to help you to discriminate between the different springs. Spring (Color) Free Length / Coil Outer Diameter mm (in.) Number of Coils @@ @@ @: Throttle Modulator Spring (None) 21.70 / 9.50 (0.8543 / 0.3740) 9.5 Accumulator Control Spring (Yellow) 28.06 / 10.60 (1.1047 / 0.4173) 13.0 Low Coast Modulator Spring (None) 21.60 / 7.90 (0.8504 / 0.3110) 11.5 Down Shift Valve Spring (Yellow) 29.76 / 8.73 (1.1717 / 0.3437) 13.5 [c A] @@ @@ @: [c B] @@ @@ @: [c C] @@ @@ @: [c D] AX–83 AUTOMATIC TRANSAXLE – UPPER VALVE BODY @@ @@ @: Throttle Valve Spring (None) 30.70 / 9.20 (1.2087 / 0.3622) 9.5 20.93 / 8.50 (0.8240 / 0.3364) 10.0 Lock–up Relay Valve spring (Green) 26.56 / 10.20 (1.0457 / 0.4016) 11.5 Cut–back Valve Spring (None) 21.80 / 6.00 (0.8583 / 0.2362) 13.5 [c E] @@ @@ @: Second Coast Modulator Valve Spring (Light Green) [c F] @@ @@ @: [c G] @@ @@ @: [c H] AX–84 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GC–02 RETAINERS, PINS, VIBRATING STOPPER AND CHECK BALLS LOCATION Retainer Height / Width / Thickness mm (in.) @@@@@: [c H] Throttle Modulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126) @@@@@: [c I] Accumulator Control Valve 11.5 / 5.0 / 3.2 (0.453 / 0.197 / 0.126) @@@@@: [c J] Cut–back Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126) @@@@@: [c K] Lock–up Relay Valve 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126) @@@@@: [c L] 2nd Coast Modulator Valve 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126) AX–85 AUTOMATIC TRANSAXLE – LOWER VALVE BODY LOWER VALVE BODY AX0GV–02 COMPONENTS AX–86 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0GD–02 VALVE BODY SPRINGS SPECIFICATIONS HINT: During re–assembly please refer to the spring specifications below to help you to discriminate between the different springs. Spring (Color) Free length / Outer diameter mm (in.) Number of Coils @@ @@ @: Secondary Regulator Valve Spring 43.60 / 10.90 (1.7165 / 0.4291) 11.5 Lock–up Signal Valve Spring (None) 30.00 / 8.20 (1.1811 / 0.3228) 11.5 3–4 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5 (None) [c A] @@ @@ @: [c B] @@ @@ @: [c C] AX–87 AUTOMATIC TRANSAXLE – LOWER VALVE BODY @@ @@ @: 1–2 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5 2–3 Shift Valve Spring (None) 29.27 / 9.70 (1.1524 / 0.3819) 10.5 Primary Regulator Valve Spring (None) 66.65 / 18.60 (2.6240 / 0.7323) 12.5 Cooler By–pass Valve Spring (None) 19.90 / 11.00 (0.7835 / 0.4331) 8.5 Pressure Relief Valve Spring (None) 11.20 / 6.40 (0.4409 / 0.2520) 7.5 [c D] @@ @@ @: [c E] @@ @@ @: [c F] @@ @@ @: [c G] @@ @@ @: [c H] AX–88 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0GE–02 RETAINER, STRAINER AND CHECK BALLS LOCATION Retainer Height / Width / Thickness mm (in.) @@@@@: [c I] Primary Regulator Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.128) @@@@@: [c J] 2–3 Shift Valve 8.0 / 6.0 / 3.2 (0.315 / 0.236 / 0.126) @@@@@: [c K] 1–2 Shift Valve 9.2 / 5.0 / 3.2 (0.362 / 0.197 / 0.126) @@@@@: [c L] 3–4 Shift Valve 8.0 / 6.0 / 3.2 (0.315 / 0.236 / 0.126) @@@@@: [c M] Secondary Regulator Valve 13.0 / 6.0 / 3.2 (0.512 / 0.236 / 0.126) @@@@@: [c N] Lock–up Signal Vave 15.0 / 5.0 / 3.2 (0.591 / 0.197 / 0.126) AX–89 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY AX0GF–02 COMPONENTS AX–90 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0GG–02 DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE RING GEAR (a) Loosen the staked part of the lock plate. (b) Remove the 8 bolts and locking plates. (c) Using a copper hammer, tap on the ring gear to remove it from the case. 2. REMOVE SIDE BEARINGS Fasten SST under the bearing above the cutouts on the speedometer drive gear. Remove the bearing from the case. SST 09502–10012 3. CHECK SIDE GEAR BACKLASH Using a dial gauge, measure the backlash of each side gear while holding one pinion toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) 4. DISASSEMBLE DIFFERENTIAL CASE (a) Drive out the pinion shaft lock pin from the side on which the ring gear is installed. AX–91 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and 2 side gears with the 4 thrust washers. 5. REMOVE LH OIL SEAL Using a hammer and screwdriver, remove the oil seal. 6. REMOVE BEARING OUTER RACE FROM LH SIDE BEARING RETAINER Using SST, press out the outer race and shim. SST 09350–32014 (09351–32090) 7. REMOVE RH OIL SEAL Using a hammer and screwdriver, remove the oil seal. AX0GH–02 DIFFERENTIAL CASE ASSEMBLY 1. INSTALL RH OIL SEAL (a) Using SST, drive in a new oil seal until its surface is flush with the surface of the case. SST 09350–32014 (09351–32130, 09351–32150) (b) Coat the oil seal lip with MP grease. AX–92 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 2. INSTALL BEARING OUTER RACE TO LH SIDE BEARING RETAINER (a) Place the shim onto the retainer. (b) Using SST, press a new outer race into the retainer. SST 09350–32014 (09351–32111, 09351–32130) HINT: Use the 2.60 mm (0.1024 in.) thick thim. 3. INSTALL LH OIL SEAL (a) Using SST, drive in a new oil seal. SST 09350–32014 (09351–32130, 09351–32150) Oil seal drive in depth: 2.7 mm (0.106 in.) (b) Coat the oil seal lip with MP grease. 4. ASSEMBLE DIFFERENTIAL CASE (a) Install the removed thrust washers to the side gears. (b) Install the side gears with thrust washers, pinion thrust washers and pinion gears. (c) Install the pinion shaft. AX–93 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (d) Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Referring to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides. Thrust washer thickness mm (in.) Thickness Thickness 0.95 (0.0374) 1.10 (0.0433) 1.00 (0.0394) 1.15 (0.0453) 1.05 (0.0413) 1.20 (0.0472) If the backlash is not within specification, install a thrust washer of a different thickness. (e) Using a hammer and punch, drive the lock pin through the case and hole in the pinion shaft. (f) Stake the differential case. 5. INSTALL SIDE BEARINGS (a) Install the speedometer drive gear onto the differential case. (b) Using SST and a press, press in the RH side bearing onto the differential case. SST 09350–32014 (09351–32090, 09351–32120) AX–94 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (c) Using SST and a press, press in the LH side bearing onto the differential case. SST 09710–28020 (09710–08040) 6. (a) (b) (c) INSTALL RING GEAR Clean the contact surface of the differential case. Heat the ring gear to about 100 °C (212 °F) in an oil bath. Carefully remove the ring gear from the water. NOTICE: Do not heat the ring gear above 110 °C (230 °F). (d) Clean the contact surface of the ring gear with cleaning solvent. (e) Quickly install the ring gear on the differential case. (f) Install new locking plates and set bolts. When the ring gear has cooled sufficiently, tighten the set bolts uniformly a little at a time. Torque the bolts. Torque: 97 N·m (985 kgf·cm, 71 ft·lbf) (g) Using a hammer and drift punch, stake the locking plates. HINT: Stake one claw flush with the flat surface of the nut. For the claw contacting the protruding portion of the nut, stake only the half on the tightening side. AX0GJ–02 DRIVE PINION DISASSEMBLY 1. REMOVE DRIVE PINION SHAFT BEARING Using SST, press out the bearing. SST 09950–00020 AX–95 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 2. REMOVE OIL SEALS FROM CAGE Using SST, press out the two oil seals together. SST 09350–32014 (09351–32090) 3. REMOVE SHAFT BEARING OUTER RACE FROM CAGE Using a hammer and brass bar, drive out the outer race from the cage. 4. REMOVE COUNTER DRIVEN GEAR BEARING Using SST, press out the bearing. SST 09950–00020 DRIVE PINION SHAFT ASSEMBLY 1. AX0GK–02 INSTALL COUNTER DRIVEN GEAR BEARING Using SST, press in a new bearing. SST 09350–32014 (09351–32090) 2. INSTALL OIL SEALS TO CAGE (a) Using SST, press in a new oil seal with the lip facing downward. SST 09350–32014 (09351–32090) Oil seal press in depth (from flat end): 9.5 mm (0.374 in.) AX–96 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (b) Measure the oil seal press in depth. Oil seal press in depth: 4 mm (0.16 in.) (c) With the oil seal lip facing upward, use SST to press in a new oil seal until its end is flush with the surface of the cage. SST 09350–32014 (09351–32090) (d) Coat the oil seal lip with MP grease. 3. INSTALL SHAFT BEARING OUTER RACE TO CAGE Using SST, press a new outer race into the cage. SST 09350–32014 (09351–32111, 09351–32130) 4. INSTALL DRIVE PINION SHAFT BEARING Using SST, press in the bearing. SST 09350–32014 (09351–32100) 5. PLACE BEARING CAGE ONTO DRIVE PINION SHAFT Be careful not to damage the oil seal with the splines. AX–97 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0GL–02 DIFFERENTIAL SIDE BEARING PRELOAD ADJUSTMENT 1. PLACE OUTER RACE AND ADJUSTING SHIM ONTO RH SIDE BEARING Use the adjusting shim which was removed or one 2.40 mm (0.0945 in.) thick. 2. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE Be sure to install the adjusting shim. 3. (a) (b) (c) INSTALL LH BEARING RETAINER Do not install the O–ring yet. Do not coat the bolt threads with sealant yet. Temporarily tighten the bolts evenly and gradually while turning the ring gear. 4. INSTALL RH SIDE BEARING CAP Tighten the bolts evenly and gradually while turning the ring gear. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 5. TIGHTEN LH BEARING RETAINER Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) AX–98 AUTOMATIC TRANSAXLE 6. – DIFFERENTIAL ASSEMBLY ADJUST SIDE BEARING PRELOAD Using SST and a torque meter, measure the preload of the ring gear. SST 09564–32011 Preload (at starting): New bearing 1.0 – 1.6 N·m (10 – 16 kgf·cm, 8.7 – 13.9 in.·lbf) Reused bearing 0.5 – 0.8 N·m (5 – 8 kgf·cm, 4.3 – 6.9 in.·lbf) If the preload is not within specification, remove the differential case assembly. Reselect the RH adjusting shim. mm (in.) Thickness Thickness 1.90 (0.0748) 2.40 (0.0945) 1.95 (0.0786) 2.45 (0.0965) 2.00 (0.0787) 2.50 (0.0984) 2.05 (0.0807) 2.55 (0.1004) 2.10 (0.0827) 2.60 (0.1024) 2.15 (0.0846) 2.65 (0.1043) 2.20 (0.0866) 2.70 (0.1063) 2.25 (0.0886) 2.75 (0.1083) 2.30 (0.0906) 2.80 (0.1103) HINT: The preload will change by about 0.3 – 0.4 N·m (3 – 4kgf·cm, 2.6 – 3.5 in.·lbf) with a change in shim thickness of 0.05 mm (0.0020 in.). 7. REMOVE DIFFERENTIAL CASE AND COMPONENT PARTS If the preload is adjusted within specification, remove the bearing retainer, differential case, RH side bearing and shim. Be careful not to lose the adjusting shim. AX–99 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION AX0GW–02 COMPONENT PARTS INSTALLATION Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately. Recommended ATF: DEXRON ® @@@@@: [g 2] GENERAL INSTALLATION NOTES: 1. The automatic transaxle is composed of highly precision–finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage and affect performance. 2. Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes. 3. Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly. 4. Use petroleum jelly to keep small parts in their places. 5. Do not use adhesive cements on gaskets and similar parts. 6. When assembling the transaxle, be sure to use new gaskets and O–rings. 7. Dry all parts with compressed air–never use shop rags. 8. Be sure to install the thrust bearings and races in the correct direction and position. AX–100 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION BEARING AND RACE DIAMETERS mm Front Bearing Race Thrust Bearing Race Rear Bearing Race (in.) Outer / Inner Diameter Outer / Inner Diameter Outer / Inner Diameter 43.0 / 30.5 (1.693 / 1.201) 42.0 / 28.9 (1.654 / 1.138) 42.0 / 27.1 (1.654 / 1.067) @@ @@ @: [c A] AX–101 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION @@ @@ @: 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.7 / 23.0 (1.406 / 0.906) 37.9 / 22.0 (1.492 / 0.866) 36.1 / 22.2 (1.421 / 0.874) 35.0 / 19.0 (1.378 / 0.748) 45.0 / 28.0 (1.772 / 1.102) 45.0 / 30.0 (1.772 / 1.181) – 37.3 / 24.1 (1.469 / 0.949) 37.6 / 24.0 (1.480 / 0.945) 37.6 / 22.2 (1.480 / 0.874) – 46.3 / 26.2 (1.823 / 1.031) 43.0 / 24.5 (1.693 / 0.965) [c B] @@ @@ @: [c C] @@ @@ @: [c D] @@ @@ @: [c E] @@ @@ @: [c F] AX0GM–02 DRIVE PINION ASSEMBLY INSTALLATION 1. INSTALL NEW O–RING ONTO BEARING CAGE 2. INSTALL DRIVE PINION SHAFT INTO CASE Slightly tap the cage into the case until the groove with the bore can be see. HINT: Drive in the bearing cage until the surface of the bearing cage passes through the groove with the bore. AX–102 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 3. INSTALL SNAP RING INTO CASE (a) Using SST, install the snap ring into the groove. SST 09350–32014 (09351–32050) (b) Slightly tap the drive pinion to fit the snap ring into the groove. 4. INSTALL ROTOR SENSOR Install the rotor sensor, facing the magnet outward. 5. INSTALL OIL SLINGER Install the oil slinger, facing the lip outward. 6. INSTALL OUTER RACE Using SST, drive the outer race into the case. SST 09350–32014 (09351–32100, 09351–32140) AX–103 AUTOMATIC TRANSAXLE 7. – COMPONENT PARTS INSTALLATION INSTALL NEW SPACER Always use new spacer. Install the spacer with the small end first. 8. INSTALL COUNTER DRIVEN GEAR ONTO SHAFT (a) Place a bar at the drive pinion side and position the outer end of the bar against a vise or similar. (b) Using SST, driven in gear onto the shaft until the nut can be installed on the threads of the shaft. NOTICE: Be careful not to cause an impact to the transaxle case. SST 09350–32014 (09351–32140) 9. ADJUST DRIVE PINION PRELOAD (a) Coat the threads and surface of the nut with MP grease. (b) Using SST to hold the gear, tighten the nut. Torque: 172 N·m (1,750 kgf·cm, 127 ft·lbf) SST 09330–00021, 09350–32014 (09351–32032) (c) Turn the gear counterclockwise and clockwise several times. (d) Using a torque meter, measure the preload of the drive pinion. Preload (at starting): New bearing 1.0 – 1.6 N·m (10 – 16 kgf·cm, 8.7 – 13.9 in.·lbf) Reused bearing 0.5 – 0.8 N·m (5 – 8 kgf·cm, 4.3 – 6.9 in.·lbf) AX–104 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION
If the preload is greater than specified, replace the bearing spacer.
If the preload is less than specified, retighten the nut 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the specified preload is reached. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload. Maximum torque: 289 N·m (2,950 kgf·cm, 213 ft·lbf) (e) If the preload is adjusted within specification, make a note of it. AX0SX–01 DIFFERENTIAL INSTALLATION 1. PLACE OUTER RACE AND SELECTED ADJUSTING SHIM ONTO RH SIDE BEARING 2. PLACE DIFFERENTIAL CASE INTO CASE Be sure to install the adjusting shim into place. 3. INSTALL LH BEARING RETAINER (a) Install a new O–ring. (b) Position the retainer by tapping it while holding the differential case center with the retainer. (c) Clean the threads of the bolts and case with white gasoline. AX–105 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (e) Temporarily tighten the bolts evenly and gradually while turning the ring gear. 4. INSTALL RH SIDE BEARING CAP Tighten the bolts evenly and gradually while turning the ring gear. Torque: 72 N·m (730 kgf·cm, 53 ft·lbf) 5. TIGHTEN LH BEARING RETAINER Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 6. MEASURE TOTAL PRELOAD Using a torque meter, measure the total preload of the drive pinion shaft. Total preload (at starting): Add drive pinion preload (See page AX–xx) New Bearing 0.3 – 0.4 N·m (2.9 – 4.0 kgf·cm, 2.5 – 3.5 in.·lbf) Reused bearing 0.1 – 0.2 N·m (1.5 – 2.0 kgf·cm, 1.3 – 1.7 in.·lbf) If the preload is not within specification, redisassemble and readjust. AX–106 AUTOMATIC TRANSAXLE 7. 8. – COMPONENT PARTS INSTALLATION STAKE COUNTER DRIVEN GEAR NUT INSTALL DRIVE PINION CAP 9. INSTALL CARRIER COVER (a) Clean the threads of the bolts and case with white gasoline. (b) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (c) Install the carrier cover over the gasket. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) AX0SY–01 4–SPEED GEAR UNIT INSTALLATION 1. INSTALL MANUAL VALVE SHAFT (a) Coat the oil seal lip with MP grease. (b) Using a socket wrench and hammer, drive in a new manual valve shaft oil seal to the case. (c) Assemble a new collar to the manual valve lever. (d) Install the manual valve lever shaft to the transaxle case through the manual valve lever. AX–107 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (e) Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface. (f) Match the collar hole to the lever calking hollow and calk the collar to the lever. (g) Install the retaining spring. (h) Make sure that the lever moves smoothly. 2. INSTALL PARKING LOCK PAWL (a) Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl. (b) Install the pin into the hole of the case through the spring and pawl. AX–108 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 3. INSTALL PARKING LOCK ROD 4. INSTALL PARKING LOCK PAWL BRACKET Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 5. CHECK OPERATION OF PARKING LOCK PAWL Make sure the counter driven gear is locked when the manual valve lever is in the P position. 6. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE (a) Coat a new O–rings with ATF. (b) Install the 2 O–rings on the piston. (c) Push the piston into the bore of the case, facing the spring seat upward. AX–109 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 7. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring on the piston. (b) Place SST, and compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040) (c) Install snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw. (d) Remove SST. 8. INSTALL OVERDRIVE UNIT (a) Install the overdrive brake apply gasket and overdrive clutch apply gasket. (b) Install the overdrive brake drum to the case. (c) Install a new case gasket to the case. (d) Make sure that the length from the top surface of the case to the counter driven gear top surface should be about 24 mm (0.94 in.). AX–110 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (e) Install the overdrive unit with overdrive case to the transaxle case. (f) Install and tighten the bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 9. CHECK INTERMEDIATE SHAFT END PLAY (a) Make sure that the intermediate shaft has thrust play. Thrust play: 0.49 – 1.51 mm (0.0193 – 0.0594 in.) If the thrust play is not within specification, check the installation of intermediate shaft. (b) Make sure that the intermediate shaft turns smoothly. 10. INSTALL FIRST AND REVERSE BRAKE IN CASE (a) Install the inner flange facing the flat end toward the oil pump side. (b) Install the discs and plates. Install in order: P=Plate D=Disc D–P–D–P–D–P–D–P–D–P–D (c) Install the outer flange, facing the flat end toward the piston side. 11. INSTALL SNAP RING Be sure the end gap of the snap ring is not aligned with one of the cutouts. 12. CHECK OPERATION OF FIRST AND REVERSE BRAKE Apply compressed air into the oil passage with the case and be sure that the piston moves. AX–111 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL RING GEAR INTO CASE (a) Coat the races and bearing with petroleum jelly and install them onto the ring gear. Bearing and races mm (in.) Outer Diameter Inner Diameter Front Race 37.3 (1.469) 24.1 (0.949) Bearing 37.6 (1.480) 24.0 (0.945) Rear Race 37.6 (1.480) 22.2 (0.874) (b) Install the ring gear into the case. 14. INSTALL REAR PLANETARY GEAR INTO CASE (a) Align the flukes of the discs in the first and reverse brake. (b) Coat the thrust washer with petroleum jelly. Align the tab of the washer with the hollow of the carrier. (c) Align the spline of the planetary carrier with either of the flukes of the discs, and install the planetary gear into the first and reverse brake discs. 15. INSTALL NO.2 ONE–WAY CLUTCH INTO CASE WITH SHINY SIDE UPWARD (a) Place the one–way clutch with the shiny side upward. (b) Install the one–way clutch onto the inner race while turning the planetary gear clockwise with SST. SST 09350–32014 (09351–32050) AX–112 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS INSTALLATION Coat the thrust washer with petroleum jelly and install it onto the planetary gear. 16. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH Turn the planetary carrier. The carrier should turn freely clockwise and lock counterclockwise. 17. INSTALL SNAP RING Be sure the end gap of the snap ring is not aligned with one of cutouts. 18. INSTALL SECOND COAST BRAKE BAND GUIDE Install the 2 band guides so that its tip touches the case. 19. INSTALL SECOND BRAKE INTO CASE (a) Install the flange, facing the flat end toward the oil pump side. (b) Install the discs and plates. Install in order: P=Plate D=Disc Flange – D – P – D – P – D – P AX–113 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL PISTON RETURN SPRING Each spring end is installed onto the protrusion with the case. 21. INSTALL SECOND BRAKE DRUM INTO CASE Align the groove of the drum with the bolt and place it into the case. 22. INSTALL SNAP RING (a) Place the snap ring into the case so that the end gap is installed into the groove. (b) While compressing the piston return springs over the drum with hammer handles, install the snap ring into the groove. (c) Be sure the end gap of the snap ring is not aligned with one of the cutouts. 23. INSTALL SECOND BRAKE DRUM GASKET Install a new gasket until it makes contact with the second brake drum. 24. CHECK OPERATION OF SECOND BRAKE Blow compressed air into the oil passage with the case, and be sure that the piston moves. AX–114 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 25. INSTALL NO.1 ONE–WAY CLUTCH AND SECOND BRAKE HUB (a) Align the flukes of the discs in the second brake. (b) Align the spline of the hub with the flukes of the discs and install the hub to the second brake discs. (c) Check the distance between the surfaces of the second brake hub and rear planetary gear. Distance: Approx. 5 mm (0.20 in.) 26. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM While turning the sun gear clockwise, install it into the one–way clutch. 27. INSTALL FRONT PLANETARY GEAR ONTO RING GEAR (a) Coat the races and bearing with petroleum jelly, and install them onto the ring gear. Bearing and race mm (in.) Outer Diameter Inner Diameter Front Race 37.9 (1.492) 22.0 (0.866) Bearing 36.1 (1.421) 22.2 (0.874) Rear Bearing 35.0 (1.378) 19.0 (1.102) AX–115 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Coat the race and bearing with petroleum jelly, and install them onto the planetary gear. Bearing and race mm (in.) Outer Diameter Inner Diameter Bearing 45.0 (1.772) 30.0 (1.181) Race 45.0 (1.772) 28.0 (1.102) (c) Install the planetary gear onto the ring gear. 28. INSTALL FRONT PLANETARY GEAR ASSEMBLY ONTO SUN GEAR (a) If the planetary gear and other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under. (b) Coat the race with petroleum jelly and install it onto the tip of ring gear flange. Race: Outer diameter 35.7 mm (1.406 in.) Inner diameter 23.0 mm (0.906 in.) 29. INSTALL INTERMEDIATE SHAFT OIL SEAL RING AX–116 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 30. INSTALL SECOND COAST BRAKE BAND (a) Place the band into the case. (b) Install the pin through the oil pump mounting bolt hole. 31. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH (a) Coat the races and bearing with petroleum jelly, and install them onto both sides of the clutch drum. Bearing and race (Front side) mm (in.) Outer Diameter Inner Diameter Bearing 42.0 (1.645) 28.9 (1.138) Race 42.0 (1.654) 27.1 (1.067) AT2765:Bearing and race (Rear side) mm (in.) Outer Diameter Inner Diameter Bearing 36.1 (1.421) 22.2 (0.874) Race 37.9 (1.492) 22.0 (0.866) (b) Coat the clutch drum thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum. (c) Align the flukes of discs in the direct clutch. AX–117 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Mesh the hub with the flukes of the direct clutch while turning the clutch drum or forward clutch. (e) If the flukes of the discs are meshed with the hub correctly, the end of the bushing with the direct clutch drum will be flush with the surface of the forward clutch. (f) Place the direct clutch and forward clutch into the case. (g) Rotate the forward clutch to mesh the front planetary ring gear and discs. (h) Check the distance between the A and B. Distance: Approx. 3 mm (0.118 in.) 32. INSTALL OIL PUMP INTO CASE (a) Coat the race with petroleum jelly and install it onto stator shaft. (b) Coat a new O–ring with ATF and install it to oil pump. AX–118 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transaxle case. (d) Hold the input shaft, and lightly press the oil pump body to slide the oil seal rings on the stator shaft through the direct clutch drum. NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum. (e) Install tighten the 7 bolts. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) AX–119 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 33. MEASURE THRUST PLAY OF INPUT SHAFT Measure the thrust play with a dial gauge. Thrust play: 0.3 – 0.9 mm (0.012 – 0.035 in.) HINT: There are 2 thickness of races for the end of stator shaft. If the thrust play is in excess of standard, select one of them. Race thicknesses: 0.8 mm (0.031 in.) 1.4 mm (0.055 in.) 34. CHECK INPUT SHAFT ROTATION Make sure that the input shaft rotates smoothly. 35. INSTALL DRIVE PINION CAP 36. INSTALL SECOND COAST BRAKE PISTON (a) Coat a new O–rings with ATF and install them on the cover. (b) Install the outer spring with the piston. (c) Place the cover into the bore. AX–120 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Using SST, install the snap ring while pressing the cover. SST 09350–32014 (09351–32050) (e) Check that the front end of the piston rod contacts the center of the second brake band depression. 37. CHECK SECOND COAST BRAKE PISTON STROKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. (b) Using SST, measure the piston stroke while applying and releasing compressed air (392 – 785 kPa, 4 – 8 kgf·cm, 57 – 114 psi). SST 09240–00020 Piston stroke: 1.5 – 3.0 mm (0.059 – 0.118 in) If the stroke is more than standard value, replace the piston rod with a longer one. Piston rod length: 72.9 mm (2.870 in) 71.4 mm (2.811 in) 38. INSTALL ACCUMULATOR PISTONS AND SPRINGS (a) Install the springs and pistons into the bore. Sprnig Free length mm (in.) Color C1 57.64 (2.2693) Red, Purple B2 69.39 (2.7323) Green, White C2 70.21 (2.7641) Purple (b) Place the cover with the gasket and tighten the bolts gradually in sequence. HINT: Each bolt length (mm, in.) is indicated in the illustration. AX–121 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 39. INSTALL NEW SECOND BRAKE APPLY GASKET 40. INSTALL THROTTLE CABLE IN CASE Push the cable through the case, being careful not to damage the O–ring. Check for full seating. NOTICE: In subsequent work, to avoid breaking the cable fitting do not roll the case over the cable. 41. INSTALL SOLENOID WIRING 42. PLACE VALVE BODY ON TRANSAXLE (a) While holding the cam down by your hand, slip the cable end into the slot. (b) Lower the valve body into place. NOTICE: Do not entangle the kick–down switch wire or solenoid wire. 43. INSTALL BOLTS IN VALVE BODY HINT: Each bolt length (mm, in.) is indicated in the illustration. Hand tighten the 12 bolts first, then torque with a torque wrench. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) AX–122 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 44. INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length (mm, in.) is indicated in the illustration. (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Hand tighten the 4 bolts first. Then, tighten them with a torque wrench. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (d) Place the detent spring on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (e) Check that the manual valve lever is touching the center of the detent spring tip roller. 45. INSTALL OIL TUBES Using a plastic hammer, install the 4 tubes into the positions indicated in the illustration. NOTICE: Be careful not to bend or damage the tubes. 46. INSTALL TUBE BRACKET Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 47. INSTALL OIL STRAINER Each bolt length (mm, in.) is indicated in the figure. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) AX–123 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 48. CONNECT SOLENOID WIRING (a) Connect the No.1 solenoid connector. (white and shorter wire) (b) Connect the No.2 solenoid connector. (black and longer wire) 49. INSTALL 3 MAGNETS IN PLACE NOTICE: Make sure that the magnets do not interfere with the oil tubes. 50. INSTALL OIL PAN WITH NEW GASKET Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 51. INSTALL COVER 52. INSTALL COVER BRACKET AX–124 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 53. INSTALL SOLENOID WIRING RETAINING PLATE 54. INSTALL THROTTLE CABLE RETAINING PLATE 55. INSTALL FILLER TUBE AND BRACKET 56. INSTALL SL SOLENOID (a) Coat the O–ring with ATF and push the tip of SL solenoid into the hole. (b) Tighten the 2 bolts evenly and gradually. 57. INSTALL PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch to the manual valve shaft. (b) Install the seal gasket and locking plate. (c) Tighten the nut and stake it with the locking plate. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) 58. ADJUST PARK/NEUTRAL POSITION SWITCH (a) Align the groove and return neutral basic line. (b) Lock the switch with 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 59. (a) (b) (c) INSTALL UNION AND ELBOW Coat a new O–rings with ATF. Install the O–rings to the union and elbow. Install the union and elbow to the transaxle case. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) HINT: Install the elbow as shown in the illustration. AX–125 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 60. INSTALL MANUAL SHIFT LEVER IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002–0W To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The


procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the back of AX section, for quick reference. IN–3 INTRODUCTION – HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS:


CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English system. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) IN–4 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1. 2. 3. 4. 5. 6. IN022–07 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (–) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminal posts and cable terminals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non–reusable parts (a) Always replace cotter pins, gaskets, O–rings and oil seals etc. with new ones. (b) Non–reusable parts are indicated in the component illustrations by the ”” symbol. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply IN–5 INTRODUCTION 7. 8. 9. – GENERAL REPAIR INSTRUCTIONS the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the preparation of AX section. 10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. 11. To pull apart electrical connectors, pull on the connector itself, not the wires. 12. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. IN–6 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS IN016–02 This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage BARO Barometric Pressure CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position – DFI Direct Fuel Injection (Diesel) DI Distributor Ignition DLC1 Data Link Connector 1 1: Check Connector DLC2 Data Link Connector 2 2: Toyota Diagnosis Communication Link (TDCL) DLC3 Data Link Connector 3 3: OBD@@@@@: [g 2] Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory – +B, Battery Voltage – – Direct Injection (DI) – – – Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Toyota Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control FEEPROM – Flash Electrically Erasable Programmable – Read Only Memory FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IN–7 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure – Indirect Injection Manifold Pressure Intake Vacuum Electric Bleed Air Control Valve (EBCV) MC Mixture Control Mixture Control Valve (MCV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Light MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer RAM Random Access Memory RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass SFI Sequential Multiport Fuel Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body TBI Throttle Body Fuel Injection TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU (Electronic Control Unit) TP Throttle Position Throttle Position TR Transmission Range Electric Air Control Valve (EACV) – Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) Random Access Memory (RAM) – – Electronic Fuel Injection (EFI), Sequential Injection Throttle Body Single Point Injection Central Fuel Injection (Ci) – IN–8 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetallic Vacuum Switching Valve (BVSV) TVV Thermal Vacuum Valve TWC Three–Way Catalytic Converter TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter WU–TWC Warm Up Three–Way Catalytic Converter 3GR Third Gear – 4GR Fourth Gear – Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) CCRO – Manifold Converter IN–9 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL IN01H–0R ATF Automatic Transaxle Fluid B0 Overdrive Brake B1 Second coast Brake B2 Second Brake B3 First and Reverse Brake C0 Overdrive Direct Clutch C1 Forward Clutch C2 Direct Clutch D Disc F Flange F0 O/D One–way Clutch F1 No.1 One–way Clutch F2 No.2 One–way Clutch MP Multipurpose O/D Overdirve P Plate SSM Special Service Materials SST Special Service Tools IN–10 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS IN008–02 IN–11 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS AX–1 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION AX0CH–05 GENERAL SPECIFICATIONS Type of Transaxle A541E Type of Engine 1MZ–FE Torque Converter Clutch Stall Torque Ratio 1.8 : 1 Torque Converter Clutch Lock–up Mechanism Gear Ratio Transaxle B1 Band Width Equipped 1st Gear 2.810 2nd Gear 1.549 3rd Gear 1.000 O/D Gear 0.735 Reverse Gear 2.296 Number of Discs and Plates O/D Direct Clutch (C0) 2/2 Forward Clutch (C1) 5/5 Direct Clutch (C2) 3/3 2nd Brake (B2) 3/3 First and Reverse Brake (B3) 6/6 O/D Brake (B0) 3/3 mm (in.) ATF Type Capacity liter (US qts, Imp.qts) 25 (0.98) ATF D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) A/T 6.75(7.1, 5.9) D/F 0.85 (0.9, 0.7) AX–2 AUTOMATIC TRANSAXLE – OPERATION OPERATION 1. MECHANICAL OPERATION AX0RF–01 AX–3 AUTOMATIC TRANSAXLE – OPERATION AX019–03 2. FUNCTION OF COMPONENTS AX–4 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit. Shift change is carried out by altering the combination of clutch and brake operation. Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle opening angle and vehicle speed, and shift change automatically occurs. The conditions of operation for each gear position are shown on the following illustrations: AX–5 AUTOMATIC TRANSAXLE – OPERATION AX01A–0B 3. HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes as well as the fluid passages which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the vehicle driving conditions. There are three solenoid valves on the valve body. The No.1 and No.2 solenoid vales are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position. The SL solenoid valve is operated by signals from the ECM to engage or disengage the lock–up clutch of the torque converter clutch. The SLN solenoid valve is operated by signals from the ECM to control the engagement speed and reduce gear shift shock. AX–6 AUTOMATIC TRANSAXLE – PREPARATION PREPARATION AX02L–06 SST (SPECIAL SERVICE TOOLS) 09226–10010 Crankshaft Front & Rear Bearing Replacer 09240–00020 Wire Gauge Set 09316–20011 Transfer Bearing Replacer 09316–60011 Transmission & Transfer Bearing Replacer (09316–00011) Replacer Pipe 09350–32014 TOYOTA Automatic Transmission Tool Set 09308–10010 Oil Seal Puller (09351–32032) Counter Driven Gear Holding Tool (09351–32040) No.1 Piston Spring Compressor (09351–32050) Snap Ring Expander (09351–32061) Oil Pump Puller (09351–32070) No.2 Piston Spring Compressor (09351–32080) Lock Nut Wrench Install RH retainer oil seal AX–7 AUTOMATIC TRANSAXLE – PREPARATION (09351–32100) Drive Pinion Bearing Replacer (09351–32120) Overdrive Bearing Replacer (09351–32140) Oil Seal Replacer (09351–32150) Oil Seal Replacer (09351–32190) Measure Terminal (09351–32200) No.3 Piston Spring Compressor 09608–16011 Rear Hub Bearing Tool– Remove differential side bearing 09612–65014 Steering Worm Bearing Puller Remove pinion shaft bearing outer race 09950–40010 Puller B Set AX02M–02 RECOMMENDED COOL 09031–00030 Pin Punch . AX–8 AUTOMATIC TRANSAXLE – PREPARATION AX02N–02 EQUIPMENT Feeler gauge Check major clearance. Vernier calipers Check length of second coast brake piston rod. Dial indicator with magnetic base Check piston stroke and end play of the output shaft. Dial indicator Check inside diameter of major bushing. Straight edge Check side clearance of oil pump. Torque wrench AX01V–08 LUBRICANT Item Capacity Automatic transaxle fluid: Dry fill Drain and refill Classification ATF D–@@@@@: [g 2] or 6.75 liters (7.10 US qts, 5.94 Imp.qts) 2.5 liters (2.6 US qts, 2.2 Imp.qts) DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) ATF D–@@@@@: [g 2] or Differential oil 0.85 liters (0.89 US qts, 0.75 Imp.qts) DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) AX02P–02 SSM (SPECIAL SERVICE MATERIALS) 08826–00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Differential LH bearing retainer Differential RH retainer 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent Differential RH retainer set bolt AX–9 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL AX02Q–02 COMPONENTS AX–10 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–11 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–12 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–13 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0TT–02 SEPARATE BASIC SUBASSEMBLY 1. REMOVE SHIFT CONTROL CABLE BRACKET 2. REMOVE UNION AND ELBOW (a) Remove the manual shift lever. (b) Using a open end wrench, remove the union and elbow. (c) Remove the O–rings from the union and elbow. 3. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Pry off the lock washer and remove the manual valve shaft nut. (b) Remove the 2 bolts and pull out the park/neutral position switch. 4. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE AX–14 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 5. REMOVE T/M REVOLUTION SENSOR (a) Remove the bolt and T/M revolution sensor. (b) Remove the O–ring from the T/M revolution sensor. 6. REMOVE TRANSAXLE CASE UPPER COVER 7. REMOVE OIL PAN AND GASKET (a) Remove the 17 bolts. (b) Remove the oil pan by lifting transaxle case. NOTICE: Do not turn the transaxle over as this will contaminate the valve body with the foreign materials in the bottom of the oil pan. (c) Place the transaxle on wooden blocks to prevent damage to the oil pipe bracket. 8. EXHAUST PARTICLES IN PAN Remove the magnet and use it to collect any steel chips. Lock carefully at the chips and particles in the oil pan and on magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear 9. REMOVE OIL PIPE BRACKET AND STRAINER AX–15 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 10. REMOVE MANUAL VALVE BODY (a) Remove the 2 bolts and detent spring. (b) Remove the 5 bolts and manual valve body with the manual valve. (c) Remove the manual valve from the manual valve body. 11. REMOVE OIL PIPES (a) Remove the bolt. (b) Pry up both pipe ends with a large screwdriver and remove the 6 pipes. 12. DISCONNECT SOLENOID CONNECTORS 13. REMOVE CONNECTOR CLAMP AND PIPE RETAINER AX–16 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 14. REMOVE B3 APPLY PIPE Pry up the pipe with a screwdriver and remove the pipe. 15. REMOVE VALVE BODY (a) Remove the 9 bolts. (b) Remove the wire harness clamp. (c) Disconnect the throttle cable from the cam, and remove the valve body. 16. REMOVE THROTTLE CABLE AX–17 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 17. REMOVE SOLENOID WIRING Remove the bolt and the solenoid wiring. 18. REMOVE SECOND BRAKE APPLY GASKET 19. REMOVE ACCUMULATOR PISTONS AND SPRINGS (a) Loosen the 4 bolts one turn at a time until the spring tension is released. (b) Remove the cover and gasket. (c) Remove the C1 accumulator piston and spring. (d) Remove the 2 O–rings from the piston. (e) Pop out pistons for C2 and B2 into a rag, using low–pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi). (f) Remove the O–rings from the pistons. AX–18 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 20. MEASURE PISTON STROKE SECOND COAST BRAKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09240–00020 Maximum thrust clearance: 2.0–3.5 mm (0.079–0.138 in.) If the piston stroke exceeds the limit, inspect the second coast brake band. 21. REMOVE SECOND COAST BRAKE PISTON (a) Using SST, remove the snap ring. SST 09350–32014 (b) Applying compressed air to the oil hole, remove the second coast brake cover, piston assembly and spring. (c) Remove the 2 O–rings from the cover. AX–19 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 22. STAND TRANSAXLE ENGINE SIDE UPWARD 23. REMOVE OIL PUMP NOTICE: Before removing the oil pump, remove the second coast brake piston. (a) Remove the 7 bolts. (b) Using SST, pull out the oil pump from the transaxle case. SST 09350–32014 24. REMOVE O–RING FROM OIL PUMP 25. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH 26. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH (a) Separate the direct clutch and forward clutch. (b) Remove the thrust washer from direct clutch. AX–20 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 27. REMOVE BEARING FROM FORWARD CLUTCH 28. REMOVE SECOND COAST BRAKE BAND (a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting. (b) Remove the brake band. 29. REMOVE FRONT PLANETARY RING GEAR 30. REMOVE FRONT PLANETARY GEAR (a) Remove the front planetary gear. (b) Remove the 2 bearings from the planetary gear. AX–21 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 31. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM (a) Remove the sun gear and the sun gear input drum. (b) Remove the thrust washer from sun gear input drum. 32. CHECK OPERATION OF SECOND BRAKE PISTON Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassembe and inspect. 33. REMOVE SECOND COAST BRAKE BAND GUIDE 34. REMOVE SECOND BRAKE DRUM (a) Remove the snap ring. AX–22 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the second brake drum. 35. REMOVE SECOND BRAKE PISTON RETURN SPRING 36. REMOVE NO.1 ONE–WAY CLUTCH 37. REMOVE PLATES, DISCS AND FLANGE 38. REMOVE SECOND BRAKE DRUM GASKET Remove the gasket. AX–23 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 39. REMOVE NO.2 ONE–WAY CLUTCH AND REAR PLANETARY GEAR (a) Remove the snap ring. (b) Remove the No.2 one–way clutch and rear planetary gear. (c) Remove the thrust washer from the rear planetary gear. 40. REMOVE REAR PLANETARY RING GEAR (a) Remove the rear planetary ring gear. (b) Remove the bearing from the ring gear. 41. CHECK FIRST AND REVERSE BRAKE (a) Check the operation of the first and reverse brake piston. Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassemble and inspect. AX–24 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a filler gauge, check the pack clearance of the first and reverse brake. Clearance: 1.92–2.68 mm (0.0756–0.1055 in.) 42. REMOVE FLANGE, DISCS AND PLATES OF FIRST AND REVERSE BRAKE (a) Remove the snap ring. (b) Remove the flange, 6 discs and plates. 43. TURN TRANSAXLE CASE AROUND 44. REMOVE OVERDRIVE UNIT (a) Remove the 13 bolts. (b) Tap on the circumference of the overdrive case with a plastic hammer to remove the overdrive case and gasket. AX–25 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS REMOVAL Remove the overdrive planetary gear from transaxle case. (d) Remove the overdrive brake drum from the transaxle case. (e) Remove the overdrive clutch apply gasket and overdrive brake apply gasket. 45. REMOVE FIRST AND REVERSE BRAKE PISTON (a) Remove the piston return spring.
Place SST, compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040)


Using snap ring pliers, remove the snap ring. Remove the SST. Remove the return spring from the case. AX–26 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Apply compressed air into the passage of the case to remove the piston. HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole. (c) If the piston does not pop out with compressed air, use needle–nose pliers to remove it. (d) Remove the 2 O–rings from the piston. (e) Remove the snap ring. 46. REMOVE PARKING LOCK PAWL BRACKET AND GUIDE AX–27 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 47. REMOVE MANUAL VALVE SHAFT (a) Using a chisel and hammer, cut the collar. (b) Remove the retaining spring. (c) Using a pin punch and hammer, drive out the pin. (d) Slide out the shaft from the transaxle case and remove the manual valve lever and parking lock rod. 48. REMOVE MANUAL VALVE SHAFT OIL SEAL Using a screwdriver, remove the oil seal. AX–28 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 49. REMOVE PIN, SPRING AND PARKING LOCK PAWL AX02S–04 DIFFERENTIAL COMPONENT PARTS REMOVAL 1. MEASURE DIFFERENTIAL TOTAL PRELOAD Using a small torque wrench, measure the total preload and make a note of it. 2. REMOVE LH BEARING RETAINER (a) Remove the 6 bolts. (b) Using a large screwdriver, remove the LH bearing retainer. NOTICE: Wrap the screwdriver tip in a rag, etc. to avoid damaging the case and retainer. 3. REMOVE RH RETAINER (a) Remove the 5 bolts. AX–29 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a large screwdriver, remove the RH retainer. NOTICE: Wrap the screwdriver tip in a rag, etc. to avoid damaging the case and retainer. 4. REMOVE CARRIER COVER (a) Remove the 10 bolts. (b) Tap the carrier cover with a plastic hammer to remove it. (c) Remove the apply gasket. 5. REMOVE DIFFERENTIAL CASE Remove the differential case, outer case and shim from the transaxle case. AX–30 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 6. REMOVE TRANSAXLE CAP (a) Remove the bolt. (b) Using pliers, pull out the drive pinion cap. (c) Remove the O–rings from the cap. 7. MEASURE DRIVE PINION PRELOAD Using a small torque wrench, measure the drive pinion preload. Preload (Reused bearing at starting): 0.5–0.8 N·m (5–8 kgf·cm, 4.3–6.9 in.·lbf) The total preload measured in step 1 minus the drive pinion preload equals 0.1–0.2 N·m (1.3–2.0 kgf·cm, 1.1–1.7 in.·lbf). If the result is not within this specification, the side bearing preload is suspect. 8. REMOVE COUNTER DRIVEN GEAR (a) Using a chisel and hammer, loosen the staked part of the nut. (b) Using SST to hold the gear, remove the nut. SST 09330–00021, 09350–32014 (09351–32032) AX–31 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS REMOVAL Using SST, remove the gear and bearing. SST 09350–32014 (09351–32061) 9. REMOVE OUTER RACE, SPACER AND OIL SLINGER (a) Using SST, remove the outer race with oil slinger and spacer. SST 09350–32014 (09308–10010) (b) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) 10. REMOVE DRIVE PINION (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Install the bar into the case hole to drive out the drive pinion. (c) Using a press, drive out the drive pinion from transaxle case. AX–32 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (d) Remove the bearing cage from drive pinion. (e) Using SST, press out the bearing. SST 09950–00020 AX–33 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX02T–07 GENERAL NOTES The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar–looking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups. Recommended fluid for the automatic transaxle: ATF D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) 1. GENERAL CLEANING NOTES: (a) All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air. (b) When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transaxle fluid or kerosene in your face. (c) The recommended automatic transaxle fluid or kerosene should be used for cleaning. 2. PARTS ARRANGEMENT: (a) After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly. (b) When disassembling a valve body, be sure to keep each valve together with the corresponding spring. (c) New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least fifteen minutes before assembly. 3. GENERAL ASSEMBLY: (a) All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly. (b) All gaskets and rubber O–rings should be replaced. (c) Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. (d) If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced. (e) Check thrust bearings and races for wear or damage. Replace if necessary. (f) Use petroleum jelly to keep parts in place. AX–34 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE SECOND COAST BRAKE AX02U–02 COMPONENTS SECOND COAST BRAKE PISTON DISASSEMBLY 1. AX02V–02 REMOVE OIL SEAL RING Remove the oil seal ring from the piston. 2. REMOVE PISTON ROD (a) Remove the E–ring while pushing the piston with needle– nose pliers. AX–35 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Remove the inner spring, plate washer and piston rod. AX02W–03 SECOND COAST BRAKE COMPONENT INSPECTION If the lining of the brake band is peeling off or discolored, or even part of the printed mark is defaced, replace the brake band. AX02X–03 SECOND COAST BRAKE PISTON ASSEMBLY 1. SELECT PISTON ROD If the band is OK but piston stroke not within the standard value, select a new piston rod. Piston stroke: 2.0–3.5 mm (0.079–0.138 in.) There are 2 lengths of piston rod. Piston rod length: 95.2 mm (3.748 in.) 96.3 mm (3.791 in.) 2. INSTALL PISTON ROD (a) Install the plate washer and inner spring to the piston rod. AX–36 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Install the E–ring while pushing the piston. 3. INSTALL OIL SEAL RING (a) Apply ATF to the oil seal ring. (b) Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary. AX–37 AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP AX02Y–02 COMPONENTS OIL PUMP DISASSEMBLY AX02Z–02 1. REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the stator shaft back side. 2. REMOVE THRUST WASHER FROM STATOR SHAFT BACK SIDE AX–38 AUTOMATIC TRANSAXLE – OIL PUMP 3. REMOVE STATOR SHAFT Remove the 11 bolts and stator shaft. HINT: Keep the gears in assembly order. 4. REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AX030–06 OIL PUMP BUSHING INSPECTION 1. CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: 0.07–0.15 mm (0.0028–0.0059 in.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than the maximum, replace the oil pump body subassembly. 2. CHECK TIP CLEARANCE OF DRIVEN GEAR Measure between the driven gear teeth and the crescent–shaped part of the pump body. Standard tip clearance: 0.11–0.14 mm (0.0043–0.0055 in.) Maximum tip clearance: 0.30 mm (0.0118 in.) If the tip clearance is greater than the maximum, replace the oil pump body subassembly. AX–39 AUTOMATIC TRANSAXLE 3. – OIL PUMP CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.002–0.005 mm (0.0008–0.0020 in.) Maximum side clearance: 0.100 mm (0.0039 in.) There are 3 different thicknesses for drive and driven gears. Drive and driven gear thickness Mark Thickness mm (in.) A 9.440–9.456 (0.3717–0.3723) B 9.456–9.474 (0.3723–0.3730) C 9.474–9.490 (0.3730–0.3736) If the thickest gear can not make the side clearance within standard specification, replace the oil pump body subassembly. 4. CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 38.18 mm (1.5031 in.) If the inside diameter is greater than the maximum, replace the oil pump body subassembly. 5. CHECK STATOR SHAFT BUSHING Using a dial indicator, measure the inside diameter stator shaft bushing. Maximum inside diameter: 21.57 mm (0.8492 in.) If the inside diameter is greater than the maximum, replace the stator shaft. AX031–02 OIL PUMP ASSEMBLY 1. INSTALL FRONT OIL SEAL Using SST and a hammer, install a new oil seal. The seal end should be flush with the outer edge of the pump body. SST 09350–32014 (09351–32140) AX–40 AUTOMATIC TRANSAXLE 2. – OIL PUMP INSTALL DRIVEN GEAR AND DRIVE GEAR Make sure the top of the gears are facing upward. 3. INSTALL STATOR SHAFT TO PUMP BODY (a) Align the stator shaft with each bolt hole. (b) Torque the 11 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollow of the pump body. 5. INSTALL OIL SEAL RINGS Install the 2 oil seal rings to the stator shaft back side. NOTICE: Do not spread the ring ends more than necessary. HINT: After installing the oil seal rings, check that they move smoothly. 6. CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip. AX–41 AUTOMATIC TRANSAXLE – DIRECT CLUTCH DIRECT CLUTCH AX032–02 COMPONENTS DIRECT CLUTCH DISASSEMBLY AX033–05 1. CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Install a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kg/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 0.91–1.35 mm (0.0358–0.0531 in.) If the piston stroke is greater than the maximum, inspect each component. AX–42 AUTOMATIC TRANSAXLE 2. 3. – DIRECT CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES 4. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with snap ring pliers. (c) Remove the piston return spring. 5. REMOVE CLUTCH PISTON (a) Install the direct clutch onto the oil pump. (b) Apply compressed air to the oil pump to remove the piston (if the piston does not come out completely, use needle– nose pliers to remove it). (c) Remove the direct clutch from the oil pump. (d) Remove the 2 O–rings from the piston. AX–43 AUTOMATIC TRANSAXLE – DIRECT CLUTCH AX034–03 DIRECT CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the direct clutch bushing. Maximum inside diameter: 48.27 mm (1.9004 in.) If the inside diameter is greater than the maximum, replace the direct clutch. DIRECT CLUTCH ASSEMBLY AX035–06 1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM (a) Install new O–rings to the piston. Coat the O–rings with ATF. (b) Being careful not to damage the O–rings, press the piston into the drum with the cup side up. 2. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring onto the piston. AX–44 AUTOMATIC TRANSAXLE – DIRECT CLUTCH (b) Place SST on the spring retainer, and compress the return spring with a press. SST 09350–32014 (09351–32070) (c) Install the snap ring using snap ring pliers. Be sure the end gap of snap ring is aligned with the spring retainer claw. 3. INSTALL PLATES, DISCS AND FLANGE (a) Install plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 4. INSTALL SNAP RING Check that the end gap of the snap ring is not aligned with one of the cutouts. 5. RECHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Install a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 0.91–1.35 mm (0.0358–0.0531 in.) If the piston stroke is non–standard, select another flange. HINT: There are 2 different thickness for the flange. Flange thickness: 2.70 mm (0.1063 in.) 3.00 mm (0.1181 in.) AX–45 AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH AX036–02 COMPONENTS FORWARD CLUTCH DISASSEMBLY 1. AX037–04 CHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.79–2.21 mm (0.0704–0.0870 in.) each component. AX–46 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. REMOVE SNAP RING FROM CLUTCH DRUM 3. REMOVE FLANGE, DISCS AND PLATES 4. REMOVE RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Using snap ring pliers, remove the snap ring. (c) Remove the return spring. 5. REMOVE CLUTCH PISTON (a) Apply compressed air into the oil passage to remove the piston. If the piston does not come out, use needle–nose pliers to remove it. AX–47 AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Remove the 2 O–rings from the piston. 6. IF NECESSARY, REMOVE OIL SEAL RINGS Remove the 3 oil seal rings from the shaft. AX038–03 FORWARD CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX039–04 FORWARD CLUTCH ASSEMBLY 1. INSTALL OIL SEAL RINGS Install the 3 oil seal rings to the shaft. NOTICE: Do not spread the ring ends more than necessary. HINT: After installing the oil seal rings, check that they move smoothly. AX–48 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. INSTALL CLUTCH PISTON TO CLUTCH DRUM (a) Install the 2 new O–rings to the piston. (b) Coat the O–ring with ATF. (c) Press the piston into the drum with the cup side up, being careful not to damage the O–rings. 3. INSTALL PISTON RETURN SPRINGS (a) Place the return spring and snap ring onto the piston. (b) Place SST on the spring retainer, and compress the springs with a press. SST 09350–32014 (09351–32070) (c) Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. 4. INSTALL PLATES, DISCS AND FLANGE (a) Install the plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 5. INSTALL SNAP RING Check that the end gap of snap ring is not aligned with one of the cutouts. AX–49 AUTOMATIC TRANSAXLE 6. – FORWARD CLUTCH RECHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.79–2.21 mm (0.0704–0.0870 in.) If the piston stroke is non–standard, select another flange. HINT: There are 2 different thicknesses for the flange. Flange thickness: 2.30 mm (0.0906 in.) 2.70 mm (1.0630 in.) AX–50 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR FRONT PLANETARY GEAR AX03A–02 COMPONENTS AX0TU–03 NO.1 ONE–WAY CLUTCH AND SUN GEAR DISASSEMBLY 1. CHECK OPERATION OF NO.1 ONE–WAY CLUTCH Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock counterclockwise. 2. REMOVE NO.1 ONE–WAY CLUTCH FROM SUN GEAR While turning the hub clockwise, remove the No.1 one– way clutch from the sun gear. AX–51 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR 3. REMOVE SUN GEAR FROM DRUM (a) Using snap ring pliers, remove the snap ring from the drum. (b) Remove the sun gear from the drum. 4. CHECK SUN GEAR BUSHINGS Using a dial indicator, measure the inside diameter of the sun gear bushings. Maximum inside diameter: 22.59 mm (0.8894 in.) If the inside diameter is greater than the maximum, replace the sun gear. AX0TV–01 NO.1 ONE–WAY CLUTCH AND SUN GEAR ASSEMBLY 1. INSTALL SUN GEAR TO DRUM (a) Install the sun gear to the drum. (b) Using snap ring pliers, install the snap ring to drum. 2. 3. INSTALL NO.1 ONE–WAY CLUTCH ON SUN GEAR While turning the hub clockwise, slide the No.1 one–way clutch onto the sun gear. RECHECK OPERATION OF NO.1 ONE–WAY CLUTCH AX03D–02 PLANETARY RING GEAR INSPECTION 1. INSPECT RING GEAR FLANGE BUSHING Using a dial indicator, measure the inside diameter of the flange bushing. Maximum inside diameter: 30.08 mm (1.1842 in.) If the inside diameter is greater than the maximum, replace the flange. AX–52 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR 2. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 3. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. FRONT PLANETARY GEAR INSPECTION AX03E–03 MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. AX–53 AUTOMATIC TRANSAXLE – SECOND BRAKE SECOND BRAKE AX03F–02 COMPONENTS AX03G–03 SECOND BRAKE PISTON DISASSEMBLY REMOVE SECOND BRAKE PISTON (a) Apply compressed air to the oil hole to remove the piston. (b) Remove the 2 O–rings from the piston. AX–54 AUTOMATIC TRANSAXLE – SECOND BRAKE AX03H–03 SECOND BRAKE COMPONENT INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX03J–06 SECOND BRAKE PISTON ASSEMBLY INSTALL PISTON (a) Coat a new O–ring with ATF. (b) Install the 2 new O–rings on the piston. (c) Press the piston into the drum, being careful not to damage the O–rings. AX–55 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REAR PLANETARY GEAR AX03K–02 COMPONENTS NO.2 ONE–WAY CLUTCH DISASSEMBLY AX03L–02 1. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH Hold the outer race and turn the rear planetary gear. The rear planetary gear should turn freely counterclockwise and should lock clockwise. 2. SEPARATE NO.2 ONE–WAY CLUTCH AND REAR PLANETARY GEAR REMOVE THRUST WASHER Remove the thrust washer from the rear side of planetary gear. 3. AX–56 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR 4. REMOVE NO.2 ONE–WAY CLUTCH FROM OUTER RACE (a) Remove the 2 snap rings and retainers from both sides. (b) Remove the No.2 one–way clutch from the outer race. AX03M–03 REAR PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. NO.2 ONE–WAY CLUTCH ASSEMBLY AX03N–02 1. INSTALL ONE–WAY CLUTCH (a) Install the No.2 one–way clutch into the outer race, facing the flange side of the No.2 one–way clutch toward the shiny side of the outer race. (b) Install the 2 retainers and snap rings to both sides. AX–57 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR 2. INSTALL PLANETARY GEAR INTO NO.2 ONE–WAY CLUTCH Install the planetary gear into the No.2 one–way clutch, facing the inner race of the rear planetary gear toward the black side of the No.2 one–way clutch outer race. 3. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH 4. INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollows of the carrier. RING GEAR FLANGE REPLACEMENT 1. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 2. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. AX03P–02 AX–58 AUTOMATIC TRANSAXLE – FIRST AND REVERSE BRAKE FIRST AND REVERSE BRAKE AX03Q–02 COMPONENTS FIRST AND REVERSE BRAKE COMPONENTS INSPECTION AX03R–03 INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX–59 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT OVERDRIVE UNIT AX03S–02 COMPONENTS AX–60 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03T–03 OVERDRIVE BRAKE DISASSEMBLY 1. REMOVE PISTON RETURN SPRING (a) While pushing the return spring, remove the snap ring with a screwdriver. (b) Remove the piston return spring. 2. REMOVE PLATES, DISCS AND FLANGE 3. REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston. HINT: Blow with the gun slightly away from the oil hole, and be careful that the piston does not tilt. 4. REMOVE O–RINGS Remove the inner and outer O–rings from the piston. AX–61 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03U–03 OVERDRIVE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX03V–05 OVERDRIVE DIRECT CLUTCH DISASSEMBLY 1. CHECK PISTON STROKE OF DIRECT CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 5–8 kgf/cm2, 57–114 psi). Piston stroke: 1.75–2.49 mm (0.0689–0.0980 in.) 2. 3. SST 09350–32014 (09351–32190) If the piston stroke is greater than the maximum, inspect each component. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE AX–62 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 4. REMOVE SNAP RING WITH SCREWDRIVER 5. REMOVE FLANGES, DISCS AND PLATES 6. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the spring with a press. SST 09350–32014 (09351–32070, 09351–32200) (b) Remove the snap ring. (c) Remove the piston return spring. 7. REMOVE PISTON FROM CLUTCH DRUM (a) Install the clutch drum on the case. (b) Apply compressed air to the pressure apply hole of the case. (c) Remove the piston from the clutch drum. If the piston does not come out completely, use needle– nose pliers to remove it. (d) Remove the clutch drum from the case. AX–63 AUTOMATIC TRANSAXLE 8. – OVERDRIVE UNIT REMOVE O–RINGS Remove the 2 O–rings from the piston. AX03W–03 OVERDRIVE DIRECT CLUTCH INSPECTION 1. INSPECT OVERDRIVE DIRECT CLUTCH (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the 2 direct clutch bushings. Maximum inside diameter: 22.13 mm (0.8713 in.) If the inside diameter is greater than the maximum, replace the direct clutch drum. AX03X–06 OVERDRIVE DIRECT CLUTCH ASSEMBLY 1. INSTALL CLUTCH PISTON (a) Install new O–rings to the piston. Coat the O–rings with ATF. AX–64 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (b) Press the piston into the drum with the cup side up, being careful not to damage the O–ring. 2. INSTALL PISTON RETURN SPRING (a) Install the return spring and seat snap ring in place. (b) Place SST on the spring retainer, and compress the spring with a press. SST 09350–32014 (09351–32070, 09351–32200) (c) Install the snap ring with a screwdriver. Be sure end gap of snap ring is aligned with the groove of the clutch drum. 3. INSTALL PLATES, DISCS AND FLANGE Install in order: P=Plate D=Disc P–D–P–D–Flange 4. INSTALL SNAP RING Be sure end gap of the snap ring is not aligned with the groove of the clutch drum. AX–65 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 5. INSTALL BEARING AND RACE (a) Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum. Bearing outer diameter: 46.3 mm (1.823 in.) Bearing inner diameter: 26.2 mm (1.031 in.) (b) Coat the race with petroleum jelly and install it to the case. Race outer diameter: 43.0 mm (1.693 in.) Race inner diameter: 24.5 mm (0.965 in.) 6. INSTALL DIRECT CLUTCH ON CASE 7. RECHECK PISTON STROKE OF DIRECT CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). Piston stroke: 1.75–2.49 mm (0.0689–0.0980 in.) SST 09350–32014 (09351–32190) AX03Y–03 COUNTER DRIVE GEAR DISASSEMBLY 1. CHECK OPERATION OF ONE–WAY CLUTCH (a) Install the O/D direct clutch into the one–way clutch. (b) Hold the O/D direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise. (c) Remove the O/D direct clutch. AX–66 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 2. CHECK COUNTER DRIVE GEAR PRELOAD (a) Hold the O/D planetary gear in a vise with soft jaws. HINT: Do not let the counter drive gear touch the vise. (b) Using a tension gauge, measure the preload. Preload (at starting): 9.2–15.3 N (940–1,560 g, 2.1–3.4 lb) HINT: Turn the counter drive gear right and left several times before measuring the preload. 3. REMOVE O/D ONE–WAY CLUTCH AND OUTER RACE (a) Remove the snap ring. (b) Remove the retaining plate. (c) Remove the O/D one–way clutch with outer race. (d) Remove the 2 retainers from both sides of the O/D one– way clutch. AX–67 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Remove the O/D one–way clutch from the outer race. HINT: Note the direction of the one–way clutch. 4. 5. REMOVE NO.3 PLANETARY THRUST WASHER REMOVE PLUGS FROM PLANETARY GEAR Remove the 4 plugs with a magnetic finger. NOTICE: Be careful not to lose them. 6. REMOVE ADJUSTING NUT AND LOCKING WASHER (a) Pry off the locking washer. (b) Using SST, loosen the adjusting nut. SST 09350–32014 (09351–32080) (c) Remove the adjusting nut and locking washer. 7. REMOVE INTERMEDIATE SHAFT BEARING Using SST, press out the bearing from the shaft. SST 09950–00020 AX–68 AUTOMATIC TRANSAXLE 8. – OVERDRIVE UNIT REMOVE COUNTER DRIVE GEAR AND FRONT BEARING Press out the gear and bearing together. 9. REMOVE REAR BEARING (a) Using SST, press out the bearing. SST 09950–00020 (b) Tag the bearings to show the location for reassembly. 10. REMOVE O/D PLANETARY RING GEAR FROM COUNTER DRIVE GEAR (a) While pulling up the ring gear, compress the snap ring with needle–nose pliers and remove it from the groove. (b) Remove the ring gear from the counter drive gear. (c) Remove the snap ring from the ring gear. AX–69 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 11. REMOVE OUTER RACES FROM COUNTER DRIVE GEAR (a) Drive out the 2 races with a brass bar and hammer. (b) Tag the races to show the location for reassembly. 12. REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring. OVERDRIVE PLANETARY GEAR INSPECTION AX03Z–03 MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater then the maximum, replace the planetary gear assembly. AX–70 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX040–03 COUNTER DRIVE GEAR ASSEMBLY 1. INSTALL SNAP RING INTO COUNTER GEAR Install the snap ring with a screwdriver. 2. INSTALL OUTER RACES INTO COUNTER DRIVE GEAR Using SST, press in the 2 outer races to both sides of the gear. SST 09350–32014 (09351–32120, 09351–32150) HINT: Press in the 2 outer races until they touch the snap ring. Tap the races in straight, so that they do not tilt. 3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO COUNTER DRIVE GEAR (a) Install the snap ring to the ring gear. (b) While pushing down the ring gear, squeeze the snap ring end with needle–nose pliers, and install it into the groove. 4. INSTALL REAR BEARING Using SST, press in the bearing onto the shaft. SST 09350–32014 (09351–32120) HINT: Press in the bearing until the side surface of the inner race touches the planetary carrier. AX–71 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 5. INSTALL COUNTER DRIVE GEAR AND FRONT BEARING (a) Install the gear onto the shaft, and mesh the ring gear with the planetary pinions. (b) Place the front bearing on to the shaft. (c) Using SST, press in the bearing until there is slight play between the bearings. SST 09350–32014 (09351–32120) HINT: Hold the ring gear to prevent it from falling. 6. INSTALL INTERMEDIATE SHAFT BEARING Using SST, press in the bearing until it slightly touches the front bearing of the counter drive gear. SST 09350–32014 (09351–32120) HINT: The counter drive gear can be turned lightly. 7. PLACE NEW LOCKING WASHER 8. INSTALL ADJUSTING NUT AND ADJUST PRELOAD OF COUNTER DRIVE GEAR (a) Hold the overdrive planetary gear in a vise with soft jaws. (b) Using SST, tighten the adjusting nut until the following gear starting load is reached on the tension gauge. SST 09350–32014 (09351–32080) Preload (at starting): 9.2–15.3 N (940–1,560 g, 2.1–3.4 lb) AX–72 AUTOMATIC TRANSAXLE (c) – OVERDRIVE UNIT HINT: Turn the counter drive gear right and left several times before measuring the preload. Lock the adjusting nut with one locking washer tab. Bend the locking washer tab until it is flat with the adjusting nut groove. 9. INSTALL NO.3 OVERDRIVE PLANETARY THRUST WASHER 10. INSTALL PINION SHAFT PLUGS Install the 4 plugs into the pinion shaft. 11. INSTALL OVERDRIVE ONE–WAY CLUTCH AND RETAINING PLATE (a) Install the one–way clutch into the outer race. (b) Install the 2 retainers on both sides of the one–way clutch. (c) Install the one–way clutch into the overdrive planetary gear. HINT: Be sure that the one–way clutch is installed in the correct direction. (d) Install the retaining plate. AX–73 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Install the snap ring. 12. CHECK OPERATION OF O/D ONE–WAY CLUTCH (a) Install the overdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise. (c) Remove the overdrive direct clutch. AX041–02 OVERDRIVE CASE DISASSEMBLY 1. REMOVE C0 ACCUMULATOR PISTON FROM OVERDRIVE CASE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retaining plate and 2 springs. (c) Remove the accumulator piston. (d) Remove the O–ring from the piston. AX–74 AUTOMATIC TRANSAXLE 2. – OVERDRIVE UNIT REMOVE OIL SEAL RINGS AX042–02 OVERDRIVE CASE ASSEMBLY 1. INSTALL OIL SEAL RINGS ON OVERDRIVE CASE Install the 2 oil seal rings to the overdrive case groove, then snug them down by squeezing their ends together. HINT: After installing the oil seal rings, check that they move smoothly. 2. INSTALL C0 ACCUMULATOR PISTON TO OVERDRIVE CASE (a) Install a new O–ring to the accumulator piston. (b) Coat the O–ring with ATF. (c) Install the accumulator piston, 2 springs and retaining plate. (d) Using snap ring pliers, install the snap ring. AX–75 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX043–05 OVERDRIVE BRAKE ASSEMBLY 1. INSTALL PISTON INTO DRUM (a) Install new O–rings to the piston. Coat the new O–rings with ATF. (b) Press the piston into the drum, being careful not to damage the O–rings. 2. INSTALL FLANGE, DISCS AND PLATES Install the flange, discs and plates. Install in order: P=Plate D=Disc Flange–D–P–D–P–D–P 3. POSITION PISTON RETURN SPRING AX–76 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 4. INSTALL SNAP RING INTO CASE Be sure the end gap of the snap ring is not aligned with one of cutouts. 5. INSTALL OVERDRIVE PLANETARY GEAR ONTO OVERDRIVE DIRECT CLUTCH While turning the overdrive planetary gear clockwise, install it onto the overdrive direct clutch. HINT: If the overdrive planetary gear is properly installed onto the direct clutch, the counter drive gear height from the overdrive case will be about 24 mm (0.94 in.). AX–77 AUTOMATIC TRANSAXLE – VALVE BODY VALVE BODY AX044–02 COMPONENTS VALVE BODY DISASSEMBLY AX0TW–01 NOTICE: When disassembling the valve body, be careful not to damage or deform the plate which overhangs the valve body. 1. REMOVE SOLENOIDS (a) Remove No.1 and No.2 solenoids with the retainer. NOTICE: When removing the solenoid, do not use a screwdriver, etc. to pry up the solenoid. (b) Remove the O–ring from each solenoid. (c) Remove the No.3 solenoid. (d) Remove the O–ring from the solenoid. AX–78 AUTOMATIC TRANSAXLE 2. – VALVE BODY REMOVE LOCK PLATE 3. REMOVE B0 ACCUMULATOR ASSEMBLY (a) Remove the 3 bolts. (b) Remove the B0 accumulator assembly. 4. DISASSEMBLE B0 ACCUMULATOR ASSEMBLY (a) Applying compressed air to the cylinder hole, remove the piston and spring. (b) Remove the 2 O–rings from the piston. 5. REMOVE NO.4 SOLENOID (a) Remove the No.4 solenoid. (b) Remove the O–ring from the solenoid. 6. REMOVE NO.1 LOWER VALVE BODY COVER Remove the 5 bolts and No.1 lower valve body cover. AX–79 AUTOMATIC TRANSAXLE – VALVE BODY 7. REMOVE OIL STRAINER, NO.1 LOWER VALVE BODY COVER GASKETS AND CHECK VALVE (a) Remove the 2 gaskets and plate from the lower valve body. (b) Remove the oil strainer, check valve and spring. 8. REMOVE PRESSURE RELIEF VALVE 9. REMOVE NO.2 LOWER VALVE BODY COVER, OIL STRAINER, CHECK BALLS AND VIBRATING STOPPER Remove the 11 bolts and lower valve body cover. (b) Remove the 2 check balls, oil strainer and vibrating stopper. AX–80 AUTOMATIC TRANSAXLE – VALVE BODY 10. REMOVE NO.2 LOWER VALVE BODY COVER GASKETS AND CHECK BALLS (a) Remove the 2 screws from the lower valve body cover. (b) Remove the 2 gaskets and plate. (c) Remove the 3 check balls from the cover. 11. REMOVE BOLTS FROM UPPER VALVE BODY Remove the 3 bolts. 12. LIFT OFF UPPER VALVE BODY AND NO.1 PLATE AS A SINGLE UNIT Hold No.1 plate to the upper valve body and lift off the upper valve body. HINT: Be careful that the check balls and oil strainer do not fall out. AX–81 AUTOMATIC TRANSAXLE – VALVE BODY 13. REMOVE 2 CHECK BALLS AND VIBRATING STOPPER FROM UPPER VALVE BODY 14. REMOVE 2 OIL STRAINERS AND CHECK BALL FROM LOWER VALVE BODY AX0TX–01 VALVE BODY ASSEMBLY 1. INSTALL 2 CHECK BALLS AND VIBRATING STOPPER TO UPPER VALVE BODY 2. INSTALL 2 OIL STRAINERS AND CHECK BALL TO LOWER VALVE BODY 3. POSITION PLATE AND NEW GASKETS ON UPPER VALVE BODY Position new No.1 gasket, plate and the new No.2 gasket on the upper valve body. HINT: Since No.1 gasket and No.2 gasket are similar, use the illustration below to discriminate between them. AX–82 AUTOMATIC TRANSAXLE – VALVE BODY 4. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON LOWER VALVE BODY Hold the upper valve body, plate and gaskets securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate. 5. INSTALL AND FINGER TIGHTEN BOLTS IN UPPER VALVE BODY TO SECURE LOWER VALVE BODY Install and finger tighten the 3 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 44 mm (1.732 in.) Bolt B: 16 mm (0.630 in.) 6. INSTALL NO.2 LOWER VALVE BODY COVER GASKETS, PLATE AND 3 CHECK BALLS (a) Install the 3 check balls into the No.2 lower valve body cover. AX–83 AUTOMATIC TRANSAXLE – VALVE BODY (b) Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. (c) Install the 2 screws. 8. INSTALL NO.2 LOWER VALVE BODY COVER (a) Position the No.2 lower valve body cover. (b) Install and finger tighten the 11 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 40 mm (1.575 in.) Bolt B: 44 mm (1.732 in.) Bolt C: 14 mm (0.551in.) 9. INSTALL OIL STRAINER AND CHECK VALVE Install the oil strainer and check valve into the lower valve body. AX–84 AUTOMATIC TRANSAXLE – VALVE BODY 10. INSTALL LOWER VALVE BODY COVER GASKETS AND NO.2 PLATE Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. 11. INSTALL LOWER VALVE BODY COVER (a) Position the lower valve body cover. (b) Install and finger tighten the 5 bolts. HINT: Each bolt length is indicated below. Bolt length Bolt A: 47 mm (1.850 in.) Bolt B: 14 mm (0.551 in.) 12. INSTALL PRESSURE RELIEF VALVE 13. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES (a) Tighten the 16 bolts in the lower valve body. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (b) Tighten the 3 bolts in the upper valve body. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) 14. INSTALL B0 ACCUMULATOR ASSEMBLY (a) Coat new O–rings with ATF and install them to the piston. (b) Install the spring and piston into the cylinder. Spring dimensions mm (in.) Color Free length Coil outer diameter Inner White 47.5 (1.870) 18.9 (0.744) Outer None 16.3 (0.642) 20.7 (0.815) AX–85 AUTOMATIC TRANSAXLE – VALVE BODY (d) Install the B0 accumulator assembly. (e) Install the torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) 15. INSTALL LOCK PLATE 16. INSTALL SOLENOIDS (a) Coat new O–rings with ATF and install them to the solenoids. (b) Install the lock–up solenoid. (c) Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (d) Install the No.4 solenoid. (e) Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (d) Install No.1 and No.2 solenoids. (e) Install and torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) AX–86 AUTOMATIC TRANSAXLE – UPPER VALVE BODY UPPER VALVE BODY AX047–03 COMPONENTS AX–87 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX048–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Mar k Name (Color) Free Length / Outer Diameter mm (in.) Total No. of Coils @@ @@ @: Lock–Up Relay Valve (Yellow) 26.8 (1.055) / 10.2 (0.402) 10.8 B1 Orifice Control Valve (White) 24.8 (0.976) / 6.4 (0.252) 12.0 Throttle Valve (Green) 31.5 (1.240) / 7.0 (0.276) 11.4 Down–Shift Plug (None) 15.0 (0.591) / 11.0 (0.433) 7.0 [c A] @@ @@ @: [c B] @@ @@ @: [c C] @@ @@ @: [c D] AX–88 AUTOMATIC TRANSAXLE – UPPER VALVE BODY @@ @@ @: [c E] Low Coast Modulator Valve (Purple) 20.2 (0.795) / 7.9 (0.311) 11.9 AX–89 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GZ–02 RETAINERS, PIN, AND CHECK BALLS LOCATION 1. PIN, RETAINERS Mark Name Height / Width / Thickness mm (in.) @@@@@: [c A] B1 Orifice Control Valve 8.9 (0.350) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] Low Coast Modulator Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) 2. CHECK BALLS AX–90 AUTOMATIC TRANSAXLE – LOWER VALVE BODY LOWER VALVE BODY AX04A–03 COMPONENTS AX–91 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX04B–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Mar k Name (Color) Free Length / Outer Diameter mm (in.) Total No. of Coils @@ @@ @: Accumulator Control Valve (Red) 25.1 (0.988) / 8.6 (0.339) 8.0 2–3 Shift Valve (None) 28.0 (1.102) / 7.6 (0.299) 10.3 1–2 Shift Valve (Light Green) 29.2 (1.150) / 8.9 (0.350) 12.0 Reverse Control Valve (White/Purple) 38.1 (1.500) / 6.5 (0.256) 19.0 [c A] @@ @@ @: [c B] @@ @@ @: [c C] @@ @@ @: [c D] AX–92 AUTOMATIC TRANSAXLE – LOWER VALVE BODY @@ @@ @: Cut–Back Valve (None) 21.8 (0.858) / 6.0 (0.236) 13.5 Primary Regulator Valve (None) 36.6 (1.441) / 16.1 (0.634) 6.3 3–4 Shift Valve (None) 28.0 (1.102) / 7.6 (0.299) 10.3 Second Lock Valve (None) 20.7 (0.815) / 7.4 (0.291) 9.5 Second Coast Modulator Valve (White) 32.2 (1.268) / 9.0 (0.354) 11.4 Solenoid Modulator Valve (Purple/Pink) 30.2 (1.189) / 5.6 (0.220) 15.3 Secondary Regulator Valve (None) 46.9 (1.846) / 5.9 (0.232) 21.8 [c E] @@ @@ @: [c F] @@ @@ @: [c G] @@ @@ @: [c H] @@ @@ @: [c I] @@ @@ @: [c J] @@ @@ @: [c K] AX–93 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0TY–01 RETAINERS AND CHECK BALLS LOCATION 1. RETAINERS Mark Name Height / Width / Thickness mm (in.) @@@@@: [c A] Accumulator Control Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] 2–3 Shift Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c C] 1–2 Shift Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c D] Reverse Control Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c E] Cut–Back Valve 6.5 (0.256) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c F] Secondary Regulator Valve 11.0 (0.433) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c G] Solenoid Modulator Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c H] Lock–Up Control Valve 9.2 (0.362) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c I] Second Coast Modulator Valve 8.0 (0.315) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c J] Second Lock Valve 9.2 (0.362) / 11.5 (0.453) / 3.2 (0.126) @@@@@: [c K] 3–4 Shift Valve 6.5 (0.256) / 5.0 (0.197) / 3.2 (0.126) 2. CHECK BALLS Upper Side AX–94 AUTOMATIC TRANSAXLE Lower Side – LOWER VALVE BODY AX–95 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY AX04D–02 COMPONENTS AX–96 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0TZ–02 DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE SIDE BEARING Using SST, remove the 2 side bearings. SST 09608–16011, 09550–40010 2. REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. (b) Remove the 12 bolts. (c) Using a plastic hammer, tap out the ring gear. 3. CHECK SIDE GEAR BACKLASH Using a dial gauge, measure the backlash of each side gear while holding one pinion toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) AX–97 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 4. DISASSEMBLE DIFFERENTIAL CASE (a) Drive out the pinion shaft lock pin from the side on which the ring gear is installed. (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and side gears with the 4 thrust washers. AX0U0–02 DIFFERENTIAL CASE ASSEMBLY 1. ASSEMBLE DIFFERENTIAL CASE (a) Install the removed thrust washers to the side gears. (b) Install the side gears with thrust washers, pinion thrust washers and pinion gears. (c) Install the pinion shaft. AX–98 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (d) Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 in.) Refering to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides. Thrust washer thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.60 (0.0630) 1.70 (0.0670) 1.80 (0.0709) If the backlash is not within specification, install a thrust washer of a different thickness. (e) Using a pin punch and hammer, drive the lock pin through the case and hole in the pinion shaft. (f) Stake the differential case. 2. INSTALL RING GEAR (a) Clean the contact surface of the differential case. (b) Heat the ring gear to about 100°C (212°F) in an oil bath. NOTICE: Do not heat the ring gear above 110°C (230°F). (c) Carefully remove the ring gear from the oil bath. (d) Clean the contact surface of the ring gear with cleaning solvent. (e) Quickly install the ring gear on the differential case. Install the 12 bolts. HINT: Align the matchmarks on the differential left case and contact the ring gear. (f) Tighten the set bolts uniformly a little at a time. Torque the bolts. Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf) AX–99 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 3. INSTALL SIDE BEARING (a) Install the speedometer drive gear onto the differential case. (b) Using SST and a press, press in the RH side bearing onto the differential case. SST 09316–20011 (c) Using SST and a press, press in the LH side bearing onto the differential case. SST 09316–60010 (09316–00010) AX–100 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION AX04G–06 Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately. Recommended ATF: D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) AX04H–03 GENERAL INSTALLATION NOTES: (a) The automatic transaxle is composed of highly precision–finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance. (b) Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes. (c) Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly. (d) Use petroleum jelly to keep small parts in their places. (e) Do not use adhesive cements on gaskets and similar parts. (f) When assembling the transaxle, be sure to use new gaskets and O–rings. (g) Dry all parts with compressed air–never use shop rags. (h) Be sure to install the thrust bearings and races in the correct direction and position. AX–101 AUTOMATIC TRANSAXLE Mark Thrust Bearing Outside Diameter – COMPONENT PARTS INSTALLATION Thrust Bearing Inside Diameter mm (in.) mm (in.) A See page AX–118 27.7 (1.091) B 47.6 (1.874) 31.4 (1.236) C 45.5 (1.791) 30.1 (1.185) D 45.5 (1.791) 30.1 (1.185) E 38.7 (1.524) 22.6 (0.890) F 46.3 (1.823) 28.6 (1.126) AX–102 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AX0U1–02 DIFFERENTIAL AND DRIVE PINION INSTALLATION 1. INSTALL DRIVE PINION INTO TRANSAXLE CASE (a) Using SST, install the bearing to the drive pinion shaft. SST 09350–32014 (09351–32120) (b) Place the bearing cage onto the drive pinion shaft. NOTICE: Be careful not to damage the oil seals with the pinion shaft. (c) Using a brass bar and hammer, slightly tap the bearing cage into the transaxle case until the snap ring groove in the bore can be seen. (d) Using SST, install snap ring into the bore. SST 09350–32014 (09351–32050) (e) Using SST, install the snap ring. SST 09350–32014 (09351–32050) AX–103 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 2. PLACE OIL SLINGER AND NEW SPACER HINT: Install the spacer with the small end downward. 3. INSTALL OUTER RACE TO TRANSAXLE CASE Using SST, press in the outer race. SST 09350–32014 (09351–32100, 09351–32140) 4. INSTALL COUNTER DRIVE GEAR (a) Place a brass bar into the transaxle hole to hold the drive pinion shaft. (b) Using SST, press in the counter driven gear until the counter driven gaer bearing almost touches the counter gear. SST 09350–32014 (09351–32140) 5. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION PRELOAD (a) Install the new lock nut. (b) Using SST to hold the gear, tighten the nut. Torque: 280 N·m (2,855 kgf·cm, 206 ft·lbf) SST 09330–00021, 09350–32014 (09351–32032) Turn the gear counterclockwise and clockwise several times. (d) Using a small torque wrench, measure the preload of the drive pinion. (c) Drive pinion preload (at starting): New bearing 1.0–1.6 N·m (10–16 kgf·cm, 8.7–13.9 in.·lbf) Reused bearing 0.5–0.8 N·m (5–8 kgf·cm, 4.3–6.9 in.·lbf)
If the preload is greater than specified, replace the bearing spacer. AX–104 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION
If the preload is less then specified, retighten the nut 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the specified preload is reached. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload. Maximum torque: 353 N·m (3,600 kgf·cm, 260 ft·lbf) (e) If the preload is adjusted within specification, make a note of it. (f) Stroke the lock nut. 6. INSTALL APPLY GASKET 7. PLACE OUTER RACE AND SHIM ONTO RH SIDE BEARING 8. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE Be sure to install the shim and outer race into place. AX–105 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 9. INSTALL CARRIER COVER (a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case. (b) Apply seal packing to the carrier cover. Seal packing: Part No.08826–00090, THREE BOND 1281 or equivalent (c) HINT: Install the carrier cover within 10 minutes after applying seal packing. Install and torque the 11 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: Each bolt length is indicated below. Bolt length: Bolt A: 100 mm (3.937 in.) Bolt B: 65 mm (2.559 in.) Bolt C: 75 mm (2.953 in.) 10. ADJUST SIDE BEARING PRELOAD (a) Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case. HINT: Do not apply seal packing yet. (b) Install the LH bearing retainer and torque the 6 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (c) Snap down the bearings by turning the differential case several times. (d) Using a small torque wrench, measure the differential total preload. Total preload (at starting): New bearing Drive pinion preload plus 0.2–0.4 N·m (2.5–5.1 kgf·cm, 2.2–3.6 in.·lbf) Reused bearing Drive pinion preload plus 0.1–0.2 N·m (1.3–2.0 kgf·cm, 1.1–1.7 in.·lbf) If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with one of a different thickness. AX–106 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AT3700:Adjusting shim thickness mm (in.) Mark Thickness Mark Thickness 0 2.00 (0.0787) 9 2.45 (0.0965) 1 2.05 (0.0807) A 2.50 (0.0984) 2 2.10 (0.0827) B 2.55 (0.1004) 3 2.15 (0.0846) C 2.60 (0.1024) 4 2.20 (0.0866) D 2.65 (0.1043) 5 2.25 (0.0886) E 2.70 (0.1063) 6 2.30 (0.0906) F 2.75 (0.1083) 7 2.35 (0.0925) G 2.80 (0.1102) 8 2.40 (0.0945) H 2.85 (0.1122) 11. INSTALL LH BEARING RETAINER (a) Remove the 6 bolts and LH bearing retainer. (b) Remove any FIPG material on the contacting surfaces of LH bearing retainer, transaxle case and carrier cover. (c) Apply FIPG to the transaxle case and carrier cover. FIPG: Part No.08826–00090, THREE BOND 1281 or equivalent HINT: Install the LH bearing retainer within 10 minutes after applying FIPG. (d) Install the LH bearing retainer. (e) Coat the threads of bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (f) Tighten the bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (g) Snap down the bearings. (h) Recheck the differential total preload. AX–107 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL NEW OIL SEAL (a) Place the oil baffle onto the LH bearing retainer. (b) Using SST, drive in a new oil seal unit its end is flush with surface of the LH bearing retainer. SST 09223–15010 13. INSTALL RH RETAINER (a) Remove any FIPG material on the contacting surfaces of RH retainer and transaxle case. (b) Apply FIPG to the RH retainer. FIPG: Part No.08826–00090, THREE BOND 1281 or equivalent HINT: Install the RH retainer within 10 minutes after applying FIPG. (c) Coat the bolts’ threads with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (d) Tighten the bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (e) Using SST, press in the oil seal. SST 09226–10010 AX–108 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 14. INSTALL DRIVE PINION CAP (a) Install a new O–ring to the cap. (b) Install the drive pinion cap to the transaxle case. AX0U2–03 4–SPEED GEAR UNIT INSTALLATION 1. INSTALL PARKING LOCK PAWL (a) Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl. (b) Instal the pin into the hole of the case through the spring and pawl. 2. INSTALL MANUAL VALVE SHAFT (a) Coat the oil seal lip with MP grease. (b) Install the manual valve shaft oil seal to the case. (c) Assembly a new collar to the manual valve lever. (d) Install the manual valve shaft to the transmission case through the manual lever. (e) Install the parking lock rod. AX–109 AUTOMATIC TRANSAXLE (f) – COMPONENT PARTS INSTALLATION Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface. (g) Match the collar hole to the lever caulking hollow and caulk the collar to the lever. (h) Install the retaining spring. 3. INSTALL PARKING LOCK PAWL BRACKET AND GUIDE Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 4. CHECK OPERATION OF PARKING LOCK PAWL Make sure the counter driven gear is locked when the manual valve lever is in the P position. AX–110 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 5. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE (a) Coat the new O–rings with ATF. (b) Install the 2 O–rings on the piston. (c) Push the piston into the bore of the case, facing the spring seat upward. 6. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring on the piston. (b) Place SST, and compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040) (c) Install snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw. (d) Remove the SST. 7. INSTALL SNAP RING TO TRANSAXLE CASE AX–111 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 8. INSTALL OVERDRIVE UNIT (a) Install the overdrive brake apply gasket and overdrive clutch apply gasket. (b) Install the overdrive brake drum to the case. (c) Install the new case gasket to the case. (d) Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 in.). (e) Place the new gasket onto the transaxle case. (f) Install the overdrive assembly with overdrive case to the transaxle case. AX–112 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (g) Coat the threads of 23 mm (0.91 in.) bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (h) Install and tighten the 13 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 61 mm (2.402 in.) Bolt B 38 mm (1.496 in.) Bolt C: 23 mm (0.906 in.) Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 9. CHECK INTERMEDIATE SHAFT END PLAY (a) Make sure that the intermediate shaft as end play in axial direction. End play: 0.47–1.50 mm (0.0185–0.0591 in.) If the end play is not within specification, check the installation of intermediate shaft. (b) Make sure that the intermediate shaft turns smoothly. 10. INSTALL REAR PLANETARY GEAR (a) Install the rear planetary ring gear. (b) Place the bearing onto the ring gear. Bearing outer diameter: 38.7 mm (1.524 in.) Bearing inner diameter: 22.6 mm (0.890 in.) (c) Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear. AX–113 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Install the rear planetary gear. 11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE (a) Install the 6 plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D–P–D–P–D (b) Install the flange, facing the flat end downward. (c) Install the snap ring. HINT: Be sure that the end gap of the snap ring is not aligned with one of the cutouts. 12. CHECK FIRST AND REVERSE BRAKE (a) Check the operation of the first and reverse brake piston. Apply compressed air into the case passage and confirm that the piston moves. (b) Using a filler gauge, check that pack clearance of the first and reverse brake. Clearance: 1.92–2.68 mm (0.0756–0.1055 in.) AX–114 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL NO.2 ONE–WAY CLUTCH INTO CASE (a) Place the No.2 one–way clutch with the shiny side of flange upward. (b) Install the one–way clutch while turning the planetary gear clockwise with SST. SST 09350–32014 (09351–32050) If the planetary gear cannot turn clockwise, check the installation of the one–way clutch. (c) Install the snap ring. HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts. (d) Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear. 14. INSTALL SECOND COAST BRAKE BAND GUIDE 15. PLACE NO.1 ONE–WAY CLUTCH (a) Coat the thrust washer with petroleum jelly and install it on the No.1 one–way clutch. AX–115 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the No.1 one–way clutch onto the rear planetary gear. 16. INSTALL SECOND BRAKE (a) Install the flange, facing the flat end upward. (b) Install the 3 discs and plates. Install in order: P=Plate D=Disc D–P–D–P–D–P (c) Place the piston return spring into the case. (d) Place the second brake drum into the case. HINT: Align the groove of the drum with the bolt. (e) Place the snap ring into the case so that end gap is installed into the groove. (f) While compressing the piston return spring over the drum with screwdriver, install the snap ring into the groove. (g) Be sure that the end gap of the snap ring is not aligned with one of cutouts. AX–116 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL NEW SECOND BRAKE GASKET Install a new gasket until it makes contact with the second brake drum. 18. CHECK OPERATION OF SECOND BRAKE Apply compressed air into the second brake gasket and confirm that the piston moves. 19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM (a) Coat the thrust washer with petroleum jelly and install it on the sun gear input drum. (b) While turning the sun gear clockwise, install it into the No.1 one–way clutch. 20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT HINT: After installing the oil seal ring, check that it moves smoothly. AX–117 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 21. INSTALL FRONT PLANETARY GEAR (a) Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear. Bearing outer diameter: 45.5 mm (1.791 in.) Bearing inner diameter: 30.1 mm (1.185 in.) (b) Install the planetary gear onto the sun gear. 22. INSTALL FRONT PLANETARY RING GEAR 23. INSTALL SECOND COAST BRAKE BAND (a) Place the band into the case. (b) Install the pin through the oil pump mounting bolt hole. 24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH (a) Coat the bearing with petroleum jelly and install it onto rear side of the forward clutch. Bearing outer diameter: 47.6 mm (1.874 in.) Bearing inner diameter: 31.4 mm (1.236 in.) AX–118 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Coat the bearing with petroleum jelly and install it onto the front side of the forward clutch. HINT: There are 2 different thickness bearings for adjustment of the input shaft thrust play. Bearing thickness mm (in.) (c) Thickness Outer diameter Inner diameter 3.60 (0.1417) 45.9 (1.807) 27.7 (1.091) 4.19 (0.1650) 47.1 (1.854) 27.7 (1.091) Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum. (d) Mesh the hub of the forward clutch flukes with the direct clutch discs. HINT: Be careful that the bearing and thrust washer do not get out of place. (e) Install the direct clutch and forward clutch into the case. HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place. 25. INSTALL OIL PUMP INTO CASE (a) Coat a new O–ring with ATF and install it to the oil pump. AX–119 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case. NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) 26. MEASURE END PLAY OF INPUT SHAFT Measure the end play with a dial gauge. End play: 0.25–0.90 mm (0.0098–0.0354 in.) HINT: There are 2 different thickness bearings for end of stator shaft. If the end play is in excess of standard, select one of them. Bearing thickness: 3.60 mm (0.1417 in.) 4.19 mm (0.1650 in.) 27. CHECK INPUT SHAFT ROTATION Make sure that the input shaft rotates smoothly. 28. INSTALL SECOND COAST BRAKE PISTON (a) Coat the new O–rings with ATF and install it to the cover. (b) Install the outer spring with the piston. (c) Place the cover into the bore. (d) Using SST, install the snap ring while pressing the cover. SST 09350–32014 (09351–32050) (e) Check that the front end of the piston rod contacts the center of the second brake band depression. 29. CHECK SECOND COAST BRAKE PISTON STROKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. AX–120 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09240–00020 Piston stroke: 2.0–3.5 mm (0.079–0.138 in.) If the stroke is more than specified, replace the piston rod with a longer one. Piston rod length: 95.2 mm (3.748 in.) 96.3 mm (3.791 in.) If the still more than standard value, replace the brake band with a new one. AX0U3–02 HYDRAULIC CONTROL UNIT INSTALLATION 1. INSTALL ACCUMULATOR PISTONS AND SPRINGS (a) Install the new O–rings to the pistons. (b) Install the springs and pistons into the bores. Spring dimensions mm (in.) Spring Color Free length C2 Yellow/Purple 51.8 (2.039) B2 None 88.2 (3.473) B2 None 70.3 (2.767) C1 None 73.6 (2.898) (c) Place the cover with a new gasket and gradually tighten the bolts a little at a time in sequence. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) AX–121 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 2. PLACE NEW SECOND BRAKE APPLY GASKET 3. INSTALL SOLENOID WIRE 4. INSTALL THROTTLE CABLE 5. INSTALL VALVE BODY TO TRANSAXLE CASE (a) While holding the cam down with your hand, slip the cable end into the slot. (b) Lower the valve body into place. NOTICE: Do not entangle the solenoid wire. AX–122 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS INSTALLATION Install and tighten the 9 bolts. HINT:
Each bolt length is indicated below.
Hand tighten the 9 bolts first, then torque with a torque wrench. Bolt length: Bolt A: 30 mm (1.181 in.) Bolt B: 43 mm (1.693 in.) Bolt C: 48 mm (1.890 in.) Bolt D: 52 mm (2.047 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 6. INSTALL B3 APPLY PIPE NOTICE: Be careful not to bend or damage the pipe. 7. INSTALL CONNECTOR CLAMP AND PIPE RETAINER HINT: Each bolt length is indicated below. Bolt length: Bolt A: 48 mm (1.890 in.) Bolt B: 39 mm (1.535 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 8. CONNECT SOLENOID CONNECTORS AX–123 AUTOMATIC TRANSAXLE 9. – COMPONENT PARTS INSTALLATION INSTALL OIL PIPES Using a plastic hammer, install the pipes into the positions. NOTICE: Be careful not to bend or damage the pipes. 10. INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length is indicated below. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 37 mm (1.457 in.) (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Hand tighten the 5 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) (d) Place the detent springs on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Bolt length: Bolt A: 14 mm (0.551 in.) Bolt B: 37 mm (1.457 in.) (e) Check that the manual valve lever is touching the center of the detent spring tip roller. 11. INSTALL PIPE BRACKET AND OIL STRAINER Each bolt length is indicated below. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 53 mm (2.087 in.) Torque: Pipe bracket: 10 N·m (100 kgf·cm, 7 ft·lbf) Oil strainer: 11 N·m (110 kgf·cm, 8 ft·lbf) AX–124 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL MAGNETS IN PLACE NOTICE: Make sure that the magnets do not interfere with the oil pipes. 13. INSTALL OIL PAN WITH NEW GASKET (a) Install a new gasket and oil pan. (b) Install and torque the 17 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 14. INSTALL THROTTLE CABLE RETAINING PLATE 15. INSTALL TRANSAXLE UPPER COVER 16. INSTALL T/M REVOLUTION SENSOR (a) Install a new O–ring to the T/M revolution sensor. (b) Install the T/M revolution sensor with the bolt. AX–125 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch to the manual valve shaft. (b) Place the new locking plate and tighten the nut. (c) Stake the nut with locking plate. (d) Install the 2 bolts. (e) Adjust the park/neutral position switch. HINT: Align the groove and neutral basic line. (f) Tighten the 2 bolts. 18. INSTALL UNION AND ELBOW (a) Install the new O–rings to the union and elbow. (b) Install the union elbow to the transaxle case. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) HINT: Install the elbow, as shown in the illustration. 19. INSTALL MANUAL SHAFT LEVER AX–126 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL SHIFT CONTROL CABLE BRACKET AX–127 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS AX0H1–06 SERVICE DATE Second Coast Brake 2.0 – 3.5 mm Piston stroke 0.079 – 0.138 in. 95.2 mm Piston rod length 3.748 in. 96.3 mm 3.791 in. Oil Pump Body clearance STD Maximum Tip clearance STD Maximum Side clearance STD Maximum Pump body bushing inside diameter Maximum 0.07 – 0.15 mm 0.0028 – 0.0059 in. 0.30 mm 0.0118 in. 0.11 – 0.14 mm 0.0043 – 0.0055 in. 0.30 mm 0.0118 in. 0.02 – 0.05 mm 0.0008 – 0.0020 in. 0.10 mm 0.0039 in. 38.18 mm 1.5031 in. Stator shaft bushing inside diameter Front side Maximum Rear side Maximum 21.57 mm 0.8492 in. 27.07 mm 1.0657 in. Direct Clutch Piston stroke Drum bushing inside diameter 0.91 – 1.35 mm 0.0358 – 0.0531 in. 48.27 mm 1.9004 in. 2.70 mm Flange thickness 0.1063 in. 3.00 mm 0.1181 in. Forward Clutch Piston stroke 1.79 – 2.21 mm 0.0704 – 0.0870 in. 2.30 mm Flange thickness 0.0906 in. 2.70 mm 0.1063 in. AX–128 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Front Planetary Gear Sun gear bushing inside diameter Maximum Ring gear flange bushing inside diameter Maximum Planetary pinion gear thrust clearance Maximum 22.59 mm 0.8894 in. 30.08 mm 1.1842 in. 0.61 mm 0.024 in. Rear Planetary Gear Planetary pinion gear thrust clearance Maximum 0.61 mm 0.024 in. First and Reverse Brake 1.92 – 2.68 mm Pack clearance 0.0756 – 0.1055 in. Overdrive Unit 1.75 – 2.49 mm Piston stroke Direct clutch bushing inside diameter 0.0689 – 0.0980 in. Maximum 22.13 mm 0.8713 in. 0.16 – 0.56 mm Planetary pinion gear thrust clearance STD 0.0063 – 0.0220 in. Maximum 0.61 mm 0.024 in. AX–129 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Valve Body Spring Free length / Coil outer diameter Spring Total No. of coils / Color mm (in.) Upper valve body Low coast modulator valve 20.2 (0.795) / 7.9 (0.311) 11.9 / Purple B1 orifice control valve 24.8 (0.976) / 6.4 (0.252) 12.0 / White Down–shift plug 15.0 (0.591) / 11.0 (0.433) 7.0 / None Throttle valve 31.5 (1.240) / 7.0 (0.276) 11.4 / Green Lock–up relay valve 26.8 (1.055) / 10.2 (0.402) 10.8 / Yellow 2–3 shift valve 28.0 (1.102) / 9.4 (0.370) 10.3 / None Second coast modulator valve 20.2 (0.795) / 7.9 (0.311) 11.9 / Purple Lower valve body Accumulator control vavle 25.1 (0.988) / 8.6 (0.339) 8.0 / Red Secondary regulator valve 46.9 (1.846) / 5.9 (0.232) 21.8 / None Second lock valve 20.7 (0.815) / 7.4 (0.291) 9.5 / None Reverse control valve 38.1 (1.500) / 6.5 (0.256) 19.0 / White/Purple 1–2 shift valve 29.2 (1.150) / 8.9 (0.350) 12.0 / Light Green 3–4 shift valve 28.0 (1.102) / 7.6 (0.299) 10.3 / None Primary regulator valve 36.6 (1.441) / 16.1 (0.634) 6.3 / None Cut–back valve 21.8 (0.858) / 6.0 (0.236) 13.5 / None Solenoid modulator valve 30.2 (1.189) / 5.6 (0.220) 15.3 / Purple/Pink Valve Body Key Height Width Thickness mm (in.) mm (in.) mm (in.) B1 orifice control valve 8.9 (0.350) 5.0 (0.197) 3.2 (0.126) Low coast modulator valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Accumulator control valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Secondary regulator valve 11.0 (0.433) 5.0 (0.197) 3.2 (0.126) 1–2 shift valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) 2–3 shift valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) 3–4 shift valve 6.5 (0.256) 5.0 (0.197) 3.2 (0.126) Key Upper valve body Lower valve body Second lock valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Second coast modulator valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) Reverse control valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Cut–back valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Solenoid modulator valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Lock–up control valve 9.2 (0.315) 5.0 (0.197) 3.2 (0.126) AX–130 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Accumulator Spring Spring C0 Free length mm (in.) Color Inner 47.5 (1.870) White Outer 16.3 (0.642) None C1 73.6 (2.898) None C2 51.8 (2.039) Yellow / Purple B0 66.8 (2.630) Red / Yellow Inner 70.3 (2.767) None Outer 88.2 (3.473) None B2 Differential Assembly Drive pinion preload (at Starting) New bearing Reused bearing 1.0 – 1.6 N·m 10 – 16 kgf·cm 8.7 – 13.9 in.·lbf 0.5 – 0.8 N·m 5 – 8 kgf·cm 4.3 – 6.9 in.·lbf Total preload (at starting) New bearing Reused bearing Pinion to side gear backlash Drive pinion preload plus 0.3 – 0.4 N·m 2.8 – 4.4 kgf·cm 2.4 – 3.8 in.·lbf Drive pinion preload plus 0.1 – 0.2 N·m 1.4 – 2.2 kgf·cm 1.2 – 1.9 in.·lbf 0.05 – 0.20 mm 0.0020 – 0.0079 in. 1.60 mm Side gear thrust washer thickness 0.0630 in. 1.70 mm 0.0670 in. 1.80 mm 0.0709 in. AX–131 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in. Side bearing adjusting shim thickness Mark 2.20 mm 0 0.0866 in. 1 2.25 mm 2 0.0886 in. 3 2.30 mm 4 0.0906 in. 5 2.35 mm 6 0.0925 in. 7 2.40 mm 8 0.0945 in. 9 2.45 mm A 0.0965 in. B 2.50 mm C 0.0984 in. D 2.55 mm E 0.1004 in. 2.60 mm F G 0.1024 in. 2.65 mm H 0.1043 in. 2.70 mm 0.1063 in. 2.75 mm 0.1083 in. 2.80 mm 0.1102 in. 2.85 mm 0.1122 in. AX–132 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS AX04N–03 TORQUE SPECIFICATIONS Part tightened N·m kgf·cm ft·lbf Oil cooler pipe union 27 275 20 Oil pan 4.9 50 43 in.·lbf Valve body x Transaxle case 11 110 8 Accumulator x Cover 10 100 7 Oil pump x Transaxle case 22 225 16 O/D case x Transaxle case 25 250 18 Differential LH side bearing retainer 19 195 14 Differential RH retainer 19 195 14 Differential carrier cover 39 400 29 Oil pump body x Stator shaft 10 100 7 Ring gear x Differential case 124 1,260 91 Upper valve body x Lower valve body 6.6 67 58 in.·lbf Accumulator cylinder x Valve body 6.6 67 58 in.·lbf Solenoid x Valve body 6.6 67 58 in.·lbf Counter drive gear lock nut 280 2,855 206 Carrire cover x Transaxle case 39 400 29 Parking lock pawl bracket 7.4 75 65 in.·lbf Oil strainer x Transaxle case 11 110 8 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN002–0W To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The


procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the back of AX section, for quick reference. IN–3 INTRODUCTION – HOW TO USE THIS MANUAL CAUTIONS, NOTICES, HINTS:


CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English system. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) IN–4 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1. 2. 3. 4. 5. 6. IN022–07 Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following: (a) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (–) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable straight up without twisting or prying it. (d) Clean the battery terminal posts and cable terminals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non–reusable parts (a) Always replace cotter pins, gaskets, O–rings and oil seals etc. with new ones. (b) Non–reusable parts are indicated in the component illustrations by the ”” symbol. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply IN–5 INTRODUCTION 7. 8. 9. – GENERAL REPAIR INSTRUCTIONS the specified seal lock adhesive to the bolt, nut or threads. (c) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found at the preparation of AX section. 10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. 11. To pull apart electrical connectors, pull on the connector itself, not the wires. 12. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. IN–6 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS IN016–02 This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE TOYOTA TERMS SAE TERMS ABBREVIATIONS ( )––ABBREVIATIONS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage BARO Barometric Pressure CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position – DFI Direct Fuel Injection (Diesel) DI Distributor Ignition DLC1 Data Link Connector 1 1: Check Connector DLC2 Data Link Connector 2 2: Toyota Diagnosis Communication Link (TDCL) DLC3 Data Link Connector 3 3: OBD@@@@@: [g 2] Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory – +B, Battery Voltage – – Direct Injection (DI) – – – Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition Toyota Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control FEEPROM – Flash Electrically Erasable Programmable – Read Only Memory FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IN–7 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure – Indirect Injection Manifold Pressure Intake Vacuum Electric Bleed Air Control Valve (EBCV) MC Mixture Control Mixture Control Valve (MCV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Light MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer RAM Random Access Memory RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass SFI Sequential Multiport Fuel Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body TBI Throttle Body Fuel Injection TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter TCM Transmission Control Module Transmission ECU (Electronic Control Unit) TP Throttle Position Throttle Position TR Transmission Range Electric Air Control Valve (EACV) – Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) Random Access Memory (RAM) – – Electronic Fuel Injection (EFI), Sequential Injection Throttle Body Single Point Injection Central Fuel Injection (Ci) – IN–8 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Bimetallic Vacuum Switching Valve (BVSV) TVV Thermal Vacuum Valve TWC Three–Way Catalytic Converter TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter WU–TWC Warm Up Three–Way Catalytic Converter 3GR Third Gear – 4GR Fourth Gear – Thermostatic Vacuum Switching Valve (TVSV) Three–Way Catalyst (TWC) CCRO – Manifold Converter IN–9 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL IN01H–0R ATF Automatic Transaxle Fluid B0 Overdrive Brake B1 Second coast Brake B2 Second Brake B3 First and Reverse Brake C0 Overdrive Direct Clutch C1 Forward Clutch C2 Direct Clutch D Disc F Flange F0 O/D One–way Clutch F1 No.1 One–way Clutch F2 No.2 One–way Clutch MP Multipurpose O/D Overdirve P Plate SSM Special Service Materials SST Special Service Tools IN–10 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS IN008–02 IN–11 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS AX–1 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION AX0CH–05 GENERAL SPECIFICATIONS Type of Transaxle A541E Type of Engine 1MZ–FE Torque Converter Clutch Stall Torque Ratio 1.8 : 1 Torque Converter Clutch Lock–up Mechanism Gear Ratio Transaxle B1 Band Width Equipped 1st Gear 2.810 2nd Gear 1.549 3rd Gear 1.000 O/D Gear 0.735 Reverse Gear 2.296 Number of Discs and Plates O/D Direct Clutch (C0) 2/2 Forward Clutch (C1) 5/5 Direct Clutch (C2) 3/3 2nd Brake (B2) 3/3 First and Reverse Brake (B3) 6/6 O/D Brake (B0) 3/3 mm (in.) ATF Type Capacity liter (US qts, Imp.qts) 25 (0.98) ATF D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) A/T 6.75(7.1, 5.9) D/F 0.85 (0.9, 0.7) AX–2 AUTOMATIC TRANSAXLE – OPERATION OPERATION 1. MECHANICAL OPERATION AX0RF–01 AX–3 AUTOMATIC TRANSAXLE – OPERATION AX019–03 2. FUNCTION OF COMPONENTS AX–4 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit. Shift change is carried out by altering the combination of clutch and brake operation. Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle opening angle and vehicle speed, and shift change automatically occurs. The conditions of operation for each gear position are shown on the following illustrations: AX–5 AUTOMATIC TRANSAXLE – OPERATION AX01A–0B 3. HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes as well as the fluid passages which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the vehicle driving conditions. There are three solenoid valves on the valve body. The No.1 and No.2 solenoid vales are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position. The SL solenoid valve is operated by signals from the ECM to engage or disengage the lock–up clutch of the torque converter clutch. The SLN solenoid valve is operated by signals from the ECM to control the engagement speed and reduce gear shift shock. AX–6 AUTOMATIC TRANSAXLE – PREPARATION PREPARATION AX02L–06 SST (SPECIAL SERVICE TOOLS) 09226–10010 Crankshaft Front & Rear Bearing Replacer 09240–00020 Wire Gauge Set 09316–20011 Transfer Bearing Replacer 09316–60011 Transmission & Transfer Bearing Replacer (09316–00011) Replacer Pipe 09350–32014 TOYOTA Automatic Transmission Tool Set 09308–10010 Oil Seal Puller (09351–32032) Counter Driven Gear Holding Tool (09351–32040) No.1 Piston Spring Compressor (09351–32050) Snap Ring Expander (09351–32061) Oil Pump Puller (09351–32070) No.2 Piston Spring Compressor (09351–32080) Lock Nut Wrench Install RH retainer oil seal AX–7 AUTOMATIC TRANSAXLE – PREPARATION (09351–32100) Drive Pinion Bearing Replacer (09351–32120) Overdrive Bearing Replacer (09351–32140) Oil Seal Replacer (09351–32150) Oil Seal Replacer (09351–32190) Measure Terminal (09351–32200) No.3 Piston Spring Compressor 09608–16011 Rear Hub Bearing Tool– Remove differential side bearing 09612–65014 Steering Worm Bearing Puller Remove pinion shaft bearing outer race 09950–40010 Puller B Set AX02M–02 RECOMMENDED COOL 09031–00030 Pin Punch . AX–8 AUTOMATIC TRANSAXLE – PREPARATION AX02N–02 EQUIPMENT Feeler gauge Check major clearance. Vernier calipers Check length of second coast brake piston rod. Dial indicator with magnetic base Check piston stroke and end play of the output shaft. Dial indicator Check inside diameter of major bushing. Straight edge Check side clearance of oil pump. Torque wrench AX01V–08 LUBRICANT Item Capacity Automatic transaxle fluid: Dry fill Drain and refill Classification ATF D–@@@@@: [g 2] or 6.75 liters (7.10 US qts, 5.94 Imp.qts) 2.5 liters (2.6 US qts, 2.2 Imp.qts) DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) ATF D–@@@@@: [g 2] or Differential oil 0.85 liters (0.89 US qts, 0.75 Imp.qts) DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) AX02P–02 SSM (SPECIAL SERVICE MATERIALS) 08826–00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Differential LH bearing retainer Differential RH retainer 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent Differential RH retainer set bolt AX–9 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL AX02Q–02 COMPONENTS AX–10 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–11 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–12 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX–13 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX0TT–02 SEPARATE BASIC SUBASSEMBLY 1. REMOVE SHIFT CONTROL CABLE BRACKET 2. REMOVE UNION AND ELBOW (a) Remove the manual shift lever. (b) Using a open end wrench, remove the union and elbow. (c) Remove the O–rings from the union and elbow. 3. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Pry off the lock washer and remove the manual valve shaft nut. (b) Remove the 2 bolts and pull out the park/neutral position switch. 4. REMOVE THROTTLE CABLE RETAINING BOLT AND PLATE AX–14 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 5. REMOVE T/M REVOLUTION SENSOR (a) Remove the bolt and T/M revolution sensor. (b) Remove the O–ring from the T/M revolution sensor. 6. REMOVE TRANSAXLE CASE UPPER COVER 7. REMOVE OIL PAN AND GASKET (a) Remove the 17 bolts. (b) Remove the oil pan by lifting transaxle case. NOTICE: Do not turn the transaxle over as this will contaminate the valve body with the foreign materials in the bottom of the oil pan. (c) Place the transaxle on wooden blocks to prevent damage to the oil pipe bracket. 8. EXHAUST PARTICLES IN PAN Remove the magnet and use it to collect any steel chips. Lock carefully at the chips and particles in the oil pan and on magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear 9. REMOVE OIL PIPE BRACKET AND STRAINER AX–15 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 10. REMOVE MANUAL VALVE BODY (a) Remove the 2 bolts and detent spring. (b) Remove the 5 bolts and manual valve body with the manual valve. (c) Remove the manual valve from the manual valve body. 11. REMOVE OIL PIPES (a) Remove the bolt. (b) Pry up both pipe ends with a large screwdriver and remove the 6 pipes. 12. DISCONNECT SOLENOID CONNECTORS 13. REMOVE CONNECTOR CLAMP AND PIPE RETAINER AX–16 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 14. REMOVE B3 APPLY PIPE Pry up the pipe with a screwdriver and remove the pipe. 15. REMOVE VALVE BODY (a) Remove the 9 bolts. (b) Remove the wire harness clamp. (c) Disconnect the throttle cable from the cam, and remove the valve body. 16. REMOVE THROTTLE CABLE AX–17 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 17. REMOVE SOLENOID WIRING Remove the bolt and the solenoid wiring. 18. REMOVE SECOND BRAKE APPLY GASKET 19. REMOVE ACCUMULATOR PISTONS AND SPRINGS (a) Loosen the 4 bolts one turn at a time until the spring tension is released. (b) Remove the cover and gasket. (c) Remove the C1 accumulator piston and spring. (d) Remove the 2 O–rings from the piston. (e) Pop out pistons for C2 and B2 into a rag, using low–pressure compressed air (98 kPa, 1 kgf/cm2, 14 psi). (f) Remove the O–rings from the pistons. AX–18 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 20. MEASURE PISTON STROKE SECOND COAST BRAKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09240–00020 Maximum thrust clearance: 2.0–3.5 mm (0.079–0.138 in.) If the piston stroke exceeds the limit, inspect the second coast brake band. 21. REMOVE SECOND COAST BRAKE PISTON (a) Using SST, remove the snap ring. SST 09350–32014 (b) Applying compressed air to the oil hole, remove the second coast brake cover, piston assembly and spring. (c) Remove the 2 O–rings from the cover. AX–19 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 22. STAND TRANSAXLE ENGINE SIDE UPWARD 23. REMOVE OIL PUMP NOTICE: Before removing the oil pump, remove the second coast brake piston. (a) Remove the 7 bolts. (b) Using SST, pull out the oil pump from the transaxle case. SST 09350–32014 24. REMOVE O–RING FROM OIL PUMP 25. REMOVE DIRECT CLUTCH AND FORWARD CLUTCH 26. SEPARATE DIRECT CLUTCH AND FORWARD CLUTCH (a) Separate the direct clutch and forward clutch. (b) Remove the thrust washer from direct clutch. AX–20 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 27. REMOVE BEARING FROM FORWARD CLUTCH 28. REMOVE SECOND COAST BRAKE BAND (a) Push the pin with a small screwdriver and remove it from the bolt hole of the oil pump mounting. (b) Remove the brake band. 29. REMOVE FRONT PLANETARY RING GEAR 30. REMOVE FRONT PLANETARY GEAR (a) Remove the front planetary gear. (b) Remove the 2 bearings from the planetary gear. AX–21 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 31. REMOVE SUN GEAR AND SUN GEAR INPUT DRUM (a) Remove the sun gear and the sun gear input drum. (b) Remove the thrust washer from sun gear input drum. 32. CHECK OPERATION OF SECOND BRAKE PISTON Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassembe and inspect. 33. REMOVE SECOND COAST BRAKE BAND GUIDE 34. REMOVE SECOND BRAKE DRUM (a) Remove the snap ring. AX–22 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the second brake drum. 35. REMOVE SECOND BRAKE PISTON RETURN SPRING 36. REMOVE NO.1 ONE–WAY CLUTCH 37. REMOVE PLATES, DISCS AND FLANGE 38. REMOVE SECOND BRAKE DRUM GASKET Remove the gasket. AX–23 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 39. REMOVE NO.2 ONE–WAY CLUTCH AND REAR PLANETARY GEAR (a) Remove the snap ring. (b) Remove the No.2 one–way clutch and rear planetary gear. (c) Remove the thrust washer from the rear planetary gear. 40. REMOVE REAR PLANETARY RING GEAR (a) Remove the rear planetary ring gear. (b) Remove the bearing from the ring gear. 41. CHECK FIRST AND REVERSE BRAKE (a) Check the operation of the first and reverse brake piston. Apply compressed air into the case passage and confirm that the piston moves. If the piston does not move, disassemble and inspect. AX–24 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a filler gauge, check the pack clearance of the first and reverse brake. Clearance: 1.92–2.68 mm (0.0756–0.1055 in.) 42. REMOVE FLANGE, DISCS AND PLATES OF FIRST AND REVERSE BRAKE (a) Remove the snap ring. (b) Remove the flange, 6 discs and plates. 43. TURN TRANSAXLE CASE AROUND 44. REMOVE OVERDRIVE UNIT (a) Remove the 13 bolts. (b) Tap on the circumference of the overdrive case with a plastic hammer to remove the overdrive case and gasket. AX–25 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS REMOVAL Remove the overdrive planetary gear from transaxle case. (d) Remove the overdrive brake drum from the transaxle case. (e) Remove the overdrive clutch apply gasket and overdrive brake apply gasket. 45. REMOVE FIRST AND REVERSE BRAKE PISTON (a) Remove the piston return spring.
Place SST, compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040)


Using snap ring pliers, remove the snap ring. Remove the SST. Remove the return spring from the case. AX–26 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Apply compressed air into the passage of the case to remove the piston. HINT: Hold the piston so it is not slanted and blow with the gun slightly away from the oil hole. (c) If the piston does not pop out with compressed air, use needle–nose pliers to remove it. (d) Remove the 2 O–rings from the piston. (e) Remove the snap ring. 46. REMOVE PARKING LOCK PAWL BRACKET AND GUIDE AX–27 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 47. REMOVE MANUAL VALVE SHAFT (a) Using a chisel and hammer, cut the collar. (b) Remove the retaining spring. (c) Using a pin punch and hammer, drive out the pin. (d) Slide out the shaft from the transaxle case and remove the manual valve lever and parking lock rod. 48. REMOVE MANUAL VALVE SHAFT OIL SEAL Using a screwdriver, remove the oil seal. AX–28 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 49. REMOVE PIN, SPRING AND PARKING LOCK PAWL AX02S–04 DIFFERENTIAL COMPONENT PARTS REMOVAL 1. MEASURE DIFFERENTIAL TOTAL PRELOAD Using a small torque wrench, measure the total preload and make a note of it. 2. REMOVE LH BEARING RETAINER (a) Remove the 6 bolts. (b) Using a large screwdriver, remove the LH bearing retainer. NOTICE: Wrap the screwdriver tip in a rag, etc. to avoid damaging the case and retainer. 3. REMOVE RH RETAINER (a) Remove the 5 bolts. AX–29 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a large screwdriver, remove the RH retainer. NOTICE: Wrap the screwdriver tip in a rag, etc. to avoid damaging the case and retainer. 4. REMOVE CARRIER COVER (a) Remove the 10 bolts. (b) Tap the carrier cover with a plastic hammer to remove it. (c) Remove the apply gasket. 5. REMOVE DIFFERENTIAL CASE Remove the differential case, outer case and shim from the transaxle case. AX–30 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL 6. REMOVE TRANSAXLE CAP (a) Remove the bolt. (b) Using pliers, pull out the drive pinion cap. (c) Remove the O–rings from the cap. 7. MEASURE DRIVE PINION PRELOAD Using a small torque wrench, measure the drive pinion preload. Preload (Reused bearing at starting): 0.5–0.8 N·m (5–8 kgf·cm, 4.3–6.9 in.·lbf) The total preload measured in step 1 minus the drive pinion preload equals 0.1–0.2 N·m (1.3–2.0 kgf·cm, 1.1–1.7 in.·lbf). If the result is not within this specification, the side bearing preload is suspect. 8. REMOVE COUNTER DRIVEN GEAR (a) Using a chisel and hammer, loosen the staked part of the nut. (b) Using SST to hold the gear, remove the nut. SST 09330–00021, 09350–32014 (09351–32032) AX–31 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS REMOVAL Using SST, remove the gear and bearing. SST 09350–32014 (09351–32061) 9. REMOVE OUTER RACE, SPACER AND OIL SLINGER (a) Using SST, remove the outer race with oil slinger and spacer. SST 09350–32014 (09308–10010) (b) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) 10. REMOVE DRIVE PINION (a) Using SST, remove the snap ring. SST 09350–32014 (09351–32050) (b) Install the bar into the case hole to drive out the drive pinion. (c) Using a press, drive out the drive pinion from transaxle case. AX–32 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL (d) Remove the bearing cage from drive pinion. (e) Using SST, press out the bearing. SST 09950–00020 AX–33 AUTOMATIC TRANSAXLE – COMPONENT PARTS REMOVAL AX02T–07 GENERAL NOTES The instructions here are organized so that you work on only one component group at a time. This will help avoid confusion from similar–looking parts of different subassemblies being on your workbench at the same time. The component groups are inspected and repaired from the converter housing side. As much as possible, complete the inspection, repair and assembly before proceeding to the next component group. If a component group cannot be assembled because parts are being ordered, be sure to keep all parts of that group in a separate container while proceeding with disassembly, inspection, repair and assembly of other component groups. Recommended fluid for the automatic transaxle: ATF D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) 1. GENERAL CLEANING NOTES: (a) All disassembled parts should be washed clean and any fluid passages and holes blown through with compressed air. (b) When using compressed air to dry parts, always aim away from yourself to prevent accidentally spraying automatic transaxle fluid or kerosene in your face. (c) The recommended automatic transaxle fluid or kerosene should be used for cleaning. 2. PARTS ARRANGEMENT: (a) After cleaning, the parts should be arranged in the correct order to allow efficient inspection, repairs, and reassembly. (b) When disassembling a valve body, be sure to keep each valve together with the corresponding spring. (c) New brakes and clutches that are to be used for replacement must be soaked in transaxle fluid for at least fifteen minutes before assembly. 3. GENERAL ASSEMBLY: (a) All oil seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with transmission fluid prior to reassembly. (b) All gaskets and rubber O–rings should be replaced. (c) Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly. (d) If a worn bushing is to be replaced, the subassembly containing that bushing must be replaced. (e) Check thrust bearings and races for wear or damage. Replace if necessary. (f) Use petroleum jelly to keep parts in place. AX–34 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE SECOND COAST BRAKE AX02U–02 COMPONENTS SECOND COAST BRAKE PISTON DISASSEMBLY 1. AX02V–02 REMOVE OIL SEAL RING Remove the oil seal ring from the piston. 2. REMOVE PISTON ROD (a) Remove the E–ring while pushing the piston with needle– nose pliers. AX–35 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Remove the inner spring, plate washer and piston rod. AX02W–03 SECOND COAST BRAKE COMPONENT INSPECTION If the lining of the brake band is peeling off or discolored, or even part of the printed mark is defaced, replace the brake band. AX02X–03 SECOND COAST BRAKE PISTON ASSEMBLY 1. SELECT PISTON ROD If the band is OK but piston stroke not within the standard value, select a new piston rod. Piston stroke: 2.0–3.5 mm (0.079–0.138 in.) There are 2 lengths of piston rod. Piston rod length: 95.2 mm (3.748 in.) 96.3 mm (3.791 in.) 2. INSTALL PISTON ROD (a) Install the plate washer and inner spring to the piston rod. AX–36 AUTOMATIC TRANSAXLE – SECOND COAST BRAKE (b) Install the E–ring while pushing the piston. 3. INSTALL OIL SEAL RING (a) Apply ATF to the oil seal ring. (b) Install the oil seal ring to the piston. NOTICE: Do not spread the ring ends more than necessary. AX–37 AUTOMATIC TRANSAXLE – OIL PUMP OIL PUMP AX02Y–02 COMPONENTS OIL PUMP DISASSEMBLY AX02Z–02 1. REMOVE OIL SEAL RINGS Remove the 2 oil seal rings from the stator shaft back side. 2. REMOVE THRUST WASHER FROM STATOR SHAFT BACK SIDE AX–38 AUTOMATIC TRANSAXLE – OIL PUMP 3. REMOVE STATOR SHAFT Remove the 11 bolts and stator shaft. HINT: Keep the gears in assembly order. 4. REMOVE FRONT OIL SEAL Pry off the oil seal with a screwdriver. AX030–06 OIL PUMP BUSHING INSPECTION 1. CHECK BODY CLEARANCE OF DRIVEN GEAR Push the driven gear to one side of the body. Using a feeler gauge, measure the clearance. Standard body clearance: 0.07–0.15 mm (0.0028–0.0059 in.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than the maximum, replace the oil pump body subassembly. 2. CHECK TIP CLEARANCE OF DRIVEN GEAR Measure between the driven gear teeth and the crescent–shaped part of the pump body. Standard tip clearance: 0.11–0.14 mm (0.0043–0.0055 in.) Maximum tip clearance: 0.30 mm (0.0118 in.) If the tip clearance is greater than the maximum, replace the oil pump body subassembly. AX–39 AUTOMATIC TRANSAXLE 3. – OIL PUMP CHECK SIDE CLEARANCE OF BOTH GEARS Using a steel straightedge and feeler gauge, measure the side clearance of both gears. Standard side clearance: 0.002–0.005 mm (0.0008–0.0020 in.) Maximum side clearance: 0.100 mm (0.0039 in.) There are 3 different thicknesses for drive and driven gears. Drive and driven gear thickness Mark Thickness mm (in.) A 9.440–9.456 (0.3717–0.3723) B 9.456–9.474 (0.3723–0.3730) C 9.474–9.490 (0.3730–0.3736) If the thickest gear can not make the side clearance within standard specification, replace the oil pump body subassembly. 4. CHECK OIL PUMP BODY BUSHING Using a dial indicator, measure the inside diameter of the oil pump body bushing. Maximum inside diameter: 38.18 mm (1.5031 in.) If the inside diameter is greater than the maximum, replace the oil pump body subassembly. 5. CHECK STATOR SHAFT BUSHING Using a dial indicator, measure the inside diameter stator shaft bushing. Maximum inside diameter: 21.57 mm (0.8492 in.) If the inside diameter is greater than the maximum, replace the stator shaft. AX031–02 OIL PUMP ASSEMBLY 1. INSTALL FRONT OIL SEAL Using SST and a hammer, install a new oil seal. The seal end should be flush with the outer edge of the pump body. SST 09350–32014 (09351–32140) AX–40 AUTOMATIC TRANSAXLE 2. – OIL PUMP INSTALL DRIVEN GEAR AND DRIVE GEAR Make sure the top of the gears are facing upward. 3. INSTALL STATOR SHAFT TO PUMP BODY (a) Align the stator shaft with each bolt hole. (b) Torque the 11 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 4. INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollow of the pump body. 5. INSTALL OIL SEAL RINGS Install the 2 oil seal rings to the stator shaft back side. NOTICE: Do not spread the ring ends more than necessary. HINT: After installing the oil seal rings, check that they move smoothly. 6. CHECK PUMP DRIVE GEAR ROTATION Turn the drive gear with 2 screwdrivers and make sure it rotates smoothly. NOTICE: Be careful not to damage the oil seal lip. AX–41 AUTOMATIC TRANSAXLE – DIRECT CLUTCH DIRECT CLUTCH AX032–02 COMPONENTS DIRECT CLUTCH DISASSEMBLY AX033–05 1. CHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Install a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kg/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 0.91–1.35 mm (0.0358–0.0531 in.) If the piston stroke is greater than the maximum, inspect each component. AX–42 AUTOMATIC TRANSAXLE 2. 3. – DIRECT CLUTCH REMOVE SNAP RING FROM CLUTCH DRUM REMOVE FLANGE, DISCS AND PLATES 4. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Remove the snap ring with snap ring pliers. (c) Remove the piston return spring. 5. REMOVE CLUTCH PISTON (a) Install the direct clutch onto the oil pump. (b) Apply compressed air to the oil pump to remove the piston (if the piston does not come out completely, use needle– nose pliers to remove it). (c) Remove the direct clutch from the oil pump. (d) Remove the 2 O–rings from the piston. AX–43 AUTOMATIC TRANSAXLE – DIRECT CLUTCH AX034–03 DIRECT CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the direct clutch bushing. Maximum inside diameter: 48.27 mm (1.9004 in.) If the inside diameter is greater than the maximum, replace the direct clutch. DIRECT CLUTCH ASSEMBLY AX035–06 1. INSTALL CLUTCH PISTON IN DIRECT CLUTCH DRUM (a) Install new O–rings to the piston. Coat the O–rings with ATF. (b) Being careful not to damage the O–rings, press the piston into the drum with the cup side up. 2. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring onto the piston. AX–44 AUTOMATIC TRANSAXLE – DIRECT CLUTCH (b) Place SST on the spring retainer, and compress the return spring with a press. SST 09350–32014 (09351–32070) (c) Install the snap ring using snap ring pliers. Be sure the end gap of snap ring is aligned with the spring retainer claw. 3. INSTALL PLATES, DISCS AND FLANGE (a) Install plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 4. INSTALL SNAP RING Check that the end gap of the snap ring is not aligned with one of the cutouts. 5. RECHECK PISTON STROKE OF DIRECT CLUTCH (a) Install the direct clutch on the oil pump. (b) Install a dial indicator and measuring terminal (SST) together, measure the direct clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 0.91–1.35 mm (0.0358–0.0531 in.) If the piston stroke is non–standard, select another flange. HINT: There are 2 different thickness for the flange. Flange thickness: 2.70 mm (0.1063 in.) 3.00 mm (0.1181 in.) AX–45 AUTOMATIC TRANSAXLE – FORWARD CLUTCH FORWARD CLUTCH AX036–02 COMPONENTS FORWARD CLUTCH DISASSEMBLY 1. AX037–04 CHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.79–2.21 mm (0.0704–0.0870 in.) each component. AX–46 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. REMOVE SNAP RING FROM CLUTCH DRUM 3. REMOVE FLANGE, DISCS AND PLATES 4. REMOVE RETURN SPRING (a) Place SST on the spring retainer and compress the springs with a press. SST 09350–32014 (09351–32070) (b) Using snap ring pliers, remove the snap ring. (c) Remove the return spring. 5. REMOVE CLUTCH PISTON (a) Apply compressed air into the oil passage to remove the piston. If the piston does not come out, use needle–nose pliers to remove it. AX–47 AUTOMATIC TRANSAXLE – FORWARD CLUTCH (b) Remove the 2 O–rings from the piston. 6. IF NECESSARY, REMOVE OIL SEAL RINGS Remove the 3 oil seal rings from the shaft. AX038–03 FORWARD CLUTCH INSPECTION 1. INSPECT CLUTCH PISTON (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX039–04 FORWARD CLUTCH ASSEMBLY 1. INSTALL OIL SEAL RINGS Install the 3 oil seal rings to the shaft. NOTICE: Do not spread the ring ends more than necessary. HINT: After installing the oil seal rings, check that they move smoothly. AX–48 AUTOMATIC TRANSAXLE – FORWARD CLUTCH 2. INSTALL CLUTCH PISTON TO CLUTCH DRUM (a) Install the 2 new O–rings to the piston. (b) Coat the O–ring with ATF. (c) Press the piston into the drum with the cup side up, being careful not to damage the O–rings. 3. INSTALL PISTON RETURN SPRINGS (a) Place the return spring and snap ring onto the piston. (b) Place SST on the spring retainer, and compress the springs with a press. SST 09350–32014 (09351–32070) (c) Install the snap ring with snap ring pliers. Be sure the end gap of the snap ring is not aligned with the spring retainer claw. 4. INSTALL PLATES, DISCS AND FLANGE (a) Install the plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D–P–D (b) Install the flange with the flat end facing downward. 5. INSTALL SNAP RING Check that the end gap of snap ring is not aligned with one of the cutouts. AX–49 AUTOMATIC TRANSAXLE 6. – FORWARD CLUTCH RECHECK PISTON STROKE OF FORWARD CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the forward clutch piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09350–32014 (09351–32190) Piston stroke: 1.79–2.21 mm (0.0704–0.0870 in.) If the piston stroke is non–standard, select another flange. HINT: There are 2 different thicknesses for the flange. Flange thickness: 2.30 mm (0.0906 in.) 2.70 mm (1.0630 in.) AX–50 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR FRONT PLANETARY GEAR AX03A–02 COMPONENTS AX0TU–03 NO.1 ONE–WAY CLUTCH AND SUN GEAR DISASSEMBLY 1. CHECK OPERATION OF NO.1 ONE–WAY CLUTCH Hold the sun gear and turn the hub. The hub should turn freely clockwise and should lock counterclockwise. 2. REMOVE NO.1 ONE–WAY CLUTCH FROM SUN GEAR While turning the hub clockwise, remove the No.1 one– way clutch from the sun gear. AX–51 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR 3. REMOVE SUN GEAR FROM DRUM (a) Using snap ring pliers, remove the snap ring from the drum. (b) Remove the sun gear from the drum. 4. CHECK SUN GEAR BUSHINGS Using a dial indicator, measure the inside diameter of the sun gear bushings. Maximum inside diameter: 22.59 mm (0.8894 in.) If the inside diameter is greater than the maximum, replace the sun gear. AX0TV–01 NO.1 ONE–WAY CLUTCH AND SUN GEAR ASSEMBLY 1. INSTALL SUN GEAR TO DRUM (a) Install the sun gear to the drum. (b) Using snap ring pliers, install the snap ring to drum. 2. 3. INSTALL NO.1 ONE–WAY CLUTCH ON SUN GEAR While turning the hub clockwise, slide the No.1 one–way clutch onto the sun gear. RECHECK OPERATION OF NO.1 ONE–WAY CLUTCH AX03D–02 PLANETARY RING GEAR INSPECTION 1. INSPECT RING GEAR FLANGE BUSHING Using a dial indicator, measure the inside diameter of the flange bushing. Maximum inside diameter: 30.08 mm (1.1842 in.) If the inside diameter is greater than the maximum, replace the flange. AX–52 AUTOMATIC TRANSAXLE – FRONT PLANETARY GEAR 2. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 3. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. FRONT PLANETARY GEAR INSPECTION AX03E–03 MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. AX–53 AUTOMATIC TRANSAXLE – SECOND BRAKE SECOND BRAKE AX03F–02 COMPONENTS AX03G–03 SECOND BRAKE PISTON DISASSEMBLY REMOVE SECOND BRAKE PISTON (a) Apply compressed air to the oil hole to remove the piston. (b) Remove the 2 O–rings from the piston. AX–54 AUTOMATIC TRANSAXLE – SECOND BRAKE AX03H–03 SECOND BRAKE COMPONENT INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX03J–06 SECOND BRAKE PISTON ASSEMBLY INSTALL PISTON (a) Coat a new O–ring with ATF. (b) Install the 2 new O–rings on the piston. (c) Press the piston into the drum, being careful not to damage the O–rings. AX–55 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR REAR PLANETARY GEAR AX03K–02 COMPONENTS NO.2 ONE–WAY CLUTCH DISASSEMBLY AX03L–02 1. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH Hold the outer race and turn the rear planetary gear. The rear planetary gear should turn freely counterclockwise and should lock clockwise. 2. SEPARATE NO.2 ONE–WAY CLUTCH AND REAR PLANETARY GEAR REMOVE THRUST WASHER Remove the thrust washer from the rear side of planetary gear. 3. AX–56 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR 4. REMOVE NO.2 ONE–WAY CLUTCH FROM OUTER RACE (a) Remove the 2 snap rings and retainers from both sides. (b) Remove the No.2 one–way clutch from the outer race. AX03M–03 REAR PLANETARY GEAR INSPECTION MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater than the maximum, replace the planetary gear assembly. NO.2 ONE–WAY CLUTCH ASSEMBLY AX03N–02 1. INSTALL ONE–WAY CLUTCH (a) Install the No.2 one–way clutch into the outer race, facing the flange side of the No.2 one–way clutch toward the shiny side of the outer race. (b) Install the 2 retainers and snap rings to both sides. AX–57 AUTOMATIC TRANSAXLE – REAR PLANETARY GEAR 2. INSTALL PLANETARY GEAR INTO NO.2 ONE–WAY CLUTCH Install the planetary gear into the No.2 one–way clutch, facing the inner race of the rear planetary gear toward the black side of the No.2 one–way clutch outer race. 3. CHECK OPERATION OF NO.2 ONE–WAY CLUTCH 4. INSTALL THRUST WASHER (a) Coat the thrust washer with petroleum jelly. (b) Align the tab of the washer with the hollows of the carrier. RING GEAR FLANGE REPLACEMENT 1. REMOVE RING GEAR FLANGE (a) Using a screwdriver, remove the snap ring. (b) Remove the flange from the ring gear. 2. INSTALL RING GEAR FLANGE (a) Position the flange into the ring gear. (b) Using a screwdriver, install the snap ring. AX03P–02 AX–58 AUTOMATIC TRANSAXLE – FIRST AND REVERSE BRAKE FIRST AND REVERSE BRAKE AX03Q–02 COMPONENTS FIRST AND REVERSE BRAKE COMPONENTS INSPECTION AX03R–03 INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX–59 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT OVERDRIVE UNIT AX03S–02 COMPONENTS AX–60 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03T–03 OVERDRIVE BRAKE DISASSEMBLY 1. REMOVE PISTON RETURN SPRING (a) While pushing the return spring, remove the snap ring with a screwdriver. (b) Remove the piston return spring. 2. REMOVE PLATES, DISCS AND FLANGE 3. REMOVE PISTON FROM DRUM Apply compressed air to oil hole to remove the piston. HINT: Blow with the gun slightly away from the oil hole, and be careful that the piston does not tilt. 4. REMOVE O–RINGS Remove the inner and outer O–rings from the piston. AX–61 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX03U–03 OVERDRIVE BRAKE INSPECTION INSPECT DISCS, PLATES AND FLANGE Check if the sliding surfaces of the discs, plates and flange are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. AX03V–05 OVERDRIVE DIRECT CLUTCH DISASSEMBLY 1. CHECK PISTON STROKE OF DIRECT CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 5–8 kgf/cm2, 57–114 psi). Piston stroke: 1.75–2.49 mm (0.0689–0.0980 in.) 2. 3. SST 09350–32014 (09351–32190) If the piston stroke is greater than the maximum, inspect each component. REMOVE OVERDRIVE DIRECT CLUTCH FROM CASE REMOVE BEARING AND RACE FROM CLUTCH DRUM AND CASE AX–62 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 4. REMOVE SNAP RING WITH SCREWDRIVER 5. REMOVE FLANGES, DISCS AND PLATES 6. REMOVE PISTON RETURN SPRING (a) Place SST on the spring retainer and compress the spring with a press. SST 09350–32014 (09351–32070, 09351–32200) (b) Remove the snap ring. (c) Remove the piston return spring. 7. REMOVE PISTON FROM CLUTCH DRUM (a) Install the clutch drum on the case. (b) Apply compressed air to the pressure apply hole of the case. (c) Remove the piston from the clutch drum. If the piston does not come out completely, use needle– nose pliers to remove it. (d) Remove the clutch drum from the case. AX–63 AUTOMATIC TRANSAXLE 8. – OVERDRIVE UNIT REMOVE O–RINGS Remove the 2 O–rings from the piston. AX03W–03 OVERDRIVE DIRECT CLUTCH INSPECTION 1. INSPECT OVERDRIVE DIRECT CLUTCH (a) Check that the check ball is free by shaking the piston. (b) Check that the valve does not leak by applying low–pressure compressed air. 2. INSPECT DISCS, PLATES AND FLANGES Check if the sliding surfaces of the discs, plates and flanges are worn or burnt. If necessary, replace them. HINT:
If the lining of the disc is peeling off or discolored, or even if a part of the printed numbers are defaced, replace all discs.
Before assembling new discs, soak them in ATF for at least 15 minutes. 3. CHECK DIRECT CLUTCH BUSHING Using a dial indicator, measure the inside diameter of the 2 direct clutch bushings. Maximum inside diameter: 22.13 mm (0.8713 in.) If the inside diameter is greater than the maximum, replace the direct clutch drum. AX03X–06 OVERDRIVE DIRECT CLUTCH ASSEMBLY 1. INSTALL CLUTCH PISTON (a) Install new O–rings to the piston. Coat the O–rings with ATF. AX–64 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (b) Press the piston into the drum with the cup side up, being careful not to damage the O–ring. 2. INSTALL PISTON RETURN SPRING (a) Install the return spring and seat snap ring in place. (b) Place SST on the spring retainer, and compress the spring with a press. SST 09350–32014 (09351–32070, 09351–32200) (c) Install the snap ring with a screwdriver. Be sure end gap of snap ring is aligned with the groove of the clutch drum. 3. INSTALL PLATES, DISCS AND FLANGE Install in order: P=Plate D=Disc P–D–P–D–Flange 4. INSTALL SNAP RING Be sure end gap of the snap ring is not aligned with the groove of the clutch drum. AX–65 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 5. INSTALL BEARING AND RACE (a) Coat the bearing with petroleum jelly and install it facing the race side downward to the clutch drum. Bearing outer diameter: 46.3 mm (1.823 in.) Bearing inner diameter: 26.2 mm (1.031 in.) (b) Coat the race with petroleum jelly and install it to the case. Race outer diameter: 43.0 mm (1.693 in.) Race inner diameter: 24.5 mm (0.965 in.) 6. INSTALL DIRECT CLUTCH ON CASE 7. RECHECK PISTON STROKE OF DIRECT CLUTCH Install a dial indicator and measuring terminal (SST) together, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). Piston stroke: 1.75–2.49 mm (0.0689–0.0980 in.) SST 09350–32014 (09351–32190) AX03Y–03 COUNTER DRIVE GEAR DISASSEMBLY 1. CHECK OPERATION OF ONE–WAY CLUTCH (a) Install the O/D direct clutch into the one–way clutch. (b) Hold the O/D direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise. (c) Remove the O/D direct clutch. AX–66 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 2. CHECK COUNTER DRIVE GEAR PRELOAD (a) Hold the O/D planetary gear in a vise with soft jaws. HINT: Do not let the counter drive gear touch the vise. (b) Using a tension gauge, measure the preload. Preload (at starting): 9.2–15.3 N (940–1,560 g, 2.1–3.4 lb) HINT: Turn the counter drive gear right and left several times before measuring the preload. 3. REMOVE O/D ONE–WAY CLUTCH AND OUTER RACE (a) Remove the snap ring. (b) Remove the retaining plate. (c) Remove the O/D one–way clutch with outer race. (d) Remove the 2 retainers from both sides of the O/D one– way clutch. AX–67 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Remove the O/D one–way clutch from the outer race. HINT: Note the direction of the one–way clutch. 4. 5. REMOVE NO.3 PLANETARY THRUST WASHER REMOVE PLUGS FROM PLANETARY GEAR Remove the 4 plugs with a magnetic finger. NOTICE: Be careful not to lose them. 6. REMOVE ADJUSTING NUT AND LOCKING WASHER (a) Pry off the locking washer. (b) Using SST, loosen the adjusting nut. SST 09350–32014 (09351–32080) (c) Remove the adjusting nut and locking washer. 7. REMOVE INTERMEDIATE SHAFT BEARING Using SST, press out the bearing from the shaft. SST 09950–00020 AX–68 AUTOMATIC TRANSAXLE 8. – OVERDRIVE UNIT REMOVE COUNTER DRIVE GEAR AND FRONT BEARING Press out the gear and bearing together. 9. REMOVE REAR BEARING (a) Using SST, press out the bearing. SST 09950–00020 (b) Tag the bearings to show the location for reassembly. 10. REMOVE O/D PLANETARY RING GEAR FROM COUNTER DRIVE GEAR (a) While pulling up the ring gear, compress the snap ring with needle–nose pliers and remove it from the groove. (b) Remove the ring gear from the counter drive gear. (c) Remove the snap ring from the ring gear. AX–69 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 11. REMOVE OUTER RACES FROM COUNTER DRIVE GEAR (a) Drive out the 2 races with a brass bar and hammer. (b) Tag the races to show the location for reassembly. 12. REMOVE SNAP RING FROM COUNTER DRIVE GEAR Using a screwdriver, remove the snap ring. OVERDRIVE PLANETARY GEAR INSPECTION AX03Z–03 MEASURE PLANETARY PINION GEAR THRUST CLEARANCE Using a feeler gauge, measure the planetary pinion gear thrust clearance. Standard clearance: 0.16–0.56 mm (0.0063–0.0220 in.) Maximum clearance: 0.61 mm (0.0240 in.) If the clearance is greater then the maximum, replace the planetary gear assembly. AX–70 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX040–03 COUNTER DRIVE GEAR ASSEMBLY 1. INSTALL SNAP RING INTO COUNTER GEAR Install the snap ring with a screwdriver. 2. INSTALL OUTER RACES INTO COUNTER DRIVE GEAR Using SST, press in the 2 outer races to both sides of the gear. SST 09350–32014 (09351–32120, 09351–32150) HINT: Press in the 2 outer races until they touch the snap ring. Tap the races in straight, so that they do not tilt. 3. INSTALL OVERDRIVE PLANETARY RING GEAR INTO COUNTER DRIVE GEAR (a) Install the snap ring to the ring gear. (b) While pushing down the ring gear, squeeze the snap ring end with needle–nose pliers, and install it into the groove. 4. INSTALL REAR BEARING Using SST, press in the bearing onto the shaft. SST 09350–32014 (09351–32120) HINT: Press in the bearing until the side surface of the inner race touches the planetary carrier. AX–71 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 5. INSTALL COUNTER DRIVE GEAR AND FRONT BEARING (a) Install the gear onto the shaft, and mesh the ring gear with the planetary pinions. (b) Place the front bearing on to the shaft. (c) Using SST, press in the bearing until there is slight play between the bearings. SST 09350–32014 (09351–32120) HINT: Hold the ring gear to prevent it from falling. 6. INSTALL INTERMEDIATE SHAFT BEARING Using SST, press in the bearing until it slightly touches the front bearing of the counter drive gear. SST 09350–32014 (09351–32120) HINT: The counter drive gear can be turned lightly. 7. PLACE NEW LOCKING WASHER 8. INSTALL ADJUSTING NUT AND ADJUST PRELOAD OF COUNTER DRIVE GEAR (a) Hold the overdrive planetary gear in a vise with soft jaws. (b) Using SST, tighten the adjusting nut until the following gear starting load is reached on the tension gauge. SST 09350–32014 (09351–32080) Preload (at starting): 9.2–15.3 N (940–1,560 g, 2.1–3.4 lb) AX–72 AUTOMATIC TRANSAXLE (c) – OVERDRIVE UNIT HINT: Turn the counter drive gear right and left several times before measuring the preload. Lock the adjusting nut with one locking washer tab. Bend the locking washer tab until it is flat with the adjusting nut groove. 9. INSTALL NO.3 OVERDRIVE PLANETARY THRUST WASHER 10. INSTALL PINION SHAFT PLUGS Install the 4 plugs into the pinion shaft. 11. INSTALL OVERDRIVE ONE–WAY CLUTCH AND RETAINING PLATE (a) Install the one–way clutch into the outer race. (b) Install the 2 retainers on both sides of the one–way clutch. (c) Install the one–way clutch into the overdrive planetary gear. HINT: Be sure that the one–way clutch is installed in the correct direction. (d) Install the retaining plate. AX–73 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT (e) Install the snap ring. 12. CHECK OPERATION OF O/D ONE–WAY CLUTCH (a) Install the overdrive direct clutch into the one–way clutch. (b) Hold the overdrive direct clutch and turn the intermediate shaft. The shaft should turn freely clockwise and should lock counterclockwise. (c) Remove the overdrive direct clutch. AX041–02 OVERDRIVE CASE DISASSEMBLY 1. REMOVE C0 ACCUMULATOR PISTON FROM OVERDRIVE CASE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retaining plate and 2 springs. (c) Remove the accumulator piston. (d) Remove the O–ring from the piston. AX–74 AUTOMATIC TRANSAXLE 2. – OVERDRIVE UNIT REMOVE OIL SEAL RINGS AX042–02 OVERDRIVE CASE ASSEMBLY 1. INSTALL OIL SEAL RINGS ON OVERDRIVE CASE Install the 2 oil seal rings to the overdrive case groove, then snug them down by squeezing their ends together. HINT: After installing the oil seal rings, check that they move smoothly. 2. INSTALL C0 ACCUMULATOR PISTON TO OVERDRIVE CASE (a) Install a new O–ring to the accumulator piston. (b) Coat the O–ring with ATF. (c) Install the accumulator piston, 2 springs and retaining plate. (d) Using snap ring pliers, install the snap ring. AX–75 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT AX043–05 OVERDRIVE BRAKE ASSEMBLY 1. INSTALL PISTON INTO DRUM (a) Install new O–rings to the piston. Coat the new O–rings with ATF. (b) Press the piston into the drum, being careful not to damage the O–rings. 2. INSTALL FLANGE, DISCS AND PLATES Install the flange, discs and plates. Install in order: P=Plate D=Disc Flange–D–P–D–P–D–P 3. POSITION PISTON RETURN SPRING AX–76 AUTOMATIC TRANSAXLE – OVERDRIVE UNIT 4. INSTALL SNAP RING INTO CASE Be sure the end gap of the snap ring is not aligned with one of cutouts. 5. INSTALL OVERDRIVE PLANETARY GEAR ONTO OVERDRIVE DIRECT CLUTCH While turning the overdrive planetary gear clockwise, install it onto the overdrive direct clutch. HINT: If the overdrive planetary gear is properly installed onto the direct clutch, the counter drive gear height from the overdrive case will be about 24 mm (0.94 in.). AX–77 AUTOMATIC TRANSAXLE – VALVE BODY VALVE BODY AX044–02 COMPONENTS VALVE BODY DISASSEMBLY AX0TW–01 NOTICE: When disassembling the valve body, be careful not to damage or deform the plate which overhangs the valve body. 1. REMOVE SOLENOIDS (a) Remove No.1 and No.2 solenoids with the retainer. NOTICE: When removing the solenoid, do not use a screwdriver, etc. to pry up the solenoid. (b) Remove the O–ring from each solenoid. (c) Remove the No.3 solenoid. (d) Remove the O–ring from the solenoid. AX–78 AUTOMATIC TRANSAXLE 2. – VALVE BODY REMOVE LOCK PLATE 3. REMOVE B0 ACCUMULATOR ASSEMBLY (a) Remove the 3 bolts. (b) Remove the B0 accumulator assembly. 4. DISASSEMBLE B0 ACCUMULATOR ASSEMBLY (a) Applying compressed air to the cylinder hole, remove the piston and spring. (b) Remove the 2 O–rings from the piston. 5. REMOVE NO.4 SOLENOID (a) Remove the No.4 solenoid. (b) Remove the O–ring from the solenoid. 6. REMOVE NO.1 LOWER VALVE BODY COVER Remove the 5 bolts and No.1 lower valve body cover. AX–79 AUTOMATIC TRANSAXLE – VALVE BODY 7. REMOVE OIL STRAINER, NO.1 LOWER VALVE BODY COVER GASKETS AND CHECK VALVE (a) Remove the 2 gaskets and plate from the lower valve body. (b) Remove the oil strainer, check valve and spring. 8. REMOVE PRESSURE RELIEF VALVE 9. REMOVE NO.2 LOWER VALVE BODY COVER, OIL STRAINER, CHECK BALLS AND VIBRATING STOPPER Remove the 11 bolts and lower valve body cover. (b) Remove the 2 check balls, oil strainer and vibrating stopper. AX–80 AUTOMATIC TRANSAXLE – VALVE BODY 10. REMOVE NO.2 LOWER VALVE BODY COVER GASKETS AND CHECK BALLS (a) Remove the 2 screws from the lower valve body cover. (b) Remove the 2 gaskets and plate. (c) Remove the 3 check balls from the cover. 11. REMOVE BOLTS FROM UPPER VALVE BODY Remove the 3 bolts. 12. LIFT OFF UPPER VALVE BODY AND NO.1 PLATE AS A SINGLE UNIT Hold No.1 plate to the upper valve body and lift off the upper valve body. HINT: Be careful that the check balls and oil strainer do not fall out. AX–81 AUTOMATIC TRANSAXLE – VALVE BODY 13. REMOVE 2 CHECK BALLS AND VIBRATING STOPPER FROM UPPER VALVE BODY 14. REMOVE 2 OIL STRAINERS AND CHECK BALL FROM LOWER VALVE BODY AX0TX–01 VALVE BODY ASSEMBLY 1. INSTALL 2 CHECK BALLS AND VIBRATING STOPPER TO UPPER VALVE BODY 2. INSTALL 2 OIL STRAINERS AND CHECK BALL TO LOWER VALVE BODY 3. POSITION PLATE AND NEW GASKETS ON UPPER VALVE BODY Position new No.1 gasket, plate and the new No.2 gasket on the upper valve body. HINT: Since No.1 gasket and No.2 gasket are similar, use the illustration below to discriminate between them. AX–82 AUTOMATIC TRANSAXLE – VALVE BODY 4. PLACE UPPER VALVE BODY WITH PLATE AND GASKETS ON LOWER VALVE BODY Hold the upper valve body, plate and gaskets securely so they do not separate. Align each bolt hole in the valve bodies with the gaskets and plate. 5. INSTALL AND FINGER TIGHTEN BOLTS IN UPPER VALVE BODY TO SECURE LOWER VALVE BODY Install and finger tighten the 3 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 44 mm (1.732 in.) Bolt B: 16 mm (0.630 in.) 6. INSTALL NO.2 LOWER VALVE BODY COVER GASKETS, PLATE AND 3 CHECK BALLS (a) Install the 3 check balls into the No.2 lower valve body cover. AX–83 AUTOMATIC TRANSAXLE – VALVE BODY (b) Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. (c) Install the 2 screws. 8. INSTALL NO.2 LOWER VALVE BODY COVER (a) Position the No.2 lower valve body cover. (b) Install and finger tighten the 11 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 40 mm (1.575 in.) Bolt B: 44 mm (1.732 in.) Bolt C: 14 mm (0.551in.) 9. INSTALL OIL STRAINER AND CHECK VALVE Install the oil strainer and check valve into the lower valve body. AX–84 AUTOMATIC TRANSAXLE – VALVE BODY 10. INSTALL LOWER VALVE BODY COVER GASKETS AND NO.2 PLATE Position a new gasket and plate and then another new gasket. HINT: Both gaskets are identical. 11. INSTALL LOWER VALVE BODY COVER (a) Position the lower valve body cover. (b) Install and finger tighten the 5 bolts. HINT: Each bolt length is indicated below. Bolt length Bolt A: 47 mm (1.850 in.) Bolt B: 14 mm (0.551 in.) 12. INSTALL PRESSURE RELIEF VALVE 13. TIGHTEN BOLTS OF UPPER AND LOWER VALVE BODIES (a) Tighten the 16 bolts in the lower valve body. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (b) Tighten the 3 bolts in the upper valve body. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) 14. INSTALL B0 ACCUMULATOR ASSEMBLY (a) Coat new O–rings with ATF and install them to the piston. (b) Install the spring and piston into the cylinder. Spring dimensions mm (in.) Color Free length Coil outer diameter Inner White 47.5 (1.870) 18.9 (0.744) Outer None 16.3 (0.642) 20.7 (0.815) AX–85 AUTOMATIC TRANSAXLE – VALVE BODY (d) Install the B0 accumulator assembly. (e) Install the torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) 15. INSTALL LOCK PLATE 16. INSTALL SOLENOIDS (a) Coat new O–rings with ATF and install them to the solenoids. (b) Install the lock–up solenoid. (c) Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (d) Install the No.4 solenoid. (e) Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) (d) Install No.1 and No.2 solenoids. (e) Install and torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) AX–86 AUTOMATIC TRANSAXLE – UPPER VALVE BODY UPPER VALVE BODY AX047–03 COMPONENTS AX–87 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX048–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Mar k Name (Color) Free Length / Outer Diameter mm (in.) Total No. of Coils @@ @@ @: Lock–Up Relay Valve (Yellow) 26.8 (1.055) / 10.2 (0.402) 10.8 B1 Orifice Control Valve (White) 24.8 (0.976) / 6.4 (0.252) 12.0 Throttle Valve (Green) 31.5 (1.240) / 7.0 (0.276) 11.4 Down–Shift Plug (None) 15.0 (0.591) / 11.0 (0.433) 7.0 [c A] @@ @@ @: [c B] @@ @@ @: [c C] @@ @@ @: [c D] AX–88 AUTOMATIC TRANSAXLE – UPPER VALVE BODY @@ @@ @: [c E] Low Coast Modulator Valve (Purple) 20.2 (0.795) / 7.9 (0.311) 11.9 AX–89 AUTOMATIC TRANSAXLE – UPPER VALVE BODY AX0GZ–02 RETAINERS, PIN, AND CHECK BALLS LOCATION 1. PIN, RETAINERS Mark Name Height / Width / Thickness mm (in.) @@@@@: [c A] B1 Orifice Control Valve 8.9 (0.350) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] Low Coast Modulator Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) 2. CHECK BALLS AX–90 AUTOMATIC TRANSAXLE – LOWER VALVE BODY LOWER VALVE BODY AX04A–03 COMPONENTS AX–91 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX04B–03 VALVE BODY SPRINGS SPECIFICATIONS HINT: During reassembly please refer to the spring specifications above to help discriminate between the different springs. Mar k Name (Color) Free Length / Outer Diameter mm (in.) Total No. of Coils @@ @@ @: Accumulator Control Valve (Red) 25.1 (0.988) / 8.6 (0.339) 8.0 2–3 Shift Valve (None) 28.0 (1.102) / 7.6 (0.299) 10.3 1–2 Shift Valve (Light Green) 29.2 (1.150) / 8.9 (0.350) 12.0 Reverse Control Valve (White/Purple) 38.1 (1.500) / 6.5 (0.256) 19.0 [c A] @@ @@ @: [c B] @@ @@ @: [c C] @@ @@ @: [c D] AX–92 AUTOMATIC TRANSAXLE – LOWER VALVE BODY @@ @@ @: Cut–Back Valve (None) 21.8 (0.858) / 6.0 (0.236) 13.5 Primary Regulator Valve (None) 36.6 (1.441) / 16.1 (0.634) 6.3 3–4 Shift Valve (None) 28.0 (1.102) / 7.6 (0.299) 10.3 Second Lock Valve (None) 20.7 (0.815) / 7.4 (0.291) 9.5 Second Coast Modulator Valve (White) 32.2 (1.268) / 9.0 (0.354) 11.4 Solenoid Modulator Valve (Purple/Pink) 30.2 (1.189) / 5.6 (0.220) 15.3 Secondary Regulator Valve (None) 46.9 (1.846) / 5.9 (0.232) 21.8 [c E] @@ @@ @: [c F] @@ @@ @: [c G] @@ @@ @: [c H] @@ @@ @: [c I] @@ @@ @: [c J] @@ @@ @: [c K] AX–93 AUTOMATIC TRANSAXLE – LOWER VALVE BODY AX0TY–01 RETAINERS AND CHECK BALLS LOCATION 1. RETAINERS Mark Name Height / Width / Thickness mm (in.) @@@@@: [c A] Accumulator Control Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c B] 2–3 Shift Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c C] 1–2 Shift Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c D] Reverse Control Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c E] Cut–Back Valve 6.5 (0.256) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c F] Secondary Regulator Valve 11.0 (0.433) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c G] Solenoid Modulator Valve 8.5 (0.335) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c H] Lock–Up Control Valve 9.2 (0.362) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c I] Second Coast Modulator Valve 8.0 (0.315) / 5.0 (0.197) / 3.2 (0.126) @@@@@: [c J] Second Lock Valve 9.2 (0.362) / 11.5 (0.453) / 3.2 (0.126) @@@@@: [c K] 3–4 Shift Valve 6.5 (0.256) / 5.0 (0.197) / 3.2 (0.126) 2. CHECK BALLS Upper Side AX–94 AUTOMATIC TRANSAXLE Lower Side – LOWER VALVE BODY AX–95 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY DIFFERENTIAL ASSEMBLY AX04D–02 COMPONENTS AX–96 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY AX0TZ–02 DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE SIDE BEARING Using SST, remove the 2 side bearings. SST 09608–16011, 09550–40010 2. REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. (b) Remove the 12 bolts. (c) Using a plastic hammer, tap out the ring gear. 3. CHECK SIDE GEAR BACKLASH Using a dial gauge, measure the backlash of each side gear while holding one pinion toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) AX–97 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 4. DISASSEMBLE DIFFERENTIAL CASE (a) Drive out the pinion shaft lock pin from the side on which the ring gear is installed. (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and side gears with the 4 thrust washers. AX0U0–02 DIFFERENTIAL CASE ASSEMBLY 1. ASSEMBLE DIFFERENTIAL CASE (a) Install the removed thrust washers to the side gears. (b) Install the side gears with thrust washers, pinion thrust washers and pinion gears. (c) Install the pinion shaft. AX–98 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY (d) Check the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 in.) Refering to the table below, select thrust washers which will ensure that the backlash is within specification. Try to select washers of the same size for both sides. Thrust washer thickness mm (in.) Thickness mm (in.) Thickness mm (in.) 1.60 (0.0630) 1.70 (0.0670) 1.80 (0.0709) If the backlash is not within specification, install a thrust washer of a different thickness. (e) Using a pin punch and hammer, drive the lock pin through the case and hole in the pinion shaft. (f) Stake the differential case. 2. INSTALL RING GEAR (a) Clean the contact surface of the differential case. (b) Heat the ring gear to about 100°C (212°F) in an oil bath. NOTICE: Do not heat the ring gear above 110°C (230°F). (c) Carefully remove the ring gear from the oil bath. (d) Clean the contact surface of the ring gear with cleaning solvent. (e) Quickly install the ring gear on the differential case. Install the 12 bolts. HINT: Align the matchmarks on the differential left case and contact the ring gear. (f) Tighten the set bolts uniformly a little at a time. Torque the bolts. Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf) AX–99 AUTOMATIC TRANSAXLE – DIFFERENTIAL ASSEMBLY 3. INSTALL SIDE BEARING (a) Install the speedometer drive gear onto the differential case. (b) Using SST and a press, press in the RH side bearing onto the differential case. SST 09316–20011 (c) Using SST and a press, press in the LH side bearing onto the differential case. SST 09316–60010 (09316–00010) AX–100 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION AX04G–06 Disassembly, inspection and assembly of each component group have been indicated in the preceding chapter. Before assembly, make sure, again, that all component groups are assembled correctly. If something wrong is found in a certain component group during assembly, inspect and repair this group immediately. Recommended ATF: D–@@@@@: [g 2] or DEXRON®@@@@@: [g 3](DEXRON®@@@@@: [g 2]) AX04H–03 GENERAL INSTALLATION NOTES: (a) The automatic transaxle is composed of highly precision–finished parts, necessitating careful inspection before assembly because even a small nick could cause fluid leakage or affect performance. (b) Before assembling new clutch discs, soak them in automatic transaxle fluid for at least 15 minutes. (c) Apply automatic transaxle fluid on the sliding or rotating surfaces of parts before assembly. (d) Use petroleum jelly to keep small parts in their places. (e) Do not use adhesive cements on gaskets and similar parts. (f) When assembling the transaxle, be sure to use new gaskets and O–rings. (g) Dry all parts with compressed air–never use shop rags. (h) Be sure to install the thrust bearings and races in the correct direction and position. AX–101 AUTOMATIC TRANSAXLE Mark Thrust Bearing Outside Diameter – COMPONENT PARTS INSTALLATION Thrust Bearing Inside Diameter mm (in.) mm (in.) A See page AX–118 27.7 (1.091) B 47.6 (1.874) 31.4 (1.236) C 45.5 (1.791) 30.1 (1.185) D 45.5 (1.791) 30.1 (1.185) E 38.7 (1.524) 22.6 (0.890) F 46.3 (1.823) 28.6 (1.126) AX–102 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AX0U1–02 DIFFERENTIAL AND DRIVE PINION INSTALLATION 1. INSTALL DRIVE PINION INTO TRANSAXLE CASE (a) Using SST, install the bearing to the drive pinion shaft. SST 09350–32014 (09351–32120) (b) Place the bearing cage onto the drive pinion shaft. NOTICE: Be careful not to damage the oil seals with the pinion shaft. (c) Using a brass bar and hammer, slightly tap the bearing cage into the transaxle case until the snap ring groove in the bore can be seen. (d) Using SST, install snap ring into the bore. SST 09350–32014 (09351–32050) (e) Using SST, install the snap ring. SST 09350–32014 (09351–32050) AX–103 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 2. PLACE OIL SLINGER AND NEW SPACER HINT: Install the spacer with the small end downward. 3. INSTALL OUTER RACE TO TRANSAXLE CASE Using SST, press in the outer race. SST 09350–32014 (09351–32100, 09351–32140) 4. INSTALL COUNTER DRIVE GEAR (a) Place a brass bar into the transaxle hole to hold the drive pinion shaft. (b) Using SST, press in the counter driven gear until the counter driven gaer bearing almost touches the counter gear. SST 09350–32014 (09351–32140) 5. INSTALL NEW LOCK NUT AND ADJUST DRIVE PINION PRELOAD (a) Install the new lock nut. (b) Using SST to hold the gear, tighten the nut. Torque: 280 N·m (2,855 kgf·cm, 206 ft·lbf) SST 09330–00021, 09350–32014 (09351–32032) Turn the gear counterclockwise and clockwise several times. (d) Using a small torque wrench, measure the preload of the drive pinion. (c) Drive pinion preload (at starting): New bearing 1.0–1.6 N·m (10–16 kgf·cm, 8.7–13.9 in.·lbf) Reused bearing 0.5–0.8 N·m (5–8 kgf·cm, 4.3–6.9 in.·lbf)
If the preload is greater than specified, replace the bearing spacer. AX–104 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION
If the preload is less then specified, retighten the nut 13 N·m (130 kgf·cm, 9 ft·lbf) at a time until the specified preload is reached. If the maximum torque is exceeded while retightening the nut, replace the bearing spacer and repeat the preload procedure. Do not back off the nut to reduce the preload. Maximum torque: 353 N·m (3,600 kgf·cm, 260 ft·lbf) (e) If the preload is adjusted within specification, make a note of it. (f) Stroke the lock nut. 6. INSTALL APPLY GASKET 7. PLACE OUTER RACE AND SHIM ONTO RH SIDE BEARING 8. PLACE DIFFERENTIAL CASE INTO TRANSAXLE CASE Be sure to install the shim and outer race into place. AX–105 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 9. INSTALL CARRIER COVER (a) Remove any packing material and be careful not to drop oil on the contacting surfaces of the carrier cover and transaxle case. (b) Apply seal packing to the carrier cover. Seal packing: Part No.08826–00090, THREE BOND 1281 or equivalent (c) HINT: Install the carrier cover within 10 minutes after applying seal packing. Install and torque the 11 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: Each bolt length is indicated below. Bolt length: Bolt A: 100 mm (3.937 in.) Bolt B: 65 mm (2.559 in.) Bolt C: 75 mm (2.953 in.) 10. ADJUST SIDE BEARING PRELOAD (a) Remove any packing material on the contacting surfaces of the LH bearing retainer and transaxle case. HINT: Do not apply seal packing yet. (b) Install the LH bearing retainer and torque the 6 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (c) Snap down the bearings by turning the differential case several times. (d) Using a small torque wrench, measure the differential total preload. Total preload (at starting): New bearing Drive pinion preload plus 0.2–0.4 N·m (2.5–5.1 kgf·cm, 2.2–3.6 in.·lbf) Reused bearing Drive pinion preload plus 0.1–0.2 N·m (1.3–2.0 kgf·cm, 1.1–1.7 in.·lbf) If the preload is not within specification, replace the adjusting shim in the LH bearing retainer with one of a different thickness. AX–106 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION AT3700:Adjusting shim thickness mm (in.) Mark Thickness Mark Thickness 0 2.00 (0.0787) 9 2.45 (0.0965) 1 2.05 (0.0807) A 2.50 (0.0984) 2 2.10 (0.0827) B 2.55 (0.1004) 3 2.15 (0.0846) C 2.60 (0.1024) 4 2.20 (0.0866) D 2.65 (0.1043) 5 2.25 (0.0886) E 2.70 (0.1063) 6 2.30 (0.0906) F 2.75 (0.1083) 7 2.35 (0.0925) G 2.80 (0.1102) 8 2.40 (0.0945) H 2.85 (0.1122) 11. INSTALL LH BEARING RETAINER (a) Remove the 6 bolts and LH bearing retainer. (b) Remove any FIPG material on the contacting surfaces of LH bearing retainer, transaxle case and carrier cover. (c) Apply FIPG to the transaxle case and carrier cover. FIPG: Part No.08826–00090, THREE BOND 1281 or equivalent HINT: Install the LH bearing retainer within 10 minutes after applying FIPG. (d) Install the LH bearing retainer. (e) Coat the threads of bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (f) Tighten the bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (g) Snap down the bearings. (h) Recheck the differential total preload. AX–107 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL NEW OIL SEAL (a) Place the oil baffle onto the LH bearing retainer. (b) Using SST, drive in a new oil seal unit its end is flush with surface of the LH bearing retainer. SST 09223–15010 13. INSTALL RH RETAINER (a) Remove any FIPG material on the contacting surfaces of RH retainer and transaxle case. (b) Apply FIPG to the RH retainer. FIPG: Part No.08826–00090, THREE BOND 1281 or equivalent HINT: Install the RH retainer within 10 minutes after applying FIPG. (c) Coat the bolts’ threads with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (d) Tighten the bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (e) Using SST, press in the oil seal. SST 09226–10010 AX–108 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 14. INSTALL DRIVE PINION CAP (a) Install a new O–ring to the cap. (b) Install the drive pinion cap to the transaxle case. AX0U2–03 4–SPEED GEAR UNIT INSTALLATION 1. INSTALL PARKING LOCK PAWL (a) Place the parking lock pawl onto the case. Hook the spring ends to the case and pawl. (b) Instal the pin into the hole of the case through the spring and pawl. 2. INSTALL MANUAL VALVE SHAFT (a) Coat the oil seal lip with MP grease. (b) Install the manual valve shaft oil seal to the case. (c) Assembly a new collar to the manual valve lever. (d) Install the manual valve shaft to the transmission case through the manual lever. (e) Install the parking lock rod. AX–109 AUTOMATIC TRANSAXLE (f) – COMPONENT PARTS INSTALLATION Using a pin punch, drive in the roll pin until its surface is flush with the manual valve lever surface. (g) Match the collar hole to the lever caulking hollow and caulk the collar to the lever. (h) Install the retaining spring. 3. INSTALL PARKING LOCK PAWL BRACKET AND GUIDE Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 4. CHECK OPERATION OF PARKING LOCK PAWL Make sure the counter driven gear is locked when the manual valve lever is in the P position. AX–110 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 5. INSTALL FIRST AND REVERSE BRAKE PISTON TO TRANSMISSION CASE (a) Coat the new O–rings with ATF. (b) Install the 2 O–rings on the piston. (c) Push the piston into the bore of the case, facing the spring seat upward. 6. INSTALL PISTON RETURN SPRING (a) Place the return spring and snap ring on the piston. (b) Place SST, and compress the return spring evenly by tightening the bolt gradually. SST 09350–32014 (09351–32040) (c) Install snap ring. Visually check to make sure it is fully seated and centered by the 3 lugs on the spring retainer. Be sure the end gap of snap ring is not aligned with the spring retainer claw. (d) Remove the SST. 7. INSTALL SNAP RING TO TRANSAXLE CASE AX–111 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 8. INSTALL OVERDRIVE UNIT (a) Install the overdrive brake apply gasket and overdrive clutch apply gasket. (b) Install the overdrive brake drum to the case. (c) Install the new case gasket to the case. (d) Make sure that the length from the top surface of the case to the counter driven gear surface should be about 24 mm (0.94 in.). (e) Place the new gasket onto the transaxle case. (f) Install the overdrive assembly with overdrive case to the transaxle case. AX–112 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (g) Coat the threads of 23 mm (0.91 in.) bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equivalent (h) Install and tighten the 13 bolts. HINT: Each bolt length is indicated below. Bolt length: Bolt A: 61 mm (2.402 in.) Bolt B 38 mm (1.496 in.) Bolt C: 23 mm (0.906 in.) Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 9. CHECK INTERMEDIATE SHAFT END PLAY (a) Make sure that the intermediate shaft as end play in axial direction. End play: 0.47–1.50 mm (0.0185–0.0591 in.) If the end play is not within specification, check the installation of intermediate shaft. (b) Make sure that the intermediate shaft turns smoothly. 10. INSTALL REAR PLANETARY GEAR (a) Install the rear planetary ring gear. (b) Place the bearing onto the ring gear. Bearing outer diameter: 38.7 mm (1.524 in.) Bearing inner diameter: 22.6 mm (0.890 in.) (c) Coat the thrust washer with petroleum jelly and place it onto the rear planetary gear. AX–113 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Install the rear planetary gear. 11. INSTALL DISCS, PLATES AND FLANGE OF FIRST AND REVERSE BRAKE (a) Install the 6 plates and discs. Install in order: P=Plate D=Disc P–D–P–D–P–D–P–D–P–D–P–D (b) Install the flange, facing the flat end downward. (c) Install the snap ring. HINT: Be sure that the end gap of the snap ring is not aligned with one of the cutouts. 12. CHECK FIRST AND REVERSE BRAKE (a) Check the operation of the first and reverse brake piston. Apply compressed air into the case passage and confirm that the piston moves. (b) Using a filler gauge, check that pack clearance of the first and reverse brake. Clearance: 1.92–2.68 mm (0.0756–0.1055 in.) AX–114 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL NO.2 ONE–WAY CLUTCH INTO CASE (a) Place the No.2 one–way clutch with the shiny side of flange upward. (b) Install the one–way clutch while turning the planetary gear clockwise with SST. SST 09350–32014 (09351–32050) If the planetary gear cannot turn clockwise, check the installation of the one–way clutch. (c) Install the snap ring. HINT: Be sure that the end gap of the snap ring is not aligned with one of cutouts. (d) Coat the thrust washer with petroleum jelly and install it onto the rear planetary gear. 14. INSTALL SECOND COAST BRAKE BAND GUIDE 15. PLACE NO.1 ONE–WAY CLUTCH (a) Coat the thrust washer with petroleum jelly and install it on the No.1 one–way clutch. AX–115 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the No.1 one–way clutch onto the rear planetary gear. 16. INSTALL SECOND BRAKE (a) Install the flange, facing the flat end upward. (b) Install the 3 discs and plates. Install in order: P=Plate D=Disc D–P–D–P–D–P (c) Place the piston return spring into the case. (d) Place the second brake drum into the case. HINT: Align the groove of the drum with the bolt. (e) Place the snap ring into the case so that end gap is installed into the groove. (f) While compressing the piston return spring over the drum with screwdriver, install the snap ring into the groove. (g) Be sure that the end gap of the snap ring is not aligned with one of cutouts. AX–116 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL NEW SECOND BRAKE GASKET Install a new gasket until it makes contact with the second brake drum. 18. CHECK OPERATION OF SECOND BRAKE Apply compressed air into the second brake gasket and confirm that the piston moves. 19. INSTALL SUN GEAR AND SUN GEAR INPUT DRUM (a) Coat the thrust washer with petroleum jelly and install it on the sun gear input drum. (b) While turning the sun gear clockwise, install it into the No.1 one–way clutch. 20. INSTALL OIL SEAL RING TO INTERMEDIATE SHAFT HINT: After installing the oil seal ring, check that it moves smoothly. AX–117 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 21. INSTALL FRONT PLANETARY GEAR (a) Coat the bearings with petroleum jelly, and install them onto the both sides of planetary gear. Bearing outer diameter: 45.5 mm (1.791 in.) Bearing inner diameter: 30.1 mm (1.185 in.) (b) Install the planetary gear onto the sun gear. 22. INSTALL FRONT PLANETARY RING GEAR 23. INSTALL SECOND COAST BRAKE BAND (a) Place the band into the case. (b) Install the pin through the oil pump mounting bolt hole. 24. INSTALL FORWARD CLUTCH AND DIRECT CLUTCH (a) Coat the bearing with petroleum jelly and install it onto rear side of the forward clutch. Bearing outer diameter: 47.6 mm (1.874 in.) Bearing inner diameter: 31.4 mm (1.236 in.) AX–118 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Coat the bearing with petroleum jelly and install it onto the front side of the forward clutch. HINT: There are 2 different thickness bearings for adjustment of the input shaft thrust play. Bearing thickness mm (in.) (c) Thickness Outer diameter Inner diameter 3.60 (0.1417) 45.9 (1.807) 27.7 (1.091) 4.19 (0.1650) 47.1 (1.854) 27.7 (1.091) Coat the thrust washer with petroleum jelly and install it with the oil groove facing upward onto the direct clutch drum. (d) Mesh the hub of the forward clutch flukes with the direct clutch discs. HINT: Be careful that the bearing and thrust washer do not get out of place. (e) Install the direct clutch and forward clutch into the case. HINT: Hold the direct clutch toward the forward clutch to prevent the thrust washer from getting out of place. 25. INSTALL OIL PUMP INTO CASE (a) Coat a new O–ring with ATF and install it to the oil pump. AX–119 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Place the oil pump through the input shaft, and align the bolt holes of the pump body with the transmission case. NOTICE: Do not push on the oil pump strongly or the oil seal ring will stick to the direct clutch drum. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) 26. MEASURE END PLAY OF INPUT SHAFT Measure the end play with a dial gauge. End play: 0.25–0.90 mm (0.0098–0.0354 in.) HINT: There are 2 different thickness bearings for end of stator shaft. If the end play is in excess of standard, select one of them. Bearing thickness: 3.60 mm (0.1417 in.) 4.19 mm (0.1650 in.) 27. CHECK INPUT SHAFT ROTATION Make sure that the input shaft rotates smoothly. 28. INSTALL SECOND COAST BRAKE PISTON (a) Coat the new O–rings with ATF and install it to the cover. (b) Install the outer spring with the piston. (c) Place the cover into the bore. (d) Using SST, install the snap ring while pressing the cover. SST 09350–32014 (09351–32050) (e) Check that the front end of the piston rod contacts the center of the second brake band depression. 29. CHECK SECOND COAST BRAKE PISTON STROKE (a) Apply a small amount of paint to the piston rod at the point it meets the case. AX–120 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION (b) Using SST, measure the piston stroke while applying and releasing compressed air (392–785 kPa, 4–8 kgf/cm2, 57–114 psi). SST 09240–00020 Piston stroke: 2.0–3.5 mm (0.079–0.138 in.) If the stroke is more than specified, replace the piston rod with a longer one. Piston rod length: 95.2 mm (3.748 in.) 96.3 mm (3.791 in.) If the still more than standard value, replace the brake band with a new one. AX0U3–02 HYDRAULIC CONTROL UNIT INSTALLATION 1. INSTALL ACCUMULATOR PISTONS AND SPRINGS (a) Install the new O–rings to the pistons. (b) Install the springs and pistons into the bores. Spring dimensions mm (in.) Spring Color Free length C2 Yellow/Purple 51.8 (2.039) B2 None 88.2 (3.473) B2 None 70.3 (2.767) C1 None 73.6 (2.898) (c) Place the cover with a new gasket and gradually tighten the bolts a little at a time in sequence. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) AX–121 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 2. PLACE NEW SECOND BRAKE APPLY GASKET 3. INSTALL SOLENOID WIRE 4. INSTALL THROTTLE CABLE 5. INSTALL VALVE BODY TO TRANSAXLE CASE (a) While holding the cam down with your hand, slip the cable end into the slot. (b) Lower the valve body into place. NOTICE: Do not entangle the solenoid wire. AX–122 AUTOMATIC TRANSAXLE (c) – COMPONENT PARTS INSTALLATION Install and tighten the 9 bolts. HINT:
Each bolt length is indicated below.
Hand tighten the 9 bolts first, then torque with a torque wrench. Bolt length: Bolt A: 30 mm (1.181 in.) Bolt B: 43 mm (1.693 in.) Bolt C: 48 mm (1.890 in.) Bolt D: 52 mm (2.047 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 6. INSTALL B3 APPLY PIPE NOTICE: Be careful not to bend or damage the pipe. 7. INSTALL CONNECTOR CLAMP AND PIPE RETAINER HINT: Each bolt length is indicated below. Bolt length: Bolt A: 48 mm (1.890 in.) Bolt B: 39 mm (1.535 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 8. CONNECT SOLENOID CONNECTORS AX–123 AUTOMATIC TRANSAXLE 9. – COMPONENT PARTS INSTALLATION INSTALL OIL PIPES Using a plastic hammer, install the pipes into the positions. NOTICE: Be careful not to bend or damage the pipes. 10. INSTALL MANUAL VALVE BODY AND DETENT SPRING HINT: Each bolt length is indicated below. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 37 mm (1.457 in.) (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Hand tighten the 5 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) (d) Place the detent springs on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) HINT: Each bolt length is indicated below. Bolt length: Bolt A: 14 mm (0.551 in.) Bolt B: 37 mm (1.457 in.) (e) Check that the manual valve lever is touching the center of the detent spring tip roller. 11. INSTALL PIPE BRACKET AND OIL STRAINER Each bolt length is indicated below. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 53 mm (2.087 in.) Torque: Pipe bracket: 10 N·m (100 kgf·cm, 7 ft·lbf) Oil strainer: 11 N·m (110 kgf·cm, 8 ft·lbf) AX–124 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 12. INSTALL MAGNETS IN PLACE NOTICE: Make sure that the magnets do not interfere with the oil pipes. 13. INSTALL OIL PAN WITH NEW GASKET (a) Install a new gasket and oil pan. (b) Install and torque the 17 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 14. INSTALL THROTTLE CABLE RETAINING PLATE 15. INSTALL TRANSAXLE UPPER COVER 16. INSTALL T/M REVOLUTION SENSOR (a) Install a new O–ring to the T/M revolution sensor. (b) Install the T/M revolution sensor with the bolt. AX–125 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch to the manual valve shaft. (b) Place the new locking plate and tighten the nut. (c) Stake the nut with locking plate. (d) Install the 2 bolts. (e) Adjust the park/neutral position switch. HINT: Align the groove and neutral basic line. (f) Tighten the 2 bolts. 18. INSTALL UNION AND ELBOW (a) Install the new O–rings to the union and elbow. (b) Install the union elbow to the transaxle case. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) HINT: Install the elbow, as shown in the illustration. 19. INSTALL MANUAL SHAFT LEVER AX–126 AUTOMATIC TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL SHIFT CONTROL CABLE BRACKET AX–127 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS AX0H1–06 SERVICE DATE Second Coast Brake 2.0 – 3.5 mm Piston stroke 0.079 – 0.138 in. 95.2 mm Piston rod length 3.748 in. 96.3 mm 3.791 in. Oil Pump Body clearance STD Maximum Tip clearance STD Maximum Side clearance STD Maximum Pump body bushing inside diameter Maximum 0.07 – 0.15 mm 0.0028 – 0.0059 in. 0.30 mm 0.0118 in. 0.11 – 0.14 mm 0.0043 – 0.0055 in. 0.30 mm 0.0118 in. 0.02 – 0.05 mm 0.0008 – 0.0020 in. 0.10 mm 0.0039 in. 38.18 mm 1.5031 in. Stator shaft bushing inside diameter Front side Maximum Rear side Maximum 21.57 mm 0.8492 in. 27.07 mm 1.0657 in. Direct Clutch Piston stroke Drum bushing inside diameter 0.91 – 1.35 mm 0.0358 – 0.0531 in. 48.27 mm 1.9004 in. 2.70 mm Flange thickness 0.1063 in. 3.00 mm 0.1181 in. Forward Clutch Piston stroke 1.79 – 2.21 mm 0.0704 – 0.0870 in. 2.30 mm Flange thickness 0.0906 in. 2.70 mm 0.1063 in. AX–128 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Front Planetary Gear Sun gear bushing inside diameter Maximum Ring gear flange bushing inside diameter Maximum Planetary pinion gear thrust clearance Maximum 22.59 mm 0.8894 in. 30.08 mm 1.1842 in. 0.61 mm 0.024 in. Rear Planetary Gear Planetary pinion gear thrust clearance Maximum 0.61 mm 0.024 in. First and Reverse Brake 1.92 – 2.68 mm Pack clearance 0.0756 – 0.1055 in. Overdrive Unit 1.75 – 2.49 mm Piston stroke Direct clutch bushing inside diameter 0.0689 – 0.0980 in. Maximum 22.13 mm 0.8713 in. 0.16 – 0.56 mm Planetary pinion gear thrust clearance STD 0.0063 – 0.0220 in. Maximum 0.61 mm 0.024 in. AX–129 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Valve Body Spring Free length / Coil outer diameter Spring Total No. of coils / Color mm (in.) Upper valve body Low coast modulator valve 20.2 (0.795) / 7.9 (0.311) 11.9 / Purple B1 orifice control valve 24.8 (0.976) / 6.4 (0.252) 12.0 / White Down–shift plug 15.0 (0.591) / 11.0 (0.433) 7.0 / None Throttle valve 31.5 (1.240) / 7.0 (0.276) 11.4 / Green Lock–up relay valve 26.8 (1.055) / 10.2 (0.402) 10.8 / Yellow 2–3 shift valve 28.0 (1.102) / 9.4 (0.370) 10.3 / None Second coast modulator valve 20.2 (0.795) / 7.9 (0.311) 11.9 / Purple Lower valve body Accumulator control vavle 25.1 (0.988) / 8.6 (0.339) 8.0 / Red Secondary regulator valve 46.9 (1.846) / 5.9 (0.232) 21.8 / None Second lock valve 20.7 (0.815) / 7.4 (0.291) 9.5 / None Reverse control valve 38.1 (1.500) / 6.5 (0.256) 19.0 / White/Purple 1–2 shift valve 29.2 (1.150) / 8.9 (0.350) 12.0 / Light Green 3–4 shift valve 28.0 (1.102) / 7.6 (0.299) 10.3 / None Primary regulator valve 36.6 (1.441) / 16.1 (0.634) 6.3 / None Cut–back valve 21.8 (0.858) / 6.0 (0.236) 13.5 / None Solenoid modulator valve 30.2 (1.189) / 5.6 (0.220) 15.3 / Purple/Pink Valve Body Key Height Width Thickness mm (in.) mm (in.) mm (in.) B1 orifice control valve 8.9 (0.350) 5.0 (0.197) 3.2 (0.126) Low coast modulator valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Accumulator control valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Secondary regulator valve 11.0 (0.433) 5.0 (0.197) 3.2 (0.126) 1–2 shift valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) 2–3 shift valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) 3–4 shift valve 6.5 (0.256) 5.0 (0.197) 3.2 (0.126) Key Upper valve body Lower valve body Second lock valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Second coast modulator valve 8.0 (0.315) 5.0 (0.197) 3.2 (0.126) Reverse control valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Cut–back valve 9.2 (0.362) 5.0 (0.197) 3.2 (0.126) Solenoid modulator valve 8.5 (0.335) 5.0 (0.197) 3.2 (0.126) Lock–up control valve 9.2 (0.315) 5.0 (0.197) 3.2 (0.126) AX–130 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS Accumulator Spring Spring C0 Free length mm (in.) Color Inner 47.5 (1.870) White Outer 16.3 (0.642) None C1 73.6 (2.898) None C2 51.8 (2.039) Yellow / Purple B0 66.8 (2.630) Red / Yellow Inner 70.3 (2.767) None Outer 88.2 (3.473) None B2 Differential Assembly Drive pinion preload (at Starting) New bearing Reused bearing 1.0 – 1.6 N·m 10 – 16 kgf·cm 8.7 – 13.9 in.·lbf 0.5 – 0.8 N·m 5 – 8 kgf·cm 4.3 – 6.9 in.·lbf Total preload (at starting) New bearing Reused bearing Pinion to side gear backlash Drive pinion preload plus 0.3 – 0.4 N·m 2.8 – 4.4 kgf·cm 2.4 – 3.8 in.·lbf Drive pinion preload plus 0.1 – 0.2 N·m 1.4 – 2.2 kgf·cm 1.2 – 1.9 in.·lbf 0.05 – 0.20 mm 0.0020 – 0.0079 in. 1.60 mm Side gear thrust washer thickness 0.0630 in. 1.70 mm 0.0670 in. 1.80 mm 0.0709 in. AX–131 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS 2.00 mm 0.0787 in. 2.05 mm 0.0807 in. 2.10 mm 0.0827 in. 2.15 mm 0.0846 in. Side bearing adjusting shim thickness Mark 2.20 mm 0 0.0866 in. 1 2.25 mm 2 0.0886 in. 3 2.30 mm 4 0.0906 in. 5 2.35 mm 6 0.0925 in. 7 2.40 mm 8 0.0945 in. 9 2.45 mm A 0.0965 in. B 2.50 mm C 0.0984 in. D 2.55 mm E 0.1004 in. 2.60 mm F G 0.1024 in. 2.65 mm H 0.1043 in. 2.70 mm 0.1063 in. 2.75 mm 0.1083 in. 2.80 mm 0.1102 in. 2.85 mm 0.1122 in. AX–132 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS AX04N–03 TORQUE SPECIFICATIONS Part tightened N·m kgf·cm ft·lbf Oil cooler pipe union 27 275 20 Oil pan 4.9 50 43 in.·lbf Valve body x Transaxle case 11 110 8 Accumulator x Cover 10 100 7 Oil pump x Transaxle case 22 225 16 O/D case x Transaxle case 25 250 18 Differential LH side bearing retainer 19 195 14 Differential RH retainer 19 195 14 Differential carrier cover 39 400 29 Oil pump body x Stator shaft 10 100 7 Ring gear x Differential case 124 1,260 91 Upper valve body x Lower valve body 6.6 67 58 in.·lbf Accumulator cylinder x Valve body 6.6 67 58 in.·lbf Solenoid x Valve body 6.6 67 58 in.·lbf Counter drive gear lock nut 280 2,855 206 Carrire cover x Transaxle case 39 400 29 Parking lock pawl bracket 7.4 75 65 in.·lbf Oil strainer x Transaxle case 11 110 8 PP–1 PREPARATION – MAINTENANCE MAINTENANCE PP0E6–01 EQUIPMENT Mirror Brake hose Torque wrench Author: Date: 53 PP–2 PREPARATION – ENGINE MECHANICAL (5S–FE) ENGINE MECHANICAL (5S–FE) PP0JQ–04 SST (Special Service Tools) 09201–10000 Valve Guide Bushing Remover & Replacer Set (09201–01060) Valve Guide Bushing Remover & Replacer 6 09201–41020 Valve Stem Oil Seal Replacer 09202–70020 Valve Spring Compressor (09202–00010) 09213–54015 (91651–60855) Attachment Crankshaft Pulley Holding Tool Bolt Crankshaft pulley (Type A) 09222–30010 Connecting Rod Bushing Remover & Replacer 09223–15030 Oil Seal & Bearing Replacer Crankshaft rear oil seal 09223–46011 Crankshaft Front Oil Seal Replacer Camshaft oil seal 09224–74010 Engine Balancer Backlash Adjusting Tool 09226–10010 Crankshaft Front & Rear Bearing Replacer Author: Crankshaft front oil seal Date: 54 PP–3 PREPARATION 09248–55040 – ENGINE MECHANICAL (5S–FE) Valve Clearance Adjust Tool Set (09248–05410) Valve Lifter Press (09248–05420) Valve Lifter Stopper 09249–63010 Torque Wrench Adaptor Camshaft timing pulley 09330–00021 Companion Flange Holding Tool Crankshaft pulley 09612–24014 Steering Gear Housing Overhaul Tool Set (09617–24011) Steering Rack Wrench Fuel inlet hose 09843–18020 Diagnosis Check Wire 09950–50012 Puller C Set (09951–05010) Hanger 150 Crankshaft pulley Crankshaft timing pulley (09952–05010) Slide Arm Crankshaft pulley Crankshaft timing pulley (09953–05010) Center Bolt 100 Crankshaft pulley Crankshaft timing pulley (09953–05020) Center Bolt 150 Crankshaft pulley Crankshaft timing pulley Author: Date: 55 PP–4 PREPARATION – ENGINE MECHANICAL (5S–FE) (09954–05010) Claw No.1 Crankshaft pulley (Type B) Crankshaft timing pulley (09954–05020) Claw No.2 Crankshaft pulley (Type A) 09950–70010 Handle Set (09951–07100) Handle 100 09960–10010 Valve guide bushing Crankshaft rear oil seal Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy Camshaft timing pulley Oil pump pulley Camshaft sub–gear gear (09963–00500) Pin 5 Oil pump pulley Camshaft sub–gear gear (09963–01000) Pin 10 Camshaft timing pulley Author: Date: 56 PP–5 PREPARATION – ENGINE MECHANICAL (5S–FE) PP0JR–04 RECOMMENDED TOOLS 09090–04020 Engine Sling Device 09200–00010 Engine Adjust Kit . 09258–00030 Hose Plug Set . 09904–00010 Expander Set . For suspending engine Plug for vacuum hose, fuel hose etc. Author: Date: 57 PP–6 PREPARATION – ENGINE MECHANICAL (5S–FE) PP0JS–04 EQUIPMENT Abrasive compound Valve Caliper gauge CO/HC meter Compression gauge Connecting aligner Cylinder gauge Dial indicator Dye penetrant Engine tune–up tester Groove cleaning tool Piston ring groove Heater Magnetic finger Micrometer OBDII scan tool Pin hole grinder Piston pin hole of piston Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Ridge reamer Cylinder Soft brush Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter V–block Vernier calipers Wire brush Valve Author: Date: 58 PP–7 PREPARATION – ENGINE MECHANICAL (5S–FE) PP1WA–02 SSM (Special Service Materials) 08826–00080 Seal Packing Black or equivalent (FIPG) Camshaft bearing cap Cylinder head cover Semi–circular plug 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent Flywheel or drive plate bolt Torque converter clutch bolt 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch Author: Date: 59 PP–8 PREPARATION – ENGINE MECHANICAL (1MZ–FE) ENGINE MECHANICAL (1MZ–FE) PP0BR–03 SST (Special Service Tools) 09201–01055 Valve Guide Bushing Remover & Re placer 5.5 09201–41020 Valve Stem Oil Seal Replacer 09202–70020 Valve Spring Compressor (09202–00010) 09213–54015 (91651–60855) Attachment Crankshaft Pulley Holding Tool Bolt 09222–30010 Connecting Rod Bushing Remover & Replacer 09223–15030 Oil Seal & Bearing Replacer 09248–55040 Valve Clearance Adjust Tool Set (09248–05410) Valve Lifter Press (09248–05420) Valve Lifter Stopper 09249–63010 Torque Wrench Adaptor Crankshaft rear oil seal RH camshaft timing pulley Author: Date: 60 PP–9 PREPARATION – ENGINE MECHANICAL (1MZ–FE) 09330–00021 Companion Flange Holding Tool Crankshaft pulley 09608–03071 Replacer Spark plug tube gasket 09816–30010 Oil Pressure Switch Socket Knock sensor 09843–18020 Diagnosis Check Wire 09950–50012 Puller C Set (09951–05010) Hanger 150 Crankshaft pulley Crankshaft timing pulley (09952–05010) Slide Arm Crankshaft pulley Crankshaft timing pulley (09953–05010) Center Bolt 100 Crankshaft pulley Crankshaft timing pulley (09953–05020) Center Bolt 150 Crankshaft pulley Crankshaft timing pulley (09954–05010) Claw No.1 Crankshaft timing pulley (09954–05020) Claw No.2 Crankshaft pulley 09950–70010 Handle Set (09951–07100) Handle 100 Valve guide bushing Crankshaft rear oil seal Author: Date: 61 PP–10 PREPARATION 09960–10010 – ENGINE MECHANICAL (1MZ–FE) Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy Camshaft timing pulley Camshaft sub–gear (09963–01000) Pin 10 Camshaft timing pulley (09963–00500) Pin 5 Camshaft sub–gear Author: Date: 62 PP–11 PREPARATION – ENGINE MECHANICAL (1MZ–FE) PP0BS–03 RECOMMENDED TOOLS 09040–00010 Hexagon Wrench Set . 09090–04020 Engine Sling Device 09200–00010 Engine Adjust Kit . 09258–00030 Hose Plug Set . 09904–00010 Expander Set . For suspending engine Plug for the vacuum hose, fuel hose etc. Author: Date: 63 PP–12 PREPARATION – ENGINE MECHANICAL (1MZ–FE) PP0BT–03 EQUIPMENT Abrasive compound Caliper gauge CO/HC meter Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune–up tester Groove cleaning tool Heater Magnetic finger Micrometer OBDII scan tool Pin hole grinder Piston pin hole Piston ring compressor Piston ring expander Plastigage Precision straight edge Ridge reamer Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers Wire brush Valve Author: Date: 64 PP–13 PREPARATION – ENGINE MECHANICAL (1MZ–FE) PP1WT–01 SSM (Special Service Materials) 08826–00080 Seal Packing Black or equivalent (FIPG) Camshaft bearing cap Semi–circular plug Cylinder head cover Rear oil seal retainer 08826–00100 Seal Packing 1282B, THREE BOND 1282B or equivalent (FIPG) Engine coolant drain union Water seal plate Water inlet housing 08833–00070 Adhesive 1324, THREE BOND 1324 or equivalent Spark plug tube Drive plate bolt 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent No.1 idler pulley pivot bolt Author: Date: 65 PP–14 PREPARATION – EMISSION CONTROL (5S–FE) EMISSION CONTROL (5S–FE) PP0JU–04 SST (Special Service Tools) 09843–18020 Diagnosis Check Wire Author: Date: 66 PP–15 PREPARATION – EMISSION CONTROL (5S–FE) PP0JV–04 EQUIPMENT Torque wrench Hose clipper Pressure gauge Vacuum gauge Author: Date: 67 PP–16 PREPARATION – EMISSION CONTROL (1MZ–FE) EMISSION CONTROL (1MZ–FE) PP0BV–03 EQUIPMENT Hose clipper MITYVAC (Hand–held vacuum pump) Torque wrench Author: Date: 68 PP–17 PREPARATION – SFI (5S–FE) SFI (5S–FE) PP1WB–02 SST (Special Service Tools) 09268–41047 Injection Measuring Tool Set (09268–41100) Clamp (09268–41110) Adaptor (90405–09015) No.1 Union 09268–45014 Except California EFI Fuel Pressure Gauge (09268–41190) Adaptor (90405–06167) I Union 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09816–30010 Oil Pressure Switch Socket Knock sensor 1 09842–30070 Wiring ”F” EFI Inspection 09843–18020 Diagnosis Check Wire Author: Date: 69 PP–18 PREPARATION – SFI (5S–FE) PP0JX–04 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09258–00030 Hose Plug Set . Plug for vacuum hose, fuel hose etc. Author: Date: 70 PP–19 PREPARATION – SFI (5S–FE) PP0JY–04 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBDII scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge Author: Date: 71 PP–20 PREPARATION – SFI (1MZ–FE) SFI (1MZ–FE) PP1WW–01 SST (Special Service Tools) 09268–41047 Injection Measuring Tool Set (09268–41100) Clamp Except California (09268–41300) Clamp For California 09268–41250 T Joint 09268–45012 EFI Fuel Pressure Gauge 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09817–16011 Back–up Light Switch Tool Knock sensor 09842–30070 Wiring ”F” EFI Inspection 09843–18020 Diagnosis Check Wire Author: Date: 72 PP–21 PREPARATION – SFI (1MZ–FE) PP1WX–01 RECOMMENDED TOOLS 09040–00010 Hexagon Wrench Set . 09082–00040 TOYOTA Electrical Tester. 09200–00010 Engine Adjust Kit . 09258–00030 Hose Plug Set . Plug for the vacuum hose, fuel hose etc. Author: Date: 73 PP–22 PREPARATION – SFI (1MZ–FE) PP1WY–01 EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBD II scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge Author: Date: 74 PP–23 PREPARATION – SFI (1MZ–FE) PP1WZ–01 SSM (Special Service Materials) 08826–00080 Seal Packing Black or equivalent (FIPG) Author: Intake air control valve Date: 75 PP–24 PREPARATION – COOLING (5S–FE) COOLING (5S–FE) PP0JZ–05 SST (Special Service Tools) 09230–01010 Radiator Service Tool Set 09231–14010 Punch Author: Date: 76 PP–25 PREPARATION – COOLING (5S–FE) PP0K0–03 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 77 PP–26 PREPARATION – COOLING (5S–FE) PP0K1–03 EQUIPMENT Heater ECT switch, Thermostat Radiator cap tester Thermometer ECT switch, Thermostat Torque wrench Vernier calipers Author: Date: 78 PP–27 PREPARATION – COOLING (5S–FE) PP0K2–03 COOLANT Item Engine coolant Capacity w/ Oil cooler w/o Oil cooler Classification 6.9 liters (7.3 US qts, 6.1 lmp. qts) 6.2 liters (6.5 US qts, 5.4 lmp. qts) Author: ”Toyota Long Life Coolant” or equivalent Date: 79 PP–28 PREPARATION – COOLING (1MZ–FE) COOLING (1MZ–FE) PP1WU–01 SST (Special Service Tools) 09230–01010 Radiator Service Tool Set 09231–14010 Punch Author: Date: 80 PP–29 PREPARATION – COOLING (1MZ–FE) PP0C1–03 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 81 PP–30 PREPARATION – COOLING (1MZ–FE) PP0C2–02 EQUIPMENT Heater ECT switch Radiator cap tester Thermometer ECT switch Torque wrench Author: Date: 82 PP–31 PREPARATION – COOLING (1MZ–FE) PP0C3–04 COOLANT Item Engine coolant Capacity Classification 9.2 liters (9.7 US qts, 8.1 lmp. qts) Author: ”Toyota Long Life Coolant” or equivalent Date: 83 PP–32 PREPARATION – LUBRICATION (5S–FE) LUBRICATION (5S–FE) PP0K3–04 SST (Special Service Tools) 09032–00100 Oil Pan Seal Cutter 09228–06501 Oil Filter Wrench 09950–60010 Replacer Set (09951–00350) Replacer 35 09950–70010 Handle Set (09951–07100) Handle 100 Oil pump oil seal Oil pump oil seal Author: Date: 84 PP–33 PREPARATION – LUBRICATION (5S–FE) PP0K4–04 RECOMMENDED TOOLS 09200–00010 Engine Adjust Kit . 09905–00013 Snap Ring Pliers . Author: Date: 85 PP–34 PREPARATION – LUBRICATION (5S–FE) PP0K5–04 EQUIPMENT Oil pressure gauge Torque wrench Author: Date: 86 PP–35 PREPARATION – LUBRICATION (5S–FE) PP0K6–04 LUBRICANT Item Engine oil Dry fill Capacity Classification w/ Oil cooler w/o Oil cooler 4.3 liters (4.5 US qts, 3.8 lmp.qts) 4.2 liters (4.4 US qts, 3.7 lmp.qts) API grade SJ, Energy–Conserving or ILSAC multigrade engine oil. SAE 5W–30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather w/ Oil filter change w/o Oil filter change 3.6 liters (3.8 US qts, 3.2 lmp.qts) 3.4 liters (3.6 US qts, 3.0 lmp.qts) Drain and refill Author: Date: 87 PP–36 PREPARATION – LUBRICATION (5S–FE) PP1WC–01 SSM (Special Service Materials) 08826–00080 Seal Packing Black or equivalent (FIPG) Oil pan 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch Author: Date: 88 PP–37 PREPARATION – LUBRICATION (1MZ–FE) LUBRICATION (1MZ–FE) PP0C4–03 SST (Special Service Tools) 09032–00100 Oil Pan Seal Cutter No.2 oil pan 09223–00010 Cover & Seal Replacer Crankshaft front oil seal 09228–07501 Oil Filter Wrench 09816–30010 Oil Pressure Switch Socket Author: Date: 89 PP–38 PREPARATION – LUBRICATION (1MZ–FE) PP0C5–03 RECOMMENDED TOOLS 09200–00010 Engine Adjust Kit . Author: Date: 90 PP–39 PREPARATION – LUBRICATION (1MZ–FE) PP0C6–02 EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench Author: Date: 91 PP–40 PREPARATION – LUBRICATION (1MZ–FE) PP0C7–04 LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity Classification 5.2 liters (5.5 US qts, 4.6 lmp. qts) 4.7 liters (5.0 US qts, 4.1 lmp. qts) 4.5 liters (4.8 US qts, 4.0 lmp. qts) Author: API grade SJ, Energy–Conserving or ILSAC multigrade engine oil. SAE 5W–30 is the best choice for your vehicle, for good fuel economy and good starting in cold weather. Date: 92 PP–41 PREPARATION – LUBRICATION (1MZ–FE) PP1WV–01 SSM (Special Service Materials) 08826–00080 Seal Packing Black or equivalent (FIPG) Oil pump No.1 oil pan No.2 oil pan 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch Author: Date: 93 PP–42 PREPARATION – IGNITION (5S–FE) IGNITION (5S–FE) PP0K8–04 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09200–00010 Engine Adjust Kit . Author: Date: 94 PP–43 PREPARATION – IGNITION (5S–FE) PP0K9–04 EQUIPMENT Megger insulation resistance meter Spark plug Spark plug cleaner Author: Date: 95 PP–44 PREPARATION – IGNITION (1MZ–FE) IGNITION (1MZ–FE) PP0CF–03 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09200–00010 Engine Adjust Kit . Author: Date: 96 PP–45 PREPARATION – IGNITION (1MZ–FE) PP0CG–02 EQUIPMENT Megger insulation resistance meter Spark plug Spark plug cleaner Author: Date: 97 PP–46 PREPARATION – STARTING (5S–FE) STARTING(5S–FE) PP0KA–01 SST (Special Service Tools) 09286–46011 Injection Pump Spline Shaft Puller Armature bearing 09810–38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820–00030 Alternator Rear Bearing Replacer Armature front bearing Author: Date: 98 PP–47 PREPARATION – STARTING (5S–FE) PP0KB–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 99 PP–48 PREPARATION – STARTING (5S–FE) PP0KC–01 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit part Pull scale Brush spring Sandpaper Commutator Torque wrench V–block Commutator Vernier calipers Commutator, Brush Author: Date: 100 PP–49 PREPARATION – STARTING (1MZ–FE) STARTING (1MZ–FE) PP0C9–01 SST (Special Service Tools) 09286–46011 Injection Pump Spline Shaft Puller Armature bearing 09810–38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820–00030 Alternator Rear Bearing Replacer Armature front bearing Author: Date: 101 PP–50 PREPARATION – STARTING (1MZ–FE) PP0CA–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 102 PP–51 PREPARATION – STARTING (1MZ–FE) PP0CB–02 EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V–block Commutator Vernier calipers Commutator, Brush Author: Date: 103 PP–52 PREPARATION – CHARGING (5S–FE) CHARGING(5S–FE) PP0KD–01 SST (Special Service Tools) 09285–76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286–46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820–00021 Alternator Rear Bearing Puller 09820–00030 Alternator Rear Bearing Replacer 09820–63010 Alternator Pulley Set Nut Wrench Set 09950–60010 Replacer Set (09951–00500) Replacer 50 Rotor rear bearing Rotor front bearing Author: Date: 104 PP–53 PREPARATION – CHARGING (5S–FE) PP0KE–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 105 PP–54 PREPARATION – CHARGING (5S–FE) PP0KF–01 EQUIPMENT Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush Author: Date: 106 PP–55 PREPARATION – CHARGING (1MZ–FE) CHARGING (1MZ–FE) PP0CC–01 SST (Special Service Tools) 09285–76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286–46011 Injection Pump Spline Shaft Puller Rectifier end frame 09820–00021 Alternator Rear Bearing Puller 09820–00030 Alternator Rear Bearing Replacer 09820–63010 Alternator Pulley Set Nut Wrench Set 09950–60010 Replacer Set (09951–00500) Replacer 50 Rotor rear bearing Rotor front bearing Author: Date: 107 PP–56 PREPARATION – CHARGING (1MZ–FE) PP0CD–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 108 PP–57 PREPARATION – CHARGING (1MZ–FE) PP0CE–02 EQUIPMENT Ammeter(A) Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush Author: Date: 109 PP–58 PREPARATION – CLUTCH CLUTCH PP0HC–01 SST (Special Service Tools) 09023–00100 Union Nut Wrench 10 mm Clutch line 09301–00210 Clutch Guide Tool 5S–FE Engine 09301–00220 Clutch Guide Tool 1MZ–FE Engine 09333–00013 Clutch Diaphragm Spring Aligner Author: Date: 110 PP–59 PREPARATION – CLUTCH PP0HD–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09905–00013 Snap Ring Pliers . Author: Date: 111 PP–60 PREPARATION – CLUTCH PP0HE–01 EQUIPMENT Calipers Dial indicator Torque wrench Author: Date: 112 PP–61 PREPARATION – MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE (E153) PP0H7–03 SST (Special Service Tools) 09223–15020 Oil Seal & Bearing Replacer Differential case oil seal 09308–00010 Oil Seal Puller Output shaft front bearing outer race 09316–20011 Transfer Bearing Replacer Differential case tapered roller bearing 09316–60011 Transmission & Transfer Bearing Replacer (09316–00011) Replacer Pipe (09316–00021) Replacer ”A” (09316–00041) Replacer ”C” 1st gear No.1 hub sleeve Differential case tapered roller bearing outer race Replacer ”F” Output shaft front bearing 09506–30012 Differential Drive Pinion Rear Bearing Cone Replacer Output shaft rear bearing 09506–35010 Differential Drive Pinion Rear Bearing Replacer No.2 hub sleeve 3rd gear Input shaft rear bearing 09608–00081 Differential Side Bearing Cone Replacer Input shaft oil seal 09612–65014 Steering Worm Bearing Puller Input shaft bearing Differential case tapered roller bearing outer race (09316–00071) Author: Date: 113 PP–62 PREPARATION – MANUAL TRANSAXLE (E153) 09950–00020 Bearing Remover 09950–00030 Bearing Remover Attachment Output shaft front bearing 09950–30010 Puller A Set 5th driven gear No.3 clutch hub 09950–40011 Puller B Set Differential case tapered roller bearing 09950–60010 Replacer Set (09951–00310) Replacer 31 Control shaft cover oil seal Installation (09951–00580) Replacer 58 Input shaft bearing 09950–70010 Handle Set (09951–07150) Handle 150 Author: Date: 114 PP–63 PREPARATION – MANUAL TRANSAXLE (E153) PP0H8–01 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) 09031–00030 Pin Punch . 09040–00010 Hexagon Wrench Set . 09042–00040 Torx Socket T50 . 09042–00050 Torx Socket T45 . 09090–04010 Engine Sling Device . 09905–00012 Snap Ring No.1 Expander . Author: Differential preload Date: 115 PP–64 PREPARATION – MANUAL TRANSAXLE (E153) PP0H9–01 EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Precision straight edge Magnetic finger Author: Date: 116 PP–65 PREPARATION – MANUAL TRANSAXLE (E153) PP0HA–01 LUBRICANT Item Manual transaxle oil (w/ Differential oil) Capacity Classification 4.2 liters (4.4 US qts, 3.7 Imp. qts) Author: API GL–4 or GL–5 SAE 75W–90 Date: 117 PP–66 PREPARATION – MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE (S51) PP0H2–04 SST (Special Service Tools) 09308–00010 Oil Seal Puller Input shaft front bearing Output shaft front bearing 09309–12020 5th Driven Gear Replacer 5th driven gear 09310–35010 Countershaft Bearing Replacer Input shaft front bearing Output shaft front bearing 09316–60011 Transmission & Transfer Bearing Replacer (09316–00011) Replacer Pipe 3rd driven gear Differential side bearing (09316–00041) Replacer ”C” Output shaft thrust washer 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32120) Overdrive Bearing Replacer Differential side bearing (09351–32130) Handle Differential side bearing retainer oil seal Differential case oil seal (Transaxle case side) (09351–32150) Oil Seal Replacer Differential side bearing retainer oil seal Differential case oil seal (Transaxle case side) 09564–32011 Differential Preload Adaptor 09608–00071 Drive Pinion Rear Bearing Cone Replacer Author: Input shaft rear bearing Date: 118 PP–67 PREPARATION – MANUAL TRANSAXLE (S51) 09608–00081 Differential Side Bearing Cone Replacer Input shaft front oil seal 09612–22011 Tilt Handle Bearing Replacer Output shaft rear bearing No.3 clutch hub 09950–00020 Bearing Remover 09950–00030 Bearing Remover Attachment 09950–30010 Puller A Set No.3 clutch hub 09950–40011 Puller B Set 5th driven gear 09950–60020 Replacer Set No.2 Differential side bearing retainer oil seal Differential side bearing outer race (09951–00680) Replacer 68 09950–70010 Handle Set (09951–07150) Handle 150 Author: Date: 119 PP–68 PREPARATION – MANUAL TRANSAXLE (S51) PP0H3–01 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) 09031–00030 Pin Punch . 09040–00010 Hexagon Wrench Set . 09090–04010 Engine Sling Device . 09905–00012 Snap Ring No.1 Expander . Author: Differential preload Date: 120 PP–69 PREPARATION – MANUAL TRANSAXLE (S51) PP0H4–01 EQUIPMENT Dial indicator Torque wrench Feeler gauge Magnetic finger Micrometer Author: Date: 121 PP–70 PREPARATION – MANUAL TRANSAXLE (S51) PP0H5–01 LUBRICANT Item Manual transaxle oil (w/ Differential oil) Capacity Classification 2.6 liters (2.7 US qts, 2.3 lmp. qts) Author: API GL–4 or GL–5 SAE 75W–90 Date: 122 PP–71 PREPARATION – AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE (A140E) PP0KG–01 SST (Special Service Tools) 09308–00010 Oil Seal Puller 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Tool (09351–32020) Stator Stopper (09351–32130) Handle (09351–32150) Oil Seal Replacer 09992–00095 Automatic Transmission Oil Pressure Gauge Set (09992–00231) Adaptor C (09992–00271) Gauge Assy Author: Date: 123 PP–72 PREPARATION – AUTOMATIC TRANSAXLE (A140E) PP0KH–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09090–04010 Engine Sling Device . Author: Date: 124 PP–73 PREPARATION – AUTOMATIC TRANSAXLE (A140E) PP0KI–01 EQUIPMENT OBD II scan tool Torque wrench Hexagon wrench Dial indicator with magnetic base Drive plate Vernier calipers Torque converter clutch Straight edge Torque converter clutch Author: Date: 125 PP–74 PREPARATION – AUTOMATIC TRANSAXLE (A140E) PP0KJ–01 LUBRICANT Item Capacity Classification Automatic transaxle Dry fill Drain and refill 5.6 liters (5.9 US qts, 4.9 Imp.qts) 2.5 liters (2.6 US qts, 2.2 Imp.qts) ATF D–II or DEXRON®III (DEXRON®II) Differential oil 1.6 liters (1.7 US qts, 1.4 Imp.qts) ATF D–II or DEXRON®III (DEXRON®II) Author: Date: 126 PP–75 PREPARATION – AUTOMATIC TRANSAXLE (A541E) AUTOMATIC TRANSAXLE (A541E) PP0M1–01 SST (Special Service Tools) 09223–15020 Oil Seal & Bearing Replacer 09308–00010 Oil Seal Puller Side gear shaft oil seal 09316–60011 Transmission & Transfer Bearing Replacer RH side bearing Replacer Pipe RH side gear shaft oil seal (09316–00011) 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Tool (09351–32020) Stator Stopper (09351–32130) Handle 09992–00095 Automatic Transmission Oil Pressure Gauge Set (09992–00231) Adaptor C (09992–00271) Gauge Assy Author: Line pressure Date: 127 PP–76 PREPARATION – AUTOMATIC TRANSAXLE (A541E) PP0M2–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09090–04010 Engine Sling Device . Author: Date: 128 PP–77 PREPARATION – AUTOMATIC TRANSAXLE (A541E) PP0M3–01 EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon Wrench (10 mm) Torque wrench OBD II scan tool Author: Date: 129 PP–78 PREPARATION – AUTOMATIC TRANSAXLE (A541E) PP0M4–01 LUBRICANT Item Automatic transaxle fluid (w/o Differential oil) Dry fill Drain and refill Capacity Classification 8.0 liters (8.5 US qts, 7.0 Imp. qts) 3.9 liters (4.1 US qts, 3.4 Imp. qts) Author: ATF D–II or DEXRON®III (DEXRON®II) Date: 130 PP–79 PREPARATION – SUSPENSION AND AXLE SUSPENSION AND AXLE PP1WM–01 SST (Special Service Tools) 09223–56010 Crankshaft Rear Oil Seal Replacer Front drive shaft 09240–00020 Wire Gauge Set Front drive shaft 09309–36010 Transmission Rear Bearing Replacer Front drive shaft 09310–35010 Countershaft Bearing Replacer Front axle hub 09316–20011 Transfer Bearing Replacer Front drive shaft 09316–60011 Transmission & Transfer Bearing Replacer Front axle hub Front suspension (09316–00011) Replacer Pipe (09316–00041) Replacer ”C” 09506–35010 Differential Drive Pinion Rear Bearing Replacer Front drive shaft 09520–00031 Rear Axle Shaft Puller Front axle hub 09521–24010 Drive Shaft Boot Clamping Tool Front drive shaft 09527–17011 Rear Axle Shaft Bearing Remover Front axle hub Author: Date: 131 PP–80 PREPARATION – SUSPENSION AND AXLE 09555–55010 Differential Drive Pinion Bearing Replacer Front drive shaft 09608–16042 Front Hub Bearing Adjusting Tool Front drive shaft (09608–02021) Bolt & Nut (09608–02041) Retainer 09608–32010 Steering Knuckle Oil Seal Replacer Front axle hub Front suspension 09610–20012 Pitman Arm Puller Front axle hub 09628–10011 Ball Joint Puller Front axle hub Rear axle hub 09628–62011 Ball Joint Puller Front axle hub Front suspension 09727–30021 Coil Spring Compressor Front suspension Rear suspension 09729–22031 Front Spring Upper Seat Holder Front suspension 09950–00020 Bearing Remover Front axle hub Front drive shaft 09950–60010 Replacer Set Front axle hub (09951–00400) Replacer 40 Author: Date: 132 PP–81 PREPARATION – 09950–70010 Handle Set (09951–07100) Handle 100 SUSPENSION AND AXLE Front axle hub Author: Date: 133 PP–82 PREPARATION – SUSPENSION AND AXLE PP08W–01 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) 09042–00010 Torx Socket T30 . 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . Author: Date: 134 PP–83 PREPARATION – SUSPENSION AND AXLE PP08X–03 EQUIPMENT Dial indicator Drill Torque wrench Author: Date: 135 PP–84 PREPARATION – SUSPENSION AND AXLE PP08Y–01 LUBRICANT Item Capacity 5S–FE: Outboard joint grease Color=Black Inboard joint grease Color=Yellow ocher 140 – 160 g (5.5 – 6.3 oz.) 185 – 215 g (7.3 – 8.5 oz.) 1MZ–FE: Outboard joint grease Inboard joint grease Color=Black Color=Gray Joint side Boot side Application 105 – 125 g (3.7 – 4.4 oz.) 142.5 – 157.5 g (5.0 – 5.6 oz.) 52.5 – 57.5 g (2.1 – 2.3 oz.) Author: Date: 136 PP–85 PREPARATION – BRAKE BRAKE PP0I7–01 SST (Special Service Tools) 09023–00100 Union Nut Wrench 10 mm 09703–30010 Brake Shoe Return Spring Tool 09709–29018 LSPV Gauge Set 09718–00010 Shoe Hold Down Spring Driver 09737–00010 Brake Booster Push Rod Gauge 09751–36011 Brake Line Union Nut 10 x 12 mm Wrench 09843–18020 Diagnosis Check Wire 09990–00150 ABS Actuator Checker and Sub–harness DENSO type ABS, ABS & TRAC type 09990–00163 ABS Actuator Checker Sheet ”A” ABS & TRAC type 09990–00250 ABS Actuator Checker Sub–harness ”G” DENSO type ABS, ABS & TRAC type 09990–00300 ABS Actuator Checker Sub–harness ”I” DENSO type ABS 09990–00360 ABS Actuator Checker Sub–harness ”L” DENSO type ABS, ABS & TRAC type Author: Date: 137 PP–86 PREPARATION – BRAKE 09990–00430 ABS Actuator Checker Sheet ”P” DENSO type ABS 09990–00450 ABS Actuator Checker Sub–harness ”P” ABS & TRAC type Author: Date: 138 PP–87 PREPARATION – BRAKE PP0I8–01 RECOMMENDED TOOLS 09042–00030 Torx Socket T20 . BOSCH type ABS 09082–00040 TOYOTA Electrical Tester. 09905–00013 Snap Ring Pliers . Author: Date: 139 PP–88 PREPARATION – BRAKE PP0I9–03 EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Brake drum gauge Brake drum and disc Vernier calipers Brake drum Author: Date: 140 PP–89 PREPARATION – BRAKE PP0IA–01 LUBRICANT Item Brake fluid Capacity Classification – SAE J1703 or FMVSS No.116 DOT3 Author: Date: 141 PP–90 PREPARATION – STEERING STEERING PP0DB–03 SST (Special Service Tools) 09249–63010 Torque Wrench Adaptor PS vane pump 09521–24010 Drive Shaft Boot Clamping Tool PS gear 09527–20011 Rear Axle Shaft Bearing Remover PS gear 09612–00012 Rack & Pinion Steering Rack Housing Stand PS gear 09612–22011 Tilt Handle Bearing Replacer PS gear 09612–24014 Steering Gear Housing Overhaul Tool Set Steering Rack Shaft Bushing Puller PS gear 09616–00010 Steering Worm Bearing Adjusting Socket PS gear 09631–10021 Rack Stopper Wrench PS gear 09631–12071 Steering Rack Oil Seal Test Tool PS gear 09631–20081 Seal Ring Tool PS gear 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set PS vane pump PS gear (09613–22011) Author: Date: 142 PP–91 PREPARATION – STEERING 09631–33010 Steering Rack Cover ”I” PS gear 09633–00020 Power Steering Hose Nut Wrench PS gear 09640–10010 Power Steering Pressure Gauge Set (09641–01010) Gauge Assy Power steering fluid (09641–01030) Attachment B Power steering fluid (09641–01060) Attachment E Power steering fluid 09922–10010 Variable Open Wrench PS gear 09950–50012 Puller C Set (09951–05010) Hanger 150 Tilt steering column (09952–05010) Slide Arm Tilt steering column (09953–05020) Center Bolt 150 Tilt steering column (09954–05020) Claw No.2 Tilt steering column 09950–60010 Replacer Set Author: Date: 143 PP–92 PREPARATION – STEERING (09951–00180) Replacer 18 PS gear (09951–00240) Replacer 24 PS gear (09951–00250) Replacer 25 PS gear (09951–00260) Replacer 26 PS gear (09951–00290) Replacer 29 PS gear (09951–00310) Replacer 31 PS gear (09951–00320) Replacer 32 PS gear (09951–00330) Replacer 33 PS vane pump (09951–00340) Replacer 34 PS gear (09951–00400) Replacer 40 PS gear (09951–00430) Replacer 43 PS gear (09952–06010) Adapter PS gear 09950–70010 Handle Set Author: Date: 144 PP–93 PREPARATION – STEERING (09951–07100) Handle 100 PS vane pump (09951–07200) Handle 200 PS gear (09951–07360) Handle 360 PS gear 09960–10010 Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy PS vane pump (09963–01000) Pin 10 PS vane pump Author: Date: 145 PP–94 PREPARATION – STEERING PP0DC–03 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 ) . PS vane pump PS gear 09042–00010 Torx Socket T30 . Tilt steering column 09904–00010 Expander Set . 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . Author: Date: 146 PP–95 PREPARATION – STEERING PP0DD–05 EQUIPMENT Belt tension gauge On–vehicle inspection Caliper gauge PS vane pump Calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench Author: Date: 147 PP–96 PREPARATION – STEERING PP0DE–05 LUBRICANT Item Capacity Classification Power steering fluid Total 0.8 liters (0.8 US qts, 0.7 lmp.qts) ATF DEXRON® II or III Author: Date: 148 PP–97 PREPARATION – STEERING PP1XK–01 SSM (Special Service Materials) 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Author: PS gear Date: 149 PP–98 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM PP0MQ–01 SST (Special Service Tools) 09082–00700 SRS Airbag Deployment Tool 09082–00750 Airbag Deployment Wire Sub–harness No.3 09082–00760 Airbag Deployment Wire Sub–harness No.4 09843–18020 Diagnosis Check Wire Author: Date: 150 PP–99 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP1XL–01 RECOMMENDED TOOLS 09042–00020 Torx Socket T40 . 09082–00050 TOYOTA Electrical Tester Set. 09082–00040 TOYOTA Electrical Tester. (09083–00150) Airbag sensor assembly Test Lead Set Seat belt pretensioner connector Author: Date: 151 PP–100 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM PP0MS–01 EQUIPMENT Torque wrench Bolt: Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam.: 6.0 mm (0.236 in.) Airbag disposal Tire Airbag disposal Width: 185 mm (7.28 in.) Inner diam.: 360mm (14.17 in.) Tire with disc wheel Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal Vinyl bag Airbag disposal Author: Date: 152 PP–101 PREPARATION – BODY ELECTRICAL BODY ELECTRICAL PP0KY–01 SST (Special Service Tools) 09843–18020 Diagnosis Check Wire Author: Date: 153 PP–102 PREPARATION – BODY ELECTRICAL PP0KZ–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09041–00030 Torx Driver T30 . For removing and installing steering wheel pad 09042–00010 Torx Socket T30 . For removing and installing steering wheel pad Author: Date: 154 PP–103 PREPARATION – BODY ELECTRICAL PP0L0–01 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb (3.4 W) Fuel sender gauge, Seat belt warning relay Bulb (21 W) Turn signal flasher relay Dry cell battery Fuel sender gauge Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire Author: Date: 155 PP–104 PREPARATION – BODY BODY PP0MU–01 SST (Special Service Tools) 09804–24010 Luggage Compartment Door Torsion Bar Tool 09812–00020 Door Hinge Set Bolt Wrench Author: Date: 156 PP–105 PREPARATION – BODY PP0MV–01 EQUIPMENT Clip remover Torque wrench Drill Drill bit, diam 3.2 mm (0.126 in.) Hand riveter Tape To avoid surface damage Adhesive tape To avoid surface damage Adhesive Cleaner Shop rag Regulator handle Water pump pliers Window regulator Knife Moulding Heat light Moulding Piano wire Windshield Rope (no projections, difficult to break) Seat belt pretensioner disposal Tire Width: 185 mm (7.28 in.) Inner diam: 360 mm (14.17 in.) Seatbelt pretensioner disposal Tire with disc wheel Width: 185 mm (7.28 in.) Inner diam 360 mm (14.17 in.) Seat belt pretinsioner disposal Vinyl bag Seat belt pretensioner disposal Author: Date: 157 PP–106 PREPARATION – BODY PP0MW–01 LUBRICANT Item Capacity Classification MP grease – – Author: Date: 158 PP–107 PREPARATION – AIR CONDITIONING AIR CONDITIONING PP1XJ–01 SST (Special Service Tools) 07110–58060 Air Conditioner Service Tool Set (07117–58060) Refrigerant Drain Service Valve (07117–58070) T–Joint (07117–58080) Quick Disconnect Adapter Discharge (diam. 16 mm) (07117–58090) Quick Disconnect Adapter Suction (diam. 13 mm) (07117–78050) Refrigerant Charging Gauge (07117–88060) Refrigerant Charging Hose Discharge (Red) (07117–88070) Refrigerant Charging Hose Suction (Blue) (07117–88080) Refrigerant Charging Hose Utility (Green) 07112–66040 Magnetic Clutch Remover 07112–76060 Magnetic Clutch Stopper 07114–84010 Snap Ring Pliers Author: Date: 159 PP–108 PREPARATION – AIR CONDITIONING 07114–84020 Snap Ring Pliers 07116–38360 Gas Leak Detector Assembly 09870–00015 A/C Quick Joint Puller No.1 Suction tube 09870–00025 A/C Quick Joint Puller No.2 Liquid tube Author: Date: 160 PP–109 PREPARATION – AIR CONDITIONING PP0B7–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. 09216–00021 Belt Tension Gauge . Author: Date: 161 PP–110 PREPARATION – AIR CONDITIONING PP0B8–02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor, ECT switch Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch Author: Date: 162 PP–111 PREPARATION – AIR CONDITIONING PP0B9–02 LUBRICANT Item Compressor oil When replacing receiver Capacity Classification – ND–OIL 8 or equivalent 20 cc (0.71 fl.oz.) When replacing condenser 40 – 50 cc (1.4 – 1.7 fl.oz.) When replacing evaporator 40 – 50 cc (1.4 – 1.7 fl.oz.) When replacing compressor 120 cc (4.1 fl.oz.) Author: Date: 163 PP–1 PREPARATION – ENGINE MECHANICAL ENGINE MECHANICAL PP24T–01 RECOMMENDED TOOLS 09200–00010 Engine Adjust Kit . Author: Date: 43 PP–2 PREPARATION – ENGINE MECHANICAL PP0JS–05 EQUIPMENT CO/HC meter Compression gauge Micrometer OBDII scan tool Torque wrench Vernier calipers PP–3 PREPARATION – SFI SFI PP24U–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. Author: Date: 45 PP–4 PREPARATION – SFI PP0JY–05 EQUIPMENT Sound scope Torque wrench Injector PP–5 PREPARATION – IGNITION IGNITION PP24V–01 RECOMMENDED TOOLS 09200–00010 Engine Adjust Kit . Author: Date: 47 PP–6 PREPARATION – IGNITION PP0K9–04 EQUIPMENT Megger insulation resistance meter Spark plug cleaner Spark plug PP–7 PREPARATION – SUSPENSION AND AXLE SUSPENSION AND AXLE PP24O–01 SST (Special Service Tools) 09608–16042 Front Hub Bearing Adjusting Tool (09608–02021) Bolt & Nut (09608–02041) Retainer Front drive shaft 09610–20012 Pitman Arm Puller Front drive shaft 09950–00020 Bearing Remover Front drive shaft 09309–36010 Transmission Rear Bearing Replacer 09316–20011 Transfer Bearing Replacer 09506–35010 Differential Drive Pinion Rear Bearing Replacer 09521–24010 Drive Shaft Boot Clamping Tool Author: Date: 49 PP–8 PREPARATION – SUSPENSION AND AXLE PP24P–01 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) PP–9 PREPARATION – SUSPENSION AND AXLE PP24Q–01 EQUIPMENT Digital indicator with magnetic base Torque wrench PP–10 PREPARATION – SUSPENSION AND AXLE PP24R–01 LUBRICANT Item Capacity Outboard joint grease Color=Black Inboard joint grease Color=Yellow ocher 100 – 120 g (3.5 – 4.2 oz.) 125 – 155 g (4.4 – 5.5 oz.) Application PP–11 PREPARATION – BODY ELECTRICAL BODY ELECTRICAL PP0KY–02 SST (Special Service Tools) 09843–18020 Diagnosis Check Wire Author: Date: 53 PP–12 PREPARATION – BODY ELECTRICAL PP24S–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. PP–13 PREPARATION – BODY ELECTRICAL PP0L0–02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Bulb (3.4 W) Torque wrench Fuel sender gauge, Engine coolant temperature sender gauge PP–14 PREPARATION – BODY BODY PP24Z–01 EQUIPMENT Clip remover Torque wrench Hog ring pliers Tape To avoid surface damage Adhesive tape To avoid surface damage Adhesive Cleaner Shop rag Regulator handle Knife Moulding Piano wire Back window glass Sealer gun Brush Putty spatula Wooden block or similar object For tying both piano wire ends Author: Date: 56 PP–15 PREPARATION – BODY PP250–01 LUBRICANT Item MP grease Capacity Classification – – PP–16 PREPARATION – BODY PP251–01 SSM (Special Service Materials) 08833–00030 Three cement black or equivalent 08850–00801 Windshield Glass Adhesive Set or equivalent MX–1 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE SYSTEM MANUAL TRANSAXLE SYSTEM MX04X–01 PRECAUTION When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non–residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. Author: Date: 1802 MX–2 MANUAL TRANSAXLE (E153) – TROUBLESHOOTING TROUBLESHOOTING MX04Y–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace parts. Symptom Suspect Area See page N i Noise 1. Oil (Level low) 2. Oil (Wrong) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) MX–4 MX–4 MX–10 MX 10 MX–10 Oil leakage l k 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. O–Ring (Worn or damaged) MX–4 MX–10 MX–10 MX 10 MX–10 1. Control cable (Faulty) 2. Synchronizer y ring g (Worn ( or damaged) g ) MX–49 MX–10 MX–24 MX–31 MX–10 MX–24 MX–31 Hard to shift or will not shift 3. 3 Shift key spring (Damaged) J Jumps outt off gear 1. Locking ball spring (Damaged) 2. Shift fork (Worn) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) Author: MX–10 MX–10 MX–10 MX 10 MX–10 Date: 1803 MX–3 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX04Z–01 COMPONENTS w/ Cruise Control : Cruise Control Actuator Hood 14 (150, 10) 13 (130, 9) Control Cable Clip 12 (120, 9) Clutch Line Bracket 21 (210, 15) Clip Washer Starter 12 (120, 9) Clutch Release Cylinder 21 (210, 15) 26 (270, 20) RH Fender Apron Seal RH Drive Shaft
32 (330, 24) Air Cleaner Case Assembly with Air Hose Clutch Accumulator Vehicle Speed Sensor 39 (400, 29) Connector 64 (650, 47) Ground Cable Transaxle Back–Up Light Switch Connector x5
Snap Ring Engine Wire 20 (200, 14) 7.8 (80, 69 in.·lbf) RH Exhaust Manifold Stay Flywheel Housing Under Cover 46 (470, 34) 37 (380, 27)
Snap Ring LH Fender Apron Seal 64 (650, 47) 19 (195, 14) 36 (370, 27) 10 (100, 7) PS Gear Assembly 181 (1,850, 134) No.1 Fuel Tube Protector Steering Return Pipe 32 (330, 24) 49 (500, 36) 66 (670, 48) 181 (1,850, 134) 294 (3,000, 217) Lock Cap Silver Bolt : 44 (450, 33) Green Bolt : 66 (670, 48)
Cotter Pin Pin Rear LH Suspension Member Brace Stabilizer Bar Link Suspension Member with Lower Suspension Arm Silver Bolt : 44 (450, 33) Green Bolt : 66 (670, 48)
Cotter 36 (370, 27) 181 (1,850, 134) Hole Plug 127 (1,300, 94)
Gasket 39 (400, 29) 48 (490, 35) Front LH Suspension Member Brace
Gasket 56 (570, 41)
Gasket 80 (820, 59) RH Fender Liner Battery LH Drive Shaft Engine LH Mounting 64 (650, 47) Insulator with Bracket Rear RH Suspension Member Brace Front RH Suspension Member Brace Hold–Down Clamp
62 (630, 46)

Front Exhaust Pipe No.1 Exhaust Pipe Support Bracket
62 (630, 46) 33 (330, 24) Exhaust Pipe Support Stay Engine Rear Side Shutter Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part LH Fender Liner 33 (330, 24) Q09981 Author: Date: 1804 MX–4 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT MX050–01 REMOVAL 1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. (See page BO–10) 2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 3. (a) (b) Q09982 4. (a) (b) 5. (a) (b) (c) Q09983 w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. Remove the 3 bolts and cruise control actuator with the bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) REMOVE STARTER Disconnect the connector and wire from the starter. Remove the 2 bolts and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Remove the 2 set bolts and nut of the clutch accumulator. Torque: Bolt: 21 N·m (210 kgf·cm, 15 ft·lbf) Nut: 26 N·m (270 kgf·cm, 20 ft·lbf) Remove the set bolt of the clutch line bracket. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) 6. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle. Q09984 7. 8. 9. (a) (b) DISCONNECT ENGINE WIRE FROM CLAMP DISCONNECT VEHICLE SPEED SENSOR AND BACK–UP LIGHT SWITCH CONNECTORS DISCONNECT CONTROL CABLE Remove the 2 clips and washers. Remove the 2 clips from the cables. Q09985 Author: Date: 1805 MX–5 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 10. Q09986 REMOVE 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 N·m (650 kgf·cm, 47 ft·lbf) 11. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 12. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. 13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS 14. Filler Plug Oil Level 0 – 5 mm 15. DRAIN TRANSAXLE OIL Oil grade: API GL–4 or GL–5 Viscosity: SAE 75W–90 Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts) Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA–25) Drain Plug Q09987 16. (a) (b) (c) Q09988 (d) (e) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts and exhaust pipe support stay. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 4 nuts and 2 gaskets from the exhaust manifold. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Remove the 2 bolts, nuts and gasket. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) Remove the 2 set bolts of the No.1 exhaust pipe support bracket. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the front exhaust pipe. Author: Date: 1806 MX–6 MANUAL TRANSAXLE (E153) 17. (a) (b) (c) – MANUAL TRANSAXLE UNIT DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Remove the 4 set bolts of the stabilizer bar bracket. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Remove the 2 bolts, nut and No.1 fuel tube protector. Q09989 (d) (e) Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. Remove the 2 set bolts and nuts of the PS gear assembly. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Q09990 18. DISCONNECT FRONT ENGINE ABSORBER FROM TRANSAXLE Remove the 2 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) Q09991 19. REMOVE RH EXHAUST MANIFOLD STAY Remove the bolt, nut and stay. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Q09992 20. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 N·m (450 kgf·cm, 33 ft·lbf) Green bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Q09993 Author: Date: 1807 MX–7 MANUAL TRANSAXLE (E153) 21. (a) (b) – MANUAL TRANSAXLE UNIT REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs, nuts and 3 bolts. Torque: Bolt: 64 N·m (650 kgf·cm, 47 ft·lbf) Nut: 80 N·m (820 kgf·cm, 59 ft·lbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket. Q09994 22. Q09995 C A C A C C 14 mm Head B A A B B Q09996 REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 23. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM–69) 24. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 25. REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. (b) Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with the lower suspension arm. Torque: Bolt A: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Bolt B: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut C: 36 N·m (370 kgf·cm, 27 ft·lbf) 26. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle. 27. 14 mm Head B (a) (b) 14 mm Head A REMOVE FLYWHEEL HOUSING UNDER COVER AND TRANSAXLE LOWER SIDE MOUNTING BOLT Remove the 2 bolts and cover. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) Remove the 3 bolts of the transaxle lower side. Torque: 14 mm head A: 46 N·m (470 kgf·cm, 34 ft·lbf) 14 mm head B: 37 N·m (380 kgf·cm, 27 ft·lbf) Q09997 Author: Date: 1808 MX–8 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT 28. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the transaxle to the engine.
Temporarily tighten the transaxle mounting bolts. Author: Date: 1809 MX–9 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE UNIT MX051–01 INSTALLATION Installation is in the reverse order of removal (See page MX–4). HINT: After installation, check and inspect items as follows.
Front wheel alignment (See page SA–4).
Do the road test. Author: Date: 1810 MX–10 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX052–02 COMPONENTS Clutch Release Fork Assembly with Bearing Clutch Release Fork Support 17 (175, 13) Control Level Housing Support Bracket 47 (480, 35) O–ring Boot 17 (175, 13) Vehicle Speed Sensor Clutch Release Line Bracket Transaxle Case Receiver Cover 7.4 (75, 65 in.·lbf) 17 (175, 13) 17 (175, 13) Transaxle Case Transmission Oil Cooler Sub–Assembly 34 (350, 25) Elbow Transmission Oil Pipe O–ring 27 (275, 20) Output Shaft Cover Tapered Roller Bearing Outer Race Front Oil Seal Transmission Oil Pipe Magnet 17 (175, 13)  17 (175, 13) Input Shaft Front Bearing 17 (175, 13) Transmission Oil Pump Assembly Differential Case Assembly Oil Pump Drive Gear N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part Z19124 Author: Date: 1811 MX–11 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Arm Bracket Assembly Snap Ring Reverse Shift Fork No.1 Shift Fork 24 (240, 17) Straight Screw Plug
25 (250, 18) Ball Seat Spring No.1 Shift Fork Shaft 17 (175, 13)
Snap Ring Interlock Roller 25 (250, 18) No.2 Shift Fork Shaft Snap Ring No.3 Shift Fork Shaft Snap Ring
25 (250, 18) Shift Head No.3 Shift Fork 24 (240, 17) 40 (410, 30) Gasket Straight Screw Plug
13 (130, 9) Slotted Spring Pin Reverse Restrict Gasket Pin No.2 Oil Receiver Pipe No.2 Shift Fork 24 (240, 17) Back–Up Light Switch Shift and Select Lever Shaft Lock Bolt
49 (500, 36) Gasket Breather Plug 20 (200, 14)
Gasket

49 (500, 36) x 17 17 (175, 13)
20 (200, 14) Shift and Select Lever Shaft Assembly No.1 Oil Receiver Pipe 29 (300, 22) Gasket No.2 Selecting Bellcrank with Selecting Bellcrank Support  Gasket 29 (300, 22) Filler Plug 49 (500, 36) Drain Plug 49 (500, 36) x 10 Transmission Case Transmission Case Cover N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part
Precoated part Q10278 Author: Date: 1812 MX–12 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY Input Shaft Assembly Tapered Roller Bearing Outer Race Output Shaft Assembly Reverse Idler Gear Reverse Idler Gear Shaft Shim Lock Bolt
29 (300, 22) Thrust Washer
42 (430, 31) x7 Rear Bearing Retainer Snap Ring Spacer 5th Driven Gear Needle Roller Bearing Key Spring 5th Gear Inner Synchronizer Ring Middle Synchronizer Ring Outer Synchronizer Ring Synchronizer Pull Ring Snap Ring Output Shaft Lock Nut  123 (1,250, 90) Key Spring No.3 Clutch Hub No.3 Hub Sleeve Snap Ring N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part
Precoated part Z17555 Author: Date: 1813 MX–13 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX053–02 DISASSEMBLY 1. 2. REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH WITH GASKET Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) 3. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) 4. REMOVE NO.2 SELECTING BELLCRANK WITH SELECTING BELLCRANK SUPPORT Remove the 2 bolts and No.2 selecting bellcrank with the selecting bellcrank support. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 5. REMOVE SHIFT AND SELECT LEVER SHAFT LOCK BOLT WITH GASKET Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 6. REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET Remove the 4 bolts, shift and select lever shaft assembly and gasket. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) 7. REMOVE TRANSMISSION CASE COVER Remove the 10 bolts and transmission case cover. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 8. REMOVE BREATHER PLUG WITH GASKET Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) FIPG Q05816 9. (a) (b) (c) (d) 10. (a) Q00449 (b) REMOVE OUTPUT SHAFT LOCK NUT Unstake the lock nut. Engage the gear double meshing. Remove the lock nut. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) Disengage the gear double meshing. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK Remove the No.3 shift fork set bolt. Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) Remove the No.3 hub sleeve and No.3 shift fork. Author: Date: 1814 MX–14 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY 11. REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 09950–30010 SST Q05849 12. MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.10 – 0.57 mm (0.0039 – 0.0224 in.) Maximum clearance: 0.65 mm (0.0256 in.) (a) Z01304 (b) Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 – 0.050 mm (0.0004 – 0.0020 in.) Maximum clearance: 0.070 mm (0.0028 in.) REMOVE NO.3 CLUTCH HUB AND 5TH GEAR Using 2 screwdrivers and a hammer, tap out the snap ring. 13. (a) Z01306 HINT: At the time of reassembly, please refer to the following item. Select a snap ring that allows the minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) a 1.75 (0.0689) f 2.00 (0.0787) b 1.80 (0.0709) g 2.05 (0.0807) c 1.85 (0.0729) h 2.10 (0.0827) d 1.90 (0.0748) j 2.15 (0.0847) e 1.95 (0.0768) – – Q00299 Author: Date: 1815 MX–15 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (b) SST Z01308 Using SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear. SST 09950–30010 14. REMOVE NEEDLE ROLLER BEARING AND SPACER 15. REMOVE REAR BEARING RETAINER Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 16. (a) (b) REMOVE SNAP RING Using a snap ring expander, remove the input shaft rear bearing snap ring. Using 2 screwdrivers and a hammer, remove the 2 snap rings. Q06190 17. (a) (b) Q01615 18. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING AND LOCKING BALL Using a hexagon wrench (6 mm), remove the plug. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the seat, spring and locking ball. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Q00056 Author: Date: 1816 MX–16 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY 19. REMOVE TRANSMISSION CASE Remove the 17 bolts and tap the case with a plastic hammer. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) FIPG Q05815 20. REMOVE SHIM HINT: At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload. (See page MX–22) MT0669 21. SST MT0693 REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE Using SST and a hammer, remove the output shaft rear taper roller bearing outer race. SST 09316–60011 (09316–00011) 22. REMOVE TRANSMISSION OIL PIPE (a) Remove the gasket from the oil pipe. (b) Remove the 2 bolts and oil pipe. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) 23. REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY Remove the bolt and pull off the reverse shift arm and bracket. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) 24. REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft, and remove the reverse idler gear and thrust washer. Q06375 Matchmarks HINT: At the time of reassembly, please refer to the following item. Align the matchmarks, as shown. Z17557 Author: Date: 1817 MX–17 MANUAL TRANSAXLE (E153) 25. (a) (b) Q01614 – MANUAL TRANSAXLE ASSEMBLY REMOVE STRAIGHT SCREW PLUG, LOCKING BALL AND SPRING Using a hexagon wrench (6 mm), remove the 2 plugs. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the 2 seats, springs and balls. 26. Q08124 REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) 27. REMOVE NO.1 SHIFT FORK SHAFT Pull up the No.3 shift fork shaft, and remove the No.1 shift fork shaft. HINT: At the time of reassembly, please refer to the following item. When it is difficult to push the fork shaft through the reverse shift fork, pull up the No.3 shift fork shaft. 28. REMOVE INTERLOCK ROLLER Using a magnetic finger, remove the interlock roller from the reverse shift fork. Q08125 29. (a) (b) REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD AND NO.1 SHIFT FORK Pull out the No.2 shift fork shaft. Remove the shift head and No.1 shift fork. Q08126 30. (a) (b) 31. (a) (b) Z00182 REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE SHIFT FORK AND NO.2 SHIFT FORK Pull out the No.3 shift fork shaft with the reverse shift fork. Remove the No.2 shift fork. REMOVE SNAP RING Using 2 screwdrivers and a hammer, remove the snap ring and reverse shift fork from the No.3 shift fork shaft. Using 2 screwdrivers and a hammer, remove the 3 snap rings from the No.1, No.2 and No.3 shift fork shafts. Author: Date: 1818 MX–18 MANUAL TRANSAXLE (E153) 32. (a) (b) 33. (a) (b) 34. 35. (a) (b) 36. (a) MT0781 – MANUAL TRANSAXLE ASSEMBLY REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY Leaning the output shaft to the differential side, remove the input shaft assembly. Lift up the differential case assembly, remove the output shaft assembly. REMOVE DIFFERENTIAL CASE ASSEMBLY Remove the oil pump drive gear. Remove the differential case assembly. REMOVE MAGNET FROM TRANSAXLE CASE REMOVE TRANSMISSION OIL PUMP ASSEMBLY AND OIL PIPE Remove the 2 bolts and oil pipe. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) Remove the 2 bolts and oil pump assembly. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub. Using a screwdriver, remove the snap ring. (b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Remove the synchronizer rings. Author: Date: 1819 MX–19 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX054–01 INSPECTION 1. (a) (b) INSPECT NO.5 SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If it does not lock, replace the synchronizer ring. MT0782 2. MEASURE SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 3. (a) (b) SST (c) IF NECESSARY, REPLACE INPUT SHAFT BEARING AND OIL SEAL Remove the 3 bolts and transaxle case receiver. Using SST, pull out the bearing. SST 09612–65014 Using a screwdriver, remove the oil seal. Z00192 (d) SST (e) Using SST, drive in a new oil seal. SST 09608–00081, 09950–70010 (09951–07150) Coat the lip of seal with MP grease. Z00194 (f) SST (g) (h) Using SST, drive in a new bearing. SST 09950–60010 (09951–00580), 09950–70010 (09951–07150) Install the transaxle case receiver. Install and torque the 3 bolts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) Q08014 Author: Date: 1820 MX–20 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (i) Using SST and a press, remove the inner race. SST 09950–00020 (j) Using SST and a press, install a new input shaft front bearing inner race. SST 09316–60011 (09316–00021) 4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER Using SST, pull out the output shaft front bearing outer race. SST 09308–00010 Remove the output shaft cover. SST Q05164 SST Q00141 SST (a) (b) Q00338 (c) Install a new output shaft cover. HINT: Install the output shaft cover projection into the case side groove. Z00197 (d) SST SST Using SST and a hammer, drive in a new output shaft front bearing outer race. SST 09316–60011 (09316–00011, 09316–00021) Q06368 Author: Date: 1821 MX–21 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (e) Using SST and a socket wrench, remove the output shaft front bearing. SST 09950–00020, 09950–00030 (f) Using SST and a press, install a new output shaft front bearing. SST 09316–60011 (09316–00071) 5. (a) (b) IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench (6 mm), remove the screw plug. Using a pin punch and hammer, drive out the slotted spring pin. Replace the reverse restrict pin. Socket Wrench SST Q00245 SST Z00199 (c) Q01611 (d) (e) (f) Z00201 Using a pin punch and hammer, drive in the slotted spring pin. Apply sealant to the screw plug threads. Sealant: Part No. 08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench (6 mm), install and torque the screw plug. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Author: Date: 1822 MX–22 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY MX055–01 REASSEMBLY Reassembly is in the reverse order of disassembly. HINT:
Before reassembly, select a shim by adjusting output shaft preload.
Coat all of the sliding and rotating surfaces with gear oil before reassembly. ADJUST OUTPUT SHAFT PRELOAD (a) Install the output shaft assembly to the transaxle case. (b) Install the transmission case to the transaxle case. HINT: If necessary, tap on the case with a plastic hammer. (c) Install and torque the 17 bolts. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) (d) Install the output shaft rear taper roller bearing outer race. (e) Install the adjusting shim. HINT: When reusing the output shaft bearing, first install a shim of the same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before. (f) Install the rear bearing retainer. (g) Using a torx wrench (T45), install and torque the 7 torx screws. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) (h) Install a new lock nut to the output shaft. (i) Turn the output shaft right and left 2 or 3 times to allow the bearing to settle. Author: Date: 1823 MX–23 MANUAL TRANSAXLE (E153) – MANUAL TRANSAXLE ASSEMBLY (j) Z12593 Using a torque wrench, measure the preload. Preload (at starting): New bearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) Reused bearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf) If the preload is not within the specification, select an appropriate adjusting shim. The preload will change approx. 0.4 – 0.5 N·m (4 – 5 kgf·cm, 3.5 – 4.3 in.·lbf) for every 0.05 mm change in adjusting shim thickness. (k) (l) Mark Thickness mm (in.) Mark Thickness mm (in.) 0 1.30 (0.0512) D 1.95 (0.0768) 1 1.35 (0.0531) E 2.00 (0.0787) 2 1.40 (0.0551) F 2.05 (0.0807) 3 1.45 (0.0571) G 2.10 (0.0827) 4 1.50 (0.0591) H 2.15 (0.0846) 5 1.55 (0.0610) J 2.20 (0.0866) 6 1.60 (0.0630) K 2.25 (0.0886) 7 1.65 (0.0650) L 2.30 (0.0906) 8 1.70 (0.0669) M 2.35 (0.0925) 9 1.75 (0.0689) N 2.40 (0.0945) A 1.80 (0.0709) P 2.45 (0.0965) B 1.85 (0.0728) Q 2.50 (0.0984) C 1.90 (0.0748) – – Remove the lock nut. Remove these parts. Removal is in the reverse order of installation.
Rear bearing retainer
Shim
Transmission case
Output shaft assembly
Output shaft rear bearing outer race Author: Date: 1824 MX–24 MANUAL TRANSAXLE (E153) – INPUT SHAFT INPUT SHAFT MX056–01 COMPONENTS Spacer Synchronizer Ring 4th Gear Snap Ring Needle Roller Bearing 3rd Gear Needle Roller Bearing Rear Bearing Spring Snap Ring
Input Shaft Front Bearing Inner Race Synchronizer Ring No.2 Hub Sleeve No.2 Clutch Hub Input Shaft Shifting Key
Non–reusable part MT0791 Author: Date: 1825 MX–25 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX057–01 DISASSEMBLY 1. 3rd Gear 4th Gear Q06369 Q00111 MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.10 – 0.35 mm (0.0039 – 0.0138 in.) 4th gear: 0.10 – 0.55 mm (0.0039 – 0.0217 in.) Maximum clearance: 3rd gear: 0.40 mm (0.0157 in.) 4th gear: 0.60 mm (0.0236 in.) 2. CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 3rd gear: 0.009 – 0.053 mm (0.0004 – 0.0021 in.) 4th gear: 0.009 – 0.051 mm (0.0004 – 0.0020 in.) Maximum clearance: 3rd and 4th gears: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. 4. REMOVE REAR BALL BEARING AND 4TH GEAR Using SST and a press, remove the rear bearing. SST 09950–00020 5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING 6. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. SST Q05165 Author: Date: 1826 MX–26 MANUAL TRANSAXLE (E153) – INPUT SHAFT 7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR Using a press, remove the No.2 hub sleeve, 3rd gear and synchronizer rings. 8. REMOVE NEEDLE ROLLER BEARING Q00115 Author: Date: 1827 MX–27 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX058–01 INSPECTION 1. (a) (b) INSPECT 3RD GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring. MT0780 (c) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring. MT0786 2. (a) (b) WM0064 INSPECT 4TH GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) WM0064 Using a feeler gauge, measure the clearance between the synchronizer ring back and spline end. Minimum clearance: 0.8 mm (0.031 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. Author: Date: 1828 MX–28 MANUAL TRANSAXLE (E153) – INPUT SHAFT 3. MEASURE NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 C B A 4. (a) (b) INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum outer diameter: Part A: 27.950 mm (1.1004 in.) Part B and C: 35.950 mm (1.4154 in.) (c) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) Q00172 Q00173 Author: Date: 1829 MX–29 MANUAL TRANSAXLE (E153) – INPUT SHAFT MX059–02 REASSEMBLY Front Q00383 HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. HINT: Direct identification groove of the hub sleeve to front of the transmission. 2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT Apply MP grease to the needle roller bearing. Assemble the needle roller bearings into the 3rd gear. Place the synchronizer rings on the gear and align the ring slots with the shifting keys. (a) (b) (c) MT0790 SST (d) Using SST and a press, install the 3rd gear and No.2 hub sleeve. SST 09506–35010 3. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play. Q00183 Q00116 Mark Thickness mm (in.) Mark Thickness mm (in.) H 2.30 (0.0906) M 2.50 (0.0984) J 2.35 (0.0925) N 2.55 (0.1004) K 2.40 (0.0945) P 2.60 (0.1024) L 2.45 (0.0965) – – (b) Using a screwdriver and hammer, tap in the snap ring. Author: Date: 1830 MX–30 MANUAL TRANSAXLE (E153) N00494 MEASURE 3RD GEAR THRUST CLEARANCE (See page MX–24) 5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BALL BEARING Install the spacer. Apply MP grease to the needle roller bearings. Place the synchronizer ring on the gear and align the ring slots with the shifting keys. Install the 4th gear. Using SST and a press, install the rear ball bearing. SST 09506–35010 INSTALL SNAP RING Select a snap ring that allows the minimum axial play. (d) (e) 6. (a) Q00116 INPUT SHAFT 4. (a) (b) (c) SST – Mark Thickness mm (in.) Mark Thickness mm (in.) 1 2.35 (0.0925) 5 2.55 (0.1004) 2 2.40 (0.0945) 6 2.60 (0.1024) 3 2.45 (0.0965) 7 2.65 (0.1043) 4 2.50 (0.0984) 8 2.70 (0.1063) (b) 7. Using a screwdriver and hammer, tap in the snap ring. MEASURE 4TH GEAR THRUST CLEARANCE (See page MX–24) Author: Date: 1831 MX–31 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT OUTPUT SHAFT MX05A–01 COMPONENTS Needle Roller Bearing 3rd Driven Gear 4th Driven Gear Spacer Needle Roller Bearing 2nd Gear Spacer No.1 Hub Sleeve Shifting Key
Output Shaft Rear Bearing Shifting Key Spring Spacer 1st Gear Synchronizer Ring No.1 Clutch Hub S
Output Shaft Front Bearing Synchronizer Ring
Non–reusable part Output Shaft N00785 Author: Date: 1832 MX–32 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05B–01 DISASSEMBLY 1. 1st Gear 2nd Gear Q06370 Z00218 MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.10 – 0.35 mm (0.0039 – 0.0138 in.) 2nd gear: 0.10 – 0.45 mm (0.0039 – 0.0177 in.) Maximum clearance: 1st gear: 0.40 mm (0.0157 in.) 2nd gear: 0.50 mm (0.0197 in.) 2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 1st gear: 0.009 – 0.051 mm (0.0004 – 0.0020 in.) 2nd gear: 0.009 – 0.053 mm (0.0004 – 0.0021 in.) Maximum clearance: 1st and 2nd gears: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER (a) Using a press, remove the bearing and 4th driven gear. (b) Remove the spacer. Z00219 4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR Using a press, remove the 3rd driven gear and 2nd gear. 5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING 6. REMOVE SNAP RING Using a snap ring expander, remove the snap ring. Z00220 Author: Date: 1833 MX–33 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST GEAR Using a press, remove the No.1 hub sleeve and 1st gear. 8. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Z00222 9. REMOVE OUTPUT SHAFT FRONT BEARING Using SST, remove the output shaft front bearing. SST 09950–00020, 09950–00030 SST Q00296 Author: Date: 1834 MX–34 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05C–02 INSPECTION 1. (a) (b) WM0064 INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) WM0065 Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.8 mm (0.031 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring. MT0780 (c) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring. MT0787 Author: Date: 1835 MX–35 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 3. MEASURE NO.1 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 4. (a) (b) INSPECT OUTPUT SHAFT Check the output shaft for wear or damage. Using a micrometer, measure the outer diameter of the output shaft journal surface. Minimum outer diameter: 38.950 mm (1.5335 in.) (c) Using a dial indicator, check the shaft runout. Maximum runout: 0.06 mm (0.0024 in.) Z00223 Z00224 Author: Date: 1836 MX–36 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT MX05D–01 REASSEMBLY Front Q00384 HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shifting keys. NOTICE: Position the key springs so that their end gaps are not aligned. 2. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT Apply MP grease to the needle roller bearing. Install the 1st gear. Place the synchronizer ring (for the 1st gear) on the gear and align the ring slots with the shifting keys. (a) (b) (c) Z00225 (d) Using SST and a press, install the 1st gear and No.1 hub sleeve. SST 09316–60011 (09316–00041) 3. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play. SST Z00385 Z00386 Mark Thickness mm (in.) Mark A 2.80 (0.1102) E 3.00 (0.1181) B 2.85 (0.1122) F 3.05 (0.1201) C 2.90 (0.1142) G 3.10 (0.1220) D 2.95 (0.1161) – – (b) Thickness mm (in.) Using a snap ring expander, install the snap ring. Author: Date: 1837 MX–37 MANUAL TRANSAXLE (E153) 4. – OUTPUT SHAFT MEASURE 1ST GEAR THRUST CLEARANCE (See page MX–31) 5. MT0792 INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR (a) Install the spacer. (b) Apply MP grease to the needle roller bearing. (c) Place the synchronizer rings (for the 2nd gear) on the gear. NOTICE: Do not install the synchronizer ring for the 1st gear. (d) Install the 2nd gear. (e) Using a press, install the 3rd driven gear. NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring. 6. MEASURE 2ND GEAR THRUST CLEARANCE (See page MX–31) N00495 7. (a) (b) INSTALL SPACER AND 4TH DRIVEN GEAR Install the spacer. Using a press, install the 4th driven gear. Z00390 8. INSTALL OUTPUT SHAFT REAR BEARING Using SST and a press, install the bearing. SST 09506–30012 SST Z00391 Author: Date: 1838 MX–38 MANUAL TRANSAXLE (E153) – OUTPUT SHAFT 9. INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install a new output shaft front bearing. SST 09316–60011 (09316–00071) SST Z00392 Author: Date: 1839 MX–39 MANUAL TRANSAXLE (E153) – OIL PUMP OIL PUMP MX05E–01 COMPONENTS
O–Ring
Gasket Oil Strainer Oil Pump Driven Rotor 10 (105, 8) Transmission Oil Pump Case Oil Pump Drive Rotor Oil Pump Drive Gear Relief Valve Ball Spring Spring Holder Oil Pump Cover 10 (105, 8) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z17558 Author: Date: 1840 MX–40 MANUAL TRANSAXLE (E153) – OIL PUMP MX05F–01 INSPECTION 1. (a) (b) CHECK ROTOR BODY CLEARANCE Install the oil pump drive gear to the drive rotor. Using a feeler gauge, measure the body clearance between the drive rotor and oil pump case. Standard clearance: 0.10 – 0.16 mm (0.0039 – 0.0063 in.) Maximum clearance: 0.30 mm (0.0118 in.) 2. (a) (b) CHECK ROTOR TIP CLEARANCE Install the oil pump drive gear to the drive rotor. Using a feeler gauge, measure the tip clearance between the drive and driven rotors. Standard clearance: 0.08 – 0.15 mm (0.0031 – 0.0059 in.) Maximum clearance: 0.30 mm (0.0118 in.) Z00242 Z00243 3. CHECK SIDE CLEARANCE Using a precision straight edge and feeler gauge, measure the side clearance of both rotors. Standard clearance: 0.03 – 0.08 mm (0.0012 – 0.0031 in.) Maximum clearance: 0.15 mm (0.0059 in.) Z00244 Author: Date: 1841 MX–41 MANUAL TRANSAXLE (E153) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX05G–02 COMPONENTS Dust Boot
Oil Seal Control Shaft Cover Snap Ring No.1 Compression Spring Shift Interlock Plate No.2 Shift Inner Lever No.2 Select Spring Seat No.1 Select Spring Seat Slotted Spring Pin Slotted Spring Pin No.2 Compression Spring Snap Ring No.1 Shift Inner Lever Shift and Select Lever Shaft
Non–reusable part MP Grease Q10276 Author: Date: 1842 MX–42 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX05H–01 COMPONENTS Transaxle Case Cover

Stud Bolt 54 (550, 40)
54 (550, 40) Differential Spider Oil Seal
Differential Pinion Differential Side Gear Side Gear Thrust Washer Pinion Thrust Washer Tapered Roller Bearing and Outer Race 63 (640, 46) Differential Right Case Vehicle Speed Sensor Drive Gear x 16 Differential Left Case Ring Gear Tapered Roller Bearing and Outer Race x 16 Shim 124 (1,260, 91) Oil Baffle Oil Seal Z17560 Author: Date: 1843 MX–43 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE MX05I–03 DISASSEMBLY SST Q05166 Matchmarks 1. REMOVE TAPERED ROLLER BEARING Using SST, remove the left and right bearings. SST 09950–40011 2. REMOVE RING GEAR (a) Place matchmarks on both the differential case and ring gear. (b) Remove the 16 bolts. (c) Using a plastic hammer, tap the ring gear and remove it. 3. (a) (b) (c) (d) DISASSEMBLE DIFFERENTIAL CASE Place matchmarks on the differential right and left cases. Using a torx wrench (T50), remove the 16 torx screws. Using a plastic hammer, tap the differential left case. Remove the vehicle speed sensor drive gear from the differential right case. (e) Remove the 2 differential side gears, side gear thrust washers, 4 differential pinions and pinion thrust washers from the differential left case. 4. Transmission Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver, remove the oil seal. Remove the oil baffle. Using a brass bar and hammer, drive out the bearing outer race lightly and evenly. Remove the shim. Install the shim. (See page MX–42) Z00281 Z00284 (a) (b) (c) Z00286 (d) (e) HINT: First select and install a shim of less thickness than before. Author: Date: 1844 MX–44 MANUAL TRANSAXLE (E153) (f) SST – DIFFERENTIAL CASE Using SST and a press, install a new tapered roller bearing outer race. SST 09316–60011 (09316–00011, 09316–00041) Z00288 (g) Install the oil baffle. HINT: Install the oil baffle projection into the case side cutout. Z00289 (h) SST (i) Using SST and a hammer, drive in a new oil seal. SST 09223–15020, 09950–70010 (09951–07150) Coat the lip of oil seal with MP grease. Q06288 5. (a) (b) (c) Transaxle Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Remove the 4 bolts and 3 nuts. Using a plastic hammer, tap the stud bolt and remove the transaxle case cover. Using a screwdriver and hammer, drive out the oil seal from the transaxle case cover. MT0659 (d) SST Using SST, a brass bar and hammer, remove the tapered roller bearing outer race. SST 09612–65014 Z01427 Author: Date: 1845 MX–45 MANUAL TRANSAXLE (E153) SST – DIFFERENTIAL CASE (e) Using SST and a press, install a new tapered roller bearing outer race. SST 09316–60011 (09316–00011, 09316–00041) (f) Using SST and a hammer, drive in a new oil seal. SST 09316–60011 (09316–00011) Coat the oil seal lip with MP grease. Z00292 (g) SST Z00293 (h) FIPG Z19038 (i) F (j) (k) Apply FIPG to the transaxle case cover, as shown. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent Apply sealant to the bolt threads. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Install the stud bolt and cover to the transaxle case. Install and torque the 4 bolts and 3 nuts. Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) Author: Date: 1846 MX–46 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE MX05J–01 REASSEMBLY Z00295 1. ASSEMBLE DIFFERENTIAL CASE HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. (a) Install the thrust washer to the side gear. (b) Install the 4 pinions and thrust washers to the spider. (c) Install the side gear and spider with the 4 pinions to the differential left case. (d) Using a dial indicator, measure the backlash of the pinion gear while holding the differential left case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) HINT: Push the pinion gear and spider with the 4 pinions to the differential left case. (e) Install the side gear and spider with the 4 pinions to the right side of the differential case. Check the side gear backlash. (f) Refer to the table below, and select the thrust washer which will ensure that the backlash is within the specification. Try to select a washer of the same size. Z00296 Thickness mm (in.) Thickness mm (in.) 0.80 (0.0315) 1.20 (0.0472) 0.90 (0.0354) 1.30 (0.0512) 1.00 (0.0394) 1.40 (0.0551) 1.10 (0.0433) – Z00297 (g) Install the vehicle speed sensor drive gear. Z00298 Author: Date: 1847 MX–47 MANUAL TRANSAXLE (E153) (h) (i) Matchmarks (j) 2. (a) Z00299 (b) (c) (d) Driven Gear Side Z00303 SST SST Q06410 – DIFFERENTIAL CASE Align the matchmarks on the differential cases. Using a plastic hammer, carefully tap the differential case to install it. Using a torx wrench (T50), install and torque the 16 torx screws. Torque: 63 N·m (640 kgf·cm, 46 ft·lbf) INSTALL RING GEAR Clean the contact surface of the differential case and the threads of the ring gear and differential case. Heat the ring gear in boiling water. Carefully remove the ring gear from the water. After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the differential left case. (e) Temporarily install the 16 bolts. NOTICE: The ring gear set bolts should not be tightened until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 124 N·m (1,260 kgf·cm, 91 ft·lbf) 3. INSTALL TAPERED ROLLER BEARING Using SST and a press, install new left and right bearings onto the differential case. SST 09316–20011, 09316–60011 (09316–00011) HINT: Press the bearing on the ring side first. 4. ADJUST OUTPUT SHAFT ASSEMBLY PRELOAD (See pages MX–22) 5. INSTALL DIFFERENTIAL CASE ASSEMBLY TO TRANSAXLE CASE 6. INSTALL OUTPUT SHAFT ASSEMBLY Lift up the differential case and install the output shaft assembly. 7. INSTALL TRANSMISSION CASE (a) Install the transmission case. HINT: If necessary, tap on the case with a plastic hammer. (b) Install and torque the 17 bolts. Torque: 29 N·m (300 kgf·cm 22 ft·lbf) Author: Date: 1848 MX–48 MANUAL TRANSAXLE (E153) – DIFFERENTIAL CASE 8. INSTALL OUTPUT SHAFT REAR TAPERED ROLLER BEARING OUTER RACE Using a plastic hammer, drive in the outer race. 9. INSTALL SHIM (See pages MX–22) HINT: Install the previously selected shim. 10. INSTALL REAR BEARING RETAINER Using a torx wrench (T45), install and torque the 7 torx screws. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 11. Q00036 Z00309 ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install a new lock nut to the output shaft. (b) Turn the output shaft right and left 2 or 3 times to allow the bearings to settle. (c) Using a torque wrench, measure the preload. Preload (at starting): New bearing (Output shaft preload plus) 0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf) Reused bearing (Output shaft preload plus) 0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf) If the preload is not within the specification, select an appropriate adjusting shim. HINT: The total preload will change by about 0.1 – 0.2 N·m (1 – 2 kgf·cm, 0.9 – 1.7 in.·lbf) with each 0.05 mm change in adjusting shim thickness. Mark Thickness mm (in.) Mark Thickness mm (in.) 0 2.00 (0.0787) 9 2.45 (0.0965) 1 2.05 (0.0807) A 2.50 (0.0984) 2 2.10 (0.0827) B 2.55 (0.1004) 3 2.15 (0.0846) C 2.60 (0.1024) 4 2.20 (0.0866) D 2.65 (0.1043) 5 2.25 (0.0886) E 2.70 (0.1063) 6 2.30 (0.0906) F 2.75 (0.1083) 7 2.35 (0.0925) G 2.80 (0.1102) 8 2.40 (0.0945) H 2.85 (0.1122) 12. REMOVE REAR BEARING RETAINER Using a torx wrench (T45), remove the 7 torx screws and rear bearing retainer. 13. REMOVE SHIM 14. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. (b) Using a plastic hammer, tap the transmission case. 15. REMOVE OUTPUT SHAFT ASSEMBLY 16. REMOVE DIFFERENTIAL CASE ASSEMBLY Author: Date: 1849 MX–49 MANUAL TRANSAXLE (E153) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX05K–01 COMPONENTS Shift Lever Knob Center Console Upper Panel Heater Control Assembly Center Cluster Finish Panel Rear Console Box Front Console Box Shift Cable Grommet Retainer Shift Cable Grommet Shift Cable Grommet Retainer Grommet 12 (120, 9) 4.9 (50, 43 in.·lbf) Clip Clip Clip 4.9 (50, 43 in.·lbf) Shift Lever Assembly Clip Shift Control Cable Clip Washer Clip Clip Select Control Cable Washer Washer Clip N·m (kgf·cm, ft·lbf) : Specified torque Q10281 Author: Date: 1850 MX–1 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE SYSTEM MANUAL TRANSAXLE SYSTEM MX04A–01 PRECAUTION When working with FIPG material, you must observe the following items.
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Thoroughly clean all components to remove all the loose material.
Clean both sealing surfaces with a non–residue solvent.
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. Author: Date: 1851 MX–2 MANUAL TRANSAXLE (S51) – TROUBLESHOOTING TROUBLESHOOTING MX04B–04 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page N i Noise 1. Oil (Level low) 2. Oil (Wrong) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) MX–4 MX–4 MX–9 MX 9 MX–9 Oil leakage l k 1. Oil (Level too high) 2. Gasket (Damaged) 3. Oil seal (Worn or damaged) 4. O–ring (Worn or damaged) MX–4 MX–9 MX–9 MX 9 MX–9 1. Control cable (Faulty) 2. Synchronizer y ring g (Worn ( or damaged) g ) MX–43 MX–9 MX–20 MX–28 MX–9 MX–20 MX–28 Hard to shift or will not shift 3. 3 Shift key spring (Damaged) J Jumps outt off gear 1. Locking ball spring (Damaged) 2. Shift fork (Worn) 3. Gear (Worn or damaged) 4. Bearing (Worn or damaged) Author: MX–9 MX–9 MX–9 MX 9 MX–9 Date: 1852 MX–3 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX04C–01 COMPONENTS w/ Cruise Control: Cruise Control Actuator Control Cable Hood 14 (145, 10) 13 (130, 9) Clip Clutch Line 6.9 (70, 61 in.·lbf) RH Drive Shaft
Snap Ring
32 (330, 24) Washer Clutch Release Cylinder 12 (120, 9) 39 (400, 29) Manifold Stay Air Cleaner Case Assembly with Air Hose Clip Bracket 12 (120, 9) Vehicle Speed Sensor 46 (470, 34) Connector Ground Cable Starter 39 (400, 29) RH Fender Apron Seal Hold–Down Clamp 39 (400, 29) RH Stiffener Back–Up Light Switch Connector Plate 37 (380, 27) Battery 64 (650, 47) LH Stiffener Plate Transaxle 37 (380, 27) Manifold Stay Rear End Plate with Oil Pan 42 (425, 31) Insulator Rear RH Suspension Member Brace 36 (370, 27)
Snap Ring 64 (650, 47) 9.3 (95, 82 in.·lbf) 64 (650, 47) PS Gear Assembly No.1 Fuel Tube Protector
Steering Return Pipe LH Fender Apron Seal 181 (1,850, 134) 19 (195, 14) 32 (330, 24) 10 (100, 7) LH Drive Shaft Engine LH Mounting Insulator with Bracket 49 (500, 36) 181 (1,850, 134) 294 (3,000, 217) Silver Bolt: 44 (450, 33) Green Bolt: 66 (670, 48) Suspension Member with Lower Suspension Arm Front RH Suspension Member Brace 36 (370, 27) 181 (1,850, 134) Silver Bolt: 44 (450, 33) Green Bolt: 66 (670, 48) Lock Cap
Cotter Pin
Cotter Pin Rear LH Suspension Member Brace Stabilizer Bar Link Hole Plug 66 (670, 48) Front LH Suspension Member Brace Hole Plug 80 (820, 59) 33 (330, 24)
Gasket RH Fender Liner 56 (570, 41) 127 (1,300, 94) 39 (400, 29)

Gasket Front Exhaust Pipe
62 (630, 46) No.1 Exhaust Pipe Support Bracket Engine Rear Side Shutter Plate 33 (330, 24) LH Fender Liner 19 (195, 14) Exhaust Pipe Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Q09998 Author: Date: 1853 MX–4 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MX04D–01 REMOVAL 1. REMOVE HOOD HINT: At the time of installation, please refer to the following item. Adjust the hood. (See page BO–10) 2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 3. (a) (b) Q09982 4. (a) (b) 5. (a) (b) A w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the cruise control actuator connector. Remove the 3 bolts and cruise control actuator with the bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) REMOVE STARTER Disconnect the connector and wire from the starter. Remove the 2 bolts and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) DISCONNECT CLUTCH RELEASE CYLINDER Remove the 2 bolts and disconnect the release cylinder. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Remove the 2 set bolts of the clutch line bracket. Torque: Bolt A: 12 N·m (120 kgf·cm, 9 ft·lbf) Bolt B: 6.9 N·m (70 kgf·cm, 61 in.·lbf) B Q09999 6. DISCONNECT GROUND CABLE Remove the set bolt of the ground cable from the transaxle. Q10000 7. REMOVE MANIFOLD STAY Remove the 2 bolts and stay. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) 8. DISCONNECT VEHICLE SPEED SENSOR AND BACK–UP LIGHT SWITCH CONNECTORS 9. DISCONNECT CONTROL CABLE (a) Remove the 2 clips and washers. (b) Remove the 2 clips from the cables. Q10001 Author: Date: 1854 MX–5 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT 10. 14 mm Head 17 mm Head Q10002 REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque: 17 mm head: 64 N·m (650 kgf·cm, 47 ft·lbf) 14 mm head: 46 N·m (470 kgf·cm, 34 ft·lbf) 11. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 12. RAISE VEHICLE NOTICE: Make sure that the vehicle is securely supported. 13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS 14. Oil Level 0 – 5 mm Filler Plug 15. Drain Plug DRAIN TRANSAXLE OIL Oil grade: API GL–4 or GL–5 Viscosity: SAE 75W–90 Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts) Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) REMOVE LH AND RH DRIVE SHAFTS (See page SA–16) Q10003 16. (a) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts, nut and exhaust pipe bracket. Torque: Bolt: 19 N·m (195 kgf·cm, 14 ft·lbf) Nut: 33 N·m (330 kgf·cm, 24 ft·lbf) (b) Remove the 3 nuts and gasket from the exhaust manifold. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Remove the 2 bolts, nuts and gasket. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) Remove the 2 set bolts of the No.1 exhaust pipe support bracket. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the front exhaust pipe. Q10010 (c) (d) (e) Q10004 Author: Date: 1855 MX–6 MANUAL TRANSAXLE (S51) 17. (a) (b) Q09989 (c) (d) (e) – MANUAL TRANSAXLE UNIT DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Remove the 4 set bolts of the stabilizer bar bracket. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Remove the 2 bolts, nut and No.1 fuel tube protector. Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely. Remove the 2 set bolts and nuts of the PS gear assembly. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Q09990 18. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS Torque: Silver bolt: 44 N·m (450 kgf·cm, 33 ft·lbf) Green bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) 19. REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET Remove the 2 hole plugs, nuts and 3 bolts. Torque: Bolt: 64 N·m (650 kgf·cm, 47 ft·lbf) Nut: 80 N·m (820 kgf·cm, 59 ft·lbf) Lift up the transaxle and remove the left engine mounting insulator with the bracket. Q10005 (a) (b) Q10006 20. Q10007 REMOVE HOLE PLUG AND 3 ENGINE REAR SIDE MOUNTING NUTS Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 21. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER (See page EM–69) 22. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Author: Date: 1856 MX–7 MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE UNIT 23. C A C A C C – B A A B Q10008 REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM (a) Remove the LH and RH fender liner set screws. (b) Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with the lower suspension arm. Torque: Bolt A: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Bolt B: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut C: 36 N·m (370 kgf·cm, 27 ft·lbf) 24. JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle. 25. REMOVE LH STIFFENER PLATE Remove the 3 bolts and LH stiffener plate. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) Q10011 26. Q10009 REMOVE REAR END PLATE WITH OIL PAN INSULATOR AND RH STIFFENER PLATE (a) Remove the 2 bolts and rear end plate with the oil pan insulator. Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) (b) Remove the 2 bolts and manifold stay. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (c) Remove the 4 bolts and RH stiffener plate. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 27. REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation, please refer to the following items.
Align the input shaft with the clutch disc and install the transaxle to the engine.
Temporarily tighten the transaxle mounting bolts. Author: Date: 1857 MX–8 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE UNIT MX04E–01 INSTALLATION Installation is in the reverse order of removal (See page MX–4). HINT:
Front wheel alignment (See page SA–4).
Do the road test. Author: Date: 1858 MX–9 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX04F–02 COMPONENTS Release Bearing Retainer 5.4 (55, 48 in.·lbf) Straight Screw Plug
13 (130, 9) Vehicle Speed Sensor Shift and Select Lever Assembly Lock Ball Assembly Reverse Restrict Pin
29 (300, 22) Back–UP Light Switch 7.4 (75, 65 in.·lbf) 37 (375, 27) 37 (380, 27) 44 (450, 33) Slotted Spring Pin Selecting Bellcrank Shim Differential Side Bearing Retainer Transmission x6 Case Protector Release Bearing Boot O–Ring Transmission Case  Gasket
 Gasket Clutch Release Fork Release Fork Support 18 (185, 13) Drain Plug
42 (430, 31) x5 Rear Bearing Retainer 39 (400, 29) Filler Plug 18 (185, 13) x 17 49 (500, 36) Lock Bolt 29 (300, 22) Spacer Lock Nut  123 (1,250, 90) 29 (300, 22)  Gasket Snap Ring Needle Roller Bearing 5th Driven Gear 5th Gear No.3 Clutch Hub Assembly N0.3 Hub Sleeve No.3 Shift Fork 18 (185, 13) Snap Ring Transmission Case Cover x8 N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part
Precoated part
29 (300, 22) Z19123 Author: Date: 1859 MX–10 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Fork Interlock Pin Transaxle Case Oil Seal No.1 Shift Fork No.2 Shift Fork Shaft No.2 Shift Fork Transaxle Case Receiver 7.4 (75, 65 in.·lbf) No.1 Shift Head No.1 Shift Fork Shaft Differential Case Assembly  Input Shaft Front Bearing Bearing Lock Plate Input Shaft Assembly Reverse Shift Arm Output Shaft Assembly 18 (185, 13) Reverse Idler Gear and Shaft  Output Shaft Front Bearing Output Shaft Cover N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part Z18962 Author: Date: 1860 MX–11 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX04G–02 DISASSEMBLY 1. 2. REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) 3. REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 4. REMOVE RELEASE BEARING RETAINER Remove the 3 bolts and retainer. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) 5. REMOVE SELECTING BELLCRANK Remove the 2 bolts and selecting bellcrank. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) 6. (a) (b) FIPG Z18142 7. REMOVE TRANSMISSION CASE COVER Remove the 8 bolts. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Using a plastic hammer, tap the transmission case cover and remove it. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent REMOVE LOCK BALL ASSEMBLY Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) REMOVE SHIFT AND SELECT LEVER ASSEMBLY 8. HINT: At the time of installation, please refer to the following item. Apply FIPG to the underside of the flanged portion of the control shaft cover. FIPG: Part No. 08826 – 00090, THREE BOND 1281 or equivalent Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Author: Date: 1861 MX–12 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY 9. (a) (b) REMOVE OUTPUT SHAFT LOCK NUT Unstake the nut. Engage the gear double meshing. (c) Rotate the lock nut clockwise and remove it. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) Q02530 Install Remove Q05696 HINT: The lock nut has LH threads. (d) Disengage the gear double meshing. 10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK (a) Remove the No.3 shift fork set bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (b) Remove the No.3 hub sleeve and No.3 shift fork. 11. REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 09950–40011 SST Q05200 HINT: At the time of installation, please refer to the following item. Using SST, install the 5th driven gear. SST 09309–12020 SST SST Z00455 12. MEASURE 5TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.20 – 0.40 mm (0.0079 – 0.0157 in.) Maximum clearance: 0.45 mm (0.0177 in.) Q02695 Author: Date: 1862 MX–13 MANUAL TRANSAXLE (S51) Q02696 – MANUAL TRANSAXLE ASSEMBLY 13. MEASURE 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0.009 – 0.050 mm (0.0004 – 0.0020 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft. 14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR (a) Using 2 screwdrivers and a hammer, tap out the snap ring. HINT: At the time of installation, please refer to the following item. Select a snap ring that allows the minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) 13 2.20–2.25 (0.0866–0.0886) 21 2.60–2.65 (0.1024–0.1043) 14 2.25–2.30 (0.0886–0.0906) 22 2.65–2.70 (0.1043–0.1063) 15 2.30–2.35 (0.0906–0.0925) 23 2.70–2.75 (0.1063–0.1083) 16 2.35–2.40 (0.0925–0.0945) 24 2.75–2.80 (0.1083–0.1102) 17 2.40–2.45 (0.0945–0.0965) 25 2.80–2.85 (0.1102–0.1122) 18 2.45–2.50 (0.0965–0.0984) 26 2.85–2.90 (0.1122–0.1142) 19 2.50–2.55 (0.0984–0.1004) 27 2.90–2.95 (0.1142–0.1161) 20 2.55–2.60 (0.1004–0.1024) – – (b) Using SST and a socket wrench, remove the No.3 clutch hub with the synchronizer ring. SST 09950–30010 SST Socket Wrench Q02726 Author: Date: 1863 MX–14 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY HINT: At the time of installation, please refer to the following item. Using SST and a press, install the No.3 clutch hub assembly. SST 09612–22011 (c) Remove the 5th gear. 15. REMOVE NEEDLE ROLLER BEARING SST Q02682 x5 Q05785 18. x 17 x6 16. REMOVE REAR BEARING RETAINER Remove the 5 bolts and retainer. Sealant: Part No.08833 – 00070, THREE BOND 1324 or equivalent Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 17. REMOVE BEARING SNAP RING Using a snap ring expander, remove the 2 snap rings. HINT: If it is difficult to remove and install the snap rings, pull up the shafts. Q05826 FIPG REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT AND GASKET Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 19. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM Remove the 6 bolts, retainer and shim. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 20. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) (b) Using a plastic hammer, tap the transmission case and remove it. FIPG: Part No. 08833 – 00090, THREE BOND 1281 or equivalent Q09474 Author: Date: 1864 MX–15 MANUAL TRANSAXLE (S51) 21. (a) (b) 22. (a) (b) 23. Q05827 24. 25. 26. (a) (b) (c) 27. (a) (b) (c) Q03065 (d) – MANUAL TRANSAXLE ASSEMBLY REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft. Remove the idler gear and thrust washer. REMOVE REVERSE SHIFT ARM Shift the fork shaft into reverse. Remove the 2 bolts and pull off the reverse shift arm. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY REMOVE DIFFERENTIAL CASE ASSEMBLY REMOVE MAGNET FROM TRANSAXLE CASE REMOVE NO.2 SHIFT FORK SHAFT Using a hexagon wrench, remove the straight screw plug. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Using a pin punch and hammer, drive out the slotted spring pin. Pull out the shaft. SEPARATE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE SHIFT FORK Mount the shift forks to the vise. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft. Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft, as shown. Separate the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks and reverse shift fork. Author: Date: 1865 MX–16 MANUAL TRANSAXLE (S51) 28. (a) MT0781 – MANUAL TRANSAXLE ASSEMBLY REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub. Using a screwdriver, remove the snap ring. (b) HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Remove the synchronizer rings. Author: Date: 1866 MX–17 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX05M–01 INSPECTION 1. INSPECT NO.5 SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If the braking effect is insufficient, replace the synchronizer ring. 2. INSPECT NO.3 SHIFT FORK AND NO.3 HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 3. SST SST (a) (b) IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING Remove the 2 bolts and transaxle case receiver. Using SST, pull out the bearing. SST 09308–00010 Z00409 (c) SST SST (d) Using SST, press in a new bearing. SST 09310–35010 Install the transaxle case receiver and torque the 2 bolts. Torque: 7.4 N·m (75 kgf·cm, 65 in.·lbf) Z00410 4. SST SST (a) (b) IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING Remove the bolt and bearing lock plate. Using SST, pull out the bearing. SST 09308–00010 Z00411 Author: Date: 1867 MX–18 MANUAL TRANSAXLE (S51) (c) SST (d) SST – MANUAL TRANSAXLE ASSEMBLY Using SST, press in a new bearing. SST 09310–35010 Install the bearing lock plate and torque the bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Front Z00593 5. 0 – 0.5mm (a) (b) SST (c) IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL Using a screwdriver, pry out the oil seal. Using SST, drive in a new oil seal. SST 09608–00081, 09950–70010 (09951–07150) Drive in depth: 0 – 0.5 mm (0 – 0.020 in.) Coat the lip of the oil seal with MP grease. Z00413 6. (a) (b) 13.5 ± 0.5mm (c) (d) Z00596 (e) (f) IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench, remove the straight screw plug. Using a pin punch and hammer, drive out the slotted spring pin. Replace the reverse restrict pin. Using a pin punch and hammer, drive in the slotted spring pin. Drive in depth: 13.5 ± 0.5 mm (0.531 ± 0.020 in.) Apply sealant to the plug threads. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a hexagon wrench, install and torque the straight screw plug. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Author: Date: 1868 MX–19 MANUAL TRANSAXLE (S51) – MANUAL TRANSAXLE ASSEMBLY MX04I–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MX–11). HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. Author: Date: 1869 MX–20 MANUAL TRANSAXLE (S51) – INPUT SHAFT INPUT SHAFT MX04J–01 COMPONENTS Spacer Needle Roller Bearing 4th Gear Rear Bearing Snap Ring Synchronizer Ring Synchronizer Ring Shifting Key No.2 Clutch Hub Input Shaft Snap Ring 3rd Gear Needle Roller Bearing No.2 Hub Sleeve Key Spring Q02560 Author: Date: 1870 MX–21 MANUAL TRANSAXLE (S51) – INPUT SHAFT MX04K–01 DISASSEMBLY 1. 3rd Gear 4th Gear Q05793 INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE Using a feeler gauge, measure the clearance. Standard clearance: 3rd gear: 0.10 – 0.25 mm (0.0039 – 0.0098 in.) 4th gear: 0.20 – 0.45 mm (0.0079 – 0.0177 in.) Maximum clearance: 3rd gear: 0.30 mm (0.0118 in.) 4th gear: 0.50 mm (0.0197 in.) 2. Z00417 INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCES Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 0.009 – 0.053 mm (0.0004 – 0.0021 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. 4. SST Q05201 REMOVE REAR BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT (a) Using SST and a press, remove the 4th gear and rear bearing. SST 09950–00020 (b) Remove the needle roller bearings, spacer and synchronizer ring. 5. REMOVE SNAP RING Using a snap ring expander, remove the snap ring. Author: Date: 1871 MX–22 MANUAL TRANSAXLE (S51) – INPUT SHAFT 6. SST CM0064 REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings. SST 09950–00020 NOTICE: Be careful not to mistake the 3rd gear synchronizer ring for the 4th gear synchronizer ring. 7. REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND SPRING FROM NO.2 CLUTCH HUB Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.2 clutch hub. SM0269 Author: Date: 1872 MX–23 MANUAL TRANSAXLE (S51) – INPUT SHAFT MX04L–01 INSPECTION 1. (a) (b) WM0064 INSPECT SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) WM0065 Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.6 mm (0.024 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace shift fork or hub sleeve. WM0066 Author: Date: 1873 MX–24 MANUAL TRANSAXLE (S51) A B C – INPUT SHAFT 3. (a) (b) D SM0182 INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum outer diameter: Part A: 26.970 mm (1.0618 in.) Part B: 32.470 mm (1.2783 in.) Part C: 33.090 mm (1.3028 in.) Part D: 29.970 mm (1.1799 in.) If the outer diameter is less than the minimum, replace the input shaft. (c) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the input shaft. CM0013 Author: Date: 1874 MX–25 MANUAL TRANSAXLE (S51) – INPUT SHAFT MX04M–01 REASSEMBLY Engine Side SM0282 HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shifting keys. NOTICE: Position the key springs so that their end gaps are not aligned. 2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT (a) Apply gear oil to the needle roller bearings. (b) Place the synchronizer ring (for the 3rd gear) on the gear and align the ring slots with the shifting keys. NOTICE: Do not install the synchronizer ring for 4th gear. SM0193 (c) Using a press, install the 3rd gear and No.2 hub sleeve. 3. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play. Z00419 Mark Thickness mm (in.) 1 1.95–2.00 (0.0768–0.0787) 2 2.00–2.05 (0.0787–0.0807) 3 2.05–2.10 (0.0807–0.0827) 4 2.10–2.15 (0.0827–0.0846) 5 2.15–2.20 (0.0846–0.0866) 6 2.20–2.25 (0.0866–0.0886) Z00604 Author: Date: 1875 MX–26 MANUAL TRANSAXLE (S51) – INPUT SHAFT (b) 4. Using a snap ring expander, install the snap ring. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX–20) 5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARING, SPACER, 4TH GEAR AND REAR BALL BEARING Apply gear oil to the needle roller bearings. Install the spacer and needle roller bearings. (a) (b) SM0189 (c) Place the synchronizer ring on the gear. HINT: Align the ring slots with the shifting keys and the ring projections with the hub slots. SM0190 (d) Using SST and a press, install the rear ball bearing. SST 09608–00071 6. (a) INSTALL SNAP RING Select a snap ring that allows the minimum axial play. SST SM0049 Mark Thickness mm (in.) A 2.15–2.20 (0.0846–0.0866) B 2.20–2.25 (0.0866–0.0886) C 2.25–2.30 (0.0886–0.0906) D 2.30–2.35 (0.0906–0.0925) E 2.35–2.40 (0.0925–0.0945) SM0050 (b) Using a screwdriver and hammer, tap in the snap ring. Author: Date: 1876 MX–27 MANUAL TRANSAXLE (S51) 7. – INPUT SHAFT INSPECT 4TH GEAR THRUST CLEARANCE (See page MX–20) Author: Date: 1877 MX–28 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT OUTPUT SHAFT MX04N–01 COMPONENTS Output Shaft Spacer 1st Gear Needle Roller Bearing Synchronizer Ring No.1 Hub Sleeve Shifting Key Shifting Key Spring No.1 Clutch Hub Needle Roller Bearing Ball Spacer Rear Bearing Synchronizer Ring 2nd Gear 2nd Gear Bushing 3rd Driven Gear 4th Driven Gear Author: Q02544 Date: 1878 MX–29 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04O–01 DISASSEMBLY 1. 2nd Gear 1st Gear Q05794 INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear: 0.10 – 0.29 mm (0.0039 – 0.0114 in.) 2nd gear: 0.20 – 0.44 mm (0.0079 – 0.0173 in.) Maximum clearance: 1st gear: 0.35 mm (0.0138 in.) 2nd gear: 0.50 mm (0.0197 in.) 2. SM0137 SST INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE Using a dial indicator, measure the radial clearance between the gear and shaft. Standard clearance: 0.009 – 0.053 mm (0.0004 – 0.0021 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER (a) Using SST and a press, remove the rear ball bearing and 4th driven gear. SST 09950–00020 (b) Remove the output gear spacer and ball. CM0065 4. SST (a) (b) (c) REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING Shift the No.1 hub sleeve into the 1st gear. Using SST and a press, remove the 3rd driven gear and 2nd gear. SST 09950–00020 Remove the needle roller bearing and synchronizer rings. MT0063 Author: Date: 1879 MX–30 MANUAL TRANSAXLE (S51) 5. (a) (b) (c) – OUTPUT SHAFT REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL Using a press, remove the No.1 hub sleeve, 1st gear and synchronizer ring. Remove the needle roller bearing and locking ball. Using a screwdriver and hammer, drive out the thrust washer. Z00427 6. REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND SPRINGS FROM NO.1 CLUTCH HUB Q02948 Author: Date: 1880 MX–31 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04P–01 INSPECTION 1. (a) (b) WM0064 INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) WM0065 Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance: 0.6 mm (0.024 in.) If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, replace the synchronizer ring. MT0780 (c) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the minimum, replace the synchronizer ring. MT0787 Author: Date: 1881 MX–32 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT 3. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. WM0066 4. (a) A B C CM0014 INSPECT OUTPUT SHAFT Using a micrometer, measure the outer diameter of the output shaft journal surface. Minimum outer diameter: Part A: 31.970 mm (1.2587 in.) Part B: 37.970 mm (1.4949 in.) Part C: 31.990 mm (1.2594 in.) If the outer diameter is less than the minimum, replace the output shaft. (b) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the output shaft. CM0015 Author: Date: 1882 MX–33 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT MX04Q–01 REASSEMBLY Front Q02949 HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. HINT: Position the identification groove of the hub sleeve to the front of the transmission. 2. (a) SST (b) INSTALL THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT Using SST and a press, install the thrust washer. SST 09316–60011 (09316–00041) Apply gear oil to the needle roller bearing. SM0199 (c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (d) 3. Using a press, install the 1st gear and No.1 hub sleeve. INSPECT 1ST GEAR THRUST CLEARANCE (See page MX–28) Z00428 Z00429 Author: Date: 1883 MX–34 MANUAL TRANSAXLE (S51) – OUTPUT SHAFT 4. MT0792 INSTALL SYNCHRONIZER RING, 2ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR (a) Install the ball. (b) Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft. (c) Place the synchronizer rings on the 2nd gear. (d) Apply gear oil to the needle roller bearing and install it. (e) Install the 2nd gear. NOTICE: Align the clutch hub grooves with the projections on the synchronizer ring. (f) 5. SST Using SST and a press, install the 3rd driven gear. SST 09316–60011 (09316–00011) INSPECT 2ND GEAR THRUST CLEARANCE (See page MX–28) SM0201 6. (a) (b) INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING Install the outer gear spacer. Using a press, install the 4th driven gear and bearing. Z00431 7. INSTALL REAR BEARING Using SST and a press, install the rear bearing. SST 09612–22011 SST SM0202 Author: Date: 1884 MX–35 MANUAL TRANSAXLE (S51) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX04R–01 COMPONENTS Shift and Select Lever Shaft E–Ring Select Spring Seat Compression Spring Shift Interlock Plate 6.4 (85, 56 in.·lbf) Compression Spring Dust Boot Washer E–Ring Slotted Spring Pin Shift Inner Lever No.1 Shift Inner Lever No.2 Select Spring Seat No.2 Lever Lock Pin
Oil Seal Control Shaft Lever Control Shaft Cover
O–Ring N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part MP Grease Q10277 Author: Date: 1885 MX–36 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX04S–01 COMPONENTS Shim
Outer Race and Side Bearing Pinion Thrust Washer Ring Gear Pinion Gear Pinion Shaft 83 (850, 61) x8
Side Bearing and Outer Race Side Gear Shim Side Gear Thrust Washer Differential Case Straight Pin Vehicle Speed Sensor Drive Gear N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19302 Author: Date: 1886 MX–37 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE MX04T–01 DISASSEMBLY SST 1. (a) Q08148 (b) 2. (a) (b) (c) Vehicle Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, remove the bearing from the drive gear side of the case. SST 09950–00020, 09950–00030 Remove the vehicle speed sensor drive gear. REMOVE RING GEAR Place matchmarks on the ring gear and case. Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the case. 3. SST Ring Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, remove the bearing from the ring gear side of the case. SST 09950–00020, 09950–00030 Q04969 AT2799 4. INSPECT SIDE GEAR BACKLASH Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) If the backlash is not within the specification, install the correct thrust washer to the side gears. 5. DISASSEMBLE DIFFERENTIAL CASE (a) Using a pin punch and hammer, drive out the straight pin. (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and side gears with the 4 thrust washers from each gear. Author: Date: 1887 MX–38 MANUAL TRANSAXLE (S51) 6. (a) SST – DIFFERENTIAL CASE Transaxle Case Side: IF NECESSARY, REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive out the oil seal from the retainer. SST 09950–60020 (09951–00680), 09950–70010 (09951–07150) Q08145 (b) (c) Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 09350–32014 (09351–32130, 09351–32150) Coat the lip of the oil seal with MP grease. SST SM0286 7. (a) (b) SST (c) Transmission Case Side: IF NECESSARY, REPLACE SIDE OIL SEAL Using a screwdriver and hammer, drive out the oil seal. Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 09350–32014 (09351–32130, 09351–32150) Coat the lip of the oil seal with MP grease. SM0155 8. (a) (b) (c) Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer, drive out the bearing outer race. Install the bearing retainer without an O–ring. Install and torque the 6 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Z00442 (d) (e) SST (f) (g) Place the thinnest shim into the case. Using SST and a press, install a new bearing outer race. SST 09950–60020 (09951–00680), 09950–70010 (09951–07150) Remove the 6 bolts. Remove the bearing retainer and shim. MT0634 Author: Date: 1888 MX–39 MANUAL TRANSAXLE (S51) 9. (a) (b) (c) SST Q08184 – DIFFERENTIAL CASE Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer, drive out the bearing outer race and shim. Place the shim into the case. Using SST and a press, install a new bearing outer race. SST 09950–60020 (09951–00680), 09950–70010 (09951–07150) Author: Date: 1889 MX–40 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE MX04U–01 REASSEMBLY 1. (a) (b) ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will ensure that the backlash is within the specification. Try to select washers of the same size for both sides. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Thickness mm (in.) Thickness mm (in.) 0.95 (0.0374) 1.10 (0.0433) 1.00 (0.0394) 1.15 (0.0453) 1.05 (0.0413) 1.20 (0.0472) Install the thrust washers and side gears in the differential case. Install the pinion shaft. (c) AT2981 Inspect the side gear backlash. Using a dial indicator, measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05 – 0.20 mm (0.0020 – 0.0079 in.) If the backlash is not within the specification, install a thrust washer of different thickness. (d) Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft. (e) Stake the differential case. 2. INSTALL RING GEAR ON DIFFERENTIAL CASE (a) Clean the contact surface of the differential case and the threads of the ring gear and differential case. (b) Heat the ring gear in boiling water. (c) Carefully take the ring gear out of the water. (d) After moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the differential case and the ring gear. (e) Temporarily install the 8 bolts. NOTICE: The ring gear set bolts should not be torqued until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) Q08147 Author: Date: 1890 MX–41 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE 3. (a) INSTALL SIDE BEARING TO DIFFERENTIAL CASE Using SST and a press, install a new side bearing to the transmission case side. SST 09316–60011 (09316–00011), 09350–32014 (09351–32120) (b) Install the vehicle speed sensor drive gear to the transaxle case side. SST SM0287 Case Side Q08649 (c) SST SM0289 Using SST and a press, install a new side bearing to the transaxle case side. SST 09316–60011 (09316–00011), 09350–32014 (09351–32120) NOTICE: Install the black cage bearing on the vehicle speed sensor drive gear side. 4. ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD (a) Install the differential to the transaxle case. (b) Install the transmission case. (c) Install and torque the case bolts. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) (d) Install the shim into the transmission case. (e) Install the bearing retainer without an O–ring. (f) Install and torque the 6 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Author: Date: 1891 MX–42 MANUAL TRANSAXLE (S51) – DIFFERENTIAL CASE (g) SST Z00620 Using SST and a torque wrench, measure the preload. SST 09564–32011 Preload (at starting): 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) If the preload is not within the specification, remove the transmission case side bearing retainer. Select another shim. HINT: The preload will change about 0.3 – 0.4 N·m (3 – 4 kgf·cm, 2.6 – 3.5 in.·lbf) with each 0.05 mm (0.0019 in.) change in shim thickness. Mark Thickness mm (in.) Mark Thickness mm (in.) 1 1.90 (0.0748) 11 2.40 (0.0945) 2 1.95 (0.0768) 12 2.45 (0.0965) 3 2.00 (0.0787) 13 2.50 (0.0984) 4 2.05 (0.0807) 14 2.55 (0.1004) 5 2.10 (0.0827) 15 2.60 (0.1024) 6 2.15 (0.0846) 16 2.65 (0.1043) 7 2.20 (0.0866) 17 2.70 (0.1063) 8 2.25 (0.0886) 18 2.75 (0.1083) 9 2.30 (0.0906) 19 2.80 (0.1102) 10 2.35 (0.0925) – – (h) (i) (j) (k) Remove Remove Remove Remove the the the the 6 bolts. bearing retainer and shim. 17 bolts. transmission case. Author: Date: 1892 MX–43 MANUAL TRANSAXLE (S51) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX04V–02 COMPONENTS Shift Lever Knob Center Console Upper Panel Heater Control Assembly Center Cluster Finish Panel Rear Console Box Front Console Box Shift Cable Grommet Retainer Shift Cable Grommet Retainer Shift Cable Grommet Grommet 4.9 (50, 43 in.·lbf) Clip Clip 12 (120, 9) Clip 4.9 (50, 43 in.·lbf) Shift Lever Assembly Clip Shift Control Cable Clip Washer Clip Clip Select Control Cable Washer Washer Clip N·m (kgf·cm, ft·lbf) : Specified torque Q10340 Author: Date: 1893 ST–1 STARTING (5S–FE) – STARTING SYSTEM STARTING SYSTEM ST03H–01 ON–VEHICLE INSPECTION NOTICE: Before changing the starter, check the following items again:
Connector connection
Accessory installation, e.g.: theft deterrent system Author: Date: 1708 ST–2 STARTING (5S–FE) – STARTER STARTER ST03I–04 COMPONENTS Hold Down Clamp Battery Throttle Cable Clamp (A/T) Battery Tray Cruise Control Cover Cruise Control Actuator Connector Starter Clamp Starter Cable Starter Connector Cruise Control Actuator B01153 Author: Date: 1709 ST–3 STARTING (5S–FE) – STARTER
Snap Ring Starter Housing Stop Collar Pinion Gear Compression Spring Spring Retainer Starter Clutch Compression Spring Starter Housing and Clutch Assembly Clutch Shaft Idler Gear Bearing Steel Ball
Front Bearing Return Spring Magnetic Switch Assembly Armature
Rear Bearing
O–Ring Field Frame (Field Coil)
O–Ring Brush Holder End Cover
Dust Protector
Non–reusable part B01154 Author: Date: 1710 ST–4 STARTING (5S–FE) – STARTER Magnetic Switch Assembly Terminal Insulator
Terminal C Kit part Contact Plate Terminal Nut 17 (173, 13) Terminal Bolt Wave Washer Terminal Insulator O–Ring End Cover
Gasket Plunger Lead Terminal O–Ring Packing Terminal Bolt Terminal Insulator Wave Washer Terminal Nut 17 (173, 13) Contact Plate
Terminal 30 Kit Part Terminal Insulator N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06418 Author: Date: 1711 ST–5 STARTING (5S–FE) – STARTER ST03J–01 REMOVAL 1. 2. (a) (b) 3. (a) (b) (c) REMOVE BATTERY AND TRAY w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR Disconnect the actuator connector and clamp. Remove the 3 bolts, and disconnect the actuator with the bracket. REMOVE STARTER Disconnect the starter connector. Remove the 2 bolts, throttle cable clamp (A/T) and starter. Remove the nut, and disconnect the starter cable. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) Author: Date: 1712 ST–6 STARTING (5S–FE) – STARTER ST03K–01 DISASSEMBLY 1. 2. (a) (b) REMOVE DUST PROTECTOR REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) Remove the 2 through bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01156 Protrusion Identation (c) Pull out the field frame together with the armature. HINT: Align the protrusion of the field frame with the identation of the magnetic switch. (d) Remove the O–ring from the field frame. HINT: At the time of installation, please refer to following items. Use a new O–ring. B01157 3. (a) REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 screws. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01158 (b) (1) (4) (3) (2) Remove these parts from the magnetic switch: (1) Starter housing and clutch assembly (2) Return spring (3) Idler gear (4) Bearing B01160 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. B01159 Author: Date: 1713 ST–7 STARTING (5S–FE) 5. (a) (b) – STARTER REMOVE BRUSH HOLDER Remove the 2 screws and end cover from the field frame. Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf) Remove the O–ring from the field frame. B01161 (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTICE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME P13528 Author: Date: 1714 ST–8 STARTING (5S–FE) – STARTER ST03L–03 INSPECTION Ohmmeter 1. (a) INSPECT ARMATURE COIL Check the commutator for open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. Continuity P10584 (b) Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 2. INSPECT COMMUTATOR (a) Check the commutator for the dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. Ohmmeter No Continuity P10585 (b) Check for the commutator circle runout. (1) Place the commutator on V–blocks. (2) Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. P10586 (c) Using vernier calipers, measure the commutator diameter. Standard diameter: 30.0 mm (1.181 in.) Minimum diameter: 29.0 mm (1.142 in.) If the diameter is less than minimum, replace the armature. P10587 (d) Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. ST0040 Author: Date: 1715 ST–9 STARTING (5S–FE) – STARTER 3. (a) INSPECT FIELD COIL Check the field coil for open circuit. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. Ohmmeter Continuity P10588 (b) Check the field coil for ground. Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Ohmmeter No Continuity P10589 4. INSPECT BRUSHES Using vernier calipers, measure the brush length. Standard length: 15.5 mm (0.610 in.) Minimum length: 10.0 mm (0.394 in.) If the length is less than minimum, replace the brush holder and field frame. Brush Holder Side Length Field Flame Side Length Z10079 5. INSPECT BRUSH SPRINGS Check the brush spring load. Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 1.2 kW 13.7 – 19.6 N (1.4 – 2.0 kgf, 3.0 – 4.4 lbf) 1.4 kW 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf) Minimum spring installed load: ST0019 1.2 kW 9.8 N (1.0 kgf, 2.2 lbf) 1.4 kW 11.8 N (1.2 kgf, 2.6 lbf) If the installed load is less than minimum, replace the brush springs. Author: Date: 1716 ST–10 STARTING (5S–FE) Ohmmeter No Continuity P13481 – STARTER 6. INSPECT BRUSH HOLDER Check the brush holder insulation. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (–) brush holders. If there is continuity, repair or replace the brush holder. 7. INSPECT CLUTCH AND GEAR (a) Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the ring gear of the flywheel/drive plate for wear or damage. (b) Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. Lock Free B01162 Ohmmeter Terminal C 8. (a) INSPECT MAGNETIC SWITCH Check the pull–in coil for open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Continuity Terminal 50 B01163 (b) Ohmmeter Continuity Terminal 50 Check the hold–in coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. 9. INSPECT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. (See page ST–11) B01164 Author: Date: 1717 ST–11 STARTING (5S–FE) – STARTER ST03M–03 REPLACEMENT 1. (a) REPLACE CLUTCH ASSEMBLY Disassemble the starter housing and the clutch assembly. (1) Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar. B01224 (2) (3) Push down the pinion gear. Using a plastic–faced hammer, tap down the stop collar. (4) Using a screwdriver, pry out the snap ring. (5) Remove these parts:
Stop collar
Pinion gear
Compression spring (6) Push down the starter housing, and remove the spring retainer. Disassemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft B01225 B01226 Stop Collar Pinion Gear Compression Spring B01227 (7) B01228 Author: Date: 1718 ST–12 STARTING (5S–FE) Starter Housing (b) Compression Spring Starter Clutch Clutch Shaft – STARTER Assemble the starter housing and the clutch assembly (1) Assemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft B01229 (2) Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar. (3) Push down the starter housing, and install these parts:
Spring retainer
Compression spring
Pinion gear
Stop collar (4) (5) Push down the pinion gear. Using snap ring pliers, install a new snap ring. (6) (7) Using pliers, compress the snap ring. Check that the snap ring fits correctly. B01230 Stop Collar Pinion Gear Compression Spring B01231 Spring Retainer B01670 B01232 B01233 Author: Date: 1719 ST–13 STARTING (5S–FE) – (8) (9) STARTER Remove the starter housing and clutch assembly from the brass bar. Using a plastic–faced hammer, tap the clutch shaft and install the stop collar onto the snap ring. B01165 SST 2. (a) REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286–46011 P10595 (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing installation direction. SST 09820–00030 Upward SST Downward P10596 SST 3. (a) REPLACE REAR BEARING Using SST, remove the bearing. SST 09286–46011 (b) Using a press, press in a new bearing. P10593 P10594 Author: Date: 1720 ST–14 STARTING (5S–FE) 4. (a) – STARTER REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS Remove the 3 bolts, end cover, gasket and plunger. B01234 (b) Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. B01235 (c) Remove the terminal kit parts. (1) Using SST, loosen the terminal nuts. SST 09810–38140 (2) Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O–ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O–ring, terminal bolt, contact plate, terminal insulator (inside). (d) Temporarily install these new terminal 30 kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O–ring (5) Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. SST B01236 Long (1) Short Inside (4) (5) (3) (2) (6)(7) Identation Protrusion B06419 Author: Date: 1721 ST–15 STARTING (5S–FE) – STARTER HINT: Match the protrusion of the insulator with the indentation of the housing. (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. (e) Long Short (7)(6) (5) (4) (2) (3) (1) (7) Inside Lead Terminal B01238 Wooden Block 40 mm 37 mm 20 mm Contact Plate B01239 Temporarily install these new terminal C kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O–ring (5) Terminal insulator (outside) (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. (f) Temporarily tighten the terminal nuts. (g) Tighten terminal nuts. (1) Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE:
Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure: 100 kgf Ram diameter (cm) 2 x 3.14 (π) 2 221 lbf 2 Ram diameter (in.) x 3.14 (π) 2 (kgf/cm2) = (psi) = (kPa) = (kgf/cm2) x 98.1 (kPa) = (psi) x 6.9 Author: Date: 1722 ST–16 STARTING (5S–FE)
– STARTER If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. (2) Using SST, tighten the nuts to the specified torque. SST 09810–38140 Torque: 17 N·m (173 kgf·cm, 13 ft·lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator. SST B01240 (h) (i) Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Reinstall the plunger, a new gasket and the end cover with the 3 bolts. Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf) B01241 Author: Date: 1723 ST–17 STARTING (5S–FE) – STARTER ST03N–02 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page ST–6) HINT: Use high–temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the starter. Author: Date: 1724 ST–18 STARTING (5S–FE) – STARTER ST03O–01 TEST Terminal C Terminal 50 Battery NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. 1. DO PULL–IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. B01242 Disconnect Terminal C 2. DO HOLD–IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (–) lead from terminal C. Check that the pinion gear remains out. Battery B01243 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (–) lead from the switch body. Check that the clutch pinion gear returns inward. Disconnect Battery B01244 4. (a) (b) Terminal 30 Battery Terminal 50 DO NO–LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: 90 A or less at 11.5 V Ammeter B01245 Author: Date: 1725 ST–19 STARTING (5S–FE) – STARTER ST03P–01 INSTALLATION Installation is in the reverse order of removal. (See page ST–5) Author: Date: 1726 ST–20 STARTING (5S–FE) – STARTER RELAY STARTER RELAY ST03Q–01 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE STARTER RELAY (Marking: ST) Starter Relay B00796 Ohmmeter No 1 Continuity Continuity 5 Ohmmeter 3 2 3. (a) INSPECT STARTER RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. P07170 (b) Inspect the relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY 5. REINSTALL RELAY BOX COVER Ohmmeter Continuity 1 5 3 2 Battery P07171 Author: Date: 1727 ST–1 STARTING (1MZ–FE) – STARTING SYSTEM STARTING SYSTEM ST01T–01 ON–VEHICLE INSPECTION NOTICE: Before changing the starter, check the following items again:
Connector connection
Accessory installation, e.g.: theft deterrent system Author: Date: 1728 ST–2 STARTING (1MZ–FE) – STARTER STARTER ST01U–04 COMPONENTS Hold Down Clamp Battery Battery Tray Throttle Cable Clamp (A/T) Cruise Control Cover Cruise Control Actuator Connector Starter Clamp Starter Wire Cruise Control Actuator Starter Connector B01274 Author: Date: 1729 ST–3 STARTING (1MZ–FE) – STARTER
Snap Ring Starter Housing Stop Collar Pinion Gear Compression Spring Spring Retainer Starter Clutch Compression Spring Starter Housing and Clutch Assembly Clutch Shaft Idler Gear Bearing Steel Ball
Front Bearing Return Spring Magnetic Switch Assembly Armature
Rear Bearing
O–Ring Field Frame (Field Coil)
O–Ring Brush Holder End Cover
Dust Protector
Non–reusable part B01154 Author: Date: 1730 ST–4 STARTING (1MZ–FE) – STARTER Magnetic Switch Assembly Terminal Insulator Terminal Nut Contact Plate 17 (173, 13)
Terminal C Kit part Terminal Bolt Wave Washer Terminal Insulator O–Ring
Gasket Plunger End Cover Lead Terminal O–Ring Packing Terminal Bolt Terminal Insulator Wave Washer Terminal Nut
Terminal 30 Kit Part 17 (173, 13) Contact Plate Terminal Insulator N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06418 Author: Date: 1731 ST–5 STARTING (1MZ–FE) – STARTER ST01V–03 REMOVAL 1. 2. (a) (b) 3. (a) (b) (c) REMOVE BATTERY AND TRAY w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR Disconnect the actuator connector and clamp. Remove the 3 bolts, and disconnect the actuator with the bracket. REMOVE STARTER Disconnect the starter connector. Remove the 2 bolts, throttle cable clamp (A/T) and starter. Remove the nut, and disconnect the starter wire. Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) Author: Date: 1732 ST–6 STARTING (1MZ–FE) – STARTER ST01W–01 DISASSEMBLY 1. 2. (a) (b) REMOVE DUST PROTECTOR REMOVE FIELD FRAME AND ARMATURE Remove the nut, and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) Remove the 2 through bolts. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01156 Identation Protrusion (c) Pull out the field frame together with the armature. HINT: Align the protrusion of the field frame with the groove of the magnetic switch. (d) Remove the O–ring from the field frame. HINT: At the time of installation, please refer to the following items. Use a new O–ring. B01157 3. (a) REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Remove the 2 screws. Torque: 5.9 N·m (60 kgf·cm, 52 in.·lbf) B01158 (b) (1) (4) (3) (2) Remove these parts from the magnetic switch: (1) Starter housing and clutch assembly (2) Return spring (3) Idler gear (4) Bearing B01160 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. B01159 Author: Date: 1733 ST–7 STARTING (1MZ–FE) 5. (a) (b) – STARTER REMOVE BRUSH HOLDER Remove the 2 screws and end cover from the field frame. Torque: 1.5 N·m (15 kgf·cm, 13 in.·lbf) Remove the O–ring from the field frame. B01161 (c) Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. NOTICE: Check that the positive (+) lead wires are not grounded. 6. REMOVE ARMATURE FROM FIELD FRAME P13528 Author: Date: 1734 ST–8 STARTING (1MZ–FE) – STARTER ST01X–03 INSPECTION Ohmmeter 1. (a) INSPECT ARMATURE COIL Check the commutator for open circuit. Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. Continuity P10584 (b) Check the commutator for ground. Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. 2. INSPECT COMMUTATOR (a) Check the commutator for the dirty and burnt surfaces. If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. Ohmmeter No Continuity P10585 (b) Check for the commutator circle runout. (1) Place the commutator on V–blocks. (2) Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. P10586 (c) Using vernier calipers, measure the commutator diameter. Standard diameter: 30.0 mm (1.181 in.) Minimum diameter: 29.0 mm (1.142 in.) If the diameter is less than minimum, replace the armature. P10587 (d) Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than minimum, correct it with a hacksaw blade. ST0040 Author: Date: 1735 ST–9 STARTING (1MZ–FE) – STARTER 3. (a) INSPECT FIELD COIL Check the field coil for open circuit. Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. Ohmmeter Continuity P10588 (b) Check the field coil for ground. Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Ohmmeter No Continuity P10589 4. INSPECT BRUSHES Using vernier calipers, measure the brush length. Standard length: 15.5 mm (0.610 in.) Minimum length: 10.0 mm (0.394 in.) If the length is less than minimum, replace the brush holder and field frame. Brush Holder Side Length Field Flame Side Length Z10079 5. INSPECT BRUSH SPRINGS Check the brush spring load. Take the pull scale reading the instant the brush spring separates from the brush. Standard spring installed load: 1.2 kW 13.7 – 19.6 N (1.4 – 2.0 kgf, 3.0 – 4.4 lbf) 1.4 kW 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf) Minimum spring installed load: ST0019 1.2 kW 9.8 N (1.0 kgf, 2.2 lbf) 1.4 kW 11.8 N (1.2 kgf, 2.6 lbf) If the installed load is less than minimum, replace the brush springs. Author: Date: 1736 ST–10 STARTING (1MZ–FE) Ohmmeter No Continuity P13481 – STARTER 6. INSPECT BRUSH HOLDER Check the brush holder insulation. Using an ohmmeter, check that there is no continuity between the positive (+) and negative (–) brush holders. If there is continuity, repair or replace the brush holder. 7. INSPECT CLUTCH AND GEAR (a) Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the ring gear of the flywheel/drive plate for wear or damage. (b) Check the clutch pinion gear. Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. Lock Free B01162 Terminal C Ohmmeter 8. (a) INSPECT MAGNETIC SWITCH Check the pull–in coil for open circuit. Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Continuity Terminal 50 B01163 (b) Ohmmeter Continuity Terminal 50 Check the hold–in coil for open circuit. Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. 9. INSPECT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. (See page ST–11) B01164 Author: Date: 1737 ST–11 STARTING (1MZ–FE) – STARTER ST01Y–03 REPLACEMENT 1. (a) REPLACE CLUTCH ASSEMBLY Disassemble the starter housing and the clutch assembly. (1) Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar. B01224 (2) (3) Push down the pinion gear. Using a plastic–faced hammer, tap down the stop collar. (4) Using a screwdriver, pry out the snap ring. (5) Remove these parts:
Stop collar
Pinion gear
Compression spring (6) Push down the starter housing, and remove the spring retainer. Disassemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft B01225 B01226 Stop Collar Pinion Gear Compression Spring B01227 (7) B01228 Author: Date: 1738 ST–12 STARTING (1MZ–FE) Starter Housing (b) Compression Spring Starter Clutch Clutch Shaft – STARTER Assemble the starter housing and the clutch assembly (1) Assemble these parts:
Starter housing
Starter clutch
Compression spring
Clutch shaft B01229 (2) Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar. (3) Push down the starter housing, and install these parts:
Spring retainer
Compression spring
Pinion gear
Stop collar (4) (5) Push down the pinion gear. Using snap ring pliers, install a new snap ring. (6) (7) Using pliers, compress the snap ring. Check that the snap ring fits correctly. B01230 Stop Collar Pinion Gear Compression Spring B01231 Spring Retainer B01670 B01232 B01233 Author: Date: 1739 ST–13 STARTING (1MZ–FE) – (8) (9) STARTER Remove the starter housing and clutch assembly from the brass bar. Using a plastic–faced hammer, tap the clutch shaft and install the stop collar onto the snap ring. B01165 SST 2. (a) REPLACE FRONT BEARING Using SST, remove the bearing. SST 09286–46011 P10595 (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing installation direction. SST 09820–00030 Upward SST Downward P10596 SST 3. (a) REPLACE REAR BEARING Using SST, remove the bearing. SST 09286–46011 (b) Using a press, press in a new bearing. P10593 P10594 Author: Date: 1740 ST–14 STARTING (1MZ–FE) 4. (a) – STARTER REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS Remove the 3 bolts, end cover, gasket and the plunger. B01234 (b) Using vernier calipers, measure the contact plate for depth of wear. Maximum wear: 0.9 mm (0.035 in.) If the depth of wear is greater than the maximum, replace the contact plate. B01235 (c) Remove the terminal kit parts. (1) Using SST, loosen the terminal nuts. SST 09810–38140 (2) Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O–ring, terminal bolt, contact plate and terminal insulator (inside). (3) Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O–ring, terminal bolt, contact plate, terminal insulator (inside). (d) Temporarily install these new terminal 30 kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O–ring (5) Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. SST B01236 (1) Long Short Inside (4) (5) (3) (2) (6) (7) Identation Protrusion B06419 Author: Date: 1741 ST–15 STARTING (1MZ–FE) – STARTER HINT: Match the protrusion of the insulator with the indentation of the housing. (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. (e) Long Short (7)(6) (5) (4) (2) (3) (1) (7) Inside Lead Terminal B01238 Wooden Block 40 mm 37 mm 20 mm Contact Plate B01239 Temporarily install these new terminal C kit parts: (1) Terminal insulator (inside) (2) Contact plate (3) Terminal bolt (4) O–ring (5) Terminal insulator (outside) (6) Wave washer (7) Terminal nut NOTICE: Be careful to install the terminal insulators (inside) and wave washers in the correct direction. (f) Temporarily tighten the terminal nuts. (g) Tighten terminal nuts. (1) Put a wooden block on the contact plate and press it down with a hand press. Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.) Press force: 981 N (100 kgf, 221 lbf) NOTICE:
Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kgf, 221 lbf) of force is applied. Gauge pressure: 100 kgf Ram diameter (cm) 2 x 3.14 (π) 2 221 lbf 2 Ram diameter (in.) x 3.14 (π) 2 (kgf/cm2) = (psi) = (kPa) = (kgf/cm2) x 98.1 (kPa) = (psi) x 6.9 Author: Date: 1742 ST–16 STARTING (1MZ–FE)
– STARTER If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut. (2) Using SST, tighten the nuts to the specified torque. SST 09810–38140 Torque: 17 N·m (173 kgf·cm, 13 ft·lbf) NOTICE: If the nut is over tightened, it may cause cracks on the inside of the insulator. SST B01240 (h) (i) Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. Reinstall the plunger, new gasket and end cover with the 3 bolts. Torque: 2.5 N·m (26 kgf·cm, 23 in.·lbf) B01241 Author: Date: 1743 ST–17 STARTING (1MZ–FE) – STARTER ST01Z–01 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page ST–6) HINT: Use high–temperature grease to lubricate the bearings, springs, steel ball and gears when assembling the starter. Author: Date: 1744 ST–18 STARTING (1MZ–FE) – STARTER ST020–01 TEST Terminal C Terminal 50 Battery NOTICE: These tests must be done within 3 to 5 seconds to avoid burning out the coil. 1. DO PULL–IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. B01242 Disconnect Terminal C 2. DO HOLD–IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (–) lead from terminal C. Check that the pinion gear remains out. Battery B01243 3. (a) (b) INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (–) lead from the switch body. Check that the clutch pinion gear returns inward. 4. (a) (b) DO NO–LOAD PERFORMANCE TEST Connect the battery and ammeter to the starter as shown. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: 90 A or less at 11.5 V Disconnect Battery B01244 Terminal 30 Battery Terminal 50 Ammeter B01245 Author: Date: 1745 ST–19 STARTING (1MZ–FE) – STARTER ST021–01 INSTALLATION Installation is in the reverse order of removal. (See page ST–5) Author: Date: 1746 ST–20 STARTING (1MZ–FE) – STARTER RELAY STARTER RELAY ST022–01 INSPECTION 1. 2. REMOVE RELAY BOX COVER REMOVE STARTER RELAY (Marking: ST) Starter Relay B00796 Ohmmeter No 1 Continuity Continuity 5 Ohmmeter 3 2 3. (a) INSPECT STARTER RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. P07170 (b) Inspect the relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. 4. REINSTALL STARTER RELAY 5. REINSTALL RELAY BOX COVER Ohmmeter Continuity 1 5 3 2 Battery P07171 Author: Date: 1747 SR–1 STEERING – STEERING SYSTEM STEERING SYSTEM SR06B–01 PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. Author: Date: 2096 SR–2 STEERING – TROUBLESHOOTING TROUBLESHOOTING SR06C–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts. Symptom Suspect Area See page Hard steering 1. Tires (Improperly inflated) 2. Power steering fluid level (Low) 3. Drive belt (Loose) 4. Front wheel alignment (Incorrect) 5. Steering system joints (Worn) 6. Suspension arm ball joints (Worn) 7. Steering column (Binding) 8. Power steering vane pump 9. Power steering gear SA–2 SR–5 SR–3 SA–4 – SA–45 – SR–18 SR–31 Poor return 1. Tires (Improperly inflated) 2. Front wheel alignment (Incorrect) 3. Steering column (Binding) 4. Power steering gear SA–2 SA–4 – SR–31 Excessive play 1. Steering system joints (Worn) 2. Suspension arm ball joints (Worn) 3. Intermediate shaft, Sliding yoke (Worn) 4. Front wheel bearing (Worn) 5. Power steering gear – SA–45 – SA–10 SR–31 Abnormal noise 1. Power steering fluid level (Low) 2. Steering system joints (Worn) 3. Power steering vane pump 4. Power steering gear SR–5 – SR–18 SR–31 Author: Date: 2097 SR–3 STEERING – DRIVE BELT DRIVE BELT SR06D–01 INSPECTION P06717 DENSO Borroughs INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG–20 (95506–00020) Borroughs No. BT–33–73F 5S–FE Engine: Drive belt tension: New belt: 95 – 145 lbf Used belt: 60 – 100 lbf 1MZ–FE Engine: Drive belt tension: New belt: 150 – 185 lbf Used belt: 95 – 135 lbf Z00038 If the belt tension is not as specified, adjust it. HINT:

CORRECT WRONG WRONG

P06723
”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After installing a belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Author: Date: 2098 SR–4 STEERING – POWER STEERING FLUID POWER STEERING FLUID SR06E–01 BLEEDING 1. Normal CHECK FLUID LEVEL (See page SR–5) 2. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS 3. TURN STEERING WHEEL With the engine stopped, turn the wheel slowly from lock to lock several times. 4. LOWER VEHICLE 5. START ENGINE Run the engine at idle for a few minutes. 6. TURN STEERING WHEEL (a) With the engine idling, turn the wheel to left or right full lock and keep it there for 2–3 seconds, then turn the wheel to the opposite full lock and keep it there for 2–3 seconds. (b) Repeat (a) several times. 7. STOP ENGINE 8. CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. CHECK FLUID LEVEL (See page SR–5) Abnormal R09599 Author: Date: 2099 SR–5 STEERING – POWER STEERING FLUID SR06F–01 INSPECTION 1. (a) (b) R00427 HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir. If the fluid is cold, check that it is within the COLD LEVEL range. (c) Start the engine and run it at idle. (d) Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) (e) Normal CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON® II or III Abnormal Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. (See page SR–4) R09599 (f) 5 mm (0.2 in.) or less Engine Idling Engine Stopped R11562 With the engine idling, measure the fluid level in the oil reservoir. (g) Stop the engine. (h) Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed power steering system. (See page SR–4) (i) Check the fluid level. Author: Date: 2100 SR–6 STEERING – POWER STEERING FLUID 2. (a) CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube. (See page SR–21) (b) Connect SST, as shown below. SST 09640–10010 (09641–01010, 09641–01030, 09641–01060) NOTICE: Check that the valve of the SST is in the open position. 5S–FE Engine : 1MZ–FE Engine : Attachment Attachment SST In SST Out Attachment In Out Pressure Feed Tube Pressure Feed Tube Attachment W03331 (c) (d) (e) Bleed the power steering system. (See page SR–4) Start the engine and run it at idle. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80 °C (176 °F) Author: Date: 2101 SR–7 STEERING – POWER STEERING FLUID (f) Oil Reservoir PS Gear Closed PS Vane Pump SST With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 7,845 kPa (80 kgf·cm2, 1,138 psi) NOTICE:
Do not keep the valve closed for more than 10 seconds.
Do not let the fluid temperature become too high. Z15498 Oil Reservoir PS Gear Open PS Vane Pump SST (g) (h) With the engine idling, open the valve fully. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf·cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Z15499 (i) Oil Reservoir Lock Position PS Gear PS Vane Pump SST Z15500 With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 7,845 kPa (80 kgf·cm2, 1,138 psi) NOTICE:
Do not maintain lock position for more than 10 seconds.
Do not let the fluid temperature become too high. (j) Disconnect the SST. (k) Connect the pressure feed tube. (See page SR–28) (l) Bleed the power steering system. (See page SR–4) Author: Date: 2102 SR–8 STEERING – STEERING WHEEL STEERING WHEEL SR06G–01 INSPECTION R07653 1. CHECK STEERING WHEEL FREEPLAY With the vehicle stopped and tires facing straight ahead, rock the steering wheel gently back and forth with light finger pressure. Freeplay should not exceed the maximum. Maximum freeplay: 30 mm (1.18 in.) 2. (a) (b) (c) (d) F01477 CHECK STEERING EFFORT Center the steering wheel. Remove the steering wheel pad. (See page SR–11) Start the engine and run it at idle. Measure the steering effort in both directions. Reference: 5.9 N·m (60 kgf·cm, 52 in.·lbf) HINT: Be sure to consider the tire type, pressure and contact surface before making your diagnosis. (e) Torque the steering wheel set nut. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) (f) Install the steering wheel pad. (See page SR–16) Author: Date: 2103 SR–9 STEERING – TILT STEERING COLUMN TILT STEERING COLUMN SR06H–03 COMPONENTS Steering Wheel Pad 35 (360, 26) Torx Screw 7.1 (72, 63 in.·lbf) Steering Wheel Lower No.2 Cover Steering Wheel Torx Screw 7.1 (72, 63 in.·lbf) Combination Switch (w/ Spiral Cable) Steering Wheel Lower No.2 Cover Column Upper Cover 35 (360, 26) Lower No.2 Cover 25 (260, 19) 35 (360, 26) Steering Column Assembly Column Lower Cover Intermediate Shaft Assembly Lower Instrument Finish Panel No.1 Lower Instrument Panel Hood Lock Control Cable Clip LH Lower Instrument Panel Front Door Inside Scuff Plate Cowl Side Trim N·m (kgf·cm, ft·lbf) : Specified torque W03348 Author: Date: 2104 SR–10 STEERING – TILT STEERING COLUMN Key Cylinder Lamp Assembly Key Unlock Warning Switch Key Cylinder w/ ENGINE IMMOBILISER SYSTEM: Transponder Key Amplifier Ignition Switch Column Upper Bracket Transponder Key Coil Turn Signal Bracket A/T: Key Interlock Solenoid Energy Absorbing Plate 7 (70, 61 in.·lbf)
Energy Absorbing Clip Column Upper Tube Energy Absorbing Plate Guide 19 (195, 14) Tilt Lever Return Spring Column Tube
Tapered–Head Bolt Energy Absorbing Plate Column Tube Support Energy Absorbing Plate Guide Lower Column Tube Attachment
Energy Absorbing Clip N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F01476 Author: Date: 2105 SR–11 STEERING – TILT STEERING COLUMN SR06I–03 REMOVAL 1. REMOVE STEERING WHEEL PAD NOTICE:
If the airbag connector is disconnected with the ignition switch at ON or ACC, DTCs will be recorded.
Never use airbag parts from another vehicle. When replacing parts, replace with new ones. Torx Screw Screw Case (a) Place the front wheels facing straight ahead. (b) Remove the 2 steering wheel lower No.2 covers. (c) Using a torx socket wrench, loosen the 2 torx screws. HINT: Loosen the 2 screws until the groove along the screw circumference catches on the screw case. W03300 (d) Pull the pad out from the steering wheel and disconnect the airbag connector. CAUTION:
When storing the wheel pad, keep the upper surface of the pad facing upward.
Never disassemble the wheel pad. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. Airbag Connector Correct Wrong W03301 Matchmarks 2. (a) (b) (c) SST (d) REMOVE STEERING WHEEL Disconnect the connector. Remove the steering wheel set nut. Place matchmarks on the steering wheel and main shaft assembly. Using SST, remove the wheel. SST 09950–50012 (09951–05010, 09952–05010, 09953–05020, 09954–05020) W03302 Author: Date: 2106 SR–12 STEERING – TILT STEERING COLUMN 3. REMOVE UPPER AND LOWER COLUMN COVERS (a) Remove the lower No.2 cover from the lower cover. (b) Remove the 3 screws. 4. REMOVE FRONT DOOR INSIDE SCUFF PLATE 5. REMOVE COWL SIDE TRIM Remove the clip. 6. REMOVE No.1 LOWER INSTRUMENT PANEL (a) Remove the 2 screws. (b) Disconnect the hood lock control cable. 7. REMOVE LH LOWER INSTRUMENT PANEL Remove the 4 bolts. 8. REMOVE LOWER INSTRUMENT FINISH PANEL 9. REMOVE COMBINATION SWITCH WITH SPIRAL CABLE (a) Disconnect the 3 connectors. (b) Disconnect the airbag connector. (c) Remove the 3 screws. 10. REMOVE SPIRAL CABLE (See page BE–23) NOTICE: Do not disassemble the cable or apply oil to it. 11. (a) Matchmarks W03303 DISCONNECT INTERMEDIATE SHAFT ASSEMBLY Place matchmarks on the intermediate shaft and control valve shaft. (b) Remove the bolt. 12. REMOVE INTERMEDIATE SHAFT ASSEMBLY Remove the bolt. 13. REMOVE STEERING COLUMN ASSEMBLY (a) Disconnect the connectors. (b) Remove the 4 column assembly set nuts. Author: Date: 2107 SR–13 STEERING – TILT STEERING COLUMN SR06J–01 DISASSEMBLY Screw Extractor W03333 NOTICE: When using a vise, do not overtighten it. 1. w/ ENGINE IMMOBILISER SYSTEM: REMOVE TRANSPONDER KEY COIL WITH KEY CYLINDER LAMP ASSEMBLY Remove the screw. 2. w/ ENGINE IMMOBILISER SYSTEM: REMOVE KEY CYLINDER LAMP ASSEMBLY Remove the lamp assembly from the key coil. 3. w/o ENGINE IMMOBILISER SYSTEM: REMOVE KEY CYLINDER LAMP ASSEMBLY Remove the screw. 4. REMOVE COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP (a) Using a centering punch, mark the center of the 2 tapered–head bolts. (b) Using a 3–4 mm (0.12–0.16 in.) drill, drill into the 2 bolts. (c) Using a screw extractor, remove the 2 bolts. 5. REMOVE TURN SIGNAL BRACKET Remove the 2 bolts. 6. REMOVE TILT LEVER RETURN SPRING 7. REMOVE COLUMN TUBE SUPPORT (a) Remove the bolt and washer. (b) Remove the tube support with lower column tube attachment. (c) Remove the tube attachment from the tube support. 8. (a) (b) REMOVE 2 ENERGY ABSORBING PLATES Using pliers, remove the energy absorbing clip. Remove the energy absorbing plate, energy absorbing plate guide. W03334 Author: Date: 2108 SR–14 STEERING – TILT STEERING COLUMN SR06K–01 INSPECTION Ignition Key 1. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates properly. W03335 2. (a) (b) W03336 IF NECESSARY, REPLACE KEY CYLINDER Place the ignition key at the ACC position. Push down the stop pin with a screwdriver, and pull out the cylinder. Install a new cylinder. (c) HINT: Make sure the key is at the ACC position. 3. INSPECT IGNITION SWITCH (See page BE–14) 4. IF NECESSARY, REPLACE IGNITION SWITCH (a) Remove the 2 screws. (b) Install a new switch with the 2 screws. 5. INSPECT KEY UNLOCK WARNING SWITCH (See page BE–14) 6. IF NECESSARY, REPLACE KEY UNLOCK WARNING SWITCH (a) Slide out the switch. (b) Install a new switch. 7. A/T: INSPECT KEY INTERLOCK SOLENOID (A140E: See page AX–13) (A541E: See page AX–17) 8. A/T: IF NECESSARY, REPLACE KEY INTERLOCK SOLENOID (a) Remove the 2 screws. (b) Install a new solenoid with the 2 screws. 9. w/ ENGINE IMMOBILISER SYSTEM: INSPECT TRANSPONDER KEY COIL (See page BE–128) 10. w/ ENGINE IMMOBILISER SYSTEM: IF NECESSARY, REPLACE TRANSPONDER KEY COIL 11. w/ ENGINE IMMOBILISER SYSTEM: IF NECESSARY, REPLACE TRANSPONDER KEY AMPLIFIER (a) Remove the 2 screws. (b) Install a new key amplifier with the 2 screws. Author: Date: 2109 SR–15 STEERING – TILT STEERING COLUMN SR06L–01 REASSEMBLY W03347 NOTICE: When using a vise, do not overtighten it. 1. INSTALL 2 ENERGY ABSORBING PLATES (a) Install the energy absorbing plate guide and absorbing plate. (b) Install the new energy absorbing clip. 2. INSTALL COLUMN TUBE SUPPORT (a) Install the tube attachment to the tube support. (b) Torque the bolt and washer. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 3. INSTALL TILT LEVER RETURN SPRING 4. INSTALL TURN SIGNAL BRACKET Torque the 2 bolts. Torque: 7 N·m (70 kgf·cm, 61 in.·lbf) 5. W03337 INSTALL COLUMN UPPER BRACKET AND COLUMN UPPER CLAMP Tighten the 2 new tapered–head bolts until the bolt heads break off. 6. w/ ENGINE EMMOBILISER SYSTEM: INSTALL KEY CYLINDER LAMP ASSEMBLY Install the lamp assembly to the key coil. 7. w/ ENGINE EMMOBILISER SYSTEM: INSTALL TRANSPONDER KEY COIL WITH KEY CYLINDER LAMP ASSEMBLY Tighten the screw. 8. w/o ENGINE EMMOBILISER SYSTEM: INSTALL KEY CYLINDER LAMP ASSEMBLY Tighten the screw. Author: Date: 2110 SR–16 STEERING – TILT STEERING COLUMN SR06M–01 INSTALLATION Matchmarks 1. (a) W03303 INSTALL STEERING COLUMN ASSEMBLY Torque the 4 column assembly set nuts. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) (b) Connect the connectors. 2. INSTALL INTERMEDIATE SHAFT ASSEMBLY Torque the bolt. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) 3. CONNECT INTERMEDIATE SHAFT ASSEMBLY (a) Align the matchmarks on the intermediate shaft and control valve shaft. (b) Torque the bolt. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) 4. INSTALL SPIRAL CABLE (See page BE–23) 5. INSTALL COMBINATION SWITCH WITH SPIRAL CABLE (a) Tighten the 3 screws. (b) Connect the airbag connector. (c) Connect the 3 connectors. 6. INSTALL LOWER INSTRUMENT FINISH PANEL 7. INSTALL LH LOWER INSTRUMENT PANEL Tighten the 4 bolts. 8. INSTALL No.1 LOWER INSTRUMENT PANEL (a) Connect the hood lock control cable. (b) Tighten the 2 screws. 9. INSTALL COWL SIDE TRIM Install the clip. 10. INSTALL FRONT DOOR INSIDE SCUFF PLATE 11. INSTALL UPPER AND LOWER COLUMN COVERS (a) Tighten the 3 screws. (b) Install the lower No.2 cover to the lower cover. 12. (a) (b) (c) Mark W02655 CENTER SPIRAL CABLE Check that the front wheels are facing straight ahead. Turn the cable counterclockwise by hand until it becomes harder to turn the cable. Then rotate the cable clockwise about 3 turns to align the mark. HINT: The cable will rotate about 3 turns to either left or right of the center. Author: Date: 2111 SR–17 STEERING – TILT STEERING COLUMN 13. (a) (b) INSTALL STEERING WHEEL Align the matchmarks on the wheel and main shaft. Torque the wheel set nut. Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) (c) Connect the connector. 14. INSTALL STEERING WHEEL PAD NOTICE:
Make sure the wheel pad is installed to the specified torque.
If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one.
When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts. Torx Screw Screw Case (a) (b) (c) (d) 15. Connect the airbag connector. Install the pad after confirming that the circumference groove of the torx screw is caught on the screw case. Using a torx socket wrench, torque the 2 screws. Torque: 7.1 N·m (72 kgf·cm, 63 in.·lbf) Install the 2 steering wheel lower No.2 covers. CHECK STEERING WHEEL CENTER POINT W03304 Author: Date: 2112 SR–18 STEERING – POWER STEERING VANE PUMP POWER STEERING VANE PUMP SR06N–03 COMPONENTS 5S–FE Engine : 43 (440, 32) *29 (293, 21) Connector Oil Pressure Switch 21 (210, 15) Union Bolt 52 (525, 38) Drive Belt Clamp Plate 10 (100, 7) Clamp Plate
Gasket Holder Return Hose 25 (250, 18) *32 (326, 24) Pressure Feed Tube PS Vane Pump Assembly Clamp 43 (440, 32) Front Fender Apron Seal RH N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part * For use with SST W03364 Author: Date: 2113 SR–19 STEERING – POWER STEERING VANE PUMP 1MZ–FE Engine : 43 (440, 32) *29 (293, 21) 7.8 (80, 69 in.·lbf) Drive Belt Connector Oil Pressure Switch 21 (210, 15) Union Bolt 52 (525, 38) Clamp Plate
Gasket Pressure Feed Tube Return Hose 25 (250, 18) *20 (203, 15) Pressure Feed Tube 43 (440, 32) PS Vane Pump Assembly Holder Clamp Plate Clamp Plate Front Fender Apron Seal RH N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part * For use with SST W03365 Author: Date: 2114 SR–20 STEERING Pressure Port Union 83 (850, 62) – POWER STEERING VANE PUMP 5S–FE Engine : TOYOTA KOUKI Made : Rear Housing 24 (240, 17) 5S–FE Engine : Rear Bracket
Oil Ring Flow Control Valve 43 (440, 32) Suction Port Union Rear Housing Spring 13 (130, 9)
O–Ring
Gasket Front Housing
O–Ring 24 (240, 17) 5S–FE Engine : Front Bracket 1MZ–FE Engine : Rear Bracket 1MZ–FE Engine : Front Bracket 43 (440, 32)
Straight Pin Vane Pump Shaft Vane Pump Pulley Vane Pump Rotor x10
Wave Washer Side Plate Cam Ring Vane Plate
O–Ring
Snap Ring 43 (440, 32) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Power steering fluid W03349 Author: Date: 2115 SR–21 STEERING – POWER STEERING VANE PUMP SR06O–01 REMOVAL 1. REMOVE FRONT FENDER APRON SEAL RH Remove the 2 bolts. 2. DISCONNECT RETURN HOSE NOTICE: Take care not to spill fluid on the drive belt. 3. (a) 5S–FE Engine : SST (b) (c) (d) 1MZ–FE Engine : (e) SST (f) (g) Pressure Feed Tube DISCONNECT PRESSURE FEED TUBE 5S–FE Engine: Remove the clamp plate set bolt and nut. 5S–FE Engine: Remove the 2 clamp plates and 2 holders from the tube. 5S–FE Engine: Remove the clamp from the tube. 1MZ–FE Engine: Remove the 2 clamp plate set nuts. 1MZ–FE Engine: Remove the bolt. 1MZ–FE Engine: Remove the 2 clamp plates and 2 holders from the tube. 5S–FE and 1MZ–FE Engines: Using SST, disconnect the tube. SST 09631–22020 W04220 Example 5S–FE Engine : A B W03360 4. REMOVE DRIVE BELT Loosen the 2 (A and B) bolts. 5. REMOVE PS VANE PUMP ASSEMBLY WITH PRESSURE FEED TUBE (a) Disconnect the connector from the oil pressure switch. (b) Loosen bolt A sufficiently so that pump assembly can be removed. HINT: Bolt A cannot be removed. 6. REMOVE PRESSURE FEED TUBE (a) Remove the oil pressure switch from the union bolt. NOTICE: Be careful not to drop the switch. If the switch is dropped or strongly damaged, replace it with a new one. (b) Remove the union bolt and gasket. Author: Date: 2116 SR–22 STEERING – POWER STEERING VANE PUMP SR06P–01 DISASSEMBLY Example 5S–FE Engine : W03338 Example 5S–FE Engine : SST W03339 NOTICE: When using a vise, do not overtighten it. 1. MEASURE PS VANE PUMP ROTATING TORQUE (a) Check that the pump rotates smoothly without abnormal noise. (b) Using a torque wrench, check the pump rotating torque. 5S–FE and 1MZ–FE Engines: Rotating torque: 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less 2. REMOVE VANE PUMP PULLEY Using SST, to stop the pulley rotating, remove the nut. SST 09960–10010 (09962–01000, 09963–01000) 3. REMOVE FRONT AND REAR BRACKETS Remove the 3 bolts and 2 nuts. 4. REMOVE SUCTION PORT UNION (a) Remove the bolt. (b) Remove the O–ring from the union. 5. REMOVE PRESSURE PORT UNION, FLOW CONTROL VALVE AND SPRING Remove the O–ring from the union. 6. REMOVE REAR HOUSING (a) Remove the 4 bolts. (b) Remove the 2 O–rings from the housing. 7. REMOVE WAVE WASHER 8. REMOVE SIDE PLATE 9. REMOVE GASKET 10. REMOVE CAM RING, 10 VANE PLATES AND VANE PUMP ROTOR Using a screwdriver, remove the snap ring from the vane pump shaft. NOTICE: Take care not to drop the plate. 11. REMOVE VANE PUMP SHAFT 12. REMOVE STRAIGHT PINS Remove the 2 pins from the front housing. Author: Date: 2117 SR–23 STEERING – POWER STEERING VANE PUMP SR06Q–01 INSPECTION NOTICE: When using a vise, do not overtighten it. 1. CHECK OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clearance. 5S–FE and 1MZ–FE Engines: Standard clearance: 0.03 – 0.05 mm (0.0012 – 0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If it is more than the maximum, replace the front housing and vane pump shaft. Caliper Gauge Micrometer Vane Pump Shaft Bushing Front Housing R15196 2. (a) Thickness Height INSPECT VANE PUMP ROTOR AND VANE PLATES Using a micrometer, measure the height, thickness and length of the plates. 5S–FE and 1MZ–FE Engines: Minimum height: 8.6 mm (0.339 in.) Minimum thickness: 1.397 mm (0.0550 in.) Minimum length: 14.991 mm (0.5902 In.) Length N00372 (b) Using a feeler gauge, measure the clearance between the rotor groove and plate. 5S–FE and 1MZ–FE Engines: Maximum clearance: 0.035 mm (0.0014 in.) If it is more than the maximum, replace the plate and/or rotor with one having the same mark stamped on the cam ring. Feeler Gauge R10282 Author: Date: 2118 SR–24 STEERING – POWER STEERING VANE PUMP 5S–FE and 1MZ–FE Engines: Inscribed mark: 1, 2, 3, 4 or None HINT: There are 5 vane lengths with the following rotor and cam ring marks: 5S–FE and 1MZ–FE Engines: Inscribed Mark Rotor and cam ring mark Vane plate part number Vane plate length mm (in.) None 44345–26010 14.999–15.001 (0.59051–0.59059) 1 44345–26020 14.997–14.999 (0.59043–0.59051) 2 44345–26030 14.995–14.997 (0.59035–0.59043) 3 44345–26040 14.993–14.995 (0.59027–0.59035) 4 44345–26050 14.991–14.993 (0.59020–0.59027) R13897 3. (a) INSPECT FLOW CONTROL VALVE Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. (b) Check the valve for leakage. Close one of the holes and apply 392–490 kPa (4–5 kgf/cm2, 57–71 psi) of compressed air into the opposite side, and confirm that air does not come out from the end holes. R11288 Compressed Air R07591 If necessary, replace the valve with one having the same letter as inscribed on the front housing. 5S–FE and 1MZ–FE Engines: Inscribed mark: A, B, C, D, E or F Inscribed Mark R11563 Author: Date: 2119 SR–25 STEERING – POWER STEERING VANE PUMP 4. INSPECT SPRING Using a calipers, measure the free length of the spring. 5S–FE and 1MZ–FE Engines: Minimum free length: 32.3 mm (1.272 in.) If it is not within the specification, replace the spring. Calipers R08702 5. (a) IF NECESSARY, REPLACE OIL SEAL Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the front housing. Vinyl Tape R11290 (b) (c) Press SST Oil Seal Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950–60010 (09951–00330), 09950–70010 (09951–07100) NOTICE: Make sure to install the oil seal facing the correct direction. W03541 Author: Date: 2120 SR–26 STEERING – POWER STEERING VANE PUMP SR06R–01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID (See page SR–18) 2. INSTALL VANE PUMP SHAFT 3. INSTALL STRAIGHT PINS Using a plastic hammer, tap in 2 new pins. NOTICE: Be careful not to damage the pins. 4. INSTALL CAM RING Align the holes of the ring and 2 straight pins, and install the ring with the inscribed mark facing outward. Inscribed Mark 5. (a) (b) INSTALL VANE PUMP ROTOR Install the rotor with the inscribed mark facing outward. Install a new snap ring to the vane pump shaft. R13458 6. INSTALL VANE PLATES Install the 10 plates with the round end facing outward. 7. INSTALL GASKET Install a new gasket. 8. INSTALL SIDE PLATE Align the holes of the plate and 2 straight pins. Round End R01149 R11292 9. INSTALL WAVE WASHER Install the washer so that its protrusions fit into the slots in the side plate. 10. INSTALL REAR HOUSING (a) Coat 2 new O–rings with power steering fluid and install them to the housing. (b) Torque the 4 bolts. 5S–FE and 1MZ–FE Engines: Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) Author: Date: 2121 SR–27 STEERING – POWER STEERING VANE PUMP 11. INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION (a) Install the valve facing the correct direction. (See page SR–18) (b) Coat a new O–ring with power steering fluid and install it to the union. (c) Torque the union. 5S–FE and 1MZ–FE Engines: Torque: 83 N·m (850 kgf·cm, 62 ft·lbf) 12. INSTALL SUCTION PORT UNION (a) Coat a new O–ring with power steering fluid and install it to the union. (b) Torque the bolt. 5S–FE and 1MZ–FE Engines: Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 13. INSTALL FRONT AND REAR BRACKETS Torque the 3 bolts and 2 nuts. 5S–FE and 1MZ–FE Engines: Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 14. INSTALL VANE PUMP PULLEY Using SST to stop the pulley rotating, torque the nut. SST 09960–10010 (09962–01000, 09963–01000) 5S–FE and 1MZ–FE Engines: Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 15. MEASURE PS VANE PUMP ROTATING TORQUE (See page SR–22) Example 5S–FE Engine : SST W03339 Author: Date: 2122 SR–28 STEERING – POWER STEERING VANE PUMP SR06S–01 INSTALLATION 5S–FE Engine : Pressure Feed Tube Stopper 1MZ–FE Engine : Pressure Feed Tube 1. INSTALL PRESSURE FEED TUBE (a) Torque the union bolt with a new gasket. HINT: Make sure the stopper of the tube is touching the front bracket, as shown, then torque the union bolt. 5S–FE and 1MZ–FE Engines: Torque: 52 N·m (525 kgf·cm, 38 ft·lbf) (b) Install the oil pressure switch to the union bolt. 5S–FE and 1MZ–FE Engines: Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) Stopper W03361 2. INSTALL PS VANE PUMP ASSEMBLY WITH PRESSER FEED TUBE Temporarily tighten the 2 (A and B) bolts. 3. INSTALL DRIVE BELT (a) Adjust drive belt tension. (See page SR–3) Example 5S–FE Engine : A B W03360 (b) 5S–FE Engine : SST 5S–FE Engine: Using SST, torque the A bolt. SST 09249–63010 Torque: 29 N·m (293 kgf·cm, 21 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). Fulcrum Length W03542 Author: Date: 2123 SR–29 STEERING (c) 1MZ–FE Engine : – POWER STEERING VANE PUMP 1MZ–FE Engine: Using SST, torque the A bolt. SST 09249–63010 Torque: 29 N·m (293 kgf·cm, 21 ft·lbf) HINT:
Clamp Engine Wire Fulcrum Length Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
Disconnect the clamp with engine wire. (d) Torque the B bolt. 5S–FE and 1MZ–FE Engines: Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) (e) Connect the connector to the oil pressure switch. NOTICE: Be careful for oil on the connector. SST W03543 4. (a) 5S–FE Engine : SST CONNECT PRESSURE FEED TUBE Using SST, connect the tube. SST 09631–22020 5S–FE Engine: Torque: 32 N·m (326 kgf·cm, 24 ft·lbf) 1MZ–FE Engine: Torque: 20 N·m (203 kgf·cm, 15 ft·lbf) HINT: Fulcrum Length
1MZ–FE Engine : Pressure Feed Tube
(b) SST Fulcrum Length (c) (d) W04221 (e) (f) (g) (h) 5. Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). This torque value is effective in case that SST is parallel to a torque wrench. 5S–FE Engine: Install the clamp to the tube. 5S–FE Engine: Install the 2 clamp plates and 2 holders to the tube. 5S–FE Engine: Install the clamp plate set bolt. 5S–FE Engine: Install the clamp plate set nut. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 1MZ–FE Engine: Install the 2 clamp plates and 2 holders to the tube. 1MZ–FE Engine: Tighten the bolt. 1MZ–FE Engine: Install the 2 clamp plate set nuts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) CONNECT RETURN HOSE Author: Date: 2124 SR–30 STEERING – POWER STEERING VANE PUMP 6. INSTALL FRONT FENDER APRON SEAL RH Tighten the 2 bolts. 7. BLEED POWER STEERING SYSTEM (See page SR–4) Author: Date: 2125 SR–31 STEERING – POWER STEERING GEAR POWER STEERING GEAR SR06T–01 COMPONENTS 19 (195, 14) Stabilizer Bar 19 (195, 14) No.1 Fuel Tube Protector Clamp Plate 10 (100, 7) Intermediate Shaft Assembly 35 (360, 26) 25 (250, 18) *32 (326, 24) 181 (1,850, 134) Return Tube 49 (500, 36) Pressure Feed Tube  181 (1,850, 134) PS Gear Assembly 49 (500, 36)  Cotter pin N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part * For use with SST W03350 Author: Date: 2126 SR–32 STEERING – POWER STEERING GEAR Rack Boot Clip Tie Rod End Rack Housing No.2 Grommet  Clamp Rack Housing No.2 Bracket Lock Nut 74 (750, 54) Rack Housing  Claw Washer 83 (850, 61) *60 (615, 45) Rack End Steering Rack  O–Ring  Teflon Ring  Oil Seal  Cylinder End Stopper Bushing 83 (850, 61) *60 (615, 45)  Wire  Oil Seal 74 (750, 54)  O–Ring N·m (kgf·cm, ft·lbf) : Specified touque  Non–reusable part Molybdenum disulfide lithium base grease Power steering fluid * For use with SST  W04225 Author: Date: 2127 SR–33 STEERING 13 (130, 9) *10 (102, 7) – POWER STEERING GEAR 13 (130, 9) *10 (102, 7) 18 (185, 13) Turn Pressure Tube  O–Ring  Dust Seal Turn Pressure Tube 13 (130, 9) 13 (130, 9) *10 (102, 7) *10 (102, 7)  Control Valve Housing  O–RIng 18 (185, 13)  Oil Seal  Bearing Control Valve Assembly  Teflon Ring
Rack Guide Spring Cap Lock Nut  Oil seal  Bearing  Gasket Rack Guide Seat 69 (700, 51) *50 (513, 37)
Rack Guide Spring Cap Rack Guide Spring Rack Housing Rack Guide  Bearing  Self–Locking Nut 25 (250, 18) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part
Precoated part Molybdenum desulfide lithium base grease Power steering fluid * For use with SST
Rack Housing Cap 59 (600, 43) Z18921 Author: Date: 2128 SR–34 STEERING – POWER STEERING GEAR SR06U–01 REMOVAL 1. 2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD REMOVE STEERING WHEEL PAD (See page SR–11) 3. REMOVE STEERING WHEEL (See page SR–11) 4. DISCONNECT RH AND LH TIE ROD ENDS (See page SA–10) 5. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY (See page SR–11) 6. DISCONNECT CLAMP PLATE Remove the nut. 7. SST W04222 DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST, disconnect the tube. SST 09631–22020 8. DISCONNECT STABILIZER BAR Remove the 4 bolts. HINT: Do not remove the bar. 9. REMOVE NO.1 FUEL TUBE PROTECTOR Remove the 2 bolts and nut. 10. REMOVE PS GEAR ASSEMBLY (a) Remove the 2 gear assembly set bolts and nuts. HINT: Lift up the stabilizer bar and remove the bolts. (b) Remove the gear assembly from the LH of the vehicle. NOTICE: Do not damage the turn pressure tubes. Author: Date: 2129 SR–35 STEERING – POWER STEERING GEAR SR06V–01 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the gear assembly in a vise. SST 09612–00012 SST W04228 2. (a) (b) REMOVE 2 TURN PRESSURE TUBES Using SST, remove the tube. SST 09633–00020 Remove the 2 O–rings from the tube. SST W04229 3. (a) (b) REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS Place matchmarks on the tie rod end and rack end. Loosen the lock nut. Matchmarks R00429 4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS Using a screwdriver, loosen the clamp. NOTICE:
Be careful not to damage the boot.
Mark the RH and LH boots. W04230 5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS (a) Using a screwdriver and hammer, stake back the washer. NOTICE: Avoid any impact to the steering rack. Claw Washer R11644 Author: Date: 2130 SR–36 STEERING – POWER STEERING GEAR (b) Using a spanner (24 mm) to hold the steering rack steady, and using SST, remove the rack end. SST 09922–10010 NOTICE:
Use SST 09922–10010 in the direction shown in the illustration.
Mark the RH and LH rack ends. (c) Remove the washer from the rack end. SST R11645 Rack Guide Spring Cap Lock Nut SST 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the nut. SST 09922–10010 NOTICE: Use SST 09922–10010 in the direction shown in the illustration. R11646 7. Rack Guide Spring Cap (a) (b) 8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE AND RACK GUIDE SEAT Using SST, remove the cap. SST 09631–10021 Remove the seat from the guide. REMOVE RACK HOUSING CAP SST R11647 9. REMOVE SELF–LOCKING NUT Using SST to stop the control valve shaft rotating, remove the nut. SST 09616–00010 10. REMOVE DUST COVER SST R11648 11. (a) Matchmarks (b) (c) REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY Place matchmarks on the valve housing and rack housing. Remove the 2 bolts. Remove the gasket from the rack housing. R11553 Author: Date: 2131 SR–37 STEERING – POWER STEERING GEAR 12. (a) Press Vinyl Tape Shop Rag R11554 REMOVE CONTROL VALVE ASSEMBLY To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. (b) Press out the valve assembly with the oil seal. NOTICE:
Place a shop rag between the valve housing and the blocks.
Be careful not to drop the valve assembly.
Be careful not to damage the oil seal lip. 13. REMOVE OIL SEAL Remove the oil seal from the control valve assembly. 14. Matchmarks (a) REMOVE RACK HOUSING NO.2 BRACKET AND GROMMET Place matchmarks on the bracket and rack housing. (b) (c) Using a screwdriver, pry the clamp of the bracket. Remove the grommet from the bracket. 15. (a) REMOVE CYLINDER END STOPPER Using SST, turn the stopper clockwise until the wire end is visible through the service hole. SST 09631–10021 Using SST, turn the stopper counterclockwise, and remove the wire. SST 09631–10021 R11649 R11650 Cylinder End Stopper Wire (b) SST R11651 Author: Date: 2132 SR–38 STEERING 16. (a) Brass Bar Bushing (b) (c) – POWER STEERING GEAR REMOVE STEERING RACK AND BUSHING Using a brass bar and hammer, tap out the rack with the bushing. Remove the bushing from the rack. Remove the O–ring from the bushing. R11555 17. REMOVE OIL SEAL Using SST, press out the oil seal. SST 09950–60010 (09951–00290), 09950–70010 (09951–07360) SST Oil Seal F01791 Author: Date: 2133 SR–39 STEERING – POWER STEERING GEAR SR06W–01 INSPECTION Dial Indicator NOTICE: When using a vise, do not overtighten it. 1. INSPECT STEERING RACK (a) Using a dial indicator, check the rack for runout and for teeth wear and damage. Maximum runout: 0.03 mm (0.0118 in.) (b) Check the back surface for wear and damage. R10072 Press 2. (a) SST Oil Seal IF NECESSARY, REPLACE OIL SEAL AND BEARING Using SST, press out the oil seal and bearing from the control valve housing. SST 09950–60010 (09951–00250), 09950–70010 (09951–07200) Bearing F01792 (b) (c) Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950–60010 (09951–00180, 09951–00320, 09952–06010), 09950–70010 (09951–07200) NOTICE: Make sure to install the oil seal facing the correct direction. Press SST Bearing SST W03560 (d) Press (e) SST Bearing Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950–60010 (09951–00340), 09950–70010 (09951–07200) F01793 3. (a) Brass Bar IF NECESSARY, REPLACE 2 BEARINGS Using a brass bar and hammer, tap out the bearing from the rack housing. Bearing F01794 Author: Date: 2134 SR–40 STEERING – POWER STEERING GEAR (b) Using SST, press out the bearing from the rack housing. SST 09950–60010 (09951–00260), 09950–70010 (09951–07200) (c) Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950–60010 (09951–00310), 09950–70010 (09951–07200) Press SST Bearing F01795 SST Press (d) Bearing F01796 (e) Press SST (f) Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing. SST 09950–60010 (09951–00320), 09950–70010 (09951–07200) Bearing F01797 4. (a) SST SST Bushing Oil Seal IF NECESSARY, REPLACE OIL SEAL Using SST, remove the oil seal from the bushing. SST 09527–20011, 09612–24014 (09613–22011) NOTICE: Be careful not to damage the bushing. F01798 (b) (c) Press SST Oil Seal Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09950–60010 (09951–00240, 09951–00400, 09952–06010) NOTICE: Make sure to install the oil seal facing the correct direction. SST F01799 Author: Date: 2135 SR–41 STEERING – POWER STEERING GEAR 5. IF NECESSARY, REPLACE TEFLON RING AND O– RING (a) Using a screwdriver, remove the teflon ring and O–ring from the steering rack. NOTICE: Be careful not to damage the groove for the teflon ring. (b) Coat a new O–ring with power steering fluid and install it. R10955 (c) Expand a new teflon ring with your fingers. NOTICE: Be careful not to over–expand the ring. R06172 (d) (e) Coat the ring with power steering fluid. Install the ring to the steering rack, and settle it down with your fingers. N00401 6. (a) Teflon Ring R11572 IF NECESSARY, REPLACE TEFLON RINGS Using a screwdriver, remove the 4 rings from the control valve assembly. NOTICE: Be careful not to damage the grooves for the teflon ring. (b) Expand 4 new teflon rings with your fingers. NOTICE: Be careful not to over–expand the teflon ring. (c) Coat the rings with power steering fluid. (d) Install the rings to the control valve assembly, and settle them down with your fingers. Author: Date: 2136 SR–42 STEERING – POWER STEERING GEAR (e) Carefully slide the tapered end of SST over the rings until the rings fit to the steering rack. SST 09631–20081 NOTICE: Be careful not to damage the rings. SST Teflon Ring R11573 Author: Date: 2137 SR–43 STEERING – POWER STEERING GEAR SR06X–01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. 1. COAT WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE (See pages SR–31) 2. INSTALL OIL SEAL (a) Coat a new oil seal lip with power steering fluid. (b) Using SST, press in the oil seal. SST 09950–60010 (09951–00240, 09951–00430, 09952–06010), 09950–70010 (09951–07360) NOTICE:
Make sure to install the oil seal facing the correct direction.
Take care that the oil seal does not get reversed as you install it. Press SST SST Oil Seal W03561 3. (a) INSTALL STEERING RACK Install SST to the rack. SST 09631–33010 HINT: If necessary, scrape the burrs off the rack teeth end and burnish. (b) Coat the SST with power steering fluid. (c) Install the rack into the rack housing. NOTICE: Be careful not to damage the oil seal lip. (d) Remove SST. Rack Teeth End SST W02101 4. (a) Vinyl Tape R11574 INSTALL BUSHING Coat a new O–ring with power steering fluid and install it to the bushing. (b) To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. (c) Install the bushing. NOTICE:
Make sure to install the bushing facing the correct direction.
Be careful not to damage the oil seal lip. Author: Date: 2138 SR–44 STEERING SST 5. (a) Wire (b) (c) – POWER STEERING GEAR INSTALL CYLINDER END STOPPER Align the installation hole for the wire of the stopper with the slot of the rack housing. Install a new wire into the stopper. Using SST, turn the stopper clockwise 450 ± 50°. SST 09631–10021 Cylinder End Stopper R11656 6. (a) AIR TIGHTNESS TEST Install SST to the rack housing. SST 09631–12071 (b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds. (c) Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. SST R00662 7. INSTALL RACK HOUSING NO.2 BRACKET AND GROMMET Install the grommet to the bracket. (a) HINT: Align the projection of the grommet with the hole of the bracket. (b) Align the matchmarks on the bracket and rack housing. R11657 (c) Place the bracket in a vise and tighten the vise to fasten the clamp. R11658 8. (a) INSTALL CONTROL VALVE ASSEMBLY To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft. (b) Coat the teflon rings with power steering fluid. (c) Install the valve assembly into the valve housing. NOTICE: Be careful not to damage the teflon rings and oil seal. Vinyl Tape R11575 Author: Date: 2139 SR–45 STEERING – POWER STEERING GEAR 9. (a) (b) Press SST Oil Seal W03562 INSTALL OIL SEAL Coat a new oil seal lip with power steering fluid. Using SST, press in the oil seal. SST 09612–22011 NOTICE: Make sure to install the oil seal facing the correct direction. 10. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY (a) Place a new gasket on the rack housing. (b) Align the matchmarks on the valve housing and rack housing. (c) Torque the 2 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 11. INSTALL SELF–LOCKING NUT Using SST to stop the control valve shaft rotating, torque a new nut. SST 09616–00010 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 12. INSTALL DUST COVER SST R11648 13. (a) Punch (b) R11659 (c) 14. (a) (b) (c) INSTALL RACK HOUSING CAP Apply sealant to 2 or 3 threads of the cap. Sealant: Part No.08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque the cap. Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) Using a punch and hammer, stake the 2 parts of the cap. INSTALL RACK GUIDE SEAT, RACK GUIDE, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP Install the seat to the guide. Apply sealant to 2 or 3 threads of the cap. Sealant: Part No.08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Temporarily install the cap. Author: Date: 2140 SR–46 STEERING 15. (a) Rack Guide Spring Cap (b) – POWER STEERING GEAR ADJUST TOTAL PRELOAD To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. Using SST, torque the rack guide spring cap. SST 09631–10021 Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) SST W03098 (c) Using SST, return the cap 12°. SST 09631–10021 (d) Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616–00010 Using SST, loosen the cap until the rack guide spring is not functioning. SST 09631–10021 12° W03099 SST (e) W03100 (f) SST SST Rack Guide Spring Cap Using SST and a torque wrench, tighten the cap until the preload is within specification. SST 09616–00010, 09631–10021 Preload (turning): 0.8 – 1.4 N·m (8 – 14 kgf·cm, 6.9 – 12.2 in.·lbf) W03101 Author: Date: 2141 SR–47 STEERING Rack Guide Spring Cap Lock Nut – POWER STEERING GEAR 16. (a) SST Fulcrum Length SST W03102 INSTALL RACK GUIDE SPRING CAP LOCK NUT Apply sealant to 2 or 3 threads of the nut. Sealant: Part No.08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent (b) Using SST to hold the rack guide spring cap, and using SST, torque the nut. SST 09631–10021, 09922–10010 Torque: 50 N·m (513 kgf·cm, 37 ft·lbf) NOTICE: Use SST 09922–10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (c) Recheck the total preload. Preload (turning): 0.8 – 1.4 N·m (8 – 14 kgf·cm, 6.9 – 12.2 in.·lbf) (d) Remove the RH and LH rack ends. 17. (a) INSTALL RH AND LH CLAW WASHERS AND RACK ENDS Install a new claw washer, and temporarily install the rack end. HINT: Align the claws of the washer with the steering rack grooves. Claw R11667 (b) Fulcrum Length SST R15545 Brass Bar Using a spanner (24 mm) to hold the steering rack steady, and using SST, torque the rack end. SST 09922–10010 Torque: 60 N·m (615 kgf·cm, 45 ft·lbf) NOTICE: Use SST 09922–10010 in the direction shown in the illustration. HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). (c) Using a brass bar and hammer, stake the washer. NOTICE: Avoid any impact to the rack. R11668 Author: Date: 2142 SR–48 STEERING 18. (a) – POWER STEERING GEAR INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS Ensure that the steering rack hole is not clogged with grease. HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned. R11669 2 mm (0.79 in.) or less SST W04223 Fulcrum Length (b) Install the boot. NOTICE: Be careful not to damage or twist the boot. (c) Using SST, tighten the clamp as shown in the illustration. SST 09521–24010 19. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS (a) Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned. (b) After adjusting toe–in, torque the nut. (See page SA–4) Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) 20. (a) SST (b) INSTALL 2 TURN PRESSURE TUBES Coat 2 new O–rings with power steering fluid and install them to the tube. Using SST, install the tube. SST 09633–00020 Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) HINT:
W04231
Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective in case that SST is parallel to a torque wrench. Author: Date: 2143 SR–49 STEERING – POWER STEERING GEAR SR06Y–01 INSTALLATION 1. INSTALL PS GEAR ASSEMBLY (a) Install the gear assembly from the LH of the vehicle. NOTICE: Do not damage the turn pressure tubes. (b) Torque the 2 gear assembly set bolts and nuts. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: Lift up the stabilizer bar and install the bolts. 2. INSTALL NO.1 FUEL TUBE PROTECTOR Install the 2 bolts and nut. 3. CONNECT STABILIZER BAR Torque the 4 bolts. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) SST Fulcrum Length W04224 4. CONNECT PRESSURE FEED AND RETURN TUBES Using SST, connect the tube. SST 09631–22020 Torque: 32 N·m (326 kgf·cm, 24 ft·lbf) HINT:
Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
This torque value is effective in case that SST is parallel to a torque wrench. 5. CONNECT CLAMP PLATE Torque the nut. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 6. CONNECT INTERMEDIATE SHAFT ASSEMBLY (See page SR–16) 7. CONNECT RH AND LH TIE ROD ENDS (See page SA–10) 8. POSITION FRONT WHEELS FACING STRAIGHT AHEAD HINT: Do it with the front of the vehicle jacked up. 9. CENTER SPIRAL CABLE (See page SR–16) 10. INSTALL STEERING WHEEL (a) Install the wheel at straight–ahead position. (b) Temporarily tighten the wheel set nut. (c) Connect the connector. 11. BLEED POWER STEERING SYSTEM (See page SR–4) 12. CHECK STEERING WHEEL CENTER POINT Author: Date: 2144 SR–50 STEERING 13. 14. 15. – POWER STEERING GEAR TORQUE STEERING WHEEL SET NUT Torque: 35 N·m (360 kgf·cm, 26 ft·lbf) INSTALL STEERING WHEEL PAD (See page SR–16) CHECK FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 2145 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U–22 GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. 2. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN–21. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Filler Cap Float Clevis Pin  Gasket Reservoir Tank Boot  Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part N17080 Author: Date: 1 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350–30020 (09350–06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown in the illustration. Piston stroke: 1.40 0.0669 in.) 1.70 mm (0.0551 Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section, for quick reference. 8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) Author: Date: 2 IN–3 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0CN–03 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label A B B01453 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. 5S–FE engine: 1MZ–FE engine: B02122 Author: Date: 3 IN–4 INTRODUCTION – REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO–04 GENERAL INFORMATION FI1066 BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (–) terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. (d) Check hose and wiring connectors to make sure that they are connected securely and correctly. (e) Non–reusable parts (1) Always replace cotter pins, gaskets, O–rings, oil seals, etc. with new ones. (2) Non–reusable parts are indicated in the component illustrations by the ”” symbol. (f) Seal Lock Adhesive Z11554 Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. Author: Date: 4 IN–5 INTRODUCTION – REPAIR INSTRUCTIONS (3) (g) (h) (i) Medium Current Fuse and High Current Fuse Equal Amperage Rating (j) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB V00076 Author: Date: 5 IN–6 INTRODUCTION (k) (l) CORRECT (3) (4) (5) IN0253 (6) WRONG CORRECT (7) (8) IN0252 REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN–8).  Cancel the parking brake on the level place and shift the transmission in Neutral (or N position).  When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels.  When jacking up the rear wheels of the vehicle at first place stoppers before the front wheels.  When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground.  After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) WRONG – To disconnect vacuum hoses, pull off the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission–related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air. Author: Date: 6 IN–7 INTRODUCTION (m) Example (n) IN0002 – REPAIR INSTRUCTIONS Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurement should be made when the engine has cooled down. Author: Date: 7 IN–8 INTRODUCTION – REPAIR INSTRUCTIONS IN0CP–03 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front..................... Front crossmember Rear..................... Rear axle beam CAUTION : When jacking–up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift ........................................... N20619 Author: Date: 8 IN–9 INTRODUCTION – REPAIR INSTRUCTIONS PLATE TYPE LIFT L B Attachment A C HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (A, C).
Align the attachment upper end (B) with the front jack supporting point (L). Attachment dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) N20620 Author: Date: 9 IN–10 INTRODUCTION – FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0CQ–03 PRECAUTION 1. (a) Negative Cable BO4111 (b) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The 1999 CAMRY is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front passenger airbag assembly, side airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI–626). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable from the battery, the SRS may deploy.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back–up power supply from another battery. Author: Date: 10 IN–11 INTRODUCTION – FOR ALL OF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly and seat belt pretensioner should be inspected (See page RS–16, RS–29, and BO–127). (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI–626). (c) SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to SR–16 of this manual concerning correct steering wheel installation. Marks W02655 Author: Date: 11 IN–12 INTRODUCTION (d) Example: – FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin–lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. In addition do not store a steering wheel pad on top of another one. Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS–18). Carry out the operation in a safe place away from electrical noise. Correct Wrong Z13953 Example: Z13950 Author: Date: 12 IN–13 INTRODUCTION (e) – FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–31). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B00696 Example: Z13951 Author: Date: 13 IN–14 INTRODUCTION (f) Example: Correct – FOR ALL OF VEHICLES SIDE AIRBAG ASSEMBLY (1) Always store a removed or new side airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the side airbag assembly and the surface should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the seat before starting work. (6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–42, RS–55). Perform the operation in a safe place away from electrical noise. Wrong B02129 Example: N21642 Author: Date: 14 IN–15 INTRODUCTION (g) – FOR ALL OF VEHICLES SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate, which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See page BO–128). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner. Example: B02121 Author: Date: 15 IN–16 INTRODUCTION (h) (i) – FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. (3) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS–73. Author: Date: 16 IN–17 INTRODUCTION – FOR ALL OF VEHICLES 2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. Author: Date: 17 IN–18 INTRODUCTION – FOR ALL OF VEHICLES 4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND–HELD TESTER CAUTION: Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand–held tester, the OBD II scan tool’s instruction book or TOYOTA hand–held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand– held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand–held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand–held tester. 5. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM NOTICE: When using a 2–wheel drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the front wheels and driving the wheels, always push in the TRAC cut (”TRAC OFF”) switch and turn the TRAC system OFF. TRAC OFF Indicator Light TRAC Cut Switch N21624 Confirm TRAC system is OFF (1) Press the TRAC cut (”TRAC OFF”) switch. (2) Check that the TRAC OFF indicator light comes on when the TRAC system is turned OFF by the TRAC cut switch. HINT: TRAC cut switch is reset after the ignition switch has been turned OFF and ON. The TRAC system can be operated. (3) Begin measurements. N21622 Author: Date: 18 IN–19 INTRODUCTION – (4) FOR ALL OF VEHICLES Press the TRAC cut switch to turn the TRAC to the operative mode and check that the TRAC OFF indicator light goes off. HINT: The SLIP indicator light blinks when the TRAC system in operation. N21623 Author: Date: 19 IN–20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05Y–07 GENERAL INFORMATION A large number of ECU controlled systems are used in the 1999 CAMRY. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: The troubleshooting procedure and how to make use of it are described on the following pages. 1. 5S–FE Engine DI–1 2. 1MZ–FE Engine DI–195 3. A140E Automatic Transaxle DI–387 4. A541E Automatic Transaxle DI–436 5. Anti–Lock Brake System (DENSO made) DI–491 6. Anti–Lock Brake System (BOSCH made) DI–537 7. ABS & Traction Control System DI–572 8. Supplemental Restraint System DI–624 9. Wireless Door Lock Control System DI–800 10.Theft Deterrent System DI–826 11.Cruise Control System DI–868 12.Engine Immobiliser System DI–919 FOR USING OBD II SCAN TOOL OR TOYOTA HAND–HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s Manual. Author: Date: 20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–21 IN05W–08 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop 1 2 1 Ask the customer about the conditions and the environment when the problem occurred. Customer Problem Analysis Symptom Confirmation and Diagnostic Trouble Code Check 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 Diagnostic Trouble Code Chart 5 6 Problem Symptoms Table Circuit Inspection or Parts Inspection 7 Repair 8 Confirmation Test End 4, 5, 6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) Author: Date: 21 IN–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis
What ––––– Vehicle model, system name
When ––––– Date, time, occurrence frequency
Where ––––– Road conditions
Under what conditions? ––––– Running conditions, driving conditions, weather conditions
How did it happen? ––––– Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Drive ability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other No initial combustion Back fire Other High ( Muffler explosion (after–fire) km miles No complete combustion rpm) Low ( rpm) Surging Others Data Problem Constant Sometimes ( times per day/month) Author: Date: 22 INTRODUCTION – IN–23 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the 1999 CAMRY fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the CAMRY. System Diagnostic Trouble Code Check Input Signal Check (Sensor Check)  (with Check Mode)  (with Check Mode)  (with Check Mode)  (with Check Mode)          Engine (5S–FE) Engine (1MZ–FE) Automatic Transaxle (A140E) Automatic Transaxle (A541E) Anti–Lock Brake System (DENSO made) Anti–Lock Brake System (BOSCH made) ABS & Traction Control System Supplemental Restraint System Wireless Door Lock Control System Theft Deterrent System Cruise Control System Engine Immobiliser System Diagnostic Test Mode (Active Test)          In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Diagnostic Trouble Code Check Problem symptoms Same diagnostic trouble code is exist displayed Normal code is displayed Normal Code Display Problem Condition Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem) No problem symptoms exist The problem occurred in the diagnostic circuit in the past Problem symptoms Normal code is exist displayed The problem is still occurring in a place other than in the diagnostic circuit No problem symptoms exist The problem occurred in a place other than in the diagnostic circuit in the past Normal code is displayed Author: Date: 23 IN–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check
Diagnostic trouble code displayed
Problem symptoms exist
Normal code displayed
Problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom Author:
Normal code displayed
No problem symptoms exist System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN–31). Date: 24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–25 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. Swing Slightly PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 Author: Date: 25 IN–26 2 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs. M a l f u n ction NOTICE: (1) Do not heat to more than 60 °C (140 °F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high–humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. HINT: If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B02390 Author: Date: 26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–27 4. DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect area of the problem.
Detection Item Indicates the system of the problem or contents of the problem. DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area MIL* P0100 (DI–24) Mass Air Flow Circuit Malfunction
Open or short in mass air flow meter circuit
Mass air flow meter
ECM P0101 (DI–28) Mass Air Flow Circuit Range/ Performance Problem
Mass air flow meter P0110 (DI–29) Intake Air Temp. Circuit Malfunction
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM P0115 (DI–33) Engine Coolant Temp. Circuit Malfunction
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM P0116 (DI–37) Engine Coolant Temp. Circuit Range/ Performance Problem
Engine coolant temp. sensor
Cooling system Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Throttle/ Pedal Position Sensor/ Switch ”A” Circuit Range / Performance Problem
Throttle position sensor Author: Date: Memory 27 IN–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Problem Symptom
Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE Symptom See page Suspect Area Engine does not crank (Does not start) 1. Starter and starter relay ST–2 ST–17 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI–147 DI–151 IN–29 No complete combustion (Does not start) 1. Fuel pump control circuit DI–151 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI–144 DI–151 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 Hot engine 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit AC–88 idling) 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit Author: Date: 28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–29 6. CIRCUIT INSPECTION How to read and use each page is shown below.
Diagnostic Trouble Code No. and Detection Item
Circuit Description The major role and operation, etc. of the circuit and its component parts are explained. DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more.
Open or short in knock sensor1 circuit
Knock sensor 1 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value.
Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM ECM Knock Sensor 1 GR 12 KNK E6 E1
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 Author: Date: 29 IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
Indicates the position of the ignition switch during the check. ON LOCK Ignition Switch ON Ignition Switch LOCK (OFF) START ACC Ignition Switch ACC Ignition Switch START
Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. INSPECTION PROCEDURE 1 Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–68). (b) Disconnect the E6 connector of ECM. LOCK KNK CHECK: Measure resistance between terminal KNK of ECM connector and body ground. E6 Connector AB0117 A00265 OK: Resistance: 1 MΩ or higher A00255 OK Go to step 3. NG 2 Check knock sensor (See page SF–61). OK Replace knock sensor.
Indicates the place to check the voltage or resistance.
Indicates the connector position to checked, from the front or back side. Wire Harness Check from the connector back side. (with harness) Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.
Indicates the condition of the connector of ECU during the check. KNK E6 Connector E6 Connector Connector being checked is connected. KNK Connector being checked is disconnected. V08425 Author: Date: 30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–31 IN05X–05 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. FI0046 FI0047 FI0048 CONNECTOR CONNECTION AND TERMINAL INSPECTION
For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.
The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, and a connector terminal pulled out, etc. HINT:
It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators
Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. Author: Date: 31 IN–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side 3. (a) ECU Side (b) IN0379 CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. ECU Side Sensor Side IN0378 4. (a) (b) ECU Side Sensor Side IN0380 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. (a) (b) Pull Lightly Looseness of Crimping IN0381 RESISTANCE CHECK (SHORT CIRCUIT CHECK) Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MΩ or higher (c) VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. Author: Date: 32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–33 (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 ECU Sensor C B 1 2 OPEN 1 1 2 2 A 1 2 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section. Z17004 (a) Fig. 2 ECU C 1 2 Sensor B 1 2 A 1 2 Z17005 Fig. 3 ECU Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 B04722 Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig. 2, Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Disconnect connector ”B” and measure the resistance between them. In the case of Fig. 3, Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. Author: Date: 33 IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (b) Fig. 4 Sensor 5V A C 5V B 1 1 1 2 2 2 0V 5V Z17007 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”. Fig. 5 C SHORT B 1 1 2 2 Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”. A 1 2 Z17008 Fig. 6 ECU Sensor C 1 2 B 1 2 A 1 2 Z17009 Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig. 6 Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. Author: Date: 34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–35 (2) Fig. 7 Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 ECU Z17808 Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less Example Ground IN0383 (2) ECU Side Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. Ground W/H Side Ground IN0384 Author: Date: 35 IN–36 INTRODUCTION – TERMS TERMS IN04Q–03 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti–Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air–Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately A/T Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi–Level B/S Bore–Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve CW Curb Weight Author: Date: 36 IN–37 INTRODUCTION – TERMS DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLI Distributorless Ignition DOHC Double Over Head Cam DP Dash Pot DS Dead Soak DSP Digital Signal Processor ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECU Electronic Control Unit ED Electro–Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR–VM Egr–Vacuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E–VRV Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front–Engine Front–Wheel–Drive F/G Fuel Gage FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front FR Front–Engine Rear–Wheel–Drive F/W Flywheel FW/D Flywheel Damper FWD Front–Wheel–Drive GAS Gasoline GND Ground HAC High Altitude Compensator H/B Hatchback H–FUSE High Current Fuse HI High Author: Date: 37 IN–38 INTRODUCTION – TERMS HID High Intensity Discharge (Head Lamp) HSG Housing HT Hard Top HWS Heated Windshield System IAC Idle Air Control IC Integrated circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension J/B Junction Block J/C Junction Connector KD Kick–Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left–Hand LHD Left–Hand Drive L/H/W Length, Height, Width LLC Long–Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MP Multipurpose MPX Multiplex Communication System M/T Manual Transmission MT Mount MTG Mounting N Neutral NA Natural Aspiration No. Number O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft Author: Date: 38 IN–39 INTRODUCTION – TERMS OHV Overhead Valve OPT Option O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PS Power Steering PTO Power Take–Off R&P Rack And Pinion R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RRS Rigid Rear Suspension RH Right–Hand RHD Right–Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear–Engine Rear–Wheel Drive RWD Rear–Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold–Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer–Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Author: Date: 39 IN–40 INTRODUCTION – TERMS TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w/ With WGN Wagon W/H Wire Harness w/o Without 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4x2) 4WD Four Wheel Drive Vehicle (4x4) Author: Date: 40 IN–41 INTRODUCTION – TERMS IN0CI–01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )––ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode – ECL Engine Control Level – ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition TOYOTA Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control – FEEPROM Flash Electrically Erasable Programmable Read Only Memory – FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) – – – Author: Date: 41 IN–42 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E–ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter – Indirect Injection (IDL) – – Author: Date: 42 IN–43 INTRODUCTION – TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three–Way Catalytic Converter Three–Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter – WU–TWC Warm Up Three–Way Catalytic Converter – 3GR Third Gear – 4GR Fourth Gear – – Author: Date: 43 IN–1 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U–30 GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. 2. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN–19. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Filler Cap Float Clevis Pin  Gasket Reservoir Tank Boot  Grommet Slotted Spring Pin Clip 12 (120, 9) Clevis 15 (155, 11) Snap Ring Washer Lock Nut Push Rod Piston Cylinder N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part N17080 Author: Date: 1 IN–2 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Task heading : what to do 21. CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration. SST 09350–30020 (09350–06120) Illustration: what to do and where Set part No. Detailed text : Component part No. how to do task (b) Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown in the illustration. Piston stroke: 1.40 0.0669 in.) 1.70 mm (0.0551 Specification This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 7. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section, for quick reference. 8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently. 9. SI UNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) Author: Date: 2 IN–3 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN0CN–05 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification Label A B B01453 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. 5S–FNE engine: B07931 Author: Date: 3 IN–4 INTRODUCTION – REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN0CO–07 GENERAL INFORMATION FI1066 BASIC REPAIR HINT (a) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. (b) During disassembly, keep parts in the appropriate order to facilitate reassembly. (c) Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative (–) terminal cable from the battery. (2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative (–) terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or other abrasive objects. (5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. (d) Check hose and wiring connectors to make sure that they are connected securely and correctly. (e) Non–reusable parts (1) Always replace cotter pins, gaskets, O–rings, oil seals, etc. with new ones. (2) Non–reusable parts are indicated in the component illustrations by the ”” symbol. (f) Seal Lock Adhesive Z11554 Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. Author: Date: 4 IN–5 INTRODUCTION – REPAIR INSTRUCTIONS (3) (g) (h) (i) Medium Current Fuse and High Current Fuse Equal Amperage Rating (j) Precoated parts are indicated in the component illustrations by the ”
” symbol. When necessary, use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. BE1367 Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE LINK FL CIRCUIT BREAKER CB V00076 Author: Date: 5 IN–6 INTRODUCTION (k) (l) CORRECT (3) (4) (5) IN0253 (6) WRONG CORRECT (7) (8) IN0252 REPAIR INSTRUCTIONS Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN–8).  Cancel the parking brake on the level place and shift the transmission in Neutral (or N position).  When jacking up the front wheels of the vehicle at first place stoppers behind the rear wheels.  When jacking up the rear wheels of the vehicle at first place stoppers before the front wheels.  When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground.  After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (2) WRONG – To disconnect vacuum hoses, pull off the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When steam cleaning an engine, protect the electronic components, air filter and emission–related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter for adjustment. Once the hose has been stretched, it may leak air. Author: Date: 6 IN–7 INTRODUCTION (m) Example (n) IN0002 – REPAIR INSTRUCTIONS Installation and removal of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identify how they should be reconnected to. (2) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. Unless otherwise stated, all resistance is measured at an ambient temperature of 20°C (68°F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurement should be made when the engine has cooled down. Author: Date: 7 IN–8 INTRODUCTION – REPAIR INSTRUCTIONS IN0CP–05 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front..................... Front crossmember Rear..................... Rear axle beam CAUTION : When jacking–up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift ........................................... N20619 IN–9 INTRODUCTION – REPAIR INSTRUCTIONS PLATE TYPE LIFT L B Attachment A C HINT : Left and right set position Place the vehicle over the center of the lift. Front and rear set position
Align the cushion gum ends of the plate with the attachment lower ends (A, C).
Align the attachment upper end (B) with the front jack supporting point (L). Attachment dimensions 85 mm (3.35 in.) 70 mm (2.76 in.) 100 mm (3.94 in.) 200 mm (7.87 in.) N20620 IN–10 INTRODUCTION – FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0DW–01 PRECAUTION 1. (a) Negative Cable BO4111 (b) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The 1999 CAMRY CNG is equipped with an SRS (Supplemental Restraint System), such as the driver airbag, front passenger airbag assembly and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page DI–223). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable from the battery, the SRS may deploy.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back–up power supply from another battery. Author: Date: 10 IN–11 INTRODUCTION – FOR ALL OF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly and seat belt pretensioner should be inspected (See Pub. No. RM654U on page SR–16, RS–29 and BO–127). (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (5) Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. (6) Never disassemble and repair the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) After work on the supplemental restraint system is completed, check the SRS warning light (See page DI–223). (c) Marks SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to 1999 CAMRY REPAIR MANUAL (Pub. No. RM654U on page SR–16) concerning correct steering wheel installation. W02655 Author: Date: 11 IN–12 INTRODUCTION (d) Example: – FOR ALL OF VEHICLES STEERING WHEEL PAD (with Airbag) (1) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin–lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. In addition do not store a steering wheel pad on top of another one. Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. (4) Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. (6) When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See Pub. No. RM654U on page RS–18). Carry out the operation in a safe place away from electrical noise. Correct Wrong Z13953 Example: Z13950 Author: Date: 12 IN–13 INTRODUCTION (e) – FOR ALL OF VEHICLES FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. (4) Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. (5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. (6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See Pub. No. RM654U on page RS–31). Perform the operation in a safe place away from electrical noise. Example: Correct Wrong B00696 Example: Z13951 Author: Date: 13 IN–14 INTRODUCTION (f) – FOR ALL OF VEHICLES SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate, which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal (See Pub. No. RM654U on page BO–128). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner. Example: B02121 Author: Date: 14 IN–15 INTRODUCTION (g) (h) – FOR ALL OF VEHICLES AIRBAG SENSOR ASSEMBLY (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. (3) Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS–73 in Pub. No. RM654U . Author: Date: 15 IN–16 INTRODUCTION – FOR ALL OF VEHICLES 2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned compressed neutral gas (CNG) flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. (a) Use only unleaded compressed neutral gas (CNG). (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c) Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (d) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (e) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off. (g) Do not dispose of used catalyst along with parts contaminated with neutral gas or oil. 3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. Author: Date: 16 IN–17 INTRODUCTION – FOR ALL OF VEHICLES 4. FOR USING OBD II SCAN TOOL OR HAND–HELD TESTER CAUTION: Observe the following items for safety reasons:
Before using the OBD II scan tool or hand–held tester, the OBD II scan tool’s instruction book or hand–held tester’s operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or hand–held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
Two persons are required when test driving with the OBD II scan tool or hand–held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or hand–held tester. Author: Date: 17 IN–18 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN05Y–10 GENERAL INFORMATION A large number of ECU controlled systems are used in the 1999 CAMRY CNG. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: The troubleshooting procedure and how to make use of it are described on the following pages. 1. Engine DI–1 2. Automatic Transaxle DI–131 3. Anti–Lock Brake System DI–175 4. Supplemental Restraint System DI–221 5. Cruise Control System DI–317 FOR USING OBD II SCAN TOOL OR HAND–HELD TESTER
Before using the scan tool or tester, the scan tool’s instruction book or tester’s operator manual should be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis data link line (Bus
line) or ECU power circuit of the vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s Manual. Author: Date: 18 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–19 IN05W–12 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop 1 2 1 Ask the customer about the conditions and the environment when the problem occurred. Customer Problem Analysis Symptom Confirmation and Diagnostic Trouble Code Check 3 Symptom Simulation 2, 3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 Diagnostic Trouble Code Chart 5 6 Problem Symptoms Table Circuit Inspection or Parts Inspection 7 Repair 8 Confirmation Test End 4, 5, 6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table. 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) IN–20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis
What ––––– Vehicle model, system name
When ––––– Date, time, occurrence frequency
Where ––––– Road conditions
Under what conditions? ––––– Running conditions, driving conditions, weather conditions
How did it happen? ––––– Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet Inspector’s Name Model and Model Year Driver’s Name Frame No. Data Vehicle Brought in Engine Model License No. Odometer Reading Problem Symptoms Customer’s Name Engine does not Start Engine does not crank Difficult to Start Engine cranks slowly Other Poor Idling Incorrect first idle Idling rpm is abnormal Rough idling Other Poor Drive ability Hesitation Knocking Engine Stall Soon after starting After accelerator pedal depressed After accelerator pedal released During A/C operation Shifting from N to D Other No initial combustion Back fire Other High ( Muffler explosion (after–fire) Others Data Problem Constant Sometimes ( times per day/month) km miles No complete combustion rpm) Low ( Surging rpm) INTRODUCTION – IN–21 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the 1999 CAMRY CNG fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the 1999 CAMRY CNG. System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Diagnostic Test Mode (Active Test)  (with Check Mode)  (with Check Mode)      Engine Automatic Transaxle Anti–Lock Brake System Supplemental Restraint System Cruise Control System   In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Diagnostic Trouble Code Check Problem symptoms Same diagnostic trouble code is exist displayed Normal code is displayed Normal Code Display Problem Condition Problem is still occurring in the diagnostic circuit The problem is still occurring in a place other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem) No problem symptoms exist The problem occurred in the diagnostic circuit in the past Problem symptoms Normal code is exist displayed The problem is still occurring in a place other than in the diagnostic circuit No problem symptoms exist The problem occurred in a place other than in the diagnostic circuit in the past Normal code is displayed IN–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation Problem symptoms exist No problem symptoms exist Simulation test using the symptom simulation methods Diagnostic trouble code check
Diagnostic trouble code displayed
Problem symptoms exist
Normal code displayed
Problem symptoms exist Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom
Normal code displayed
No problem symptoms exist System Normal If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN–29). INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–23 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. Shake Slightly WIRE HARNESS Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. Swing Slightly PARTS AND SENSOR Vibrate Slightly Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. V07268 IN–24 2 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs. M a l f u n ction NOTICE: (1) Do not heat to more than 60 °C (140 °F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. 3 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high–humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic components. HINT: If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken. 4 OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. ON B02389 B02390 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–25 4. DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.
DTC No. Indicates the diagnostic trouble code.
Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.
Trouble Area Indicates the suspect area of the problem.
Detection Item Indicates the system of the problem or contents of the problem. DTC CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. If a malfunction code is displayed during the DTC check mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the ”See page” for the respective ”DTC No.” in the DTC chart. DTC No. (See page) Detection Item Trouble Area P0100 (DI–24) Mass Air Flow Circuit Malfunction
Open or short in mass air flow meter circuit
Mass air flow meter
ECM P0101 (DI–28) Mass Air Flow Circuit Range/ Performance Problem
Mass air flow meter P0110 (DI–29) Intake Air Temp. Circuit Malfunction
Open or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM P0115 (DI–33) Engine Coolant Temp. Circuit Malfunction
Open or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM P0116 (DI–37) Engine Coolant Temp. Circuit Range/ Performance Problem
Engine coolant temp. sensor
Cooling system Throttle/ Pedal Position Sensor/Switch ”A” Circuit Malfunction
Open or short in throttle position sensor circuit
Throttle position sensor
ECM Throttle/ Pedal Position Sensor/ Switch ”A” Circuit Range / Performance Problem
Throttle position sensor MIL* Memory IN–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 5. PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system.
Page Indicates the page where the flow chart for each circuit is located.
Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.
Problem Symptom
Circuit or Part Name Indicates the circuit or part which needs to be checked. PROBLEM SYMPTOMS TABLE Symptom Suspect Area See page Engine does not crank (Does not start) 1. Starter and starter relay ST–2 ST–17 No initial combustion (Does not start) 1. ECM power source circuit 2. Fuel pump control circuit 3. Engine control module (ECM) DI–147 DI–151 IN–29 No complete combustion (Does not start) 1. Fuel pump control circuit DI–151 Engine cranks normally (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit 3. Compression DI–144 DI–151 EM–3 Cold engine (Difficult to start) 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 Hot engine 1. Starter signal circuit 2. Fuel pump control circuit DI–144 DI–151 High engine idle speed (Poor idling) 1. A/C signal circuit (Compressor circuit) 2. ECM power source circuit AC–88 idling) 1. A/C signal circuit 2. Fuel pump control circuit 1. Compression 2. Fuel pump control circuit INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–27 6. CIRCUIT INSPECTION How to read and use each page is shown below.
Diagnostic Trouble Code No. and Detection Item
Circuit Description The major role and operation, etc. of the circuit and its component parts are explained. DTC P0325 Knock Sensor 1 Circuit Malfunction CIRCUIT DESCRIPTION Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. P0325 DTC Detecting Condition Trouble Area No knock sensor 1 signal to ECM with engine speed, 1,200 rpm or more.
Open or short in knock sensor1 circuit
Knock sensor 1 (looseness)
ECM If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle value is set to the maximum value.
Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM ECM Knock Sensor 1 GR 12 KNK E6 E1
Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. V08423 IN–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
Indicates the position of the ignition switch during the check. ON LOCK Ignition Switch ON Ignition Switch LOCK (OFF) START ACC Ignition Switch ACC Ignition Switch START
Inspection Procedure Use the inspection procedure to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sensors, actuators, wire harness or ECU. INSPECTION PROCEDURE 1 Check continuity between terminal KNK of ECM connector and body ground. PREPARATION: (a) Remove the glove compartment (See page SF–68). (b) Disconnect the E6 connector of ECM. LOCK KNK CHECK: Measure resistance between terminal KNK of ECM connector and body ground. E6 Connector AB0117 A00265 OK: Resistance: 1 MΩ or higher A00255 OK Go to step 3. NG 2 Check knock sensor (See page SF–61). OK Replace knock sensor.
Indicates the place to check the voltage or resistance.
Indicates the connector position to checked, from the front or back side. Wire Harness Check from the connector back side. (with harness) Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.
Indicates the condition of the connector of ECU during the check. KNK E6 Connector Connector being checked is connected. KNK E6 Connector Connector being checked is disconnected. V08425 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–29 IN05X–10 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. FI0046 FI0047 FI0048 CONNECTOR CONNECTION AND TERMINAL INSPECTION
For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.
When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.
The instructions ”Check wire harness and connector” and ”Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, and a connector terminal pulled out, etc. HINT:
It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators
Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 2. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. FI7187 Sensor Side 3. (a) ECU Side (b) IN0379 CONTINUITY CHECK (OPEN CIRCUIT CHECK) Disconnect the connectors at both ECU and sensor sides. Measure the resistance between the applicable terminals of the connectors. Resistance: 1 Ω or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. ECU Side Sensor Side IN0378 4. (a) (b) ECU Side Sensor Side IN0380 HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5. (a) (b) Pull Lightly Looseness of Crimping IN0381 RESISTANCE CHECK (SHORT CIRCUIT CHECK) Disconnect the connectors on both ends. Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MΩ or higher (c) VISUAL CHECK AND CONTACT PRESSURE CHECK Disconnect the connectors at both ends. Check for rust or foreign material, etc. in the terminals of the connectors. Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–31 (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. Fig. 1 ECU Sensor C B 1 2 OPEN 1 1 2 2 A 1 2 6. CHECK OPEN CIRCUIT For the open circuit in the wire harness in Fig. 1, perform ”(a) Continuity Check” or ”(b) Voltage Check” to locate the section. Z17004 (a) Fig. 2 ECU C 1 2 Sensor B 1 2 A 1 2 Z17005 Fig. 3 ECU Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 B04722 Check the continuity. (1) Disconnect connectors ”A” and ”C” and measure the resistance between them. In the case of Fig. 2, Between terminal 1 of connector ”A” and terminal 1 of connector ”C” → No continuity (open) Between terminal 2 of connector ”A” and terminal 2 of connector ”C” → Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. (2) Disconnect connector ”B” and measure the resistance between the connectors. In the case of Fig. 3, Between terminal 1 of connector ”A” and terminal 1 of connector ”B1” → Continuity Between terminal 1 of connector ”B2” and terminal 1 of connector ”C” → No continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. IN–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS (b) Fig. 4 Sensor 5V A C 5V B 1 1 1 2 2 2 0V 5V Z17007 7. CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ”continuity check with ground”. Fig. 5 C SHORT B 1 1 2 2 Check the voltage. In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ”A” at the ECU 5V output terminal, terminal 1 of connector ”B”, and terminal 1 of connector ”C”, in that order. If the results are: 5V: Between Terminal 1 of connector ”A” and Body Ground 5V: Between Terminal 1 of connector ”B” and Body Ground 0V: Between Terminal 1 of connector ”C” and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ”B” and terminal 1 of ”C”. A 1 2 Z17008 Fig. 6 ECU Sensor C 1 2 B 1 2 A 1 2 Z17009 Check the continuity with ground. (1) Disconnect connectors ”A” and ”C” and measure the resistance between terminal 1 and 2 of connector ”A” and body ground. In the case of Fig. 6 Between terminal 1 of connector ”A” and body ground → Continuity (short) Between terminal 2 of connector ”A” and body ground → No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector ”A” and terminal 1 of connector ”C”. INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–33 (2) Fig. 7 Sensor C 1 2 B2 1 2 B1 1 2 A 1 2 ECU Z17808 Disconnect connector ”B” and measure the resistance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. Between terminal 1 of connector ”A” and body ground → No continuity Between terminal 1 of connector ”B2” and body ground → Continuity (short) Therefore, it is found out that there is a short circuit between terminal 1 of connector ”B2” and terminal 1 of connector ”C”. 8. CHECK AND REPLACE ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 Ω or less Example Ground IN0383 (2) ECU Side Ground W/H Side Ground IN0384 Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. IN–34 INTRODUCTION – TERMS TERMS IN04Q–03 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning ABS Anti–Lock Brake System AC Alternating Current ACC Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential A/F Air–Fuel Ratio AHC Active Height Control Suspension ALR Automatic Locking Retractor ALT Alternator AMP Amplifier ANT Antenna APPROX. Approximately A/T Automatic Transmission (Transaxle) ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B/L Bi–Level B/S Bore–Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif. California CB Circuit Breaker CCo Catalytic Converter For Oxidation CD Compact Disc CF Cornering Force CG Center Of Gravity CH Channel COMB. Combination CPE Coupe CPS Combustion Pressure Sensor CPU Central Processing Unit CRS Child Restraint System CTR Center C/V Check Valve CV Control Valve CW Curb Weight Author: Date: 34 IN–35 INTRODUCTION – TERMS DC Direct Current DEF Defogger DFL Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection DLI Distributorless Ignition DOHC Double Over Head Cam DP Dash Pot DS Dead Soak DSP Digital Signal Processor ECAM Engine Control And Measurement System ECD Electronic Controlled Diesel ECDY Eddy Current Dynamometer ECU Electronic Control Unit ED Electro–Deposited Coating EDU Electronic Driving Unit EDIC Electric Diesel Injection Control EFI Electronic Fuel Injection E/G Engine EGR–VM Egr–Vacuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E–VRV Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front–Engine Front–Wheel–Drive F/G Fuel Gage FIPG Formed In Place Gasket FL Fusible Link F/P Fuel Pump FPU Fuel Pressure Up Fr Front FR Front–Engine Rear–Wheel–Drive F/W Flywheel FW/D Flywheel Damper FWD Front–Wheel–Drive GAS Gasoline GND Ground HAC High Altitude Compensator H/B Hatchback H–FUSE High Current Fuse HI High Author: Date: 35 IN–36 INTRODUCTION – TERMS HID High Intensity Discharge (Head Lamp) HSG Housing HT Hard Top HWS Heated Windshield System IAC Idle Air Control IC Integrated circuit IDI Indirect Diesel Injection IFS Independent Front Suspension IG Ignition IIA Integrated Ignition Assembly IN Intake (Manifold, Valve) INT Intermittent I/P Instrument Panel IRS Independent Rear Suspension J/B Junction Block J/C Junction Connector KD Kick–Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left–Hand LHD Left–Hand Drive L/H/W Length, Height, Width LLC Long–Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP & PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensing Proportioning Valve MAX. Maximum MIC Microphone MIL Malfunction Indicator Lamp MIN. Minimum MP Multipurpose MPX Multiplex Communication System M/T Manual Transmission MT Mount MTG Mounting N Neutral NA Natural Aspiration No. Number O/D Overdrive OEM Original Equipment Manufacturing OHC Overhead Camshaft Author: Date: 36 IN–37 INTRODUCTION – TERMS OHV Overhead Valve OPT Option O/S Oversize P & BV Proportioning And Bypass Valve PCS Power Control System PCV Positive Crankcase Ventilation PKB Parking Brake PPS Progressive Power Steering PS Power Steering PTO Power Take–Off R&P Rack And Pinion R/B Relay Block RBS Recirculating Ball Type Steering R/F Reinforcement RFS Rigid Front Suspension RRS Rigid Rear Suspension RH Right–Hand RHD Right–Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear–Engine Rear–Wheel Drive RWD Rear–Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Injection SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard STJ Cold–Start Fuel Injection SW Switch SYS System T/A Transaxle TACH Tachometer TBI Throttle Body Electronic Fuel Injection TC Turbocharger TCCS TOYOTA Computer–Controlled System TCV Timing Control Valve TDC Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Author: Date: 37 IN–38 INTRODUCTION – TERMS TIS Total Information System For Vehicle Development T/M Transmission TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky, Inc. TRAC Traction Control System TURBO Turbocharge U/D Underdrive U/S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control Vehicle Stability Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w/ With WGN Wagon W/H Wire Harness w/o Without 1st First 2nd Second 2WD Two Wheel Drive Vehicle (4x2) 4WD Four Wheel Drive Vehicle (4x4) Author: Date: 38 IN–39 INTRODUCTION – TERMS IN0CI–01 GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their TOYOTA equivalents. SAE ABBREVIATIONS TOYOTA TERMS ( )––ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner, A/CL AIR Secondary Air Injection Air Injection (AI) AP Accelerator Pedal B+ Battery Positive Voltage +B, Battery Voltage BARO Barometric Pressure HAC CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle CL Closed Loop Closed Loop CMP Camshaft Position Cam Angle CPP Clutch Pedal Position – CTOX Continuous Trap Oxidizer – CTP Closed Throttle Position LL ON, Idle ON DFI Direct Fuel Injection (Diesel) Direct Injection (DI) DI Distributor Ignition DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Total Diagnosis Comunication Link (TDCL) 3: OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode – ECL Engine Control Level – ECM Engine Control Module Engine ECU (Electronic Control Unit) ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EGR Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) EI Electronic Ignition TOYOTA Distributorless Ignition (TDI) EM Engine Modification Engine Modification (EM) EPROM Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) EVAP Evaporative Emission Evaporative Emission Control (EVAP) FC Fan Control – FEEPROM Flash Electrically Erasable Programmable Read Only Memory – FEPROM Flash Erasable Programmable Read Only Memory – FF Flexible Fuel – FP Fuel Pump Fuel Pump GEN Generator Alternator GND Ground Ground (GND) – – – IN–40 INTRODUCTION – TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO2S) IAC Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IFI Indirect Fuel Injection IFS Inertia Fuel–Shutoff – ISC Idle Speed Control – KS Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum MC Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI Multiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Lamp MST Manifold Surface Temperature – MVZ Manifold Vacuum Zone – NVRAM Non–Volatile Random Access Memory – O2S Oxygen Sensor Oxygen Sensor, O2 Sensor (O2S) OBD On–Board Diagnostic On–Board Diagnostic System (OBD) OC Oxidation Catalytic Converter Oxidation Catalyst Convert (OC), CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module – PNP Park/Neutral Position – PROM Programmable Read Only Memory – PSP Power Steering Pressure – PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) RM Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed SC Supercharger Supercharger SCB Supercharger Bypass E–ABV SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter – SRI Service Reminder Indicator – SRT System Readiness Test – ST Scan Tool – TB Throttle Body Throttle Body TBI Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) TC Turbocharger Turbocharger TCC Torque Converter Clutch Torque Converter – Indirect Injection (IDL) – – IN–41 INTRODUCTION – TERMS TCM Transmission Control Module Transmission ECU, ECT ECU TP Throttle Position Throttle Position TR Transmission Range TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three–Way Catalytic Converter Three–Way Catalytic (TWC) Manifold Converter CCRO TWC+OC Three–Way + Oxidation Catalytic Converter CCR + CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter – WU–TWC Warm Up Three–Way Catalytic Converter – 3GR Third Gear – 4GR Fourth Gear – – FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 1999 CAMRY CNG. Applicable models: SXV 23 Series For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals; Manual Name
1999 CAMRY Repair Manual Volume 1 Volume 2
1999 CAMRY CNG Repair Manual Supplement
1999 CAMRY CNG New Car Features Pub. No. RM654U1 RM654U2 RM683U NCF167U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. NOTICE When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction. A INTRODUCTION This manual consists of the following 13 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. I GROUND POINT Shows ground positions of all parts described in this manual. J POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. K CONNECTOR LIST Describes the form of the connectors for the parts appeared in this book. This section is closely related to the system circuit. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. M OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. A H HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Point section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. B HOW TO USE THIS MANUAL ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 66) ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, [C] 15A STOP 7. 5A GAUGE 4 IB 2 1 ,,,, @@@@ €€€€ ÀÀÀÀ @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, 7 3C [G] 15 3C R–L W–R R (W/G) 3 IB L (S/D) [B] R–L 4 2 C7 REAR LIGHTS WARNING LIGHT [COMB. METER] S6 STOP LIGHT SW 14 [E] IE1 13 1 G–W [D] L (S/D) I5 [F] G–W Y–G G–W TO ABS ECU [H] 7 L4 LIGHT FAILURE SENSOR 8 DELAY CIRCUIT [J] B18 H17 HIGH MOUNTED STOP LIGHT [L] 1 W–B B18 W–B 1 BV1 W–B W–B W–B 3 2 BO 50 [N] [M] BL W–B 4 [K] (SHIELDED) R6 STOP LIGHT RH [REAR COMB. LIGHT LH] R7 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R G–R G–R 1 BV1 3 11 G [I] 4 1 G–R 2 4 B [I] [A] : System Title [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example: Indicates Relay Block No.1 : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red G = Green LG = Light Green [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. P Y GR = Gray [D] : Indicates related system. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. [E] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. = Pink = Yellow O = Orange Example: L–Y L (Blue) Female Male ( ) Y (Yellow) [J] : Indicates a wiring Splice Point (Codes are ”E” for the Engine Room, ”I” for the Instrument Panel, and ”B” for the Body). The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, No.3 ,,,, ,,,, The Location of splice Point I 5 is indicated by the shaded section. [K] : Indicates a shielded cable. [L] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order from upper left to lower right Female Numbered in order from upper right to lower left Male [M] : Indicates a ground point. [H] : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. [N] : Page No. B HOW TO USE THIS MANUAL [O] SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] SERVICE HINTS S6 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed L4 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : Approx. 12 volts with the stop light SW on 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON position 11–GROUND : Always continuity [Q] : PARTS LOCATION Code See Page See Page Code See Page 34 L4 36 R7 37 H17 36 R6 37 S6 35 : RELAY BLOCKS [R] Code 1 [S] Code C7 @@@ €€€ ÀÀÀ ,,, ,,, @@@ €€€ ÀÀÀ ,,, @@@ €€€ ÀÀÀ Code See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Left) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR See Page Junction Block and Wire Harness (Connector Location) IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Left Side) [T] : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel) BV1 50 Luggage Room Wire and Floor Wire (Luggage Compartment Left) [U] : GROUND POINTS Code See Page Ground Points Location BL 50 Under the Left Quarter Pillar BO 50 Back Panel Center [V] : SPLICE POINTS Code I5 See Page 44 Wire Harness with Splice Points Cowl Wire Code B18 See Page 50 Wire Harness with Splice Points Luggage Room Wire B [O] : Explains the system outline. [P] : Indicates values or explains the function for reference during troubleshooting. [Q] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual. ∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example : L 4 Á Á Parts is 4th in order Light Failure Sensor [R] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [S] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [T] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [U] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center. [V] : Indicates the reference page showing the position of the splice points on the vehicle. Example : Splice point ”I5” is on the Cowl Wire Harness and is described on page 44 of this manual. B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( EA , IB and IC shown below) can also be checked this way. I GROUND POINT FAN MAIN RELAY 5 A/C FAN RELAY NO.2 5 A/C FAN RELAY NO.3 5 E3 O/D MAIN SW E3 CLOCK W–B W–B A A A A E5 E6 W–B FRONT SIDE MARKER LIGHT RH W–B FRONT SIDE MARKER LIGHT LH W–B BRAKE FLUID LEVEL WARNING SW W–B W–B ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, W–B I4 W–B 2 IA1 B4 COMBINATION METER W–B 1 3D W–B CRUISE CONTROL MIRROR SW 3 3F W–B REMOTE CONTROL MIRROR SW 13 3G W–B TURN SIGNAL FLASHER 5 W–B 3E I2 REAR WINDOW DEFOGGER SW 6 3E I2 LIGHT CONTROL SW [COMB. SW] WIPER AND WASHER SW [COMB. SW] W–B I5 15 ID1 W–B W–B I5 W–B W–B BLOWER RESISTOR 8 IB1 W–B I8 W–B A/C AMPLIFIER 4 4 POWER WINDOW CONTROL RELAY B5 DOOR KEY LOCK SW LH B5 DOOR LOCK CONTROL SW FUEL CONTROL SW 3 IC3 I5 W–B WOOFER AMPLIFIER BR COMBINATION METER 4 BR BR 4 I3 BR I3 COMBINATION METER BR FUEL SENDER W–B 4 BR BR 5 BA1 W–B AUTO ANTENNA MOTOR B5 (4A–GZE) W–B HEATER RELAY POWER WINDOW MASTER SW I5 4 W–B BR B5 DOOR LOCK MOTOR LH W–B 4 RADIO AND PLAYER UNLOCK WARNING SW W–B W–B HORN SW [COMB. SW] DIMMER SW [COMB. SW] I2 W–B 10 EA2 I4 BLOWER SW I5 W–B B4 W–B I6 W–B EA ELECTRICAL IDLE−UP CUT RELAY (M/T) HEATER SERVO MOTOR AMPLIFIER PARKING BRAKE SW 7 W–B 3C E4 B4 I6 W–B 7 3B W–B DOOR LOCK MOTOR RH A E5 E4 W–B HEATER CONTROL ASSEMBLY J1 JUNCTION CONNECTOR W–B W–B W–B E4 W–B DOOR KEY LOCK SW RH A E2 E4 W–B W–B E3 W–B DOOR LOCK CONTROL SW RH DOOR LOCK CONTROL RELAY CIGARETTE LIGHTER E3 W–B RETRACT MOTOR LH PARKING LIGHT LH W–B W–B RETRACT MOTOR RH FRONT TURN SIGNAL LIGHT LH W–B W–B RETRACT CONTROL RELAY PARKING LIGHT RH W–B W–B RADIATOR FAN MOTOR FRONT TURN SIGNAL LIGHT RH W–B W–B 5 W–B FAN MAIN RELAY IB ∗ IC The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. J POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. 10A ECU–B Short Pin 2 2 7.5A DOME 15A EFI Battery 30A AM2 Fusible Link Block 2 10A HAZARD 6 2 20A RADIO NO.1 Starter S2 10A HORN 100A ALT 60A ABS 6 5 Engine Room R/B (See Page 20) Fuse 20A 10A System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission and A/T Indicator Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter and Clock Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off Theft Deterrent and Door Lock Control 214 230 112 122 POWER SOURCE 40A DOOR LOCK CB 1.25B FL MAIN W W W 2 2 7 EB1 W W B W B 1 7.5A DOME I2 50A MAIN E7 2 W–L W W W I2 1 1 R W I2 1 B W 1 W B 2 2 4 W–B 2 B 4 B B 2 3 2 4 1 2 1 W–B 2 2 3 B–W 1 3 2 G 15A TAIL 1 20A DEFOG B–Y 1 G W–R 1 B 2 1 4 I8 IGNITION SW B–W STARTER RELAY E7 8 IG1 3 ACC 2 1 IG2 B 2 1 TAIL RELAY INJECTION RELAY B–O E7 2 W 15A HAZ–RADIO AM1 2 6 EB1 W–R W–R 2 AM2 E7 7.5A AM2 B G–W W BATTERY 3 EA2 1 EA1 W–B 1 1 E6 15A RAD CIG B–Y 1 ∗ P–L 1 The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. B HOW TO USE THIS MANUAL K CONNECTOR LIST [A] I14 I15 DARK GRAY GRAY 1 1 2 I16 J1 J2 BLACK 2 A A 1 2 A A A A B B D D A A B CC CD D A 6 7 8 [B] J3 J4 K1 K2 L1 1 2 1 2 DARK GRAY A A A A A A A A A B B DD A A B CC CDD L2 L3 L4 M1 M2 1 2 3 4 5 6 7 8 9 101112 1 2 3 45 6 78 M3 1 2 1 1 2 3 4 2 M4 [D] N1 GRAY 1 2 3 [C] BLACK GRAY 1 1 1 7 5 6 2 3 4 8 9 10 N2 O1 O2 GRAY BLACK DARK GRAY 1 1 1 2 [A] : Indicates connector to be connected to a part. (The numeral indicates the pin No.) [B] : Junction Connector Indicates a connector which is connected to a short terminal. Junction Connector Junction connector in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. Same Color Short Terminal [C] : Parts Code The first letter of the code is taken from the first letter of part, and the numbers indicates its order in parts which start with the same letter. [D] : Connector Color Connectors not indicated are milky white in color. B L PART NUMBER OF CONNECTORS Code A1 Part Name A/C Ambient Temp. Sensor Part Name Part Number Part Number Code 90980–11070 D4 Diode (Door Courtesy Light) 90980–11608 90980–10962 A2 A/C Condenser Fan Motor 90980–11237 D5 Diode (Key Off Operation) A3 A/C Condenser Fan Relay 90980–10940 D6 Diode (Luggage Compartment Light) 90980–11608 D7 Door Lock Control Relay 90980–10848 ÁÁ ÁÁ A4 [A] A5 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A/T Oil Temp. Sensor [B] ÁÁ ÁÁ 90980–10943 D8 Door Courtesy Light LH [C] 90980–11413 D9 Door Courtesy Light RH 90980–11148 A6 ABS Actuator 90980–11151 D10 Door Courtesy SW LH A7 ABS Actuator 90980–11009 D11 Door Courtesy SW RH A8 ABS Speed Sensor Front LH 90980–10941 D12 Door Courtesy SW Front LH A9 ABS Speed Sensor Front RH 90980–11002 D13 Door Courtesy SW Front RH A10 Airbag Sensor Front LH D14 Door Courtesy SW Rear LH A11 Airbag Sensor Front RH A12 Auto Antenna Motor 90980–11097 90980–11856 D15 Door Courtesy SW Rear RH 90980–11194 D16 Door Key Lock and Unlock SW LH 90980–11194 D17 Door Key Lock and Unlock SW RH 90980–11156 90980–11170 [A] : Part Code [B] : Part Name [C] : Part Number Toyota Part Number are indicated. Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). C TROUBLESHOOTING To Ignition SW IG Terminal Fuse [A] SW 1 Voltmeter [B] VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Ohmmeter SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. Digital Type Analog Type C To Ignition SW IG Terminal Test Light Fuse Case Short [A] SW 1 Short [B] Disconnect Disconnect Light (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: Relay Short [C] Disconnect SW 2 FINDING A SHORT CIRCUIT (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Solenoid DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Press Down Pull Up Press Down C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 1 Example: (Case 1) 0.2 (mm) Up Tool 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer For Non–Waterproof Type Connector HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. [Retainer at Full Lock Position] Stopper ”Case 1” Raise the terminal retainer up to the temporary lock position. Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) Secondary Locking Device ”Case 2” Open the secondary locking device. C Tool Tab Tab Example: (Case 1) [B] Terminal Retainer Tool [Male] Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black [Female] ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (
Mark) and pull the terminal retainer up to the temporary lock position. HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] Example: (Case 2) [Female] ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. ABS = Anti–Lock Brake System A/C = Air Conditioning A/T = Automatic Transaxle COMB. = Combination ECU = Electronic Control Unit EGR = Exhaust Gas Recirculation ESA = Electronic Spark Advance EVAP = Evaporative Emission FL = Fusible Link IAC = Idle Air Control J/B = Junction Block LH = Left–Hand O/D = Overdrive R/B = Relay Block RH = Right–Hand SFI = Sequential Multiport Fuel Injection SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature VSV = Vacuum Switching Valve w/ = With w/o = Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE filament to heat up and emit light. A FILAMENT headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E RELAY Basically, an electrically operated 1. NORMALLY switch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. SPEAKER An electromechanical device which creates sound waves from current flow. 2. NORMALLY OPEN SWITCH, MANUAL 1. NORMALLY OPEN RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. Opens and closes circuits, i it thereby th b stopping (1) or allowing (2) current flow. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. (Reed Switch Type) SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are j nott joined; j i d crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. F RELAY LOCATIONS [Engine Compartment] [Instrument Panel] F [Body] F RELAY LOCATIONS ,,, ,,, ,,,: Instrument Panel J/B Lower Finish Panel (See Page 20) F [Instrument Panel J/B Inner Circuit] F RELAY LOCATIONS ,,, ,,, ,,,: Engine Room J/B No.2 Engine Compartment Left (See Page 20) F [Engine Room J/B No.2 Inner Circuit] F RELAY LOCATIONS 1 Engine Compartment Left (See Page 20) : Engine Room R/B No.1 (Inside Engine Room J/B No.2) 3 : Engine Room R/B No.3 Radiator Upper Support RH (See Page 20) F Fusible Link Block Engine Compartment Left (See Page 20) (Inside Engine Room J/B No.2) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment A 1 A/C Condenser Fan Motor A 2 A/C Magnetic Clutch and Lock Sensor A 3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A 4 ABS Actuator A 5 ABS Actuator A 6 ABS Speed Sensor Front LH A 7 ABS Speed Sensor Front RH A 8 Air Fuel Ratio Sensor A 9 Airbag Sensor Front LH A 10 Airbag Sensor Front RH B 1 Brake Fluid Level Warning SW C 1 Camshaft Position Sensor C 2 Crankshaft Position Sensor C 3 Cruise Control Actuator D 1 Data Link Connector 1 E 1 Electronically Controlled Transmission Solenoid E 2 Electronically Controlled Transmission Solenoid E 3 Engine Coolant Temp. Sensor F 1 F 2 F 3 F 4 F 5 F 6 F 7 F 8 F 9 F 10 F 11 F 12 F 13 F 14 Front Turn Signal Light and Parking Light LH Front Turn Signal Light and Parking Light RH Front Wiper Motor Fuel Pressure Sensor (Delivery Pipe) Fuel Pressure Sensor (Fuel Pipe) Fuel Shutoff Valve (Delivery Pipe) Fuel Shutoff Valve (Fuel Pressure Regulator) Fuel Temp. Sensor (Delivery Pipe) Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block G 1 Generator G 2 Generator H H H H 1 2 3 4 Headlight LH Headlight RH Horn (High) Horn (Low) G Position of Parts in Engine Compartment I I I I I I I I 1 2 3 4 5 6 7 8 Idle Air Control Valve Ignition Coil and Igniter No.1 Ignition Coil and Igniter No.2 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Intake Air Temp. Sensor R 1 Radiator Fan Motor S 1 Starter S 2 Starter T 1 Throttle Position Sensor V 1 Vehicle Speed Sensor (Combination Meter) V 2 VSV (EGR) M 1 Manifold Absolute Pressure Sensor N 1 Noise Filter (Ignition) O 1 Oil Pressure SW P 1 Park/Neutral Position SW,A/T Indicator Light SW and Back–Up Light SW P 2 Power Steering Oil Pressure SW W W W W 1 2 3 4 Washer Level Warning SW Washer Motor Water Temp. Sender Water Temp. SW No.1 G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel A 11 A 12 A 13 A 14 A 15 A 16 A 17 A 18 A/C Evaporator Temp. Sensor A/C SW ABS ECU ABS ECU Air Vent Mode Control Servo Motor Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Steering Wheel Pad) Ashtray Illumination B 2 Blower Motor B 3 Blower Resistor B 4 Blower SW C 4 C 5 C 6 C 7 C 8 C 9 C10 C 11 C12 C13 C14 C15 C16 Center Airbag Sensor Assembly Center Airbag Sensor Assembly Center Airbag Sensor Assembly Cigarette Lighter Cigarette Lighter Illumination Clock Combination Meter Combination Meter Combination Meter Combination SW Combination SW Combination SW Cruise Control ECU D D D D D 2 3 4 5 6 Data Link Connector 2 Data Link Connector 3 Diode (Courtesy) Diode (Dome) Diode (Idle–Up) E E E E 4 5 6 7 Engine Control Module Engine Control Module Engine Control Module Engine Control Module G 3 Glove Box Light and SW H 5 Hazard SW H 6 Heated Oxygen Sensor H 7 Heater Control SW I 9 Ignition Key Cylinder Light I 10 Ignition SW I 11 Integration Relay I 12 Integration Relay G Position of Parts in Instrument Panel J 1 J 2 J 3 J 4 J 5 J 6 J 7 J 8 J 9 J 10 J 11 J 12 J 13 J 14 J 15 J 16 J 17 J 18 J 19 J 20 J 21 J 22 J 23 J 24 J 25 J 26 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector J 27 J 28 J 29 J 30 J 31 J 32 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector K 1 Key Interlock Solenoid O 2 O/D Main SW and A/T Shift Lever Illumination P 3 Parking Brake SW P 4 Power Outlet R R R R R 2 3 4 5 6 Radio and Player Radio and Player Rear Window Defogger SW Remote Control Mirror SW Rheostat S 3 Shift Lock ECU S 4 Stop Light SW T 2 Turn Signal Flasher U 1 Unlock Warning SW G ELECTRICAL WIRING ROUTING Position of Parts in Body A 19 ABS Speed Sensor Rear LH A 20 ABS Speed Sensor Rear RH F 15 Front Door Speaker LH F 16 Front Door Speaker RH F 17 Fuel Temp. Sensor and Fuel Shutoff Valve (Fuel Tank) B 5 Buckle SW LH H 8 High Mounted Stop Light C17 Condenser I 13 Interior Light D 7 D 8 D 9 D10 D 11 D12 D13 D14 Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Key Lock and Unlock SW Front LH Door Key Lock and Unlock SW Front RH Door Lock Control SW RH Door Lock Motor and Door Unlock Detection SW Front LH D15 Door Lock Motor and Door Unlock Detection SW Front RH D16 Door Lock Motor and Door Unlock Detection SW Rear LH D17 Door Lock Motor and Door Unlock Detection SW Rear RH J 33 Junction Connector J 34 Junction Connector J 35 Junction Connector L L L L L 1 2 3 4 5 License Plate Light LH License Plate Light RH Light Failure Sensor Luggage Compartment Light Luggage Compartment Light SW G Position of Parts in Body N 2 Noise Filter (Rear Window Defogger) P P P P 5 6 7 8 P 9 P 10 P 11 P 12 P 13 P 14 Power Window Control SW Front RH Power Window Control SW Rear LH Power Window Control SW Rear RH Power Window Master SW and Door Lock Control SW LH Power Window Motor Front LH Power Window Motor Front RH Power Window Motor Rear LH Power Window Motor Rear RH Pretensioner LH Pretensioner RH R 7 R 8 R 9 R10 R 11 R12 R13 R14 Rear Combination Light LH Rear Combination Light LH Rear Combination Light RH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Remote Control Mirror LH Remote Control Mirror RH G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) EA1 Engine Room Main Wire and Engine Room Main No.3 Wire (Radiator LH) EB1 EB2 Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) IA1 Cowl Wire and Cowl Wire (Left Kick Panel) IB1 Floor Wire and Cowl Wire (Left Kick Panel) IC1 IC2 ID1 ID2 IE1 IE2 IF1 Floor Wire and Instrument Panel Wire (Left Kick Panel) Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) Instrument Panel Wire and Cowl Wire (Under the Blower Motor) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Splice Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) IG1 IG2 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) IG3 IH1 Engine Wire and Instrument Panel Wire (Under the Blower Motor) II1 Engine Room Main Wire and Cowl Wire (Cowl Side Panel RH) IJ1 IJ2 IK1 IL1 IL2 IM1 Engine Room Main Wire and Cowl Wire (Right Kick Panel) Floor No.2 Wire and Cowl Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) BA1 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BB1 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) POWER SOURCE G2 GENERATOR B 1 60A FL ABS B–G 1 3 2 B–R W–B 1 4 L–B 1 1 B–R 2 3 5 L–R 1 1 1 HTR RELAY 1 E3 1 C 1 D 2 3 5 1 2 30A CDS 4 2F W–B 5 2C W–B 6 2K 20A EFI 10A HAZARD 20A RADIO NO. 1 10A HORN B–R 4 2L B–G 30A AM2 SHORT PIN B–R 10A ECU–B 2 FL MAIN 3. 0W W–B 1 W–R B 1 2A B 3 2B 5A ALT–S 7. 5A DOME 40A MAIN HEAD RELAY 2 1 2 4 3 3 2G R–B 1 4 2G BATTERY 15A HEAD (RH) 15A HEAD (LH) EB W–B 1 A 50A HTR 1 ENGINE MAIN RELAY FUSIBLE LINK BLOCK 1 E F 9 A , F10 B , F11 C , L–B 2 F 4 2 2B F12 D , F13 E , F14 F B–R 1 F 100A ALT 2 30A RDI B–R 1 B L–R 1 10A A/C L–B 1 2 W–B B–G L–W 1 B–R 4 1B 5 3 1 2 10A TAIL 25A DOOR 7. 5A PANEL 15A STOP TAILLIGHT RELAY 7. 5A OBD 30A POWER 1 POWER RELAY 5 3 2 1 2 NOISE FILTER 1 2 B–R NOISE FILTER 1 2 I2 40A DEF 1 2 7 1J W–B DEFOGGER RELAY 5 3 10A MIRROR–HEATER B–R 1 1B W 2 1K 1 1 2 2 40A AM1 15A CIG 7. 5A RAD–NO. 2 2 AM1 ACC 3 L–R IG1 4 B–Y 6 1K 1 1K 15A POWER–OUTLET 15A ECU–IG 10A HEATER 10A GAUGE IG2 6 B–R ST2 8 R 25A WIPER 7. 5A TURN I10 IGNITION SW W–R W–R B–R 3 1K 4 1K 5 1K 5 1B 6 1A 5A IGN 5A STARTER W–B 7 AM2 A J9 JUNCTION CONNECTOR IF POWER SOURCE SERVICE HINTS HEAD RELAY 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position TAILLIGHT RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position I10 IGNITION SW 2–3 : Closed with the ignition SW at ACC or ON position 2–4 : Closed with the ignition SW at ON or ST position 7–6 : Closed with the ignition SW at ON or ST position 7–8 : Closed with the ignition SW at ST position : PARTS LOCATION Code See Page Code See Page Code See Page F9 A 28 F12 D 28 G2 28 F10 B 28 F13 E 28 I10 30 F11 C 28 F14 F 28 J9 31 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 1 26 Engine Room R/B No.1 (Engine Compartment Left) 3 26 Engine Room R/B No.3 (Radiator Upper Support RH) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1K 2A 2B 2C 2F 2G 2K 2L : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support IF 36 Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 34 Wire Harness with Splice Points Cowl Wire Code I2 See Page 38 Wire Harness with Splice Points Cowl Wire MEMO STARTING AND IGNITION W–R 7 AM2 IG2 6 B–R ST2 8 R I10 IGNITION SW 3 1K 8 1C 12 IG3 B–R B–R 4 1K 5A STARTER 5 1K J22 JUNCTION CONNECTOR B B B–W B–W B 3 1J W–R B–W 5 1B B–W 11 IG2 B–W 4 2L 2 5 30A AM2 40A MAIN 1 ST RELAY 5 P 1 2A 1 3 2 3 2B 5 2D 9 2K P1 PARK/NEUTRAL POSITION SW N 11 2J 6 GR B B 10 IG2 GR F 9 A , F11 C W–B B–R 1 C FUSIBLE LINK BLOCK B–G GR 1 A C B J6 A , J7 B JUNCTION CONNECTOR B A B A FL MAIN 3. 0W 1 B 1 A W–B B–R M BATTERY S1 A , S2 B STARTER J9 JUNCTION CONNECTOR A IF GR GR J19 JUNCTION CONNECTOR C C B–R C B–R C B–R B–R 1 1 1 +B GND IGF 2 3 4 3 2 W–R BR W–R Y–R IGT I3 IGNITION COIL AND IGNITER NO. 2 IGT B I2 IGNITION COIL AND IGNITER NO. 1 IGF A B–W A W–R 20 C 3 C IGT1 IGF BR W–R NSW 4 A I4 6 A GND BR +B N1 NOISE FILTER (IGNITION) B–W 19 C IGT2 STA 11 A E4 A , E6 C ENGINE CONTROL MODULE BR GR EC J18 JUNCTION CONNECTOR STARTING AND IGNITION SERVICE HINTS I10 IGNITION SW 7–6 : Closed with the ignition SW at ON or ST position 7–8 : Closed with the ignition SW at ST position P1 PARK/NEUTRAL POSITION SW 5–6 : Closed with the A/T shift lever in P or N position S1 (A), S2 (B) STARTER Points closed with the Park/Neutral position SW at P or N position and the ignition SW at ST position : PARTS LOCATION Code See Page Code See Page I10 Code See Page E4 A 30 30 J22 31 E6 C 30 J6 F9 A 28 J7 A 31 N1 29 B 31 P1 F11 C 28 J9 31 S1 A 29 I2 29 J18 31 S2 B 29 I3 29 J19 31 29 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1K 2A 2B 2D 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG2 IG3 See Page 38 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code See Page Ground Points Location EC 34 Intake Manifold IF 36 Instrument Panel Brace LH : SPLICE POINTS Code I4 See Page 38 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points MEMO CHARGING B–G ACC 2 AM1 IG1 4 B–Y 7 AM2 IG2 6 B–R W W–R ST2 2 1K 5 1K 3 1K I10 IGNITION SW 1 1K 5A IGN 10A GAUGE 2 40A AM1 2 1J B–R 8 1T C10 A , C11 B 3 2C B–R 4 2L 4 B 5A ALT–S Y 30A AM2 13 A R–L 5 1B W–R 1 1B CHARGE WARNING LIGHT [COMB. METER] 1 4 E3 IE2 B–R B 1 F 2 F 1 C Y B–R 1 B W B–G 1 2A 6 EB1 4 R–L Y B–G 1 A IJ2 B–G 100A ALT F 9 A , F10 B , F11 C , F14 F FUSIBLE LINK BLOCK G1 B , G2 A 3 A 1 A 2 A S L IG FL MAIN 3. 0W BATTERY IC REGULATOR 1 B B GENERATOR SERVICE HINTS G1 (B), G2 (A) GENERATOR (A)3–GROUND : 13.5–14.3 volts with the engine running at 5000 rpm and 115
C (239
F) (B)1–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page C10 A 30 C11 B F9 A Code See Page Code F10 B 28 G1 30 F11 C 28 G2 28 F14 F 28 See Page 28 A 28 I10 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page B 30 Junction Block and Wire Harness (Connector Location) 1B 1J 22 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1K 1T 2A 2C 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) EB1 34 Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) IE2 36 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IJ2 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) : SPLICE POINTS Code E3 See Page 34 Wire Harness with Splice Points Cowl Wire Code See Page Wire Harness with Splice Points ENGINE CONTROL R FROM POWER SOURCE SYSTEM (SEE PAGE 44) B–R 20A EFI IG2 6 B–R 7 AM2 R B–R 8 2J 7 2K W–R ST2 8 I10 IGNITION SW B–R 1 5 EFI RELAY B–R B–R W–R 3 5 2C 4 2F 10 2C 1 1 5 1B 2 B–R 1 W–B 7 1W W–B 5 1K 3 1K B–Y 2 2J B–Y 5 5A IGN CIR OPN RELAY 4 2L 2 30A AM2 8 1C 3 1 1 L–B L–B 1 2A G–R B–R L–B B LG–B 1 C 4 EB1 2 IG1 LG–B L–B FUSIBLE LINK BLOCK 5 EB1 G–R F 9 A , F11 C 1 3 2 4 F17 FUEL TEMP. SENSOR AND SHUTOFF VALVE (FUEL TANK) LG–B IB1 BR G–R B–R W–B B–R W–B BATTERY 4 L–B FL MAIN 3. 0W IB1 W–B 7 W–B B–G 1 A BR A BK J34 JUNCTION CONNECTOR EB R B–Y 4 1K 5A STARTER L–B B–W B–Y 9 IG3 5 11 IG2 B–W 3 1J P P1 PARK/NEUTRAL POSITION SW N B–Y B–Y E3 6 B B–Y B B–Y E A E A J22 JUNCTION CONNECTOR B–W 10 IG2 B B A GR B–Y GR B–Y C B B A J6 A , J23 A , J24 B J7 B JUNCTION CONNECTOR JUNCTION CONNECTOR B–Y B–W B A B B GR L–B B–Y W–B LG–B E4 A , E5 B , E6 C , E7 D 12 A THCNG1 +B BATT 11 A NSW 20 C 3 C 19 C Y–R IGT2 22 A W–R IGF 14 A B IGT1 STA B–R +B1 ENGINE CONTROL MODULE 6 A G–R FC 1 A E05 26 C BR 1 D 3 IGT IGF +B GND 4 W–R 2 IGF IGT +B GND 1 4 B–R B–R 12 IG3 C B–R C BR B–R G–R B–R BR 1 3 I3 IGNITION COIL AND IGNITER NO. 2 2 I2 IGNITION COIL AND IGNITER NO. 1 W–R I4 J19 JUNCTION CONNECTOR C A BR A A A BR J18 JUNCTION CONNECTOR B–Y BR W–B BR BR EC Y BR 2 IB1 I4 VOUT 2 3 BR VC GND 1 I4 I5 BR Y 1 B BR 3 IG2 1 VC VCNG3 2 A HTAF 11 B VTA 9 B BR 3 VTA E2 I4 Y I4 2 E2 BR 1 E2 3 VC 2 AF– 2 B PIM 3 B THA 2 1 I4 BR 2 1 P–B 4 D 14 B 6 B 4 B THW BR 23 C L HT F8 FUEL TEMP. SENSOR (DELIVERY PIPE) 1 G–B 4 BR +B BR 10 C B–W 2 A8 AIR FUEL RATIO SENSOR G 1 (SHIELDED) G 2 E3 ENGINE COOLANT TEMP. SENSOR VC Y–B EGR B B–Y J18 JUNCTION CONNECTOR BR P B–Y B I8 INTAKE AIR TEMP. SENSOR B–Y 7 D BR 5 D F6 FUEL SHUTOFF VALVE (DELIVERY PIPE) 1 LG P–B V2 VSV (EGR) B–Y L–B B–Y 1 VC 2 Y PCNG1 Y PCNG2 B Y GND 3 B BR 2 RSD F5 FUEL PRESSURE SENSOR (FUEL PIPE) VCNG2 Y 3 G–R W–B W 9 D 2 LG Y VOUT I1 IDLE AIR CONTROL VALVE L–B B T1 THROTTLE POSITION SENSOR BR 2 BR B–Y 1 W–B Y–G 6 IG1 BR G–B B–Y F4 FUEL PRESSURE SENSOR (DELIVERY PIPE) BR F7 FUEL SHUTOFF VALVE (FUEL PRESSURE REGULATOR) ENGINE CONTROL B B–Y B BR L 3 AF+ AF– 1 7 IG1 I4 E4 A , E5 B , E6 C , E7 D AF+ ENGINE CONTROL MODULE THCNG2 6 D 2 1 BR I4 BR PIM M 1 MANIFOLD ABSOLUTE PRESSURE SENSOR BR B–Y B–Y 2 1 A12 A/C SW 5 F/PS B 2 4 21 A MGC 8 IG1 7 IJ2 10 D PRS 1 IG2 B 1 IG1 B–L 12 D W–L A/CS B–R B–R A G–O (SHIELDED) B–W L A B–Y J12 JUNCTION CONNECTOR G–O 10A MIRROR– HEATER 10A TAIL BR C1 CAMSHAFT POSITION SENSOR BR 9 1C 3 1 5 C G 18 C A 9 IJ2 A P2 POWER STEERING OIL PRESSURE SW W–L L I4 W–L NE– G 17 C G NE L–Y 4 C 1 TO A/C MAGNETIC CLUTCH AND LOCK SENSOR 1 10 A 2 L–Y L TE1 BR TE1 C2 CRANKSHAFT POSITION SENSOR 8 1 FROM A/C DUAL PRESSURE SW B L 15 B B–R E1 J8 JUNCTION CONNECTOR 15 A (SHIELDED) L–W B–Y D1 DATA LINK CONNECTOR 1 3 R–B LOCK J12 JUNCTION CONNECTOR R–B R–B R–W L–R 10 B +B FROM MG CLT RELAY L L–W THR 12 H7 HEATER CONTROL SW BR A11 A/C EVAPORATOR TEMP. SENSOR B–Y BR BR BR FROM POWER SOURCE SYSTEM (SEE PAGE 44) BR 2 11 1J D6 DIODE (IDLE–UP) 2 I4 9 IG1 3 D E4 A , E5 B , E6 C , E7 D ELS ENGINE CONTROL MODULE LOCK IN 12 B PSW 10 IG3 1 C5 CENTER AIRBAG SENSOR ASSEMBLY BR B–Y ENGINE CONTROL BR BR BR BR BR BR BR B–Y B–Y BR 12 IG2 BR 4 2 V–W E1 +B HT OX G–R 3 (SHIELDED) W B (SHIELDED) 5 B W 21 C G–R B 1 IG3 P–B 2 IG3 V–W P–B 1 H6 HEATED OXYGEN SENSOR 9 A 5 A 16 A E4 A , E5 B , E6 C , E7 D 2 1 I4 E03 16 B BR E02 22 C BR E01 13 C BR E04 13 A BR 16 C BR E1 24 C O # 40 14 C J20 JUNCTION CONNECTOR BR A A BR 2 A BR 2 1 SIL W R 1 # 40+ (SHIELDED) G B–R #30 25 C W I7 INJECTOR NO. 4 2 # 30+ 15 C I6 INJECTOR NO. 3 1 #20 11 C BR (SHIELDED) # 20+ SPD 1 C I5 INJECTOR NO. 2 I4 INJECTOR NO. 1 B–W #10 12 C L (SHIELDED) # 10+ 2 C OX2 (SHIELDED) HT2 ENGINE CONTROL MODULE BR A BR BR A BR BR A BR BR BR A BR A A BR 3 IG1 4 IG1 BR J21 JUNCTION CONNECTOR BR W–B A BR A B–Y IH BR BR W–B B–Y EC EC FROM POWER SOURCE SYSTEM (SEE PAGE 44) BR BR 7. 5A OBD 15A STOP 10 1J 7 1C B W BR BR B–Y V–W V–W CG C A A B 2 D 8 D Y–R J7 B B B JUNCTION CONNECTOR W–B 4 A J6 A , BR 8 A G–W FUELW G–W FUEL B–O STP G–R C A G–W 1 W–B 4 A A TACH S4 STOP LIGHT SW BAT J7 B SG 5 16 J6 A , SIL BR I1 7 2 BR BR BR BR BR B–Y E4 A , E5 B , E6 C , E7 D ENGINE CONTROL MODULE (SHIELDED) (SHIELDED) (SHIELDED) D3 DATA LINK CONNECTOR 3 W W JUNCTION CONNECTOR W J2 JUNCTION CONNECTOR C C (SHIELDED) G–R 8 1J 4 1R 7 1J 5 1R BR BR G–W BR I6 6 IG3 Y–R J23 A , J24 B BR A A JUNCTION CONNECTOR BR W–B BR BR C B G–R G–W G–W B–O B–Y A J9 JUNCTION CONNECTOR IF ENGINE CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE 2 1D R–L 1 1J R–L D J3 JUNCTION CONNECTOR J15 JUNCTION CONNECTOR B B D 3 IF1 V–W F B V–W F B R–L R–L V–W 7 C 14 B 15 B 6 C J24 B JUNCTION CONNECTOR C11 B , C12 C SPEEDOMETER MALFUNCTION INDICATOR LAMP TACHOMETER IF1 P 10 7 IH1 2 IH1 P IF1 L 6 5 C BR 2 C G–R G–W IF1 8 C B–O 3 B L 9 6 B Y–R D J19 JUNCTION CONNECTOR R–L 2 IG2 FUEL FUEL R–L COMBINATION METER 3 2 SI V1 VEHICLE SPEED SENSOR (COMBINATION METER) G–W B–O G–W F A J23 A F A Y–R G–R G–R B–O 4 IH1 JUNCTION CONNECTOR 5 IG1 Y–R R–L Y–R D SE IG+ 1 R–L BR B–O IG SYSTEM OUTLINE This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline of the engine control is explained here. 1. INPUT SIGNALS (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. thus the engine coolant temp. is input in the form of a control signal into TERMINAL THW of the engine control module. (2) Intake air temp. signal circuit The intake air temp. sensor detects the intake air temp. , which is input as a control signal into TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust gases is detected and input as a control signal into TERMINAL OX2 of the engine control module. (4) RPM signal circuit Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. Camshaft position is input as a control signal to TERMINAL G of the engine control module, and engine RPM is input into TERMINAL NE. (5) Throttle signal circuit The throttle position sensor detects the throttle valve opening angle, which is input as a control signal into TERMINAL VTA of the engine control module. (6) Vehicle speed signal circuit The vehicle speed sensor, installed inside the transmission, detects the vehicle speed and inputs a control signal into TERMINAL SPD of the engine control module. (7) Park/Neutral position SW signal circuit The Park/Neutral position SW detects whether the shift position are in neutral, parking or not, and inputs a control signal into TERMINAL STA of the engine control module. (8) A/C SW signal circuit The A/C amplifier is built in the engine control module. The signal from the A/C SW is input into TERMINAL A/CS of the engine control module. (9) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the voltage for engine control module start–up power supply is applied to TERMINAL +B of engine control module via EFI relay. (10) Intake air volume signal circuit Intake air volume is detected by the manifold absolute pressure sensor (for manifold pressure) and is input as a control signal into TERMINAL PIM of the engine control module. (11) Starter signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor during cranking is detected and the signal is input into TERMINAL NSW of the engine control module as a control signal. (12) Electrical load signal circuit The signal when systems such as the rear window defogger, headlights, etc. Which cause a high electrical burden are on is input to TERMINAL ELS as a control signal. (13) Air fuel ratio signal circuit The air fuel ratio is detected and input as a control signal into TERMINAL AF+ of the engine control module. ENGINE CONTROL 2. CONTROL SYSTEM ∗ SFI system The SFI system monitors the engine condition through the signals, which are input from each sensor to the engine control module. The best fuel injection volume is decided based on this data and the program memorized by the engine control module, and the control signal is output to TERMINALS #10+, #20+, #30+ and #40+ of the engine control module to operate the injector. (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals, which are input to the engine control module from each sensor the best ignition timing is detected according to this data and the memorized data in the engine control module, and the control signal is output to TERMINALS IGT1 and IGT2. This signal controls the igniter to provide the best ignition timing for the driving conditions. ∗ IAC system The IAC system (Step motor type) increases the RPM and provides idling stability for fast idle–up when the engine is cold and when the idle speed has dropped due to electrical load, etc. The engine control module evaluates the signals from each sensor, outputs current to TERMINAL RSD , and controls the idle air control valve. ∗ Fuel control system The engine control module operation outputs to TERMINAL FC and controls the CIR OPN relay. Thus controls the fuel shutoff valve open and close. ∗ EGR control system The EGR control system controls the VSV (EGR) by evaluating the signals from each sensor which are input to the engine control module and by sending output to TERMINAL EGR of the engine control module. ∗ A/C conditioning operation system In addition to the conventional A/C cut control, the engine control module performs the air conditioning operation as well since the A/C amplifier function is built in it. 3. DIAGNOSIS SYSTEM With the diagnosis system, when there is a malfunctioning in the engine control module signal system, the malfunction system is recorded in the memory. The malfunctioning system can then be found by reading the display (Code) of the malfunction indicator lamp. 4. FAIL–SAFE SYSTEM When a malfunction occurs in any system, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail–safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. SERVICE HINTS E4 (A), E5 (B), E6 (C), E7 (D) ENGINE CONTROL MODULE BATT–E1 : Always 9.0–14.0 volts +B–E1 : 9.0–14.0 volts with the ignition SW at ON or ST position VC–E2 : 4.5– 5.5 volts with the ignition SW on VTA–E2 : 0.3– 0.8 volts with the ignition SW on and throttle valve fully closed 3.2–4.9 volts with the ignition SW on and throttle valve open PIM–E2 : 3.3– 3.9 volts with the ignition SW on THA–E2 : 0.5–3.4 volts with the ignition SW on and intake air temp. 20°C (68°F) THW–E2 : 0.2– 1.0 volts with the ignition SW on and coolant temp. 80°C (176°F) STA–E1 : 6.0–14.0 volts with the engine cranking W–E1 : 9.0–14.0 volts with the no trouble and engine running TE1–E1 : 9.0–14.0 volts with the ignition SW on NSW–E1 : 0– 3.0 volts with the ignition SW on and Park/Neutral position SW position P or N position 9.0–14.0 volts with the ignition SW on and except Park/Neutral position SW position P or N position IGT1, IGT2–E1 : Pulse generation with the engine cranking or idling #10+, #20+, #30+, #40+–E01, E02 : 9.0–14.0 volts with the ignition SW on : PARTS LOCATION Code See Page A8 28 Code See Page F8 Code See Page 28 J9 31 A11 30 F9 A 28 J12 31 A12 30 F11 C 28 J15 31 C1 28 F17 32 J18 31 C2 28 H6 30 J19 31 C5 30 H7 30 J20 31 31 C11 B 30 I1 29 J21 C12 C 30 I2 29 J22 D1 28 I3 29 J23 A 31 D3 30 I4 29 J24 B 31 D6 30 I5 29 J34 32 E3 28 I6 29 M1 29 A 30 I7 29 P1 29 E5 B 30 I8 29 P2 29 E6 C 30 I10 30 S4 31 E7 D 30 J2 31 T1 29 F4 28 J3 31 V1 29 F5 28 J6 A 31 V2 29 F6 28 J7 B 31 F7 28 E4 J8 31 31 : RELAY BLOCKS Code 1 See Page 26 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1C 1D See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1J 1K 1R 1W 2A 2C 2F 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) EB1 34 Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) IB1 36 Floor Wire and Cowl Wire (Left Kick Panel) IF1 36 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 38 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) IH1 38 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IJ2 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IG1 IG2 IG3 ENGINE CONTROL : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support EC 34 Intake Manifold IF 36 Instrument Panel Brace LH IG 36 Instrument Panel Brace RH IH 36 Cowl Side Panel RH BK 40 Under the Left Center Pillar : SPLICE POINTS Code See Page Wire Harness with Splice Points Code E3 34 Cowl Wire I5 I1 38 Cowl Wire I6 I4 38 Engine Wire See Page 38 Wire Harness with Splice Points Cowl Wire MEMO HEADLIGHT 2 4 1 40A MAIN 15A HEAD (LH) HEAD RELAY 2 3 2G 4 2G 6 2G R R–B B J30 JUNCTION CONNECTOR B 3 3 H1 HEADLIGHT LH B 1 1 R–L R–B 2 3 H2 HEADLIGHT RH 2 R–L R–B B 8 2C R–W 3 8 2K R–B 1 3 2B 15A HEAD (RH) I11 INTEGRATION RELAY 1 A F B F B D B D B J25 A , J26 B JUNCTION CONNECTOR R–B F 9 A , F11 C FUSIBLE LINK BLOCK R–B 1 C D A F A F A R–L 4 R–Y R–B R–L 8 17 LOW HIGH FLASH W–B J6 JUNCTION CONNECTOR C15 COMBINATION SW A A 8 9 W–B HEAD R–L 3 IE1 TAIL 16 A W–B FL MAIN 3. 0W 7 C11 HIGH BEAM INDICATOR LIGHT [COMB. METER] DIMMER SW B–G LIGHT CONTROL SW 13 OFF 8 1J A W–B W–B BATTERY 7 1J A J9 JUNCTION CONNECTOR IF IE J4 JUNCTION CONNECTOR SERVICE HINTS HEAD RELAY 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position C15 COMBINATION SW 13–16 : Continuity with the light control SW at HEAD position 8–16 : Continuity with the dimmer SW at FLASH position 7–16 : Continuity with the dimmer SW at HIGH or FLASH position : PARTS LOCATION Code See Page C11 C15 Code See Page H2 28 J25 J26 30 I11 30 F9 A 28 J4 31 F11 C 28 J6 31 28 J9 31 H1 Code 30 See Page A 31 B 31 J30 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 2B 2C 2G 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 See Page 36 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) : GROUND POINTS Code See Page Ground Points Location IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH 31 LIGHT AUTO TURN OFF FROM POWER SOURCE SYSTEM (SEE PAGE 44) B B–R 4 1B 1 3 2B 5 TAILLIGHT RELAY 25A DOOR 2 10A GAUGE 1 7. 5A DOME 40A MAIN 12 2J 3 2 1 1D 6 1C G–R 4 1B 4 1 3 2 A L–W HEAD RELAY J1 JUNCTION CONNECTOR 8 2K C B J31 A , J32 B B B R–B G–R A A B–R B–R B 1 F 2 F 1 1W 13 A 2 B 1 C J30 JUNCTION CONNECTOR L–W JUNCTION CONNECTOR E3 R R–B B–R B–R A 7 3 B 1 100A ALT 1 A F 9 A , F11 C , F14 F 1 B 10 4 B G I12 A 7 1S C15 COMBINATION SW W–B W–B FL MAIN 3. 0W I11 B , INTEGRATION RELAY 14 13 OFF TAIL R–G 8 1J LIGHT CONTROL SW 7 1J 6 R–Y B–G FUSIBLE LINK BLOCK HEAD 16 A BATTERY A W–B 1 A J9 JUNCTION CONNECTOR IF J6 JUNCTION CONNECTOR D7 DOOR COURTESY SW FRONT LH SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 7 of the integration relay through GAUGE fuse. Voltage is applied at all times to TERMINAL (B) 2 of the integration relay through the TAILLIGHT relay coil side, and to TERMINAL (B) 3 through the HEAD relay coil side. 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into TERMINAL (B) 1 of the integration relay. Due to this signal, the current flowing to TERMINAL (B) 2 of the relay flows to TERMINAL (B) 1 to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and TAILLIGHT relay causes taillights to turn on. With the light control SW turned to HEAD position, a signal is input into TERMINALS (B) 1 and (B) 4 of the integration relay. Due to this signal, the current flowing to TERMINALS (B) 3 and (B) 2 of the relay flows to TERMINALS (B) 4 and (B) 1 to TERMINALS 13 and 14 of the light control SW to TERMINAL 16 to GROUND, and causes TAILLIGHT and HEAD relay to turn the lights on. 2. LIGHT AUTO TURN OFF OPERATION When the driver’s door is opened with the lights on and the ignition SW off, the relay is activated, and the current flow from TERMINAL (B) 2 of the relay to TERMINAL (B) 1, and from TERMINAL (B) 3 to TERMINAL (B) 4 are cut, and all the lights are turned off. SERVICE HINTS HEAD RELAY 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position TAILLIGHT RELAY 3–5 : Closed with the light control SW at TAIL or HEAD position D7 DOOR COURTESY SW FRONT LH 1–GROUND : Continuity with the front LH door open I11 (B), I12 (A) INTEGRATION RELAY 7–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 6–GROUND : Continuity with the front LH door open 1–GROUND : Always approx. 12 volts 10–GROUND : Always continuity (A)13–GROUND : Always approx. 12 volts (B) 2–GROUND : Always approx. 12 volts (B) 3–GROUND : Always approx. 12 volts (B) 4–GROUND : Continuity with the light control SW at HEAD position (B) 1–GROUND : Continuity with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page C15 D7 Code 30 I11 32 I12 See Page B 30 A Code See Page J30 31 30 J31 A 31 F9 A 28 J1 31 J32 B 31 F11 C 28 J6 31 F14 F 28 J9 31 LIGHT AUTO TURN OFF ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2B 24 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 24 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1C 2J 2K : GROUND POINTS Code IF See Page 36 Ground Points Location Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 34 Wire Harness with Splice Points Cowl Wire Code See Page Wire Harness with Splice Points MEMO TURN SIGNAL AND HAZARD WARNING LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 44) 2 1L 3 2K W H5 HAZARD SW 10A HAZARD G–R 7. 5A TURN 10 8 C15 TURN SIGNAL SW [COMB. SW] OFF RH HAZARD TURN G–W 6 2 1 3 G–Y 1 5 G–B G–R 9 G–B 7 T2 TURN SIGNAL FLASHER 2 G–Y LH G–B ON C D G–B 3 G–Y D G–B C J15 JUNCTION CONNECTOR G–B G–Y D 5 1A 10 1C 8 1H 6 1H G–B W–B C 8 1V 11 1S 6 1S 2 1A G–B G–Y 1 B 1 C LH RH 16 B W–B C11 B , C12 C TURN SIGNAL INDICATOR LIGHT [COMB. METER] 2 F2 FRONT TURN SIGNAL LIGHT RH 3 W–B 5 R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 5 6 W–B 6 W–B 2 R8 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 3 W–B IF A J4 JUNCTION CONNECTOR E2 A EB W–B A W–B J9 JUNCTION CONNECTOR B6 BM W–B F1 FRONT TURN SIGNAL LIGHT LH G–Y B B J25 A , J26 B G–Y G–B G–B B A JUNCTION CONNECTOR G–Y 1 EB1 IE SERVICE HINTS T2 TURN SIGNAL FLASHER 2–GROUND : Approx. 12 volts with the ignition SW at ON or ST position or the hazard SW on 1–GROUND : Changes from 12 to 0 volts with the ignition SW at ON or ST position and the turn signal SW LH or RH position, and with the hazard SW on 3–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code J26 See Page C11 B 30 H5 30 B 31 C12 C 30 J4 31 R8 33 C15 30 J9 31 R10 33 F1 28 J15 31 T2 31 F2 28 J25 A 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1H 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1L 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2K 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 See Page 34 Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH BM 40 Back Panel Center : SPLICE POINTS Code E2 See Page 34 Wire Harness with Splice Points Engine Room Main Wire Code B6 See Page 40 Wire Harness with Splice Points Floor Wire STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 44) 15A STOP 10A GAUGE 1 1S 2 1D W R–L 7 1C D J3 JUNCTION CONNECTOR 2 R–L S4 STOP LIGHT SW R–L D 7 C 1 C10 A , C12 C G–W REAR LIGHTS WARNING LIGHT [COMB. METER] Y–G 3 A 4 1R 5 IC2 G–W Y–G 2 1S L3 LIGHT FAILURE SENSOR 7 4 8 + – DELAY HOLD 1 11 G–R 2 5 B6 J34 JUNCTION CONNECTOR A BK W–B W–B A BM W–B G–R 2 W–B 5 R10 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R 2 W–B W–B 1 R8 STOP LIGHT LH [REAR COMB. LIGHT LH] 2 H8 HIGH MOUNTED STOP LIGHT R B3 SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINAL 2 and 1 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on holding and the warning light on until the ignition SW is turned off. SERVICE HINTS S4 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed L3 LIGHT FAILURE SENSOR 7–GROUND : Approx. 12 volts with the stop light SW on 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 11–GROUND : Always continuity : PARTS LOCATION Code C10 C12 See Page Code See Page Code See Page A 30 J3 31 R8 33 C 30 J34 32 R10 33 32 L3 32 S4 31 H8 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1C 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1R 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC2 See Page 36 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Instrument Panel Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location BK 40 Under the Left Center Pillar BM 40 Back Panel Center : SPLICE POINTS Code B3 See Page 40 Wire Harness with Splice Points Floor Wire Code B6 See Page 40 Wire Harness with Splice Points Floor Wire INTERIOR LIGHT B W–B 1 2A 1 SHORT PIN 2 7. 5A DOME 12 2J R B R 1 1 2 R B1 R C17 CONDENSER R R L3 LIGHT FAILURE SENSOR R L4 LUGGAGE COMPARTMENT LIGHT OFF ON 1 A DOOR 2 I13 INTERIOR LIGHT F 9 A , F11 C FUSIBLE LINK BLOCK 1 C 1 2 R–W B–G W–B 1 R–Y R–W BATTERY L5 LUGGAGE COMPARTMENT LIGHT SW FL MAIN 3. 0W A J9 JUNCTION CONNECTOR IF 1 R–G 1 R–G J31 A 1 2 R–G D A D A E D4 DIODE (COURTESY) JUNCTION CONNECTOR J31 A , J32 B E 4 1G D A R–W 1 1 R–G 10 6 1F 12 1S 8 IM1 D8 DOOR COURTESY SW FRONT RH 11 JUNCTION CONNECTOR JUNCTION CONNECTOR 2 11 1H A A D7 DOOR COURTESY SW FRONT LH D5 DIODE (DOME) 1 1M R–G INTEGRATION RELAY R–W L–W R–G R R–W I12 A R–W 1 1D R–W R 2 1M R–W C B D10 DOOR COURTESY SW REAR RH 1 4 R–W R R–W 8 1G 2 G–R 1 R 9 1S R–Y 5 1F R 1 1W R 10 I9 IGNITION KEY CYLINDER LIGHT R J16 JUNCTION CONNECTOR 7 1J D9 DOOR COURTESY SW REAR LH C11 OPEN DOOR WARNING LIGHT [COMB. METER] FROM POWER SOURCE SYSTEM (SEE PAGE 44) W–B 25A DOOR L–W J31 A , J32 B 13 A 6 8 A 7 1S R–W 1 2 E A E A D B R–W 6 IM1 1 INTERIOR LIGHT SERVICE HINTS I12 (A) INTEGRATION RELAY 1–GROUND : Always approx. 12 volts 4–GROUND : Continuity with the one of each door (Front RH, rear LH and RH) open 6–GROUND : Continuity with the front LH door open 10–GROUND : Always continuity (A) 8–GROUND : Continuity with the front RH door open D7, D8, D9, D10 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1–GROUND : Closed with the door open L5 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : Closed with the luggage compartment door open : PARTS LOCATION Code See Page Code See Page D10 Code 32 See Page C11 30 C17 32 F9 A 28 J31 A 31 D4 30 F11 C 28 J32 B 31 D5 30 D7 32 D8 32 D9 32 I9 J16 31 30 L3 32 30 L4 32 I13 32 L5 32 J9 31 I12 A ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1F 22 Roof Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2A 24 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2J 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1G 1H 1J 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IM1 See Page 38 Joining Wire Harness and Wire Harness (Connector Location) Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IF See Page 36 Ground Points Location Instrument Panel Brace LH : SPLICE POINTS Code B1 See Page 40 Wire Harness with Splice Points Floor Wire Code See Page Wire Harness with Splice Points MEMO ILLUMINATION G 1 5 TAILLIGHT RELAY 7. 5A PANEL 2 4 1B 3 6 1C 4 1J 5 1D J1 JUNCTION CONNECTOR 6 1 3 7 A B A B A B A A A A G 1 2 B G B B G B 1 4 B A A18 ASHTRAY ILLUMINATION 2 2 B B–G 1 A 6 B B B4 BLOWER SW I11 INTEGRATION RELAY B B G 2 B B B G G–R B B JUNCTION CONNECTOR A12 A/C SW 100A ALT B A C8 CIGARETTE LIGHTER ILLUMINATION G B F 9 A , F14 F B–R 2 F J13 A , J14 B A FUSIBLE LINK BLOCK B–R E3 1 F G G A R4 REAR WINDOW DEFOGGER SW B–R G–R G FL MAIN 3. 0W LIGHT CONTROL SW C15 COMBINATION SW 14 OFF A B TAIL A A W–B 16 B J6 JUNCTION CONNECTOR B A J13 A , J14 B JUNCTION CONNECTOR W–B A B 8 1J 6 1V 7 1J 4 1H B W–B BATTERY HEAD A J9 JUNCTION CONNECTOR IF B E B E B 3 D A D A B 13 12 1 2 A B JUNCTION CONNECTOR J16 A , J17 B IE G3 GLOVE BOX LIGHT AND SW G G A A C12 COMBINATION METER ILLUMINATION [COMB. METER] G A A 2 G W–B 5 B G G A A W–B 3 1 O2 A/T SHIFT LEVER ILLUMINATION [O/D MAIN SW] G A B B B 10 A R2 B , R3 A 2 RADIO AND PLAYER G A A W–B B G G G W–G B H5 HAZARD SW G J28 A , J29 B JUNCTION CONNECTOR A B J4 JUNCTION CONNECTOR A A D A 3 E 1 T ILL R6 RHEOSTAT ILLUMINATION SERVICE HINTS TAILLIGHT RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position C15 COMBINATION SW 14–16 : Continuity with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page Code See Page Code See Page A12 30 H5 30 J17 B 31 A18 30 I11 30 J28 A 31 B4 30 J1 31 J29 B 31 C8 30 J4 31 C12 30 J6 31 R2 O2 B 31 31 C15 30 J9 31 R3 A 31 F9 A 28 J13 A 31 R4 31 F14 F 28 J14 B 31 R6 31 30 J16 A 31 G3 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1C 1D 1H 1J 1V See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : GROUND POINTS Code See Page Ground Points Location IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 34 Wire Harness with Splice Points Cowl Wire Code See Page Wire Harness with Splice Points MEMO TAILLIGHT 1 5 10A TAIL TAILLIGHT RELAY 9 1C 8 1S G–O 6 1C G–R 4 1B 3 A A J1 JUNCTION CONNECTOR G 2 J12 JUNCTION CONNECTOR A A G G G–R G–O B–R B1 2 J25 A , J26 B W–B 16 FL MAIN 3. 0W A 2 2 L1 LICENSE PLATE LIGHT LH C15 COMBINATION SW 1 2 1 L2 LICENSE PLATE LIGHT RH G G–O G–O G HEAD 1 G I11 INTEGRATION RELAY TAIL F2 FRONT PARKING LIGHT RH B–G 1 A B5 C B 14 OFF F1 FRONT PARKING LIGHT LH 100A ALT JUNCTION CONNECTOR C B 1 LIGHT CONTROL SW 2 F F 9 A , F14 F B–R 1 F FUSIBLE LINK BLOCK B–R E3 A A 2 1 J6 JUNCTION CONNECTOR W–B W–B W–B W–B W–B A 8 1J BATTERY W–B 7 1J E2 B5 W–B A W–B J9 JUNCTION CONNECTOR IF EB W–B B5 3 1 3 5 B6 W–B BM G 1 W–B A BK W–B G–O G–O G G–O DELAY + – L3 LIGHT FAILURE SENSOR 3 TAIL SIDE MARKER R10 REAR COMBINATION LIGHT RH TAIL SIDE MARKER B3 W–B 4 G–O W–B 3 B4 R8 REAR COMBINATION LIGHT LH G–O Y–G G G Y–G R–L G W–B W–B W–B 4 R9 TAILLIGHT RH [REAR COMB. LIGHT RH] G–O W–B W–B R7 TAILLIGHT LH [REAR COMB. LIGHT LH] R–L FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE 2 1D R–L 1 1S D D B1 8 9 11 B3 G 3 5 B6 A J34 JUNCTION CONNECTOR J3 JUNCTION CONNECTOR 7 C REAR LIGHTS WARNING LIGHT [COMB. METER] C10 A , C12 C 3 A 5 IC2 4 TAILLIGHT SYSTEM OUTLINE When the light control SW is turned to TAIL or HEAD position. The current flows to TERMINAL 3 of the light failure sensor through the TAIL fuse. When the ignition SW is turned on, the current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. TAILLIGHT DISCONNECTION WARNING With the ignition SW on and the light control SW turned to TAIL or HEAD position, if the taillight circuit is open, the light failure sensor detects the failure by the change in current flowing from TERMINAL 3 of the light failure sensor to TERMINAL 9, and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on, which remains on until the light control SW is turned off SERVICE HINTS TAILLIGHT RELAY 5–3 : Closed with the light control SW at TAIL or HEAD position L3 LIGHT FAILURE SENSOR 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 3–GROUND : Approx. 12 volts with the light control SW at TAIL or HEAD position 11–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page C10 A 30 J1 31 L1 32 C12 C 30 J3 31 L2 32 C15 30 J6 31 L3 32 F1 28 J9 31 R7 33 F2 28 J12 31 R8 33 F9 A 28 J25 A 31 R9 33 F14 F 28 J26 B 31 R10 33 I11 30 J34 32 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1B 22 1C 22 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC2 See Page 36 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Instrument Panel Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support IF 36 Instrument Panel Brace LH BK 40 Under the Left Center Pillar BM 40 Back Panel Center : SPLICE POINTS Code See Page Wire Harness with Splice Points Code E2 34 Engine Room Main Wire B4 E3 34 Cowl Wire B5 40 Floor Wire B1 B3 B6 See Page 40 Wire Harness with Splice Points Floor Wire BACK–UP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE R–L 1 1J F J24 JUNCTION CONNECTOR R–B F R–L C J23 JUNCTION CONNECTOR R–B C 2 IG2 3 IG3 R–L 5 1V 13 1S D R–B R–B J19 JUNCTION CONNECTOR R–L D R–B R–B R9 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] 8 1 3 W–B 2 W–B B5 W–B R7 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] P1 BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW] R–B B4 A J34 JUNCTION CONNECTOR BK 1 3 SERVICE HINTS P1 BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW] 2–8 : Closed with the shift lever at R position : PARTS LOCATION Code See Page J19 31 J23 J24 Code See Page J34 32 31 P1 29 31 R7 33 Code R9 See Page 33 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG2 IG3 See Page 38 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code BK See Page 40 Ground Points Location Under the Left Center Pillar : SPLICE POINTS Code B4 See Page 40 Wire Harness with Splice Points Floor Wire Code B5 See Page 40 Wire Harness with Splice Points Floor Wire WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 44) 25A WIPER E B E A 1 1A L L J25 A , J26 B 4 1C JUNCTION CONNECTOR 2 M W2 WASHER MOTOR 1 EW L L–W WF WIPER SW WASHER SW OFF 6 HI LO INT WF 11 L–W EW 2 W–B 16 L–Y +1 7 L–B +2 8 L–O +B 17 L IJ1 +S INT1 INT2 B1 OFF ON +B A L A L L–O L–B A C13 WIPER AND WASHER SW [COMB. SW] 3 5 2 1 +2 +1 B S M E 4 W–B F3 FRONT WIPER MOTOR W–B 10 2J J9 JUNCTION CONNECTOR IF 4 2F W–B A L–Y J15 JUNCTION CONNECTOR +2 L +1 +S EB SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 17 of the wiper and washer SW, TERMINAL 2 of the washer motor and TERMINAL 2 of the front wiper motor through the WIPER fuse. 1. LOW SPEED POSITION With the wiper and washer SW turned to LO position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND and causes the front wiper motor to run at low speed. 2. HIGH SPEED POSITION With the wiper and washer SW turned to HI position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 8 to TERMINAL 3 of the front wiper motor to TERMINAL 4 to GROUND and causes the front wiper motor to run at high speed. 3. INT POSITION With the wiper and washer SW turned to INT position, the wiper relay operates and current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 2 to GROUND. This activates the intermittent circuit and the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND and the wiper operates. Intermittent operation is controlled by a condenser charge and discharge function in the relay. 4. WASHER CONTINUOUS OPERATION With the wiper and washer SW pulled to WASHER position (Washer SW ON position), the current flows from the WIPER fuse to TERMINAL 2 of the washer motor to TERMINAL 1 to TERMINAL 11 of the wiper and washer SW to TERMINAL 2 to GROUND and causes the washer motor to run and the window washer to spray. Simultaneously, current flows from the WIPER fuse to TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND, causing the wiper to function. SERVICE HINTS C13 WIPER AND WASHER SW [COMB. SW] 2–GROUND : Always continuity 17–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 7–GROUND : Approx. 12 volts with the wiper and washer SW at LO position Approx. 12 volts every approx. 1.6 to 10.7 seconds intermittently with the wiper and washer SW at INT position 16–GROUND : Approx. 12 volts with the ignition SW at ON or ST position and unless the front wiper motor at STOP position 8–GROUND : Approx. 12 volts with the wiper and washer SW at HI position F3 FRONT WIPER MOTOR 1–2 : Closed unless the front wiper motor at STOP position : PARTS LOCATION Code See Page Code See Page C13 30 J15 31 F3 28 J25 A 31 J9 31 J26 B 31 Code W2 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1A See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2F 24 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2J 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IJ1 See Page 38 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Right Kick Panel) See Page 29 WIPER AND WASHER : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support IF 36 Instrument Panel Brace LH MEMO POWER WINDOW FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE 30A POWER B B L B L 25A DOOR J33 JUNCTION CONNECTOR 1 L 2 P8 POWER WINDOW MASTER SW 10 11 BW 10 ID2 BW FRONT LH 5 DOWN L 1 POWER RELAY 5 1G 7 1J 3 1S 13 1G W–B L L C B A A L–W JUNCTION CONNECTOR J31 A , J32 B L–W 1 1D 3 R–B 12 1G 2 R DD 5 G 10 12 A DU 1 W–B 7 13 A E 4 W–B E 3 6 J33 JUNCTION CONNECTOR L 8 A I12 A R–G INTEGRATION RELAY 7 1S A A A L E A W–B D B R–G W–B G W–B D8 DOOR COURTESY SW FRONT RH R–G 6 IM1 D7 DOOR COURTESY SW FRONT LH R 1 20 ID1 7 1G 1 3 1V A J9 JUNCTION CONNECTOR IF W–B R–G J31 A , J32 B JUNCTION CONNECTOR ID 1 M 2 P9 POWER WINDOW MOTOR FRONT LH P8 POWER WINDOW MASTER SW FRONT RH REAR LH REAR RH WINDOW LOCK SW LOCK NORMAL PU PD RLU RRD R–B 7 ID2 9 ID2 6 ID2 12 ID2 J3 JUNCTION CONNECTOR A A L R–B G–B 5 ID2 G–B R–Y 13 R–Y 8 G–Y R–L RRU 12 G–Y 11 ID2 RLD 9 R–L G–W 6 G–W 14 5 IM1 7 IM1 L L R–Y 2 BB1 3 BB1 1 BB1 2 BA1 3 BA1 1 BA1 2 M 1 P10 POWER WINDOW MOTOR FRONT RH 5 2 M 1 P11 POWER WINDOW MOTOR REAR LH 4 3 SD B U D 1 5 2 M 1 P12 POWER WINDOW MOTOR REAR RH DOWN R–B G–B D 2 SU R U 1 DOWN 3 B UP 4 SD R R G 1 R–B G–B D 2 SU G U 3 P5 POWER WINDOW CONTROL SW FRONT RH 4 B DOWN R–L 2 SD UP 5 SU UP IL2 G 6 L IL2 P6 POWER WINDOW CONTROL SW REAR LH 5 L IL2 G–W 4 L L P7 POWER WINDOW CONTROL SW REAR RH G–Y L 9 IM1 R–B 5 IC1 G–B 1 IC1 L R–L G–W A POWER WINDOW SYSTEM OUTLINE With the ignition SW turned on, current flows through the GAUGE fuse to TERMINAL 7 of the integration relay to TERMINAL (A) 12 to TERMINAL 1 of the POWER relay to TERMINAL 2 to GROUND, this activates the relay and the current flowing to TERMINAL 5 of the relay from the POWER fuse flows to TERMINAL 3 of the relay to TERMINALS 10 and 11 of the power window master SW. 1. MANUAL OPERATION (DRIVER’S WINDOW) With the ignition SW turned on and with the power window master SW (Driver’s) pulled to the up side the current flowing from TERMINALS 10 and 11 of the power window master SW flows to TERMINAL 1 of the master SW to TERMINAL 1 of the power window motor to TERMINAL 2 to TERMINAL 5 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor to rotate in the up direction. The window ascends only while the SW is being pushed. In down operation, the flow of current from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 of the master SW causes the flow of current from TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the master SW to TERMINALS 3 and 4 to GROUND, flowing in the opposite detection to manual up operation and causing the motor to rotate in reverse, lowering the window. 2. AUTO DOWN OPERATION (DRIVER’S WINDOW) When the driver’s window SW is pushed strongly to the down side, the current flowing to TERMINALS 10 and 11 of the power window master SW flows to the down contact point and auto down contact point of the driver’s SW. This activates the relay (Down side) inside the power window master SW and the hold circuit also turns on at the same time, so the relay (Down side) remains activated even when the SW is released. Current flows at this time from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the power window master SW to TERMINALS 3 and 4 to GROUND, so the motor continues to operate until the driver’s window is fully down. When the driver’s window finishes down operation and the hold circuit goes off, so the relay (Down side) also turns off. This stops the current flowing from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 is cut off, so the power window motor stops and auto down operation stops. When the driver’s SW is pulled to the up side during auto down operation, the hold circuit is turned off so the current flowing from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 is cut off and the power window motor stops. If the SW remains pulled up the relay (Up side) is activated, so current flows from TERMINALS 10 and 11 of the power window master SW to TERMINAL 1 to TERMINAL 1 of the power window motor to TERMINAL 2 to TERMINAL 5 to TERMINALS 3 and 4 to GROUND, the power window motor rotates in the up direction and manual up operation occurs while the SW is pulled up. 3. MANUAL OPERATION (FRONT RH WINDOW) With the power window control SW front RH pulled to the up side, the current flowing from TERMINAL 4 of the power window control SW flows to TERMINAL 3 of the power window control SW to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the power window control SW to TERMINAL 2 to TERMINAL 6 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor front RH to rotate in the up direction. The up operation continues only while the power window control SW is pulled to the up side. When the window descends, the current flowing to the motor flows in the opposite direction, from TERMINAL 1 to TERMINAL 2, and the motor rotates in reverse. When the window lock SW is pushed to the lock side, the ground circuit to the front RH window becomes open. As a result, even if Open/Close operation of the front RH window is tried, the current from TERMINALS 3 and 4 of the power window master SW is not grounded and the motor does not rotate, so the front RH window can not be operated and window lock occurs. 4. MANUAL OPERATION (REAR LH, RH WINDOW) With the power window control SW rear LH, RH pulled to the up side, the current flowing from TERMINAL 3 of the power window control SW flows to TERMINAL 1 of the power control SW to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 5 of the power window control SW to TERMINAL 4 to TERMINAL 12 or 13 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor rear LH, RH to rotate in the up direction. The up operation continues only while the power window control SW is pulled to the up side. When the window descends, the current flowing to the motor flows in the opposite direction, from TERMINAL 1 to TERMINAL 2, and the motor rotates in reverse. When the window lock SW is pushed to the lock side, the ground circuit to the rear LH, RH window becomes open. As a result, even if Open/Close operation of the rear LH, RH window is tried, the current from TERMINALS 3 and 4 of the power window master SW is not grounded and the motor does not rotate, so the rear LH, RH window can not be operated and window lock occurs. 5. KEY OFF POWER WINDOW OPERATION With the ignition SW turned from on to off, the integration relay operates and current flows from the DOOR fuse to TERMINAL (A) 13 of the relay to TERMINAL (A) 12 to TERMINAL 1 of the power relay to TERMINAL 2 to GROUND for about 43 seconds. The same as normal operation, the current flows from the POWER fuse to TERMINAL 5 of the power relay to TERMINAL 3 to TERMINALS 10 and 11 of the power window master SW and TERMINAL 4 (Front RH) or 3 (Rear LH, RH) of the power window control SW. As a result, for about 43 seconds after the ignition SW is turned off, the functioning of this relay makes it possible to raise and lower the power window. Also, by opening the front doors (Door courtesy SW on) within about 43 seconds after turning the ignition SW to off, a signal is input to TERMINAL 6 or (A) 8 of the integration relay. As a result, the relay turned off, and up and down movement of the power window stops. SERVICE HINTS P8 POWER WINDOW MASTER SW 10, 11–GROUND : Approx. 12 volts with the ignition SW at ON or ST position or key off power window operation 3, 4–GROUND : Always continuity 1–GROUND : Approx. 12 volts with the power window master SW (Driver’s window) at UP position 5–GROUND : Approx. 12 volts with the power window master SW (Driver’s window) at DOWN or AUTO DOWN position WINDOW LOCK SW Open with the window lock SW at LOCK position : PARTS LOCATION Code See Page D7 32 D8 Code J32 See Page B Code See Page 31 P9 33 32 J33 32 P10 33 30 P5 33 P11 33 J3 31 P6 33 P12 33 J9 31 P7 33 31 P8 33 I12 A J31 A ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC1 ID1 ID2 See Page Joining Wire Harness and Wire Harness (Connector Location) 36 Floor Wire and Instrument Panel Wire (Left Kick Panel) 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IL2 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IM1 38 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BA1 40 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BB1 40 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code See Page Ground Points Location ID 36 Cowl Side Panel LH IF 36 Instrument Panel Brace LH IF J9 JUNCTION CONNECTOR 7 W–B 2 A A W–B 3 1 7 1G IL1 3 1V 3 2 IL1 A 13 3 1 W–B W–B ID 9 A L–R 13 A IL1 A J33 A JUNCTION CONNECTOR W–B 20 12 6 5 3 A A A 20 ID1 IL1 II INTEGRATION RELAY LG IL1 3 ID2 A J35 JUNCTION CONNECTOR 8 ID2 L–R D J5 JUNCTION CONNECTOR L–W 25A DOOR L–B L–R 12 A L–R 4 I12 A L–W 5 1G L–B 3 ID1 G POWER RELAY L–R 4 ID1 A LG 1 D14 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH L–W B G B A UNLOCK B W–B B 5 1M R–B 5 LG 10 LOCK B L–B J27 JUNCTION CONNECTOR 5 A L 3 1M D13 DOOR LOCK CONTROL SW RH 12 ID1 L U1 UNLOCK WARNING SW L E 1 UNLOCK E 2 J5 JUNCTION CONNECTOR 4 A R–G W–B D12 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK D R–G W–B UNLOCK 3 A L–W TO POWER WINDOW MASTER SW 30A POWER W–B 4 G 7 1J J27 JUNCTION CONNECTOR 2 A G 12 1G W–B 13 ID1 E L–W G 2 W–B G 1 A LG L J31 A , J32 B 3 D11 DOOR KEY LOCK AND UNLOCK SW FRONT LH L–W LOCK UNLOCK D J5 JUNCTION CONNECTOR LG J5 JUNCTION CONNECTOR 5 W–B W–B 2 P8 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] LG LOCK W–B DOOR LOCK CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 44) 1 10A GAUGE 2 1 1D C B JUNCTION CONNECTOR A A 7 L–R F F 2 3 4 L–B R–G 11 ID1 M 1 W–B D8 DOOR COURTESY SW FRONT RH 1 R–G D7 DOOR COURTESY SW FRONT LH R–G 1 R–G 6 IM1 D B J31 A , J32 B JUNCTION CONNECTOR R–G E A 7 1S I12 A L–B 6 IC2 L–B L–Y W–B Y 11 IL1 7 BB1 4 BB1 2 3 4 2 3 1 M 1 M 4 W–B 6 BB1 W–B A W–B BK B2 W–B J34 JUNCTION CONNECTOR IJ 3 IM1 L–Y IL2 6 BA1 W–B W–B JUNCTION CONNECTOR 4 L–Y J10 A , J11 B D16 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 5 BB1 L–Y W–B M D A D A 3 D17 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH E B IL2 Y L–Y 1 7 L–B L–B 3 JUNCTION CONNECTOR L–R L–R 2 1 IM1 L–B L–Y 4 BA1 L–Y 7 BA1 C L–B J28 A , J29 B 2 IC2 5 BA1 C B C B L–Y L–B J27 JUNCTION CONNECTOR L–B L–B C L–R L–B L–R 2 IM1 L–R L–R 7 IC2 B B B B L–R L–R L–Y 10 A C A C A C A B A B A B A 8 A Y L–R L–B 11 A 7 A L–R L–R 6 D15 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 6 A INTEGRATION RELAY BL DOOR LOCK CONTROL SYSTEM OUTLINE Current always flows to TERMINAL (A) 13 of the integration relay through the DOOR fuse. When the ignition SW is turned on, the current flowing through the GAUGE Fuse flows to TERMINAL 7 of the integration relay to TERMINAL (A) 12 to the POWER relay (Coil side) to GROUND. 1. MANUAL LOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to LOCK position, a lock signal is input to TERMINAL (A) 1 or (A) 3 of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 of the relay to TERMINAL (A) 6 to TERMINAL 2 of the door lock motors to TERMINAL 3 to TERMINAL (A) 7 of the relay to TERMINAL 10 to GROUND and the door lock motor causes the door to lock. 2. MANUAL UNLOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to UNLOCK position, an unlock signal is input to TERMINAL (A) 2, (A) 4 or (A) 5 of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 of the relay to TERMINAL (A) 7 to TERMINAL 3 of the door lock motors to TERMINAL 2 to TERMINAL (A) 6 of the relay to TERMINAL 10 to GROUND and door lock motors causes door to unlock. 3. DOUBLE OPERATION UNLOCK OPERATION When the door key lock and unlock SW front LH is turned to the unlock side, only the driver’s door to unlock. Turning the door key lock and unlock SW front LH to the unlock side causes a signal to be input to TERMINAL (A) 4 of the relay, and if the signal is input again within 3 seconds by turning the SW to the unlock side again, current flows from TERMINAL (A) 7 of the integration relay to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 of the relay to TERMINAL 10 to GROUND, causing the door lock motors to operate and unlock the doors. 4. IGNITION KEY REMINDER OPERATION When the door is locked using the door lock knob with the ignition key remaining in the key cylinder and door opened, it is automatically unlocked. Additionally, if lock operation is made by the door lock control SW or door key lock and unlock, after the lock operation is completed, the doors are unlocked automatically. SERVICE HINTS I12 (A) INTEGRATION RELAY 10–GROUND : Always continuity 6–GROUND : Continuity with the front LH door open 7–GROUND : Approx. 12 volts with the ignition SW at ON or ST position (A)13–GROUND : Always approx. 12 volts (A) 6–GROUND : Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW locked ∗ Locking the front LH, RH door cylinder with key (A) 1–GROUND : Continuity with the door lock control SW locked (A) 8–GROUND : Continuity with the front RH door open (A) 2–GROUND : Continuity with the door lock control SW unlocked (A) 5–GROUND : Continuity with the front RH door lock cylinder unlocked with key (A) 4–GROUND : Continuity with the front LH door lock cylinder unlocked with key (A) 3–GROUND : Continuity with the front LH, RH door lock cylinder locked with key (A) 7–GROUND : Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW unlocked ∗ Door lock control SW locked with the ignition key in cylinder and the front LH door open (Ignition key reminder function) ∗ Door lock knob locked with the ignition key in cylinder and the front LH door open (Ignition key reminder function) ∗ Unlocking the front LH, RH door cylinder with key D7, D8 DOOR COURTESY SW FRONT LH,RH 1–GROUND : Closed with the each door open D11, D12 DOOR KEY LOCK AND UNLOCK SW FRONT LH,RH 1–2 : Closed with the door lock cylinder locked with key 1–3 : Closed with the door lock cylinder unlocked with key D14, D15 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH,RH 1–4 : Closed with the door lock knob UNLOCK position U1 UNLOCK WARNING SW 1–2 : Closed with the ignition key in cylinder : PARTS LOCATION Code See Page D7 32 Code See Page D17 I12 A Code See Page 32 J29 B 31 D8 32 30 J31 A 31 D11 32 J5 31 J32 B 31 D12 32 J9 31 J33 32 D13 32 J10 A 31 J34 32 D14 32 J11 B 31 J35 32 D15 32 31 P8 33 D16 32 31 U1 31 J27 J28 A ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G 1J 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC2 ID1 ID2 IL1 IL2 See Page Joining Wire Harness and Wire Harness (Connector Location) 36 Floor Wire and Instrument Panel Wire (Left Kick Panel) 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IM1 38 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BA1 40 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BB1 40 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code See Page Ground Points Location ID 36 Cowl Side Panel LH IF 36 Instrument Panel Brace LH 36 Right Kick Panel BK 40 Under the Left Center Pillar BL 40 Under the Right Center Pillar II IJ : SPLICE POINTS Code B2 See Page 40 Wire Harness with Splice Points Floor No.2 Wire Code See Page Wire Harness with Splice Points ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR FROM POWER SOURCE SYSTEM (SEE PAGE 44) 7 AM2 5A STARTER ST2 B–R W–R B–R W–R 8 2J B B–Y B–Y B–R B B B B–W 1 2A J23 A , J24 B B A JUNCTION CONNECTOR 30A AM2 T1 THROTTLE POSITION SENSOR B–Y W–B W–B 4 2L BR 7 2K 12 A 22 A 2 1 E2 VC VTA 1 3 2 G–B 2 2J B 5 2C BR 4 2F I4 LG 3 Y 2 5 1B J22 JUNCTION CONNECTOR 5 B–W 1 3 1J E3 ENGINE COOLANT TEMP. SENSOR BR 7 1W I10 IGNITION SW EFI RELAY 5 1K 5A IGN 20A EFI IG2 6 1 B 11 B 9 B 4 B F 9 A , F11 C FUSIBLE LINK BLOCK 1 C +B 6 A 1 A +B1 BATT 1 A NSW VC VTA E2 THW E4 A , E5 B , E6 C ENGINE CONTROL MODULE A A A BR W–B E1 A , E2 B EB J18 JUNCTION CONNECTOR P 1 A J20 JUNCTION CONNECTOR S1 BR S2 BR 3 B ECT LOCK–UP L–B A W L–B 1 B E1 16 C BR BR L–B Y–B 6 C16 CRUISE CONTROL ECU E05 26 C 3 IG1 B L–R 14 OD E04 13 A B 13 IDL W–B SL 8 C B B NO. 2 BATTERY S1 7 C V 7 IG2 FL MAIN 3. 0W J19 JUNCTION CONNECTOR L–B S2 6 C BR OD1 20 A NO. 1 B–G IDLO 3 A ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID EC FROM POWER SOURCE SYSTEM (SEE PAGE 44) R–L 15A STOP 10A GAUGE 1 1J 2 1D R–L W 7 1C 2 D R–L F B S4 STOP LIGHT SW F B J24 B D R–L J3 JUNCTION CONNECTOR JUNCTION CONNECTOR Y G–W 1 L–W R–L 4 1R R–B 17 A 9 A L 2 R 3 IF1 COMBINATION METER D SPD D E4 A , E5 B , E6 C J19 JUNCTION CONNECTOR ENGINE CONTROL MODULE 7 C 5 C 12 A P 7 IH1 2 IH1 P G–O 6 C L 15 B R–L 7 A G–O OD2 22 C BR E02 13 C BR E01 16 B BR E03 14 B R–L L STP J23 A , J24 B JUNCTION CONNECTOR C10 A , C11 B , C12 C D R–B O/D OFF V–W 18 A C A R–L R–B 19 A R–B V–W L–W 4 A J15 JUNCTION CONNECTOR B B V–W A B C A SPEEDOMETER Y R–L G–W 3 2 SI IF1 J5 JUNCTION CONNECTOR IG+ 1 C C C G–O R–L EC SE V1 VEHICLE SPEED SENSOR (COMBINATION METER) BR BR BR G–O 11 BR C B J23 A , J24 B A A 2 IG2 JUNCTION CONNECTOR G–W 5 1R IG G–O ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR R–L R–L P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 2 RB 7 3 IG3 4 IG2 E L–W L–W A D A R–B D D R E J22 JUNCTION CONNECTOR E Y G–W 1 IH1 B–R 9 IG2 L–W 6 IG2 J22 JUNCTION CONNECTOR 5 IG2 Y G–W PL 8 R–B RL 9 R NL 10 B–R DL 3 L–W 2L 4 Y LL R–B B–R IF1 15 10 A 8 A 2 16 B C10 A , C11 B , C12 C W–B COMBINATION METER A 2 4 O2 O/D MAIN SW W–B A A W–B G–O IE J4 JUNCTION CONNECTOR IF1 G–W R–B 7 A R 11 A N 6 A D R 10 1H B–R 14 O IF1 9 A P Y 13 5 1V Y IF1 L 16 G–W R–B L–W R–B SYSTEM OUTLINE The electronically controlled transmission, however, electrically controls the line pressure and lock–up pressure etc., through the solenoid valve. Engine control module controls of the solenoid valve based on the input signals from each sensor which makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module, and also the input signals to TERMINAL SPD of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st gear, current flows from TERMINAL S1 of the engine control module to TERMINAL (B) 3 of the solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd gear, current flows from TERMINAL S1 of the engine control module to TERMINAL (B) 3 of the solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL (B) 1 of the solenoid to GROUND, and continuity to solenoids No.1 and No.2 causes the shift. For 3rd gear, there is no continuity to No.1 solenoid, only to No.2, causing the shift. Shifting into 4th gear (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK–UP OPERATION When the engine control module judges from each signal that lock–up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL (A) 1 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock–up solenoid and causing lock–up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock–up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock–up solenoid is cut. 4. OVERDRIVE CIRCUIT ∗ O/D main SW on When the O/D main SW is turned on (O/D off indicator light turns off), a signal is input into TERMINAL OD2 of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. ∗ O/D main SW off When the O/D main SW is turned to off, the current through the O/D off indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input into TERMINAL OD2 of the engine control module and engine control module operation prevents shift into overdrive. SERVICE HINTS E4 (A), E5 (B), E6 (C) ENGINE CONTROL MODULE S1, S2–E1 : 9.0–14.0 volts with the solenoid on 0–1.5 volts with the solenoid off L–E1 : 7.5–14.0 volts with the shift lever at L position 2–E1 : 7.5–14.0 volts with the shift lever at 2 position R–E1 : 7.5–14.0 volts with the shift lever at R position STP–E1 : 9.0–14.0 volts with the brake pedal depressed THW–E2 : 0.2–1.0 volts with the ignition SW on and coolant temp. 80°C (176°F) VTA–E2 : 0.3–0.8 volts with the throttle valve fully closed 3.2–4.9 volts with the throttle valve fully opened VC–E2 : 4.5–5.5 volts OD2–E1 : 9.0–14.0 volts with the O/D main SW turned on 0–3.0 volts with the O/D main SW turned off +B–E1 : 9.0–14.0 volts O2 O/D MAIN SW 2–4 : Closed with the O/D main SW off, open with the O/D main SW on ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR : PARTS LOCATION Code C10 See Page Code See Page Code See Page A 30 F9 C11 B 30 F11 C12 C 30 I10 30 J3 31 O2 31 C16 A 28 J22 31 C 28 J23 A 31 30 J24 B 31 E1 A 28 J4 31 P1 29 E2 B 28 J5 31 S4 31 28 J15 31 T1 29 E4 E3 A 30 J18 31 V1 29 E5 B 30 J19 31 E6 C 30 J20 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1B 1C 1D 1H See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1J 1K 1R 1V 1W 2A 2C 2F 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF1 See Page Joining Wire Harness and Wire Harness (Connector Location) 36 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 38 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) 38 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IG1 IG2 IG3 IH1 : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support EC 34 Intake Manifold IE 36 Left Kick Panel IG 36 Instrument Panel Brace RH : SPLICE POINTS Code I4 See Page 38 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points MEMO CRUISE CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE J19 JUNCTION CONNECTOR D D R–L R–L R–L F R–L D J24 JUNCTION CONNECTOR D 2 D 10 B–R R–L F P1 D POSITION SW [PARK/NEUTRAL POSITION SW] 2 IG2 J3 JUNCTION CONNECTOR 1 1J R–L D 2 1D B–R R–L 9 IG2 A J22 JUNCTION CONNECTOR C11 B , C12 C COMBINATION METER A C16 CRUISE CONTROL ECU CRUISE V–W O D O V–W 2 D SE LG–R B B B 11 IG3 10 4 11 LG–R LG–R V1 VEHICLE SPEED SENSOR (COMBINATION METER) SI D O 3 5 IE2 LG–R P IF1 J1 JUNCTION CONNECTOR L 3 O 2 IH1 SPD A/D IG+ TC TC B B D2 DATA LINK CONNECTOR 2 D1 DATA LINK CONNECTOR 1 CCS 11 10 5 4 CMS CCS RESUME/ ACCEL SET/ COAST CANCEL EP 3 BR 1 R–L CMS 12 W BR TC 5 W–L P PI 4 CRUISE 10 C V–W 14 B J15 JUNCTION CONNECTOR 5 C V–W 6 C L D 15 B 7 IH1 3 J2 JUNCTION CONNECTOR SPEEDOMETER B–R 7 C C14 CRUISE CONTROL SW [COMB. SW] W–B IG FROM POWER SOURCE SYSTEM (SEE PAGE 44) E4 A , E6 C 15A ECU–IG ENGINE CONTROL MODULE S2 9 1J 7 1C 1 J19 JUNCTION CONNECTOR B W B B–R L–B L–B S2 6 C Y–B OD1 20 A L–R IDLO 3 A E2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 15A STOP L–B B C J12 JUNCTION CONNECTOR 7 IG2 OD 6 9 ECT GND MO 15 MC L 7 W–B W–B W–B A A 8 1J 1 2 A A 4 1 G–W JUNCTION CONNECTOR 2 R–Y J7 B R–B J6 A , R–G A B A A 2 W S4 STOP LIGHT SW 3 A A STP– 8 G–B 16 B G–W IDL G–W C16 CRUISE CONTROL ECU 14 B–R 13 L–B C 3 W–B 7 1J A W–B IF J9 JUNCTION CONNECTOR 5 1R M 4 1R C3 CRUISE CONTROL ACTUATOR 4 W–B J23 JUNCTION CONNECTOR CRUISE CONTROL SYSTEM OUTLINE The cruise control system is a constant vehicle speed controller which controls the opening angle of the engine throttle valve by the SW, and allows driving at a constant speed without depressing the accelerator pedal. SET CONTROL When the SET/COAST SW is operated while traveling with the CRUISE SW on, the speed when the SET/COAST SW is operated to off is memorized, and the vehicle speed is controlled at that speed. COAST CONTROL When the SET/COAST SW is operated to on, the motor in the actuator rotates the throttle valve until it is closed fully to decrease the vehicle speed, and the speed when the SET/COAST SW is operated to off is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the SET/COAST SW is operated momentarily (Approx. 0.5 sec.) to on, the memorized vehicle speed is decreased by approx. 1.5 km/h (0.9 mph). ACCEL CONTROL When the RESUME/ACCEL SW is operated to on, the motor in the actuator rotates the throttle valve to open direction to increase the vehicle speed, and the speed when the RESUME/ACCEL SW is operated to off is memorized, and the vehicle speed is controlled at that speed. Furthermore, every time the RESUME/ACCEL SW is operated momentarily (Approx. 0.5 sec.) to on, the memorized vehicle speed is increased by approx. 1.5 km/h (0.9 mph). MANUAL CANCEL MECHANISM While traveling with the cruise control, if the following signal is input, the magnetic clutch of the actuator is cut, the motor is controlled to close the throttle valve, and the cruise control is canceled. (1) Stop lamp SW is on (Brake pedal is depressed) (2) The CANCEL SW of the control SW is on (3) CRUISE SW is off RESUME CONTROL After canceling the cruise control by the Manual Cancel operation, (Except when the CRUISE SW is off) if the vehicle speed is above the minimum speed limit (Approx. 40km/h, 25mph), operating the RESUME/ACCEL SW to on from off will cause the system to accelerate and resume to the vehicle speed before manual cancellation. OVERDRIVE FUNCTION The overdrive may be cut on an uphill grade, while traveling with the cruise control. After the overdrive is cut, if the vehicle speed reaches the overdrive resume speed (Set speed minus 2 km/h (1.2 mph) ), and if the system determines that the uphill grade has finished, the overdrive will resume after the overdrive timer operation. AUTO CANCEL OPERATION If any of the following conditions are detected, the set speed is erased and the control is canceled. (1) Overcurrent to the magnetic clutch traction transistor (2) The motor does not operate (3) Short in the magnetic clutch (4) Disconnection in the magnetic clutch (Includes blown stop lamp fuse) (5) No vehicle speed signal input (6) Ground short of the control SW input (7) The actual vehicle speed becomes slower than the minimum speed limit SERVICE HINTS C3 CRUISE CONTROL ACTUATOR 3–4 : Approx. 38.5 Ω C14 CRUISE CONTROL SW [COMB. SW] 5–3 : Continuity with the CRUISE SW on 4–3 : Approx. 418 Ω with the CANCEL SW on Approx. 68 Ω with the RESUME/ACCEL SW on Approx. 198 Ω with the SET/COAST SW on C16 CRUISE CONTROL ECU 9–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 10–GROUND : Approx. 418 Ω with the CANCEL SW on in the cruise control SW Approx. 198 Ω with the SET/COAST SW on in the cruise control SW Approx. 68 Ω with the RESUME/ACCEL SW on in the cruise control SW 16–GROUND : Always continuity : PARTS LOCATION Code See Page C3 28 Code E6 See Page C Code See Page 30 J19 31 C11 B 30 J1 31 J22 31 C12 C 30 J2 31 J23 31 C14 30 31 J24 31 C16 30 J6 A 31 P1 29 D1 28 J7 B 31 S4 31 D2 30 J9 31 V1 29 E2 28 J12 31 30 J15 31 E4 A J3 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1C 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE2 36 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IF1 36 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 38 Engine Wire and Cowl Wire (Under the Blower Motor) 38 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IG2 IG3 IH1 : GROUND POINTS Code See Page Ground Points Location IF 36 Instrument Panel Brace LH IG 36 Instrument Panel Brace RH ABS FROM POWER SOURCE SYSTEM (SEE PAGE 44) 1 8 IJ2 R–L BR 60A FL ABS C A GR–R 2 4 IG3 3 4 3 3 3 E1 WB (SHORT PIN) ABS 6 3 D1 DATA LINK CONNECTOR 1 23 3 TC 14 4 TC 1 TS 11 W–L W–R GR–L 3 W–B J20 JUNCTION CONNECTOR D2 DATA LINK CONNECTOR 2 3 GR–R BR 2 A 5 2 ABS MOTOR RELAY 6 IG3 4 WA 16 22 G–B 1 R–Y 3 ABS SOL RELAY BR 1 LG–R 3 B B LG–R 3 BR JUNCTION CONNECTOR R–L J7 B R–L J6 A , A R–L 11 IG3 8 IG3 5 IG3 IJ1 BR B B LG–R GR–R 7 A 26 B R–Y GR G–B J2 JUNCTION CONNECTOR GR–L LG–R B A13 A , A14 B E 4 A BM 13 5 A IJ2 8 B SRLH 4 B SRRR W–B BR SFRH 2 B 12 A4 A , A5 B 7 B SRRH 3 B SFLR 11 5 B SFLH MT 10 A R–B IJ2 W–R 2 B SRLR ABS ACTUATOR EA SFRR 1 B W–R 6 A M EC SFLH 11 A G–Y 6 B BS SFLR 12 A L–B IJ2 LG–B W–L W–R W–B 2 A 1 A SRRH TS G–Y LG–B 5 E1 SRRR 21 B TC W–L SRLH 15 B D/G W–R W–B SRLR 14 B R+ ABS ECU IJ2 R–W SR 8 B R–G MR 24 B R–B 1 A 1 B SFRR 3 A SFRH MT FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A GAUGE 15A ECU–IG 9 1J 7 1C W R–L 2 1D 15A STOP D 2 S4 STOP LIGHT SW J3 JUNCTION CONNECTOR R–L D 7 A7 ABS SPEED SENSOR FRONT RH 2 1 R G G–W 1 B–R C12 ABS WARNING LIGHT [COMB. METER] A6 ABS SPEED SENSOR FRONT LH 2 1 4 1R R–L 4 5 1R 1 IJ2 6 IJ2 G–W IF1 G–B 12 A A IB1 G 9 1 2 A19 ABS SPEED SENSOR REAR LH IF B 9 A RL– FR+ FR– RR+ RR– 10 B 23 B 2 B 9 B R A 3 A FL– W RL+ 22 B 3 IB1 J9 JUNCTION CONNECTOR 2 A FL+ IK1 1 IK1 B STP G 12 B W–B GND 25 B W 5 B IG1 W–B GND 13 B R WA G–W G–B A13 A , A14 B ABS ECU 11 B 8 A C B C C G JUNCTION CONNECTOR W C J12 JUNCTION CONNECTOR R J22 JUNCTION CONNECTOR B–R G–B J23 A , J24 B C C 1 2 A20 ABS SPEED SENSOR REAR RH ABS SYSTEM OUTLINE This system controls the respective brake fluid pressures acting on the disc brake cylinders of the right front wheel, left front wheel and rear wheels when the brakes are applied in a panic stop so that the wheels do not lock. This results in improved directional stability and steerability during panic braking. 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+ and RR+ of the ABS ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the ABS ECU when the brake pedal is depressed. 2. SYSTEM OPERATION During sudden braking the ABS ECU has signals input from each sensor, which controls the current to the solenoid inside the actuator and lets the hydraulic pressure acting on each wheel cylinder escape to the reservoir. The pump inside the actuator is also operating at this time and it returns the brake fluid from the reservoir to the master cylinder, thus preventing locking of the vehicle wheels. If the ABS ECU judges that the hydraulic pressure acting on the wheel cylinder is insufficient, the current on the solenoid is controlled and the hydraulic pressure is increased. Holding of the hydraulic pressure is also controlled by the ABS ECU, by the same method as above. Pressure reduction, holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking. SERVICE HINTS A6, A7 ABS SPEED SENSOR FRONT LH, RH 2–1 : Approx. 1.6 kΩ (20°C, 68°F) A19, A20 ABS SPEED SENSOR REAR LH, RH 2–1 : Approx. 1.6 kΩ (20°C, 68°F) A14 (B) ABS ECU (B)13–GROUND : Approx. 12 volts with the ignition SW at ON or ST position (B) 5–GROUND : Approx. 12 volts with the brake pedal depressed (B)12, (B) 25–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page A4 A 28 C12 30 J12 31 A5 B 28 D1 28 J20 31 A6 28 D2 30 J22 A7 28 J2 31 J23 A 31 J3 31 J24 B 31 A13 A 30 A14 B 30 J6 A 31 A19 32 J7 B 31 A20 32 J9 31 : RELAY BLOCKS Code 3 See Page 26 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Radiator Upper Support RH) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1C 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R S4 31 31 : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 36 Floor Wire and Cowl Wire (Left Kick Panel) IF1 36 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) IG3 38 Engine Wire and Cowl Wire (Under the Blower Motor) 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) 38 Floor No.2 Wire and Cowl Wire (Right Kick Panel) IJ1 IJ2 IK1 : GROUND POINTS Code See Page Ground Points Location EA 34 Right Radiator Side Support EC 34 Intake Manifold IF 36 Instrument Panel Brace LH : SPLICE POINTS Code E1 See Page 34 Wire Harness with Splice Points Engine Room Main Wire Code See Page Wire Harness with Splice Points MEMO SRS NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model year.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)
When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back–up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, seat belt pretensioner, center airbag sensor assembly or front airbag sensor assembly directly to hot air or flames.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, seat belt pretensioner, center airbag sensor assembly and front airbag sensor assembly should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, seat belt pretensioner, center airbag sensor assembly or front airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, seat belt pretensioner, center airbag sensor assembly or front airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. SRS FROM POWER SOURCE SYSTEM (SEE PAGE 44) 5A IGN 15A CIG 4 1N 10A ECU–B 2 1N 7 2J A9 AIRBAG SENSOR FRONT LH W–R A10 AIRBAG SENSOR FRONT RH 3 1W 2 1G E7 ENGINE CONTROL MODULE F/PS A CONNECTION DETECTION PIN 2 2 IA1 L 1 IA1 8 IG1 B–W W–R BR–W 1 12 B L CONNECTION DETECTION PIN 2 BR 1 B GR B–O A A 1 II1 2 II1 6 B +SL ACC L 15 B –SL B–W 26 B IG2 BR–W W–R 5 B BR A 20 B 9 B 4 B –SR +SR GSW C4 A , C5 B , C6 C E1 E2 D– P+ P– 27 B 28 B 14 B 13 B 10 B 11 B W–B W–B Y–B Y Y–R Y–G CENTER AIRBAG SENSOR ASSEMBLY 1 1N 3 1N 1 2 1 2 3 1V W–B W–B 7 1J A J9 JUNCTION CONNECTOR IF ID D+ SPIRAL CABLE A17 AIRBAG SQUIB (STEERING WHEEL PAD) A16 AIRBAG SQUIB (FRONT PASSENGER AIRBAG ASSEMBLY) J8 JUNCTION CONNECTOR W–R AB TC 11 IG3 3 BR LG–R 7 IG3 W–R E1 D1 DATA LINK CONNECTOR 1 11 LG 5 12 C11 SRS WARNING LIGHT [COMB. METER] LG–R IE2 A J2 JUNCTION CONNECTOR B A B P–B B B–Y A 3 B 19 B LA LG–R LG D2 DATA LINK CONNECTOR 2 2 LG LG 13 TC C4 A , C5 B , C6 C 4 TC E1 3 CENTER AIRBAG SENSOR ASSEMBLY PL– PR+ 5 C PR– SIL 12 B 6 C B B BR J6 A , C A BR W (SHIELDED) C C A JUNCTION CONNECTOR J2 JUNCTION CONNECTOR Y Y–B Y C Y–B J7 B W 1 A BR PL+ 2 A I1 6 IG3 P13 PRETENSIONER LH P14 PRETENSIONER RH J20 JUNCTION CONNECTOR BR 7 BR 2 A A A BR 1 D3 DATA LINK CONNECTOR 3 2 SIL 1 EC SRS SYSTEM OUTLINE The SRS is a driver and front passenger protection device which has a supplemental role to the seat belts. When the ignition SW is turned to ACC or ON, current from the CIG fuse flows to TERMINAL (B) 6 of the center airbag sensor assembly. Only when the ignition SW is on does the current flow from the IGN fuse to TERMINAL (B) 5 of the center airbag sensor assembly. If an accident occurs while driving, when the frontal impact exceeds a set level, current from the CIG or IGN fuse flows to TERMINALS (B) 14, (B) 10, (A) 2 and (C) 5 of the center airbag sensor assembly to TERMINAL 1 of the airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (B) 13, (B) 11, (A) 1 and (C) 6 of the center airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, so that current flows to the front airbag squibs and the pretensioners and causes them to operate. The airbag stored inside the steering wheel pad is instantaneously expanded to soften the shock to the driver. The airbag stored inside the passenger’s instrument panel is instantaneously expanded to soften the shock to the front passenger. : PARTS LOCATION Code See Page Code See Page Code J7 See Page A9 28 C11 30 B 31 A10 28 D1 28 J8 31 A16 30 D2 30 J9 31 A17 30 D3 30 J20 31 C4 A 30 E7 30 P13 33 C5 B 30 J2 31 P14 33 C6 C 30 J6 A 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1G See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1J 1N 1V 1W 2J : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IA1 36 Cowl Wire and Cowl Wire (Left Kick Panel) IE2 36 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) 38 Engine Wire and Cowl Wire (Under the Blower Motor) 38 Engine Room Main Wire and Cowl Wire (Cowl Side Panel RH) IG1 IG3 II1 : GROUND POINTS Code See Page Ground Points Location EC 34 Intake Manifold ID 36 Cowl Side Panel LH IF 36 Instrument Panel Brace LH : SPLICE POINTS Code I1 See Page 38 Wire Harness with Splice Points Cowl Wire Code See Page Wire Harness with Splice Points MEMO SHIFT LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 44) 15A CIG 15A ECU–IG 8 1D 7 1C W 1 1T 15A STOP P–L B–R 2 S4 STOP LIGHT SW A C J16 JUNCTION CONNECTOR A 1 G–W J5 JUNCTION CONNECTOR C B–R 1 3 2 1H G–W P–L 4 1R ACC S3 SHIFT LOCK ECU 6 IG SHIFT LOCK CONTROL SW STP P1 P P2 SLS– G–R 3 G 2 G–W 1 L SHIFT LOCK SOLENOID SLS+ KLS+ E 5 W–B L–B 4 L–B 5 IE1 A J4 JUNCTION CONNECTOR 2 K1 KEY INTERLOCK SOLENOID W–B A A J6 JUNCTION CONNECTOR W–B 8 1J 7 1J W–B W–B 1 A A J9 JUNCTION CONNECTOR IF IE L–R 2 1 SYSTEM OUTLINE When the ignition SW is turned to ACC position the current from the CIG fuse flows to TERMINAL 1 of the shift lock ECU, in the ON position, the current from the ECU–IG fuse flows to TERMINAL 3 of the ECU. 1. SHIFT LOCK MECHANISM With the ignition SW on, when a signal that the brake pedal is depressed (Stop light SW on) and a signal that the shift lever is put in P position (Continuity between P1 and P of the shift lock control SW) is input to the shift lock ECU, the ECU operates and current flows from TERMINAL 3 of the ECU to TERMINAL SLS+ of the shift lock solenoid to solenoid to TERMINAL SLS– to TERMINAL 5 of the ECU to GROUND. This causes the shift lock solenoid to turn on (Plate stopper disengages) and the shift lever can shift into position other than the P. 2. KEY INTERLOCK MECHANISM With the ignition SW ON or ACC position, when the shift lever is put in P position (No continuity between P2 and P of shift lock control SW), the current flowing from TERMINAL 4 of the shift lock ECU to the key interlock solenoid is cut off. This causes the key interlock solenoid to turn off (Lock lever disengages from LOCK position) and the ignition key can be turned from ACC to LOCK position. SERVICE HINTS S3 SHIFT LOCK ECU 1–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 3–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 5–GROUND : Always continuity 6–GROUND : Approx. 12 volts with the brake pedal depressed S4 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed : PARTS LOCATION Code See Page Code See Page Code See Page J4 31 J9 31 S3 31 J5 31 J16 31 S4 31 J6 31 K1 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1C 1D 1H 1J 1R 1T See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 See Page 36 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) : GROUND POINTS Code See Page Ground Points Location IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH HORN FROM POWER SOURCE SYSTEM (SEE PAGE 44) 10A HORN 1 5 2 3 10 2K 1 2F G–B G–W HORN RELAY C G–W C G–B J1 JUNCTION CONNECTOR 6 G–W C14 HORN SW [COMB. SW] 1 1 H3 HORN (HIGH) H4 HORN (LOW) SERVICE HINTS HORN RELAY 5–3 : Closed with the horn SW on : PARTS LOCATION Code See Page Code See Page C14 30 H4 28 H3 28 J1 31 Code ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 2F 24 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2K 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) See Page CIGARETTE LIGHTER AND CLOCK FROM POWER SOURCE SYSTEM (SEE PAGE 44) 15A CIG 7. 5A PANEL 1 1T 5 1D 12 2J G R 6 1J 7. 5A DOME P–L 1 1W A A J28 A , J29 B R–Y P–L A B 8 1G JUNCTION CONNECTOR 1 A D5 DIODE (DOME) J5 JUNCTION CONNECTOR 2 R A D B E A G J16 A , J17 B R JUNCTION CONNECTOR C7 CIGARETTE LIGHTER 1 P–L 2 3 1 C9 CLOCK 2 W–B W–B 4 A J4 JUNCTION CONNECTOR W–B A A J9 JUNCTION CONNECTOR IF IE SERVICE HINTS C7 CIGARETTE LIGHTER 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1–GROUND : Always continuity C9 CLOCK 4–GROUND : 1–GROUND : 2–GROUND : 3–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position Always approx. 12 volts Always continuity Approx. 12 volts with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page Code See Page C7 30 J5 C9 30 D5 30 J16 A 31 J4 31 J17 B 31 J9 Code J28 A 31 31 J29 B 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D 1G See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1T 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) : GROUND POINTS Code See Page Ground Points Location IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH See Page 31 KEY REMINDER AND SEAT BELT WARNING FROM POWER SOURCE SYSTEM (SEE PAGE 44) 25A DOOR 10A GAUGE R–L 2 1D 1 1D 7 C C10 A , C12 C C B SEAT BELT WARNING LIGHT [COMB. METER] 4 A 1 1W 13 A 1 I12 A INTEGRATION RELAY 9 L–W R–W A A 3 1T 12 2J L–W J3 JUNCTION CONNECTOR 7 R D J31 A , J32 B D JUNCTION CONNECTOR R–L 7. 5A DOME 5 6 8 5 1M 7 1S 4 1S R–Y 1 1 L–B 10 R–G BUZZER 1 U1 UNLOCK WARNING SW W–B 2 3 1M B5 BUCKLE SW LH D7 DOOR COURTESY SW FRONT LH 2 A W–B W–B 7 1J J9 JUNCTION CONNECTOR IF A J34 JUNCTION CONNECTOR BK SYSTEM OUTLINE Current always flows to TERMINAL 1 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 7 of the integration relay. At the same time, current flows to TERMINAL 9 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the relay and the current flowing through the warning light flows from TERMINAL 9 of the relay to TERMINAL 10 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL 8 of the relay to TERMINAL 10 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL 8 of the relay, the current flowing to TERMINAL 1 of the relay flows from TERMINAL 10 to GROUND and the seat belt warning buzzer sounds for approx. 6 seconds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL 8 of the relay stops and the current flow from TERMINAL 1 of the relay to TERMINAL 10 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver’s door open (Door courtesy SW on), when a signal is input to TERMINAL 6 of the integration relay, the relay operates, current flows from TERMINAL 1 of the relay to TERMINAL 10 to GROUND and key reminder buzzer sounds. SERVICE HINTS B5 BUCKLE SW LH 1–2 : Closed with driver’s seat belt in use D7 DOOR COURTESY SW FRONT LH 1–GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1–2 : Closed with ignition key in cylinder I12 (A) INTEGRATION RELAY 10–GROUND : Always continuity 6–GROUND : Continuity with the front LH door open 5–GROUND : Continuity with the ignition key in cylinder 8–GROUND : Continuity with the driver’s seat belt in use 1–GROUND : Always approx. 12 volts (A)13–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page B5 C10 C12 32 A 30 C 30 D7 Code I12 See Page A J3 J9 32 J31 A 30 Code J32 1D See Page J34 32 31 U1 31 31 Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 22 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1T 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1J 1M : GROUND POINTS Code See Page Ground Points Location IF 36 Instrument Panel Brace LH BK 40 Under the Left Center Pillar 31 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page B POWER OUTLET FROM POWER SOURCE SYSTEM (SEE PAGE 44) 15A POWER– OUTLET V 5 1J 2 P4 POWER OUTLET W–B 1 4 1V W–B 3 1V ID SERVICE HINTS P4 POWER OUTLET 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1–GROUND : Always continuity : PARTS LOCATION Code See Page P4 Code See Page 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1J 1V See Page 22 Junction Block and Wire Harness (Connector Location) Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : GROUND POINTS Code ID See Page 36 Ground Points Location Cowl Side Panel LH Code See Page REMOTE CONTROL MIRROR FROM POWER SOURCE SYSTEM (SEE PAGE 44) * 1 : W/ MIRROR HEATER * 2 : W/O MIRROR HEATER 15A CIG P–L 1 1T A J5 JUNCTION CONNECTOR P–L A R5 REMOTE CONTROL MIRROR SW 9 J3 JUNCTION CONNECTOR C C M IL1 4 A 3 B 2 A 1 B M M R13 A , B R14 A , B REMOTE CONTROL MIRROR LH REMOTE CONTROL MIRROR RH OPERATION SW SELECT SW RIGHT/ DOWN E 6 10 W–B A J4 JUNCTION CONNECTOR A LG–R LG–B BR–R 14 15 IL1 LG–R M 3 A (*1) 2 B (*2) IL1 LG–B 2 A 1 B 16 BR–R LG–R 4 A 3 B LG–R 15 ID1 BR–Y 14 ID1 BR–W 16 ID1 BR–Y C M+ W–B 7 LG–B VR 1 BR–Y VL 8 BR–R HR 5 BR–W HL MV LG–R MH LEFT/ UP DOWN UP LEFT RIGHT B 3 A (* 1) 2 B (* 2) IE SERVICE HINTS R5 REMOTE CONTROL MIRROR SW 9–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 6–10 : Continuity with the operation SW at UP or LEFT position 9–6 : Continuity with the operation SW at DOWN or RIGHT position : PARTS LOCATION Code See Page J3 31 J4 31 J5 31 Code See Page R5 R13 31 A 33 B 33 Code R14 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1T See Page 22 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IL1 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IE See Page 36 Ground Points Location Left Kick Panel See Page A 33 B 33 REAR WINDOW DEFOGGER AND MIRROR HEATER FROM POWER SOURCE SYSTEM (SEE PAGE 44) 1 10A HEATER 40A DEF 10A MIRROR– HEATER 2 1 5 NOISE FILTER 2 DEFOGGER RELAY L–B 5 1T 8 IB1 4 1D 5 ID1 5 7 1J W–B Y–G 1 1L B–Y 13 1J B–Y 12 1J 3 B 3 1R L–B 1 2 IL1 R14 MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] W–B B–Y A J35 JUNCTION CONNECTOR A R13 MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] W–B B–Y J30 JUNCTION CONNECTOR J33 JUNCTION CONNECTOR A L–B 1 B 5 5 D A A 5 A A W–B W–B 4 IG 1 1 20 IL1 W–B 20 ID1 TIMER CIRCUIT W–B 7 1G E REAR WINDOW DEFOGGER 3 1V W–B R4 REAR WINDOW DEFOGGER SW N2 NOISE FILTER (REAR WINDOW DEFOGGER) W–B W–B 3 A J9 JUNCTION CONNECTOR A IF W–B ID II SERVICE HINTS DEFOGGER RELAY 5–3 : Closed with the ignition SW at ON or ST position and the rear window defogger SW on R4 REAR WINDOW DEFOGGER SW 4–GROUND : Approx. 12 volts with the ignition SW at ON or ST position 3–GROUND : Always continuity R13, R14 MIRROR HEATER LH, RH [REMOTE CONTROL MIRROR LH, RH] 1–GROUND : Approx. 12 volts with the rear window defogger SW on 5–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page J9 31 J35 32 R13 33 J30 31 N2 33 R14 33 J33 32 R4 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 1T 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1V 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G 1J 1L 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IB1 36 Floor Wire and Cowl Wire (Left Kick Panel) ID1 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IL1 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location ID 36 Cowl Side Panel LH IF 36 Instrument Panel Brace LH II 36 Right Kick Panel RADIO AND PLAYER FROM POWER SOURCE SYSTEM (SEE PAGE 44) 20A RADIO NO. 1 7. 5A RAD–NO. 2 3 1H GR L–Y 11 2K 5 1W L–Y 6 1G B A J16 JUNCTION CONNECTOR GR A L–Y B 4 A 3 A BU +B ACC +B R2 B , R3 A 2 BR F15 FRONT DOOR SPEAKER LH 1 2 F16 FRONT DOOR SPEAKER RH W 9 IC1 3 IC1 10 IC1 4 IC1 1 2 R11 REAR SPEAKER LH W R L IL1 RR– 3 B R 1 RR+ 1 B Y IL1 RL– 6 B Y L LG 9 RL+ 2 B B FR– 5 A LG V 1 ID1 V 9 ID1 1 IG FR+ 1 A B FL– 6 A P BR FL+ 2 A P GND 7 A RADIO AND PLAYER 1 2 R12 REAR SPEAKER RH SERVICE HINTS R3 (A) RADIO AND PLAYER (A) 4–GROUND : Always approx. 12 volts (A) 3–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position (A) 7–GROUND : Always continuity : PARTS LOCATION Code See Page Code F15 32 R2 F16 32 R3 J16 31 R11 See Page B 31 A 31 33 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1G 22 1H 22 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2K 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IC1 36 Floor Wire and Instrument Panel Wire (Left Kick Panel) ID1 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IL1 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IG See Page 36 Ground Points Location Instrument Panel Brace RH Code R12 See Page 33 COMBINATION METER 10A GAUGE 1 1J 7. 5A DOME TO CRUISE CONTROL ECU TO ENGINE CONTROL MODULE FROM POWER SOURCE SYSTEM (SEE PAGE 44) 8 1G R–Y 2 1D 1 1W 12 2J R D R–L V–W V–W D5 DIODE (DOME) R 2 B E 3 IF1 J16 JUNCTION CONNECTOR E V–W R F J3 JUNCTION CONNECTOR J15 JUNCTION CONNECTOR B B V–W D J24 JUNCTION CONNECTOR R–L F R–L R–L 1 C10 A , C11 B , C12 C MALFUNCTION INDICATOR LAMP WATER TEMP. 3 IH1 6 IH1 2 C G–R Y–G P P G–R BR Y–G V1 VEHICLE SPEED SENSOR (COMBINATION METER) SE IF1 TO ENGINE CONTROL MODULE 2 TO DOOR COURTESY SW B–O E7 ENGINE CONTROL MODULE 1 A 10 G–W 2 FUEL 2 A BR DOOR L 2 IH1 SI FROM ENGINE CONTROL MODULE IG+ 1 IG 1 W3 WATER TEMP. SENDER BR BR R–L J19 JUNCTION CONNECTOR D D R–L 8 FUELW 10 B 7 IH1 3 5 IG1 6 C IF1 4 IH1 Y–R IF1 Y–R R–L 9 15 B L 6 2 IG2 11 B R–W 8 C B–O 5 C 14 B SPEEDOMETER TRIP METER ODOMETER TACHOMETER FUEL 3 B BR R–L Y–R 6 B COMBINATION METER G–W FUEL 7 C EC FROM POWER SOURCE SYSTEM (SEE PAGE 44) 5A STARTER B–W 3 1J C B J6 A , B–W 5 P B A P1 PARK/NEUTRAL POSITION SW N 6 6 IE1 10 IG2 GR J7 B JUNCTION CONNECTOR GR 11 IG2 B–W B–O B GR J22 JUNCTION CONNECTOR B C10 A , C11 B , C12 C COMBINATION METER G–O TO O/D MAIN SW R–W B B R–W B R–W Y–G W1 WASHER LEVEL WARNING SW TO ABS ECU TO INTEGRATION RELAY 2 J1 JUNCTION CONNECTOR P–L O IE2 IC2 IJ2 1 O/D OFF BULB CHECK RELAY BRAKE Y–G 3 5 3 TO CRUISE CONTROL ECU IF1 12 A 1 7 B1 BRAKE FLUID LEVEL WARNING SW IE1 R–W 17 P–L IE2 7 B R–W 3 A O 5 5 IH1 Y–B REAR LIGHTS WASHER LEVEL 11 C P–L 4 C R–L ABS SEAT BELT 4 A R–W OIL CRUISE 10 C Y–B 5 B 2 B 2 EB TO LIGHT FAILURE SENSOR P3 PARKING BRAKE SW 1 W–B O1 OIL PRESSURE SW W–B 1 A J9 JUNCTION CONNECTOR IF COMBINATION METER FROM POWER SOURCE SYSTEM (SEE PAGE 44) 5A IGN FROM A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 8 1T R B–R O Y G 10 A 7 A 11 A 6 A 13 C C10 A , C11 B , C12 C B COMBINATION METER 12 C Y W–B D B R6 RHEOSTAT J16 JUNCTION CONNECTOR 16 B L 2 P 4 B ILLUMINATION R–B 8 A D G–W 9 A N B–R 13 A R G–Y 1 C CHARGE G–B G 1 B D 2 ILL TO GENERATOR E A J4 JUNCTION CONNECTOR A IE T 1 G 3 W–B TURN RH TURN LH FROM HAZARD SW OR TURN SIGNAL SW [COMB. SW] A W–B A W–B G W–B FROM POWER SOURCE SYSTEM (SEE PAGE 44) 7. 5A PANEL 10A ECU–B 5 1D 7 2J G W–R R–L 3 FROM HEADLIGHT LH, RH IE1 A G A A 3 1W R–L J28 JUNCTION CONNECTOR G W–R 2 1G W–B W–B G COMBINATION METER C10 A , C11 B , C12 C 9 B LG SRS 13 B TO CENTER AIRBAG SENSOR ASSEMBLY G 8 B HIGH BEAM 12 B COMBINATION METER SERVICE HINTS B1 BRAKE FLUID LEVEL WARNING SW 1–2 : Closed with the float down C10 (A), C11 (B), C12 (C) COMBINATION METER (B) 2–GROUND : Approx. 12 volts with the ignition SW at ST position and the shift lever at P or N position (A) 13, (C) 7–GROUND : Approx. 12 volts with the ignition SW at ON or ST position (B)11, (B) 12–GROUND: Always approx. 12 volts (A) 2, (B) 9, (B) 16, (C) 5–GROUND : Always continuity O1 OIL PRESSURE SW 1–GROUND : Closed with the oil pressure above approx. 19.6 kpa (2.8 psi, 0.2 kgf/cm2) P3 PARKING BRAKE SW 1–GROUND : Closed with the parking brake lever pulled up W3 WATER TEMP. SENDER 1–GROUND : Approx. 160–240 Ω (50°C, 122°F) Approx. 17.1–21.2 Ω (120°C, 248°F) : PARTS LOCATION Code See Page B1 Code 28 J6 J7 See Page Code See Page A 31 O1 29 B C10 A 30 31 P1 29 C11 B 30 J9 31 P3 31 C C12 30 J15 31 R6 31 D5 30 J16 31 V1 29 E7 30 J19 31 W1 29 J1 31 J22 31 W3 29 J3 31 J24 31 J4 31 J28 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1D 1G See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1T 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IC2 See Page Joining Wire Harness and Wire Harness (Connector Location) 36 Floor Wire and Instrument Panel Wire (Left Kick Panel) 36 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) 36 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 38 Engine Wire and Cowl Wire (Under the Blower Motor) IH1 38 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IJ2 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IE1 IE2 IF1 IG1 IG2 : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support EC 34 Intake Manifold IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH IG 36 Instrument Panel Brace RH RADIATOR FAN AND CONDENSER FAN ACC 2 AM1 1 1 IG1 4 30A RDI 30A CDS 2 B–Y 2 1 FAN NO. 1 RELAY 1 1K 2 40A AM1 15A ECU–IG 1 2C 2 3 2 2F 1 2G 7 2G 2 2C B–R 2 1K 4 L W I10 IGNITION SW 2 2H M G–W W–B B–R 4 2F B–R 2 2B B–R E3 1 F 2 F 1 D 3 3 2 2 FAN NO. 3 RELAY 1 5 W–R W–B W4 WATER TEMP. SW NO. 1 W–B 1 FL MAIN 3. 0W 2 EA1 W–B BATTERY E2 W–B W–B B–G F14 F FUSIBLE LINK BLOCK EB W–B 2 1 3 4 1 5 1 B–R L–W 2 F 9 A , F12 D , 1 W–B 1 EA1 1 A 1 3 1 100A ALT 1 R G–W 1 FAN NO. 2 RELAY ENGINE MAIN RELAY 1 M B–W 5 4 2 1 A3 A/C SINGLE PRESSURE SW 2 1 L–W B–R 6 2K R1 RADIATOR FAN MOTOR A1 A/C CONDENSER FAN MOTOR 2 1 1 W–B 6 1A B–R 1 1B FROM MG CLT RELAY L B–R G–W 1 SYSTEM OUTLINE FAN MOTOR OPERATION With the ignition SW turned on, the current through the ECU–IG fuse flows to the FAN NO.1 relay (Coil side), FAN NO.2 relay (Coil side). furthermore, the current through the FAN NO.1 relay (Coil side) or the FAN NO.2 relay (Coil side) flows to TERMINAL 3 of the A/C single pressure SW to TERMINAL 2 to TERMINAL 2 of the water temp. SW no.1 to TERMINAL 1 to GROUND, causing the FAN NO.1 relay to turn off and the FAN NO.2 relay to turn on. 1. LOW SPEED OPERATION When the ignition SW is turned on and the A/C system is activated, the A/C condenser fan motor and the radiator fan motor rotates at low speed. When the A/C system is activated, the current from MG CLT relay flows to the FAN NO.3 relay (Coil side) to GROUND, causing the FAN NO.3 relay to turn on. As a result, the current through the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 5 to TERMINAL 5 of the FAN NO.3 relay to TERMINAL 3 to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. 2. HIGH SPEED OPERATION Only when the A/C single pressure SW is turned off or the water temp. SW no.1 is turned off, the A/C condenser fan motor and the radiator fan motor rotate at high speed. When the A/C single pressure SW is turned off or the water temp. SW no.1 is turned off. the current from the RDI fuse flows to the FAN NO.1 relay (Point side) to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. At the same time, the current from the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 4 to GROUND. SERVICE HINTS A3 A/C SINGLE PRESSURE SW 3–2 : Open above approx. 15.5 kgf/cm2 (220 psi, 1520 kpa) Closed below approx. 12.5 kgf/cm2 (177 psi, 1225 kpa) W4 WATER TEMP. SW NO.1 2–1 : Open above approx. 95°C (203° F) : PARTS LOCATION Code See Page A1 A3 F9 A Code 28 F12 28 F14 28 I10 See Page Code 28 R1 29 F 28 W4 29 30 : RELAY BLOCKS Code 1 See Page 26 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 22 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 24 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1K 2B 2C 2F 2G 2H 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 See Page 34 See Page D Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room Main No.3 Wire (Radiator LH) RADIATOR FAN AND CONDENSER FAN : GROUND POINTS Code EB See Page 34 Ground Points Location Left Radiator Side Support : SPLICE POINTS Code E2 See Page 34 Wire Harness with Splice Points Engine Room Main Wire Code E3 See Page 34 Wire Harness with Splice Points Cowl Wire MEMO AIR CONDITIONING 50A HTR FROM POWER SOURCE SYSTEM (SEE PAGE 44) F13 FUSIBLE LINK BLOCK 10A HEATER 2 1W 3 1R L–B L–B 1 5 2K A L–B 1 5 HTR RELAY A 2 1 J30 JUNCTION CONNECTOR 9 2C 3 1 L–B 1 L–W L–R L–R 5 MG CLT RELAY 3 1 W–B 1 4 2 1 L–B 1 1 1 L–B 1 L–B L–B L–B L–B B–W B–W L–Y L–Y B–W TO FAN NO. 3 RELAY 10A A/C 1 1 3 EB1 L–R L–R B3 BLOWER RESISTOR 2 M 2 2 EB1 L–R 1 EB2 1 3 B2 BLOWER MOTOR 6 2 1 4 M1 LO L–B 8 M2 W–B 5 HI W–B L–W B–W I6 L–O B–W L–B B–W 1 W–B W–B OFF 3 A 1 B4 BLOWER SW W–B A J9 JUNCTION CONNECTOR W–B L–B EB A IF W–B I3 W–B H7 HEATER CONTROL SW L–B B–W FACE B/L FOOT F/D DEF 3 GND FACE B/L FOOT F/D DEF 1 8 7 6 5 4 2 L–B B–W 7 IJ2 L–Y L–O B–L L–R L R–B L–R L–W L–Y W–B L–Y D L–R D D L–R J12 JUNCTION CONNECTOR W–B 1 2 3 4 5 FACE B/L FOOT F/D DEF R–B A R–B M L–R R–B 2 5 R–W 1 CONTROL CIRCUIT B L–B 6 IG OFF W–B 7 GND ON A15 AIR VENT MODE CONTROL SERVO MOTOR A12 A/C SW AIR CONDITIONING L–B B–W B–W 1 4 A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR A3 A/C DUAL PRESSURE SW 4 2 BR G W–L 1 L–Y IJ2 10 IJ2 BR 9 W–L IJ2 G 2 B J7 JUNCTION CONNECTOR 1 B J12 JUNCTION CONNECTOR BR R–B 2 BR B L–W R–B B A11 A/C EVAPORATOR TEMP. SENSOR L–R BR 10 IG3 6 IG3 BR 3 IG2 W–L 1 IG2 L–Y R–B 1 IG1 G B R–W A LOCK 10 A A/CS 21 A 10 D MGC PRS 10 B THR 9 B E2 J20 JUNCTION CONNECTOR 18 C LOCK IN A BR 15 A E4 A , E5 B , E6 C , E7 D ENGINE CONTROL MODULE EC SYSTEM OUTLINE Current always flows from the HTR fuse to TERMINAL 1 of the HTR relay. When the ignition SW is turned on, the current from the HEATER fuse flows to TERMINAL 6 of the air vent mode control servo motor, and to the MG CLT relay (Coil side) to TERMINAL (A) 21 of the engine control module, and to TERMINAL 1 of the A/C dual pressure SW to TERMINAL 4 to TERMINAL (D) 10 of the engine control module, and to the HTR relay (Coil side) to TERMINAL 3 of the blower SW. 1. AIR VENT MODE CONTROL SERVO MOTOR OPERATION When the damper is in FACE position and B/L mode on the heater control SW is selected, current flows from TERMINAL 7 of the heater control SW to TERMINAL 2 of the air vent mode control serve motor so that a signal that the ground circuit is activated is input into TERMINAL B of the control circuit inside the air vent mode control servo motor. Simultaneously, a signal that the ground circuit is not activated is input into TERMINAL A of the control circuit inside the servo motor. These two signals activate the control circuit so that current flows from the HEATER fuse to the servo motor, causing the servo motor to operate and the damper to move to B/L position. When the damper reaches B/L position. A ground cut signal is input into TERMINAL B of the control circuit, the control circuit operates, the servo motor stops rotating and the damper stops at B/L. When another mode position is selected, input of signals into TERMINAL A and TERMINAL B of the control circuit that ground is made or not (as explained above) activates the control circuit and moves the serve motor to the desired position. 2. AIR CONDITIONING OPERATION When the blower SW is on, current flows from the HEATER fuse to the HTR relay (Coil side) to TERMINAL 3 of the blower SW to TERMINAL 1 to GROUND, activating the HTR relay. This causes current to flow from the HTR fuse to the HTR relay (Point side) to A/C fuse to TERMINAL 2 of the A/C SW. If the A/C SW is turned on at this time, a signal is input into the engine control module. This activates the engine control module and MG CLT relay so that current flows from the HEATER fuse to the MG CLT relay (Point side) to A/C magnetic clutch. Causing The compressor to operate. When blower SW is on and heater control SW is at DEF position, it causes A/C to run whether A/C SW is on or not. SERVICE HINTS HTR RELAY 1–2 : Closed with the ignition SW at ON or ST position and the blower SW on MG CLT RELAY 5–3 : Closed with the ignition SW at ON or ST position, the blower SW on and the A/C SW on or the heater control SW at DEF position A3 A/C DUAL PRESSURE SW 1–4 : Open with pressure less than approx. 2.0 kgf/cm2 (28 psi, 196 kpa) or above approx. 32 kgf/cm2 (455 psi, 3138 kpa) B3 BLOWER RESISTOR 2–1 : Approx. 1.64 Ω 2–3 : Approx. 3.24 Ω 2–6 : Approx. 0.47 Ω : PARTS LOCATION Code See Page A2 28 Code See Page B4 30 Code See Page J7 31 A3 28 E4 A 30 J9 31 A11 30 E5 B 30 J12 31 A12 30 E6 C 30 J20 31 A15 30 E7 D 30 J30 31 B2 30 F13 28 B3 30 H7 30 : RELAY BLOCKS Code 1 See Page 26 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) AIR CONDITIONING ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1R See Page Junction Block and Wire Harness (Connector Location) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2C 24 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2K 24 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1W : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 EB2 See Page Joining Wire Harness and Wire Harness (Connector Location) 34 Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) 38 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IG1 IG2 IG3 IJ2 : GROUND POINTS Code See Page Ground Points Location EB 34 Left Radiator Side Support EC 34 Intake Manifold IF 36 Instrument Panel Brace LH : SPLICE POINTS Code I3 See Page 38 Wire Harness with Splice Points Cowl Wire Code I6 See Page 38 Wire Harness with Splice Points Cowl Wire MEMO I GROUND POINT W–B FRONT TURN SIGNAL LIGHT AND PARKING LIGHT LH E1 W–B RADIATOR FAN MOTOR W–B WASHER LEVEL WARNING SW W–B WATER TEMP. SW NO. 1 W–B E2 W–B FRONT TURN SIGNAL LIGHT AND PARKING LIGHT RH W–B E2 W–B E2 2 EA1 W–B W–B E2 1 FAN NO. 3 RELAY 1 HTR RELAY 1 W–B E2 W–B FAN NO. 2 RELAY W–B W–B E2 W–B W–B W–B E2 ENGINE MAIN RELAY EFI RELAY W–B 10 2J 4 2F W–B FRONT WIPER MOTOR 3 W–B 5 2C W–B W–B EB EA W–B ABS SOL RELAY ABS ACTUATOR COMBINATION METER (ET) 3 IH1 BR 3 IG1 BR (E04) BR (E01) W–B IDLE AIR CONTROL VALVE BR (E02) BR BR IGNITION COIL AND IGNITER NO. 1 (E03) A IGNITION COIL AND IGNITER NO. 2 A BR A A BR BR W–B (E05) BR (E1) J18 JUNCTION CONNECTOR ENGINE CONTROL MODULE ENGINE CONTROL MODULE BR BR EC BR EC A DATA LINK CONNECTOR 1 BR A DATA LINK CONNECTOR 2 BR C A B B BR 6 IG3 BR C A B B BR 10 IJ2 A BR I4 BR 12 IG2 BR HEATED OXYGEN SENSOR BR J20 A JUNCTION CONNECTOR DATA LINK CONNECTOR 3 (SG) J6 A , A/C MAGNETIC CLUTCH AND LOCK SENSOR BR J7 B JUNCTION CONNECTOR RADIO AND PLAYER BR BR IG 6 BB1 W–B B2 IJ W–B W–B W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH BL (ES) COMBINATION METER I GROUND POINT CRUISE CONTROL ECU DATA LINK CONNECTOR 3 (CG) W–B A B A A W–B CRUISE CONTROL ACTUATOR W–B A B A A W–B CRUISE CONTROL SW [COMB. SW] A A W–B LIGHT CONTROL AND DIMMER SW [COMB. SW] A A W–B KEY INTERLOCK SOLENOID A A J6 A , W–B W–B UNLOCK WARNING SW J7 B W–B (E1) CENTER AIRBAG SENSOR ASSEMBLY JUNCTION CONNECTOR A W–B A DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH W–B A DOOR KEY LOCK AND UNLOCK SW FRONT LH W–B A 8 1J 3 1M 1 1N POWER RELAY J33 JUNCTION CONNECTOR W–B POWER WINDOW MASTER SW INTEGRATION RELAY NOISE FILTER NOISE FILTER MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] W–B 7 1J A W–B W–B A W–B W–B 9 2K W–B W–B W–B 3 1N A W–B 4 1V I3 W–B W–B 3 1V W–B J9 JUNCTION CONNECTOR W–B A W–B A W–B HEATER CONTROL SW AIR VENT MODE CONTROL SERVO MOTOR BLOWER RESISTOR REAR WINDOW DEFOGGER SW BLOWER SW A W–B W–B W–B CIGARETTE LIGHTER BRAKE FLUID LEVEL WARNING SW W–B POWER OUTLET (E2) ST RELAY W–B 7 1G W–B WIPER AND WASHER SW [COMB. SW] W–B 20 ID1 CENTER AIRBAG SENSOR ASSEMBLY TURN SIGNAL FLASHER A A W–B ID IH IF (GND) ABS ECU (GND) O/D MAIN SW SHIFT LOCK ECU (–) COMBINATION METER (EP) CLOCK GLOVE BOX LIGHT AND SW RHEOSTAT W–B A W–B A W–B A W–B A W–B A W–B A W–B A W–B A J35 JUNCTION CONNECTOR A W–B DOOR KEY LOCK AND UNLOCK SW FRONT RH A W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH A W–B DOOR LOCK CONTROL SW RH W–B MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] A J4 JUNCTION CONNECTOR A W–B REMOTE CONTROL MIRROR SW 20 IL1 W–B W–B A W–B IE HIGH MOUNTED STOP LIGHT II A W–B A W–B B5 W–B LICENSE PLATE LIGHT RH W–B LICENSE PLATE LIGHT LH W–B REAR COMBINATION LIGHT RH W–B REAR COMBINATION LIGHT LH W–B W–B BUCKLE SW LH REAR COMBINATION LIGHT RH W–B B6 W–B B5 A W–B W–B W–B REAR COMBINATION LIGHT LH W–B B6 A W–B A W–B GAS TEMP. SENSOR 1 W–B LIGHT FAILURE SENSOR W–B J34 JUNCTION CONNECTOR B5 B6 BM BK 6 BA1 W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH I GROUND POINT : PARTS LOCATION Code See Page J4 Code See Page Code See Page 31 J9 31 J33 32 J6 A 31 J18 31 J34 32 J7 B 31 J20 31 J35 32 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 1 26 Engine Room R/B No.1 (Engine Compartment Left) 3 26 Engine Room R/B No.3 (Radiater Upper support RH) ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code 1G See Page Junction Block and Wire Harness (Connector Location) 22 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 24 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 24 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 1M 1N 1V 2C 2F 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) EA1 34 Engine Room Main Wire and Engine Room Main No.3 Wire (Radiator LH) ID1 36 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 38 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) IH1 38 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IJ2 38 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IL1 38 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BA1 40 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BB1 40 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) IG1 IG2 IG3 : GROUND POINTS Code See Page Ground Points Location EA 34 Right Radiator Side Support EB 34 Left Radiator Side Support EC 34 Intake Manifold ID 36 Cowl Side Panel LH IE 36 Left Kick Panel IF 36 Instrument Panel Brace LH IG 36 Instrument Panel Brace RH IH 36 Cowl Side Panel RH 36 Right Kick Panel BK 40 Under the Left Center Pillar BL 40 Under the Right Center Pillar BM 40 Back Panel Center II IJ : SPLICE POINTS Code E1 See Page Wire Harness with Splice Points 34 Engine Room Main Wire I3 38 Cowl Wire I4 38 Engine Wire E2 Code B2 B5 B6 See Page Wire Harness with Splice Points 40 Floor No.2 Wire 40 Floor Wire J POWER SOURCE (Current Flow Chart) J J POWER SOURCE (Current Flow Chart) Instrument Panel J/B (See Page 22) Fuse 5A IGN System Page Charging Combination Meter Electronically Controlled Transmission and A/T Indicator Engine Control 52 138 102 54 SRS 117 138 102 54 48 5A STARTER Combination Meter Electronically Controlled Transmission and A/T Indicator Engine Control Starting and Ignition 7.5A OBD Engine Control 54 7.5A PANEL Cigarette Lighter and Clock Combination Meter Illumination 126 138 80 7.5A RAD–NO.2 Radio and Player 136 7.5A TURN Turn Signal and Hazard Warning Light 72 ABS Back–Up Light Charging Combination Meter 112 88 52 138 Cruise Control Door Lock Control Electronically Controlled Transmission and A/T Indicator Engine Control 108 98 102 54 Key Reminder and Seat Belt Warning Light Auto Turn Off Power Window Stop Light 128 68 94 74 Taillight 84 10A GAUGE 10A HEATER Air Conditioning Rear Window Defogger and Mirror Heater 148 134 10A MIRROR–HEATER Engine Control Rear Window Defogger and Mirror Heater 54 134 10A TAIL Engine Control Taillight 54 84 CIG Cigarette Lighter and Clock Remote Control Mirror Shift Lock SRS 126 132 122 117 ECU–IG ABS Cruise Control Radiator Fan and Condenser Fan Shift Lock 112 108 144 122 15A 15A ∗ These are the page numbers of the first page on which the related system is shown. J Fuse 15A 15A 25A POWER–OUTLET STOP DOOR System Page Power Outlet 130 ABS Cruise Control Electronically Controlled Transmission and A/T Indicator Engine Control 112 108 102 54 Shift Lock Stop Light 122 74 Door Lock Control Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off 98 76 128 68 Power Window 94 25A WIPER Wiper and Washer 90 30A POWER Door Lock Control Power Window 98 94 40A AM1 Charging Radiator Fan and Condenser Fan 52 144 40A DEF Rear Window Defogger and Mirror Heater 134 Engine Room J/B No.2 (See Page 24) Fuse 5A 7.5A ALT–S DOME System Page Charging 52 Cigarette Lighter and Clock Combination Meter Interior Light Key Reminder and Seat Belt Warning 126 138 76 128 Light Auto Turn Off 68 10A ECU–B Combination Meter SRS 66 68 10A HAZARD Turn Signal and Hazard Warning Light 48 10A HORN Horn 52 15A HEAD (LH) Headlight 144 15A HEAD (RH) Headlight 144 20A EFI Electronically Controlled Transmission and A/T Indicator Engine Control 102 54 20A RADIO NO.1 Radio and Player 48 30A AM2 Charging Electronically Controlled Transmission and A/T Indicator Engine Control Starting and Ignition 136 102 54 66 30A CDS Radiator Fan and Condenser Fan 66 30A RDI Radiator Fan and Condenser Fan 138 ∗ These are the page numbers of the first page on which the related system is shown. J POWER SOURCE (Current Flow Chart) Fuse 40A MAIN System Headlight Light Auto Turn Off Starting and Ignition Page 124 117 72 Engine Room R/B No.1 (See Page 26) Fuse 10A A/C System Air Conditioning Page 148 Engine Room R/B No.3 (See Page 26) Fuse 60A FL ABS System ABS Page 112 Fusible Link Block (F8 on See Page 27) Fuse 50A 100A HTR ALT System Page Air Conditioning 148 Charging Illumination Light Auto Turn Off Radiator Fan and Condenser Fan 52 80 68 144 Taillight 84 ∗ These are the page numbers of the first page on which the related system is shown. MEMO K CONNECTOR LIST A1 A2 A3 A4 A5 GRAY GRAY BLACK GRAY BLACK 1 1 2 3 4 2 2 1 4 1 3 3 1 2 3 4 2 4 5 6 7 8 5 A6 A7 A8 A9 A10 GRAY GRAY DARK GRAY YELLOW YELLOW 1 1 2 2 A12 1 2 3 4 1 A13 2 1 A14 12345 1 2 3 4 5 6 7 8 9 10 11 12 13 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 A16 A17 A18 YELLOW BLACK 2 1 2 A15 1 2 3 4 5 6 YELLOW A11 1 2 3 4 5 6 7 A19 A20 B1 GRAY 1 2 1 2 1 2 1 2 B2 B3 2 1 B4 1 B5 2 C1 DARK GRAY 1 1 2 3 2 4 5 1 2 3 4 5 6 7 8 C2 C3 C4 C5 DARK GRAY BLACK YELLOW YELLOW 1 2 1 2 3 4 A 1 2 1 2 6 B 1 2 3 1 2 3 4 5 6 7 8 9 101112 A B 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 K C6 C7 C8 YELLOW C9 C10 BLACK BLUE 1 A 1 2 B 2 1 2 3 4 5 6 1 2 3 4 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 101112 C11 C12 BROWN 1 2 3 4 5 6 7 8 1 2 3 4 5 6 9 10 11 12 13 14 15 16 C13 C14 BLACK BLACK 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 12 13 C15 C16 1 2 3 4 5 6 7 8 1 C17 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 9 10 1112131415 16 17 10 11 12 13 14 15 16 17 18 1 2 2 4 D1 D2 BLACK DARK GRAY 5 6 18 19 7 8 9 12 13 14 10 11 20 15 17 16 16 17 21 22 23 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 D3 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 D4 D5 D6 BLACK BLACK ORANGE 1 2 1 2 1 2 3 D7 1 K CONNECTOR LIST D8 D9 D10 D11 D12 D13 D14 BLACK 1 1 1 2 345 6 1 1 2 3 1 2 3 1 2 3 4 D15 D16 D17 E1 E2 BLACK BLACK BLACK BLACK BLACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 1 E3 2 E4 E5 E6 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 15 16 14 15 16 17 18 19 20 21 22 23 24 25 26 GREEN 1 2 E7 F1 F2 F3 F4 DARK GRAY GRAY GRAY GRAY BLACK 1 2 3 4 5 6 1 2 3 1 2 3 1 2 3 1 2 3 7 8 9 10 11 12 4 5 F5 F6 F7 F8 BLACK BLUE GRAY GREEN F9 1 1 2 1 2 3 1 F10 1 2 F11 2 F12 F13 F14 ORANGE (See Page 27) 1 1 1 1 2 K F15 F16 BLUE BLUE F17 G1 G2 G3 BLACK BLACK 1 1 2 1 2 1 1 2 3 4 2 1 3 2 H1 H2 H3 H4 H5 H6 BLACK BLACK BLACK BLACK BLACK DARK GRAY 1 1 1 2 3 2 H7 1 5 6 7 8 9 10 4 2 I2 I3 I4 GRAY BLACK BROWN 1 2 3 1 2 3 4 1 2 3 4 I6 I7 I8 BROWN GRAY BLACK 12 12 12 1 2 I12 12 I9 I13 I10 1 2 J1 ORANGE 1 2 3 4 5 6 7 8 J2 BLACK J3 J4 BLACK ORANGE A A A B B CCCDD DB 1 2 1 2 3 4 5 6 7 8 9 10111213 A A A B B CCCDDDB 2 3 I1 I5 1 2 3 4 1 GRAY GRAY I11 3 4 1 2 3 H8 12 3 456 7 8 1 J5 A A B C C A A B B B B C C J6 GRAY A A A A A B B B B CC C D D DE E E F F F F A A A A A A A A A A A A A A A A A A A B B B C C C J7 J8 GRAY BLACK A A A A A A A A A A B B B C C C J9 A A J10 J11 BLACK BLACK A A B B C C A A B B C C D D D E E E D D D E E E A A A A K CONNECTOR LIST J12 J13 J14 J15 BLACK BLUE BLUE BLACK A A A B B CCCDDDB J16 A A A B B CCCDD DB A A A A A A A A A A A A B B B B B B B B B B B B J18 J19 BLACK BLACK GRAY BLUE A A B B C C A A B B C C A A A B B A A A B B B B B A B B C C A A B DD D C C D D D E E E D D D E E E J20 A A A A A A A A A A A J17 J21 J22 J23 A A A A A B B B B CC C DD DE E E F F F F A A B C C A A B B B B C C A A B B C C D D E E F F J24 J25 J26 J27 A A B B C C A A B B C C A A B B C C A A B C C A A B B B B C C D D E E F F D D E E F F D D E E F F J28 J29 J30 J31 GRAY GRAY GRAY BLACK A A B CC A A B B B CC A A A A A A A A A A A A A A B B C C B B B C C C B B B C C C D D D E E E J32 J33 J34 J35 BLACK A A A B B A A A B B B B A A B B C C D D D E E E A A A A A A A A A B B A A A B B B B K K1 L1 L2 BLACK GRAY GRAY 1 1 2 L3 1 2 3 4 5 6 7 8 9 101112 2 1 2 M1 N1 BLACK GRAY 1 2 3 1 2 N2 P1 P2 BLACK L5 GRAY 1 2 1 O1 O2 GRAY BLUE 1 1 2 3 4 1 GRAY L4 GRAY P3 P4 P5 ORANGE BLACK P6 1 1 7 5 6 2 8 1 3 4 9 10 P7 P8 12345 1 2 3 4 5 6 7 8 9 1011121314 P13 P14 R1 YELLOW YELLOW GRAY 1 2 1 2 1 2 3 4 5 P9 P10 P11 P12 1 2 1 2 1 2 1 2 R2 R3 2 1 2 3 4 5 6 3 4 5 6 7 8 9 10 1 2 3 4 5 6 2 R6 R5 R4 BLACK 1 1 12345 2 1 R7 R8 R9 R10 1 2 3 4 1 2 3 1 2 3 4 1 2 3 BLACK 1 2 5 6 7 R11 3 4 8 9 10 1 2 3 R12 R13 (w/ Mirror Heater) 1234 5 1 2 1 2 4 5 6 R13 R14 R14 (w/o Mirror Heater) (w/ Mirror Heater) (w/o Mirror Heater) 1 2 3 12345 1 2 3 4 5 6 K CONNECTOR LIST S1 S2 S3 BLACK 1 1 2 3 4 5 6 1 S4 T1 BLUE BLACK 1 2 3 1 3 T2 U1 1 2 4 V1 V2 W1 BLACK BLUE BLACK 1 2 3 1 2 1 3 W2 W3 W4 BLACK GRAY GRAY 1 1 2 1 2 3 2 2 1 2 MEMO L PART NUMBER OF CONNECTORS Code Part Name Part Number Code Part Name A1 A/C Condenser Fan Motor 90980–10928 D4 Diode (Courtesy) A2 A/C Magnetic Clutch and Lock Sensor 90980–10942 D5 Diode (Dome) A3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 90980–10943 D6 Diode (Idle–Up) D7 Door Courtesy SW Front LH D8 Door Courtesy SW Front RH D9 Door Courtesy SW Rear LH D10 Door Courtesy SW Rear RH A4 ABS Actuator 90980–11413 A5 ABS Actuator 90980–10891 A6 ABS Speed Sensor Front LH A7 ABS Speed Sensor Front RH A8 Air Fuel Ratio Sensor 90980–11075 90980–11178 A9 Airbag Sensor Front LH A10 Airbag Sensor Front RH A11 A/C Evaporator Temp. Sensor 90980–10825 A12 A/C SW 90980–10631 A13 ABS ECU 90980–11424 A14 ABS ECU 90980–11390 A15 Air Vent Mode Control Servo Motor 90980–11165 A16 Airbag Squib (Front Passenger Airbag Assembly) 90980–11884 A17 Airbag Squib (Steering Wheel Pad) 90980–10850 A18 Ashtray Illumination 81945–33010 A19 ABS Speed Sensor Rear LH A20 ABS Speed Sensor Rear RH 90980–11856 90980–11060 B1 Brake Fluid Level Warning SW 90980–11207 B2 Blower Motor 90980–10903 Part Number 90980–10962 90980–11071 90980–10871 D11 Door Key Lock and Unlock SW Front LH D12 Door Key Lock and Unlock SW Front RH D13 Door Lock Control SW RH D14 Door Lock Motor and Door Unlock Detection SW Front LH D15 Door Lock Motor and Door Unlock Detection SW Front RH D16 Door Lock Motor and Door Unlock Detection SW Rear LH D17 Door Lock Motor and Door Unlock Detection SW Rear RH E1 Electronically Controlled Transmission Solenoid 90980–11156 E2 Electronically Controlled Transmission Solenoid 90980–11143 E3 Engine Coolant Temp. Sensor 90980–10737 E4 Engine Control Module 90980–11392 E5 Engine Control Module 90980–11391 E6 Engine Control Module 90980–11390 E7 Engine Control Module 90980–11408 B3 Blower Resistor 90980–10976 B4 Blower SW 90980–10877 B5 Buckle SW LH 90980–10825 F1 Front Turn Signal Light and Parking Light LH C1 Camshaft Position Sensor 90980–10947 F2 Front Turn Signal Light and Parking Light RH 90980–11490 90980–11326 90980–11150 90980–11020 C2 Crankshaft Position Sensor C3 Cruise Control Actuator 90980–11150 F3 Front Wiper Motor C4 Center Airbag Sensor Assembly 90980–11869 F4 Fuel Pressure Sensor (Delivery Pipe) C5 Center Airbag Sensor Assembly 90980–11872 F5 Fuel Pressure Sensor (Fuel Pipe) C6 Center Airbag Sensor Assembly 90980–11867 F6 Fuel Shutoff Valve (Delivery Pipe) 90980–11156 C7 Cigarette Lighter 90980–10760 F7 90980–11038 C8 Cigarette Lighter Illumination 90980–11148 Fuel Shutoff Valve (Fuel Pressure Regulator) C9 Clock 90980–11013 F8 Fuel Temp. Sensor (Delivery Pipe) 90980–10737 C10 Combination Meter 90980–11114 C11 Combination Meter 90080–98046 C12 Combination Meter 90980–11115 C13 Combination SW 90980–11594 C14 Combination SW 90980–11616 C15 Combination SW 90980–11672 C16 Cruise Control ECU 90980–11391 C17 Condenser 90980–10860 D1 Data Link Connector 1 90980–11323 D2 Data Link Connector 2 90980–11417 D3 Data Link Connector 3 90980–11665 90980–11599 90980–10845 F9 Fusible Link Block 90980–09566 F10 Fusible Link Block 90980–09567 F11 Fusible Link Block 90980–09566 F12 Fusible Link Block 99141–13006 F13 Fusible Link Block 82620–06010 F14 Fusible Link Block 90980–11579 F15 Front Door Speaker LH F16 Front Door Speaker RH F17 Fuel Temp. Sensor and Fuel Shutoff Valve (Fuel Tank) 90980–10795 G1 Generator 90980–09213 90980–10825 Note: Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). L Code Part Name Part Number Code Part Name G2 Generator 90980–11349 J23 Junction Connector G3 Glove Box Light and SW 90980–11098 J24 Junction Connector H1 Headlight LH J25 Junction Connector H2 Headlight RH J26 Junction Connector H3 Horn (High) J27 Junction Connector H4 Horn (Low) H5 Hazard SW H6 H7 90980–11314 90980–10619 Part Number 90980–11661 90980–11542 J28 Junction Connector 90980–10801 J29 Junction Connector Heated Oxygen Sensor 90980–11028 J30 Junction Connector Heater Control SW 90980–10799 J31 Junction Connector H8 High Mounted Stop Light 90980–11148 J32 Junction Connector I1 Idle Air Control Valve 90980–11145 J33 Junction Connector 90980–10803 I2 Ignition Coil and Igniter No.1 J34 Junction Connector 90980–10976 J35 Junction Connector 90980–10803 K1 Key Interlock Solenoid 90980–10825 L1 License Plate Light LH L2 License Plate Light RH L3 Light Failure Sensor I3 Ignition Coil and Igniter No.2 I4 Injector No.1 I5 Injector No.2 90980–11150 90980–11153 90980–11661 90980–10803 90980–11661 90980–11148 I6 Injector No.3 I7 Injector No.4 I8 Intake Air Temp. Sensor 90980–11163 L4 Luggage Compartment Light 90980–11148 I9 Ignition Key Cylinder Light 90980–10906 L5 Luggage Compartment Light SW 90980–11097 I10 Ignition SW 90980–11615 M1 Manifold Absolute Pressure Sensor 90980–10845 90980–10803 I11 Integration Relay 90980–11107 N1 Noise Filter (Ignition) 90980–10843 I12 Integration Relay 90980–11542 N2 Noise Filter (Rear Window Defogger) 90980–11259 I13 Interior Light 90980–10121 O1 Oil Pressure SW 90980–11363 J1 Junction Connector 90980–10803 O2 Junction Connector 90980–11542 O/D Main SW and A/T Shift Lever Illumination 90980–10795 J2 J3 Junction Connector 90980–10803 P1 Park/Neutral Position SW,A/T Indicator Light SW and Back–Up Light SW 90980–11332 J4 Junction Connector 90980–11542 P2 Power Steering Oil Pressure SW 90980–11428 J5 Junction Connector 90980–11502 P3 Parking Brake SW 90980–10871 J6 Junction Connector P4 Power Outlet 90980–10760 J7 Junction Connector P5 Power Window Control SW Front RH 90980–10789 J8 Junction Connector 90980–11398 P6 Power Window Control SW Rear LH J9 Junction Connector 90980–10976 P7 Power Window Control SW Rear RH J10 Junction Connector J11 Junction Connector 90980–11661 P8 Power Window Master SW and Door Lock Control SW LH J12 Junction Connector 90980–10803 P9 Power Window Motor Front LH J13 Junction Connector P10 Power Window Motor Front RH J14 Junction Connector P11 Power Window Motor Rear LH J15 Junction Connector P12 Power Window Motor Rear RH J16 Junction Connector P13 Pretensioner LH J17 Junction Connector P14 Pretensioner RH J18 Junction Connector R1 Radiator Fan Motor 90980–10928 J19 Junction Connector R2 Radio and Player 90980–10996 J20 Junction Connector 90980–11539 R3 Radio and Player 90980–10997 J21 Junction Connector 90980–11529 R4 Rear Window Defogger SW 90980–11280 J22 Junction Connector 90980–11502 R5 Remote Control Mirror SW 90980–11450 90980–11661 90980–11661 90980–10803 90980–11661 90980–11542 90980–10631 90980–10807 90980–10860 90980–11862 L PART NUMBER OF CONNECTORS Code Part Name Part Number R6 Rheostat 90980–10908 R7 Rear Combination Light LH 90980–10795 R8 Rear Combination Light LH 90980–11001 R9 Rear Combination Light RH 90980–10795 R10 Rear Combination Light RH 90980–11001 R11 Rear Speaker LH R12 Rear Speaker RH 90980–10558 Remote Control Mirror LH (w/o Mirror Heater) 90980–10395 Remote Control Mirror RH (w/ Mirror Heater) 90980–10558 Remote Control Mirror RH (w/o Mirror Heater) 90980–10395 S1 Starter 90980–09689 S2 Starter 90980–11400 S3 Shift Lock ECU 90980–11488 S4 Stop Light SW 90980–11118 T1 Throttle Position Sensor 90980–11261 T2 Turn Signal Flasher 82751–50010 U1 Unlock Warning SW 90980–10860 V1 Vehicle Speed Sensor (Combination Meter) 90980–11143 V2 VSV (EGR) 90980–11156 W1 Washer Level Warning SW 90980–11068 W2 Washer Motor 90980–10981 W3 Water Temp. Sender 90980–11428 W4 Water Temp. SW No.1 90980–11235 R14 Part Name Part Number 90980–10860 Remote Control Mirror LH (w/ Mirror Heater) R13 Code Note: Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). L Code Part Name Part Number Code Part Name Part Number M OVERALL ELECTRICAL WIRING DIAGRAM [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red O = Orange LG = Light Green P Y = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: GR = Gray G = Green The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, ,,,,No.3 ,,,, L–Y [G] : Indicates related system. L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Numbered in order from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example : [K] : Indicates and located on ground point. [L] : The same code occuring on the next page indicates that the wire harness is continuous. Indicates Relay Block No.1 M SYSTEMS LOCATION SYSTEMS LOCATION ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–3 Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–2 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1~19–1 Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Radiator Fan and Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–3 Cigarette Lighter and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4 Radio and Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–7 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–2 Rear Window Defogger and Mirror Heater . . . . . . . . . . . . . . . . . . . . 18–2 Cruse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–2 Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2 Electronically Controlled Transmission and A/T Indicator . . . . . . . . . . 3–2 SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–2 Engine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 Starting and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–4 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2 Key Reminder and Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . 16–2 Light Auto Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 M OVERALL ELECTRICAL WIRING DIAGRAM SYSTEM INDEX M 1 CAMRY CNG ELECTRICAL WIRING DIAGRAM P ow er S ou rce S ta rtin g an d Ig nitio n 1 C h arg in g 4 3 2 W B–Y ACC 3 1K 8 1T 1 1K 5A STARTER 5A IGN W I10 IGNITION SW 3 1J 4 B 8 1C 10A GAUGE ST2 8 C10 A , C11 B 13 A 5 1K B–Y 4 1K CHARGE WARNING LIGHT[COMB. METER] IG2 6 B–R W–R 7 AM2 R B–R IG1 4 B–R 2 AM1 W B–R 2 1J 5 1B B B–R 2 3 2B 5 2D 9 2K P P1 PARK/NEUTRAL POSITION SW 10 IG2 B A 1 N1 NOISE FILTER (Ignition) 6 EB1 R–L GR Y FL MAIN 3. 0W J18 JUNCTION CONNECTOR A A Intake manifold EC G1 B , G2 A A BR GENERATOR IF To Engine Control Module<2–11> BR Instrument panel brace LH To Engine Control Module<2–11> J9 JUNCTION CONNECTOR A To Bulb Check Relay [Comb. Meter]<17–6> BATTERY 4 IJ2 4 BR B A 2 Y–R B A 3 W–R 1 B GR B–G 1 A 3 W–R B–R 2 B STARTER 1 A 4 BR J6 A , J7 B JUNCTION CONNECTOR S1 A , S2 B I3 IGNITION COIL AND IGNITER IGF IGT GND NO. 2 Y C B +B W–R FUSIBLE LINK BLOCK C 1 +B I2 IGNITION COIL AND IGNITER NO. 1 GND IGT IGF GR GR B–R W–B F 9 A , F10 B , F11 C , F14 F 100A ALT C 4 IE2 B–R 1 C C 1 B B–R B–R 6 GR 11 2J B–R 3 J19 JUNCTION CONNECTOR C B–R B–G 1 5 B–W ST RELAY 40A MAIN B–R 30A AM2 5A ALT–S 1 B 2 F 12 IG3 11 IG2 5 N 1 F R–L 2 1 2A 1 B B–W B 4 2L 1 1 1B J22 JUNCTION CONNECTOR B B–W Y W–R W 40A AM1 3 2C B–R 2 B–W To Engine Control Module<2–10> 2 1K 1 A L B B IG A S A 1 B–G 2 3 W B 7. 5A OBD 40A AM1 B–R B–R B–R Left radiator side support L–B L–B W–B 30A AM2 B–R B–R EB 1 IG2 1 W–B B–G BK A 2 W–B BATTERY G–R FL MAIN 3. 0W E A 4 IB1 3 4 LG–B B–Y Under the left center pillar J34 JUNCTION CONNECTOR 2 IG1 LG–B F 9 A , F11 C , F14 F FUSIBLE LINK BLOCK 5 EB1 B–Y E A 1 F17 FUEL TEMP. SENSOR AND FUEL SHUTOFF VALVE (Fuel Tank) 1 A G–R 4 EB1 B A L–W 100A ALT B 1 C CIR OPN RELAY G–R 10 IF1 R–L 1 2 B A BR 1 3 2 2 LG–B 2 F EFI RELAY 10 2C 4 2F 5 2C J23 A , J24 B JUNCTION CONNECTOR PIM 2 3 VC E2 1 BR 3 4 1 2 B B–Y G–R G–R L–R LG–B B–Y LG Y BR L–B B–R B–Y B–Y B–Y O N M L K J I H G F E D C B A (Cont. next page) BR 1 F 20A EFI 2 2J J3 JUNCTION CONNECTOR B B B–Y B–R 1 2A 7 D L–B 1 1 1 9 IG3 3 IG2 BR 1 1B 2 5 1 R–L 3 1 D 2 IB1 BR 7 IB1 BR 4 1B W–R 5 B–R B–Y 2 B–Y 7 2K 2 1D 10A GAUGE L–B 8 2J 5A IGN 1 1K L–B 4 2L B–R 7 1W 3 1K BR BR 2 1K I10 IGNITION SW B–R B–R B–R 3 E ng in e C ontro l BR 10 1J W 5 1B 5 1K ST2 IG2 6 IG1 4 B–Y 7 AM2 2 AM1 ACC 2 B–Y W–R 1 P o w er S o urc e 2 CAMRY CNG M OVERALL ELECTRICAL WIRING DIAGRAM T1 THROTTLE POSITION SENSOR Y LG M1 MANIFOLD ABSOLUTE PRESSURE SENSOR Y B–Y A11 A/C EVAPORATOR TEMP. SENSOR L–R B–Y B–Y B–Y C12 MALFUNCTION INDICATOR LAMP [COMB. METER] B G–R B–R W–B B–Y B–Y B–Y I1 IDLE AIR CONTROL VALVE P P–B L W Y–R L Y–R G–W B–R B–Y B–Y B–L G–W E3 ENGINE COOLANT TEMP. SENSOR I8 INTAKE AIR TEMP. SENSOR Y–B G–B F7 FUEL SHUTOFF VALVE (Fuel Pressure Regulator) L–B Y–G P2 POWER STEERING OIL PRESSURE SW Y–R L V2 VSV(EGR) F6 FUEL SHUTOFF VALVE (Delivery Pipe) From Center Airbag Sensor Assembly <14–4> From Combination Meter<17–6> L–B BR BR BR P–B G–O B–Y P–B B–R B P–B From ” TAIL” Fuse <8–2> From ” MIRROR–HEATER” Fuse<18–1> H6 HEATED OXYGEN SENSOR BR B–R B (Shielded) (Shielded) W (Shielded) G–R G–R L–R LG–B B–Y LG Y Y B–Y From Center Airbag Sensor Assembly<14–4> W–B J6 A , J7 B JUNCTION CONNECTOR BR BR B B B A B 7 1J W–B BR BR D BR BR E1 E Instrument panel brace LH IF 4 BR J9 JUNCTION CONNECTOR A HT 3 F8 FUEL TEMP. SENSOR (Delivery Pipe) G–B G–R G–R F5 FUEL PRESSURE SENSOR (Fuel Pipe) BR F4 FUEL PRESSURE SENSOR (Delivery Pipe) G–B Y 12 IG2 B–Y N B O 1 OX W–B 8 IG1 3 1 2 Y 2 G–R L G–R M BR SIL +B L–R K 8 1J J 7 C A C A A A LG–B C 3 B–Y I 5 4 SG CG BAT W–B 9 IG1 D6 DIODE (Idle–Up) 2 IG3 Y VC VC 16 H LG 3 3 1 IG3 G 2 W W ELS HT2 RSD VOUT 1 D3 DATA LINK CONNECTOR 3 3 D 21 C 5 B 16 A OX2 SIL FC W J2 JUNCTION CONNECTOR C C 5 A 14 A 10 B 1 D THR PIM THCNG1 VTA VC 2 B 1 B 11 B ENGINE CONTROL MODULE E4 A , E5 B , E6 C , E7 D 10 C 4 D 23 C VCNG3 EGR F/PS FUELW FUEL 12 D 8 D 2 D 12 B 1 A PSW BATT +B +B1 VCNG2 12 A 22 A 9 D 4 B 3 B 9 B THW THA E2 THCNG2 PCNG1 PCNG2 6 D 5 D 7 D GND 2 VOUT 1 BR 1 C GND 2 2 2 2 2 BR 6 IG1 2 2 1 5 IG1 A 4 IH1 1 A 1 J8 JUNCTION CONNECTOR 9 IF1 1 1 1 1 BR BR BR BR BR F A B–Y B B E B–R D L–B B B B J18 B JUNCTION CONNECTOR C B–Y B B B–Y B 8 7 6 5 B–Y A (Cont. next page) 2 CAMRY CNG (Cont’ d) E n gine C on trol M M OVERALL ELECTRICAL WIRING DIAGRAM W–B W–B BR A 1 2 2 W 1 #40 #40+ 24 C I7 INJECTOR NO. 4 O (Shielded) A Cowl side panel RH IH E BR BR 6 IG3 BR D W–B C B B A 2 1 #10 12 C #10+ L (Shielded) B–Y W–B I4 INJECTOR NO. 1 B–W 2 C 14 B AF– HTAF 7 IG1 G 2 A 4 AF– HT G 1 AF+ 3 2 +B 9 B–W A A W–B (Shielded) 4 IG1 A 2 BR 1 #20 11 C #20+ AF+ 6 B B–R 1 C I5 INJECTOR NO. 2 (Shielded) A8 AIR FUEL RATIO SENSOR J21 JUNCTION CONNECTOR A 2 G 1 #30 25 C I6 INJECTOR NO. 3 R (Shielded) L EC Intake manifold BR 1 2 G 5 C 17 C NE– NE 4 C B–R 14 C ENGINE CONTROL MODULE C1 CAMSHAFT POSITION SENSOR (Shielded) JUNCTION CONNECTOR 2 CAMRY CNG (Cont’ d) L BR J23 A BR 3 IG1 E04 IGT2 3 C 19 C IGF IGT1 STA 20 C B–O L C2 CRANKSHAFT POSITION SENSOR #30+ B–O B–W 15 C To Tachometer [Comb. Meter] <17–5> NSW 11 A V–W LOCK 6 A G–W From Speedometer [Comb. Meter] <17–8> 8 A From Stop Light SW <8–4> 4 A W–L 9 A W–L F A 10 To A/C Magnetic Clutch and Lock Sensor<19–4> G E4 A , E5 B , E6 C , E7 D G From A/C Dual Pressure SW<19–4> 15 A L–Y 10 A From MG CLT Relay<19–2> 10 D 21 A R–B 18 C From A/C SW <19–4> 1 IG1 R–W 10 IG3 From A/C SW <19–4> A/CS B–W MGC From ” STARTER” Fuse<1–2> PRS GR LOCK IN From Park/Neutral Position SW<1–2> F A E ng ine C o ntrol B BR (Shielded) STP W–R SPD 11 From Ignition Coil and Igniter No. 1, No. 2<1–3> TACH Y–R BR A BR A A BR J20 JUNCTION CONNECTOR A BR A BR BR BR BR A BR A BR Intake manifold BR EC BR BR BR BR BR J18 JUNCTION CONNECTOR E03 E02 E01 13 C 22 C 16 B EO5 E1 BR 16 C TE1 15 B TE1 8 +B D1 DATA LINK CONNECTOR 1 12 L–W BR 13 A 12 B–Y BR 26 C 3 E1 BR M 3 CAMRY CNG P o w e r S ou rc e E le c tron ic ally C o ntro lled T ra ns m is s io n a nd A /T In dic ato r 1 2 3 R–L ACC 2 AM1 W IG1 4 3 1K B–Y 1 1K F B 1 1J 7 Y E 3 IG3 A D L–W 7 2K 8 2J D R–B R–B A J22 JUNCTION CONNECTOR W–R D B–R B–R E B–Y 4 2L 9 IG2 R W E L–W J22 JUNCTION CONNECTOR R–L 4 IG2 G–W 6 IG2 R 2 1D B–R 1 IH1 G–W PL 8 R–B RL 9 5 IG2 5 1B 2 1K NL 10 Y I10 IGNITION SW DL 3 B–R 2 IG2 7 1W 5 1K 2L 4 To Cruise Control ECU <13–2> B–R LL L–W ST2 D P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] Y B–R 10A GAUGE J19 JUNCTION CONNECTOR JUNCTION CONNECTOR R–L IG2 6 2 RB R–L 5A IGN D J24 B F B W–R 7 AM2 4 R–L R–L B–Y B–R A 2 1 5 R–B G–O C O2 O/D MAIN SW 11 IF1 A W–B 2 4 A W–B A EC EC Intake manifold W–B A Intake manifold C10 A , C11 B , C12 C COMBINATION METER G–O E1 A , E2 B ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 16 B J5 JUNCTION CONNECTOR C G–O A 9 A IE J4 JUNCTION CONNECTOR Left kick panel P 12 A BR Left radiator side support OD2 7 A G–O A J20 JUNCTION CONNECTOR NO. 2 NO. 1 LOCK–UP From Cruise Control ECU<13–3> A J18 JUNCTION CONNECTOR B W B–Y S2 From Speedometer [Comb. Meter] <17–8> BR BR BR BR 1 B S1 BR BR L–B 3 B L–B B A 8 A C 7 IG2 G–W SPD 9 A V–W J19 JUNCTION CONNECTOR B L–B E02 10 A R E01 13 C 22 C R–B E03 16 B 7 A N E1 16 C 11 A R E04 13 A BR EB IDLO 3 IG1 B 1 A E05 26 C W–B BATTERY V B B OD1 ENGINE CONTROL MODULE BR L–B B R 6 A 15 IF1 3 A D S2 6 C 2 7 C B–R S1 7 C L 20 A 10 1H O/D OFF SL 8 C P B–G FL MAIN 3. 0W +B 12 A B–Y 1 A J23 A , J24 B JUNCTION CONNECTOR 100A ALT F 9 A , F11 C , F14 F FUSIBLE LINK BLOCK 1 C STP 17 A 14 IF1 2 TE1 E4 A , E5 B , E6 C 19 A 18 A 13 IF1 O E2 4 A 16 IF1 L THW 15 B D Y VTA 9 B 5 1V D R–L VC 4 B L–R 11 B Y–B NSW 1 B R–B 6 A +B1 L–W BATT Y B–Y W–B W–B B B–R B–R 2 F B–R B–Y B–R 1 F 1 A 22 A J23 A , J24 B JUNCTION CONNECTOR B–R 3 5 2C 4 2F 2 2J 1 2A From Cruise Control ECU <13–3> See Engine Control System <2–5><2–6><2–10><2–12> A B 1 1B R–B L–W 2 C A Y 1 C A R–L 20A EFI J3 JUNCTION CONNECTOR EFI RELAY 40A AM1 30A AM2 M OVERALL ELECTRICAL WIRING DIAGRAM 4 CAMRY CNG P ow er S o urc e H e ad lig ht 1 2 4 1 HEAD RELAY 40A MAIN 4 3 2 15A HEAD (RH) 15A HEAD (LH) 3 2 1 3 2B 8 2K 3 2G 4 2G 6 2G 8 2C R–W R R–B R–B B J31 JUNCTION CONNECTOR 3 B B R–B B 2 3 J25 A , J26 B JUNCTION CONNECTOR H T HF HL D A HI F A F A OFF R–L R–L TAIL HEAD LOW 3 IE1 HIGH R–L FLASH J6 JUNCTION CONNECTOR W–B 16 BATTERY D B 8 R–B LIGHT DIMMER SW CONTROL SW B–G FL MAIN 3. 0W D B R–L 13 EL R–L C15 COMBINATION SW F B 2 R–Y 1 A F B 4 1 R–B F 9 A , F11 C FUSIBLE LINK BLOCK H2 HEADLIGHT RH 1 R–B R–B I11 INTEGRATION RELAY 1 C 3 H1 HEADLIGHT LH 17 7 8 R–B C11 HIGH BEAM INDICATOR LIGHT [COMB. METER] A R–L A 9 W–B W–B 8 1J A 7 1J A W–B W–B A J9 JUNCTION CONNECTOR IF J4 JUNCTION CONNECTOR Instrument panel brace LH IE Left kick panel 5 CAMRY CNG P ow er S ourc e T urn S ig nal and H az ard W arning Light 1 B ac k– U p L ig ht 3 2 4 B–Y ACC 2 AM1 B IG1 4 1 1K 1 2A F 3 2K R–L 40A AM1 G–B W 10 TB 2 IG2 R–L H5 HAZARD SW 2 J24 JUNCTION CONNECTOR F 1 1J G–R 2 1K F 10A HAZARD R–L 2 1L R–L R–L 10A GAUGE W 7. 5A TURN I10 IGNITION SW 2 8 B1 TL B2 TL TR LH ON RH C15 TURN SIGNAL SW [COMB. SW] D 1 7 9 5 3 G–Y 2 G–Y D G–Y D B–R G–B 2 F 5 1A 3 6 1H 10 1C 6 1S 2 1A 3 R9 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] R–B W–B Back panel center 1 C 5 1V C W–B W–B BM W–B W–B IE R7 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] R–B J23 JUNCTION CONNECTOR 2 F2 FRONT TURN SIGNAL LIGHT RH 3 3 13 1S R–B A W–B Left kick panel R–B JUNCTION CONNECTOR B B G–Y W–B A R–B R–B J25 A , J26 B A J4 JUNCTION CONNECTOR 1 3 IG3 B A W–B W–B Left radiator side support 8 G–Y 5 R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] G–Y C11 B , C12 C 6 W–B EB TURN SIGNAL INDICATOR LIGHT [COMB. METER] IF G–Y Instrument panel brace LH 16 B W–B J9 JUNCTION CONNECTOR W–B A W–B 2 BATTERY F1 FRONT TURN SIGNAL LIGHT LH G–B 3 1 C LH W–B FL MAIN 3. 0W 5 1 EB1 1 B RH B–G B C 6 G–B G–B 1 C C G–B C J15 JUNCTION CONNECTOR R8 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] F14 F FUSIBLE LINK BLOCK G–B 100A ALT D G–Y P1 BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW] 8 1H 11 1S G–B F 9 A , F11 C , J15 JUNCTION CONNECTOR G–Y 8 1V T2 TURN SIGNAL FLASHER B–R B–R 1 F 1 G–B 2 1 A 1 6 G–B G–W G–R 1 1B J19 JUNCTION CONNECTOR TR R–L OFF D TB J34 JUNCTION CONNECTOR Under the left center pillar BK M M OVERALL ELECTRICAL WIRING DIAGRAM 6 CAMRY CNG P o w e r S ou rc e Ligh t A uto T u rn O ff In te rio r L igh t 1 2 B ACC 2 AM1 IG1 4 1 B–Y C17 CONDENSER 2 1 R R From Light Failure Sensor<8–4> To Clock<12–4> SHORT PIN B 25A DOOR W 2 1K 1 1D 1 1 1K D B J16 A , J17 B JUNCTION CONNECTOR C B 12 2J E A 5 1F L–W 6 I11 B , 4 I12 A 2 12 1S 10 1 2 R–W G–R R–W G–R R–W R–W 1 D4 DIODE (Courtesy) 11 11 1H 6 1F 1 1M R–W R–G 4 1G R–W W–B R–G 7 1S 2 1 INTEGRATION RELAY 7 1J I9 IGNITION KEY CYLINDER LIGHT 10 1 L4 LUGGAGE COMPARTMENT LIGHT 1 13 A ON OFF 8 A F 9 A , F11 C , F14 F FUSIBLE LINK BLOCK 2 R–Y R–W R–G R–G 1 A 7 4 B DOOR 2 F 100A ALT 3 B I13 INTERIOR LIGHT 1 F 2 B B–R B–R 1 C 1 B C11 OPEN DOOR WARNING LIGHT [COMB. METER] 2 B–R R R 2 1M R R 8 1G E A R R–Y 9 1S R R 1 1W A A B–R B B–R R 1 1B J31 A , J32 B 1 JUNCTION CONNECTOR See Headlight System<4–2> See Taillight System<8–1> 10A GAUGE 2 R 7. 5A DOME L–W 2 R D5 DIODE (Dome) 2 R–Y I10 IGNITION SW 40A AM1 R 1 2A 4 1B 4 3 B B–R B–G E A E A D A D A D A FL MAIN 3. 0W D B J31 A , J32 B 1 BATTERY 8 IM1 1 D10 DOOR COURTESY SW REAR RH R–W 1 D9 DOOR COURTESY SW REAR LH 1 D8 DOOR COURTESY SW FRONT RH R–G 1 D7 DOOR COURTESY SW FRONT LH IF J9 JUNCTION CONNECTOR Instrument panel brace LH R–G W–B A 6 IM1 L5 LUGGAGE COMPARTMENT LIGHT SW R–W R–W R–G JUNCTION CONNECTOR M 7 CAMRY CNG P o w e r S ou rc e Illu m ina tio n 1 4 3 2 G G 1 5 G TAILLIGHT RELAY G 7. 5A PANEL 2 A A 3 A A A A A A J28 A , J29 B JUNCTION CONNECTOR 4 1B 6 1C 4 1J 5 1D G 3 B B W–G A A A A A W–B W–B B FL MAIN 3. 0W A A 2 W–B B B B J13 A , J14 B JUNCTION CONNECTOR 12 A B B–G A A G 5 B 1 G3 GLOVE BOX LIGHT AND SW 3 1 13 J4 JUNCTION CONNECTOR C12 COMBINATION METER ILLUMINATION [COMB. METER] 2 R2 B , R3 A RADIO AND PLAYER 2 10 A H5 HAZARD SW A18 ASHTRAY ILLUMINATION 1 O2 A/T SHIFT LEVER ILLUMINATION [O/D MAIN SW] G G B4 BLOWER SW 6 7 A B B B G 3 B B A B 4 A12 A/C SW 1 B A B C8 CIGARETTE LIGHTER ILLUMINATION 2 2 B B G G R4 REAR WINDOW DEFOGGER SW 6 B B G B B G B B B A G JUNCTION CONNECTOR G 1 A F 9 A , F14 F FUSIBLE LINK BLOCK 100A ALT B A G See Taillight System <8–1> B–R 2 F A B J13 A , J14 B B–R B–R 1 F A B G B B E B 3 D A D A B 6 1V 4 1H B E B D A 1 E T ILL 2 R6 RHEOSTAT B BATTERY J16 A , J17 B JUNCTION CONNECTOR W–B IE Left kick panel M OVERALL ELECTRICAL WIRING DIAGRAM 8 CAMRY CNG W G–W G–W J23 A , J24 B R–L JUNCTION CONNECTOR TAILLIGHT RELAY G–W G–W R–L G–R G–O G B–R G Y–G G G To Cruise Control ECU <13–4> 2 1H G–R B–R To Shift Lock ECU <12–3> R G–R G–O To Diode(Idle–Up) <2–8> G G G–O G G–O W–B G–O H8 HIGH MOUNTED STOP LIGHT W–B W–B W–B W–B W–B W–B W–B W–B W–B R To Condenser <6–3> R10 STOP LIGHT RH [REAR COMB. LIGHT RH] R8 STOP LIGHT LH [REAR COMB. LIGHT LH] W–B R9 TAILLIGHT RH [REAR COMB. LIGHT RH] G–O W–B R7 TAILLIGHT LH [REAR COMB. LIGHT LH] G–O W–B R10 REAR COMBINATION LIGHT RH SIDE MARKER TAIL R8 REAR COMBINATION LIGHT LH SIDE MARKER TAIL W–B W–B F2 FRONT PARKING LIGHT RH G–O F1 FRONT PARKING LIGHT LH LIGHT CONTROL SW B–G W–B W–B J34 JUNCTION CONNECTOR A G–W G–W Y–G G G L2 LICENSE PLATE LIGHT RH W–B L1 LICENSE PLATE LIGHT LH W–B G–O G–O I11 INTEGRATION RELAY B–R 2 S4 STOP LIGHT SW To Engine Control Module <2–10> G–W W 14 F 9 A , F14 F FUSIBLE LINK BLOCK A W–B W–B A Under the left center pillar BK BM Back panel center Back panel center 5 5 3 W–B W–B A BM BK Under the left center pillar W–B W–B 2 2 4 1 2 9 11 1 5 5 W–B J9 JUNCTION CONNECTOR EB Left radiator side support IF Instrument panel brace LH A BATTERY W–B 8 1J 7 1J J6 JUNCTION CONNECTOR 2 2 J34 JUNCTION CONNECTOR A TAIL G–R G–O G–O G–O 4 HEAD FL MAIN 3. 0W 16 C15 COMBINATION SW EL 3 A 1 3 1 3 1 1 OFF 5 IC2 A 7 4 8 3 B–R 2 F H T 1 A 1 1 JUNCTION CONNECTOR A A C B C B 1 100A ALT 2 2 1S A 2 4 1R 2 J25 A , J26 B 5 1R J12 JUNCTION CONNECTOR A B–R G 8 1S 2 To ABS ECU <15–3> W D 1 3 A J1 JUNCTION CONNECTOR A A 9 1C L3 LIGHT FAILURE SENSOR 1 F A A A 7 C 6 1C 4 1B A C10 A , C12 C REAR LIGHTS WARNING LIGHT [COMB. METER] C B 1 R–L 2 1D C B 1 1B B–Y ACC J3 JUNCTION CONNECTOR 1 1S 3 2 D 10A TAIL 15A STOP 40A AM1 10A GAUGE 7 1C 5 1 2 1 1K I10 IGNITION SW 2 1K B–Y IG1 4 2 AM1 4 3 2 1 S to p L igh t T aillig ht P ow er S o urc e M 9 CAMRY CNG P ow er S o urc e W ipe r a nd W as he r 1 B–Y I10 IGNITION SW * 1 : w/ Mirror Heater * 2 : w/o Mirror Heater L–R L–R IG1 4 4 3 2 ACC 3 2 AM1 R e mo te C on trol M irro r 1 1K 6 1K W 25A WIPER 4 1C 1 1A 40A AM1 E A +B +2 +1 +S INT1 INT2 B1 EW P–L 2 1 1T C13 WIPER AND WASHER SW [COMB. SW] L J25 A , J26 B JUNCTION CONNECTOR 2 1K 15A CIG WF A OFF A LO P–L E B 1 HI M WF EW WIPER RELAY +2 2 8 +1 7 +S LEFT +B 16 RIGHT UP L L–Y L–B L–O 6 IJ1 DOWN LEFT/ UP HL VR 7 14 ID1 15 ID1 16 IL1 14 IL1 W–B 16 ID1 C J3 JUNCTION CONNECTOR LG–R LG–B W–B FL MAIN 3. 0W BR–R 2 B LG–R 1 S BR–Y 5 +1 10 C BR–W B–G +2 E 6 C L 1 A M+ LG–B LG–R A 1 BR–Y J15 JUNCTION CONNECTOR A VL BR–R A L MV HR 8 5 L–W 3 RIGHT/ DOWN 17 MH W–B F 9 A , F14 F FUSIBLE LINK BLOCK 100A ALT 11 SELECT SW B–R B–R 2 F L–W 1 1 F WASHER OPERATION SW B–R W2 WASHER MOTOR 2 R5 REMOTE CONTROL MIRROR SW 9 B L L 1 1B J5 JUNCTION CONNECTOR INT 15 IL1 4 2F 4 3 A 4 A 2 A 3 A (*1) 1 B 2 B 3 B 1 B 2 B (*2) M M M M A J4 JUNCTION CONNECTOR A W–B Instrument panel brace LH LG–R 2 A 3 B F3 FRONT WIPER MOTOR J9 JUNCTION CONNECTOR IF LG–B A BR–R E 4 A W–B W–B BATTERY LG–R 10 2J BR–Y BR–W W–B M Left radiator side support EB R13 A , B REMOTE CONTROL MIRROR LH R14 A , B REMOTE CONTROL MIRROR RH IE Left kick panel M OVERALL ELECTRICAL WIRING DIAGRAM 10 CAMRY CNG P ow er S ou rce P o w er W ind ow 1 4 3 2 L B–R R–B ACC 2 AM1 10 ID2 IG1 4 5 1G 4 1B 12 1G L B I10 IGNITION SW 1 B B 25A DOOR 30A POWER L L B–Y W J33 JUNCTION CONNECTOR 10 BW 2 1 1K FRONT LH 13 12 ID2 R–B R–B 6 ID2 G–B G–B 9 ID2 R–Y R–Y 7 ID2 G–Y 5 ID2 R G W–B J33 JUNCTION CONNECTOR W–B 11 ID2 1 IC1 5 IC1 5 IM1 7 IM1 A A 9 IM1 L L L R–Y L G–B R–B 3 BA1 1 BB1 2 BB1 3 BB1 R–B L 5 B U D 1 5 R G R 2 1 M P11 POWER WINDOW MOTOR REAR LH 4 SD DOWN D 1 2 SU UP U P7 POWER WINDOW CONTROL SW REAR RH B G 2 1 M P10 POWER WINDOW MOTOR FRONT RH 3 DOWN 1 4 SD R–B G–B D 3 2 SU UP U P6 POWER WINDOW CONTROL SW REAR LH B R P9 POWER WINDOW MOTOR FRONT LH 3 DOWN 2 2 SD G ID M 5 SU UP Cowl side panel LH 1 P5 POWER WINDOW CONTROL SW FRONT RH IF W–B Instrument panel brace LH R G W–B J9 JUNCTION CONNECTOR 1 BA1 G–W L W–B B–G 4 3 1V 5 IL2 L 4 IL2 R–L W–B 6 IL2 G–B G–Y 2 BA1 L See Light Auto Turn Off System<6–1><6–2> F 9 A , F14 F 100A ALT FUSIBLE LINK BLOCK J3 JUNCTION CONNECTOR A L A A 7 1G A DOWN RRD 8 A FL MAIN 3. 0W UP RRU 12 20 ID1 BATTERY DOWN RLD 9 G–Y 5 UP DD 1 RLU 6 R–L DU 4 PD 14 R–L E 3 PU G–W E REAR RH G–W 13 1G L L W–B L–W B–R B–R A A 1 A 3 1S J31 A , J32 B JUNCTION CONNECTOR C B 2 F 7 1J L–W 13 A 7 1S B–R 3 LOCK 1 1D 8 A 2 10 12 A 6 NORMAL WINDOW LOCK SW R–B 7 I12 A B–R B–R INTEGRATION RELAY 1 1B 5 POWER RELAY 1 REAR LH DOWN 1 10A GAUGE 40A AM1 FRONT RH UP UP 2 1 F DOWN 2 1K P8 POWER WINDOW MASTER SW 11 BW 2 1 M P12 POWER WINDOW MOTOR REAR RH MEMO W L–W JUNCTION CONNECTOR J31 A , J32 B B–R B–R B–R B–R LG W–B LOCK LG ID UNLOCK B–G Cowl side panel LH W–B 7 1G W–B 3 1V W–B P8 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] G UNLOCK W–B II Right kick panel W–B Instrument panel brace LH J9 JUNCTION CONNECTOR W–B W–B W–B W–B J35 JUNCTION CONNECTOR 1 4 BK D14 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH IF A W–B M 3 L–R 2 11 ID1 8 ID2 7 A W–B 6 BA1 M 3 Under the left center pillar A 2 4 1 4 BA1 7 BA1 5 BA1 6 IC2 7 IC2 11 A 6 A 10 A L–Y L–B L–B L–B L–R L–R L–R Y L–Y L–Y L–R W–B D16 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH BATTERY B 3 ID2 L–R L–B 20 IL1 A D12 DOOR KEY LOCK AND UNLOCK SW FRONT RH L UNLOCK J35 A JUNCTION CONNECTOR A L–B 20 ID1 L–W A See Key Reminder and Seat Belt Warning System<16–2> L–R FUSIBLE LINK BLOCK LOCK W–B D11 DOOR KEY LOCK AND UNLOCK SW FRONT LH L–W LOCK A 1 3 L–R L–R J33 A JUNCTION CONNECTOR A 2 L–R L–B FL MAIN 3. 0W R–G A 1 2 See Light Auto Turn Off System<6–1><6–2> F 9 A , F11 C , F14 F D13 DOOR LOCK CONTROL SW RH G UNLOCK W–B 3 7 1S 6 L–R L–Y 1 A 3 5 3 IL1 8 A L–B 100A ALT 6 4 IL1 J5 JUNCTION CONNECTOR 1 C LG 7 4 ID1 F F 9 A L–B 2 F 4 G 2 3 ID1 5 1M 5 4 L–R 1 F 1 2A 1 LG 12 IL1 G 13 IL1 R–G 12 ID1 L–W 13 ID1 E L–W 4 1B 25A DOOR SHORT PIN D A A L 1 1B B–R L–W 2 B B J27 JUNCTION CONNECTOR 1 40A AM1 L–Y D B 5 A 3 A L–R 2 D B B 4 A J5 JUNCTION CONNECTOR I12 A INTEGRATION RELAY R–G 1 1D L–W 7. 5A DOME R 20A RADIO NO. 1 W–B C B 1 A LG J5 JUNCTION E CONNECTOR E 2 A G 12 2J 7 1J 10 L–W 1 1W 1 3 L 11 2K 13 A 2 Y A A L–R D o or L oc k C o ntrol L K J I H G F E D C B A (Cont. next page) L–Y 2 1K IG1 ACC 3 I10 IGNITION SW 2 AM1 1 P ow er S o urc e 11 CAMRY CNG M OVERALL ELECTRICAL WIRING DIAGRAM W–B W–B W–B LOCK 11 CAMRY CNG (Cont’ d) D oo r L oc k C on trol A B R ad io an d P lay er 5 L–R 8 7 6 L–Y L–Y L–R 5 1W 6 1K 7. 5A RAD–NO. 2 L–Y L–Y L–B L–Y 7 IL2 3 IL2 11 IL1 5 BB1 7 BB1 4 BB1 W–B IJ RR+ RR– 1 B 3 B BL GND 7 A 1 IL1 1 2 1 2 F16 FRONT DOOR SPEAKER RH 9 IC1 3 IC1 10 IC1 4 IC1 1 2 R11 REAR SPEAKER LH 1 2 R12 REAR SPEAKER RH BR Right kick panel RL– 6 B W–B W–B 9 IL1 1 ID1 F15 FRONT DOOR SPEAKER LH 6 BB1 W–B RL+ 2 B W 4 FR– 5 A 9 ID1 P M W–B L 1 D17 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 3 L–Y 1 2 L–B M L–R 4 D15 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH L–Y 3 Y 2 L–B 2 IC2 L–R JUNCTION CONNECTOR FR+ 1 A BR L–R J28 A , J29 B Y L–Y 6 A W B A FL– 2 A R L–B FL+ 3 IM1 R L–B Y C B Y B A B L–B 1 IM1 B L–B L C B L B A ACC +B LG L–B BU +B LG L–R RADIO AND PLAYER V B B 3 A V C A R2 B , R3 A 4 A P L–R 2 IM1 L–B K L–R L–R J B B GR I C A J16 JUNCTION CONNECTOR A L–Y H L–R A B L–Y G C A Y F L–R B L–Y C E E B GR J28 JUNCTION CONNECTOR C Y 3 1H L–Y D L–Y 6 1G J10 A , J11 B C D A JUNCTION CONNECTOR D A Under the right center pillar Instrument panel brace RH IG M M OVERALL ELECTRICAL WIRING DIAGRAM 12 CAMRY CNG P ow er S ou rce 1 2 2 AM1 ACC 3 L–R IG1 4 B–Y C ig are tte L igh ter an d C loc k 4 3 G L–R W P ow er O utle t S h ift Lo c k 1 1K G I10 IGNITION SW 6 1K 15A ECU–IG G W 5 1D 2 1K 8 1D 15A POWER– OUTLET B–R J16 JUNCTION CONNECTOR C C G–W 3 ACC STP SLS+ L–R 5 1 4 1B 1 1B L–B A 4 1V 7 1J 3 1V Instrument panel brace LH W–B W–B IF J9 JUNCTION CONNECTOR W–B W–B ID J4 JUNCTION CONNECTOR A W–B 1 A Left kick panel 2 A BATTERY IE 4 W–B A 2 J6 JUNCTION CONNECTOR L–B K1 KEY INTERLOCK SOLENOID J4 JUNCTION CONNECTOR A 1 W–B 8 1J A 1 3 W–B W–B 5 IE1 B–G FL MAIN 3. 0W 1 2 R C9 CLOCK S3 SHIFT LOCK ECU 4 W–B 1 A F 9 A , F14 F 100A ALT KLS+ 5 A B G 2 F FUSIBLE LINK BLOCK See Taillight System<8–1> E 1 F 2 2 G A P–L B–R B–R P G–R 3 P4 POWER OUTLET P1 A A A SHIFT LOCK CONTROL SW C7 CIGARETTE LIGHTER B–R B–R B–R P2 G–W 1 A From Diode(Dome) <6–4> 6 1C P–L SLS– SHIFT LOCK SOLENOID 1 2 L V 1 1 1T J5 JUNCTION CONNECTOR TAILLIGHT RELAY 40A AM1 6 1J J28 A , J29 B JUNCTION CONNECTOR IG 2 6 P–L 3 5 1J 1 P–L 2 From Stop Light SW <8–4> P–L B–R 7. 5A PANEL 15A CIG A Cowl side panel LH IF J9 JUNCTION CONNECTOR Instrument panel brace LH IE Left kick panel M 13 CAMRY CNG P ow er S o urc e C ru is e C o ntro l 1 4 3 2 ACC 2 AM1 W IG1 4 B–Y 2 1K I10 IGNITION SW 2 1 1K 40A AM1 15A ECU–IG B–R R–L B–R C 9 PI TC 14 IDL 8 12 OD 5 CMS 11 CCS SPD 4 1 L A A M 8 1J W–B 4 7 1J BATTERY W–B W–B To Data Link Connector 1, 2 <15–3> To Data Link Connector 2 <15–3> CANCEL EP 3 C14 CRUISE CONTROL SW [COMB. SW] A J9 JUNCTION CONNECTOR W–B IF Instrument panel brace LH From Stop Light SW<8–4> A A 3 2 G–W A A 2 C3 CRUISE CONTROL ACTUATOR O SET/ COAST 1 A B STP– R–Y W–B CRUISE RESUME/ ACCEL MC 7 R–B CMS CCS J1 JUNCTION CONNECTOR D 4 MO 15 R–G D D J6 A , J7 B JUNCTION CONNECTOR 5 O 16 W W–L O LG–R O B–G 5 IE2 GND 10 W–B 4 10 1 A FL MAIN 3. 0W 13 ECT See Stop Light System<8–4> C12 CRUISE CONTROL INDICATOR LIGHT [COMB. METER] 6 D R–Y 100A ALT C16 CRUISE CONTROL ECU 3 B 7 2 V–W 2 F 3 B–R B–R R–L F 9 A , F14 F FUSIBLE LINK BLOCK 1 F Y–B C L–R D J12 JUNCTION CONNECTOR L–B B–R B–R J3 JUNCTION CONNECTOR G–B S4 STOP LIGHT SW D From Speedometer [Comb. Meter]<17–8> 9 1J From D Position SW [Park/Neutral Position SW] <3–4> 2 1D To Engine Control Module <3–3> To Electronically Controlled Transmission Solenoid<3–2> 1 1B See Stop Light System<8–4> 10A GAUGE 1 M OVERALL ELECTRICAL WIRING DIAGRAM 14 CAMRY CNG P o w e r S ou rc e SR S 1 4 3 2 W–R ACC 3 W 2 AM1 W–R A9 AIRBAG SENSOR FRONT LH L–R A10 AIRBAG SENSOR FRONT RH 3 1W IG1 B–R 12 A 3 1K 5 1K 6 1K 2 13 1 2 7 IG3 A A LG 4 1N 2 1K 2 1N 1 II1 2 II1 4 2L A IG2 26 B ACC 15 B –SL E1 1 1B 1 2A 27 B D+ 14 B D– P+ P– 13 B 10 B 11 B 20 B +SL C4 A , C5 B , C6 C 1 1 B–W 6 B 5 B BR–W 30A AM2 W–R SHORT PIN 40A AM1 BR 2 GR B–O 2 9 B –SR +SR CENTER AIRBAG SENSOR ASSEMBLY PL+ PL– PR+ PR– 2 A 1 A 5 C 6 C E2 SIL 28 B 12 B GSW 4 B L To Data Link Connector 3 <2–7> To Engine Control Module<2–7> B W B–R B–R B–R W–B Y Y–B Y Y–B Y–G Y–R Y 1 A B–G F 9 A , F11 C , F14 F FUSIBLE LINK BLOCK 100A ALT 1 C Y–B 2 F W–B 1 F 1 1N 7 1J 1 2 SPIRAL CABLE 3 1N 1 W–B FL MAIN 3. 0W 2 1 2 1 2 3 1V J9 JUNCTION CONNECTOR Instrument panel brace LH IF A16 AIRBAG SQUIB (Front Passenger Airbag Assembly) P13 PRETENSIONER LH P14 PRETENSIONER RH W–B A BATTERY A17 AIRBAG SQUIB (Steering Wheel Pad) ID Cowl side panel LH P–B 2 IE2 J2 JUNCTION CONNECTOR LG B–Y B–W BR–W W–R 2 IA1 W–R 1 IA1 LG 1 15A CIG B CONNECTION DETECTION PIN BR 10A ECU–B 5 1B A CONNECTION DETECTION PIN I10 IGNITION SW 5A IGN B LG 7 2J To Data Link Connector 1 <15–3> IG2 6 ST2 C11 SRS WARNING LIGHT [COMB. METER] 7 AM2 W–R W–R W W–R To Data Link Connector 1, 2 <15–3> 2 1G 3 B 19 B LA TC M 15 CAMRY CNG P ow er S ou rce AB S 1 2 AM1 IG1 4 R–L B–Y 4 IG3 BR A13 A , A14 B ABS ECU 24 B 5 B D/G STP 2 A 8 A FL– FL+ 6 IG3 9 A 3 A FR– FR+ RR– 23 B RR+ 10 B 1 B 5 A SFLR SRRH SRRR 6 A 11 A 12 A SRLH 15 B SRLR 14 B MT GND GND 25 B 12 B 10 A RL– 9 B RL+ 22 B W 9 IB1 3 IB1 1 IK1 B SRLR MT A A A 2 IK1 BR FL MAIN 3. 0W M E 1 A 2 W–B W–R W–L BM 2 A A W–B W–B W–R W G BS 4 A BATTERY B A4 A , A5 B ABS ACTUATOR W–B SRLH 3 A W–B SRRH SRRR 6 B R 2 B R–W SFLR 8 B LG–B SFRR SFLH 4 B 5 IJ2 G–Y 7 B R–G 3 B W–R SFRH W–L 5 B L–B W–R B–G 1 B 13 IJ2 R G 12 IJ2 J20 JUNCTION CONNECTOR LG–B G–Y W–R 11 IJ2 R–B F 9 A , F10 B , F14 F FUSIBLE LINK BLOCK EA Right radiator side support IF J9 JUNCTION CONNECTOR Instrument panel brace LH 1 A19 ABS SPEED SENSOR REAR LH 2 1 A20 ABS SPEED SENSOR REAR RH Intake manifold BR SFRR SFLH 1 B BR SFRH 2 B R–B 100A ALT 1 A W TC B LG–R B B BR R 8 B TS P–B B G–W J2 JUNCTION B CONNECTOR B C A J6 A , J7 B R 1 IJ2 G B A7 ABS SPEED SENSOR FRONT RH 1 2 JUNCTION CONNECTOR G From Stop Light SW<8–4> From Cruise Control ECU<13–2> From Center Airbag Sensor Assembly<14–4> 6 IJ2 B 21 B WA 14 LG–R 11 B IG1 11 IG3 R–Y 13 B R+ ABS 4 R–L C 12 IF1 G–B 2 F SR 4 R–L 1 F GR–R GR GR–L 7 A 26 B MR C C O B–R W–L W–B GR–L W–R B–G B–R B–R 1 A 7 G–B GR B–R 1 IJ1 TC TC LG–R 3 8 IG3 A6 ABS SPEED SENSOR FRONT LH 1 2 BR LG–R 3 5 IG3 3 LG–R 3 D R–Y 3 C A/D E1 11 J22 JUNCTION CONNECTOR G–B 3 6 D 16 G–B 3 3 C TS 22 J3 JUNCTION CONNECTOR R–L R–L 4 5 E1 BR 3 10 AB WA 2 1D C12 ABS WARNING LIGHT [COMB. METER] 2 1 4 2 J12 JUNCTION CONNECTOR 1 1B 1 9 1J ABS SOL RELAY 60A FL ABS 1 3 3 B–R 1 ABS MOTOR RELAY 2 3 LG 3 D2 DATA LINK CONNECTOR 2 5 WB (Short Pin) 2 D1 DATA LINK CONNECTOR 1 23 10A GAUGE R–L 15A ECU–IG W GR–R GR–R 40A AM1 R–L 1 1K 2 1K From Cruise Control ECU<13–2> From Airbag Sensor Assembly<14–4> B–Y I10 IGNITION SW 4 3 2 8 IJ2 ACC EC M OVERALL ELECTRICAL WIRING DIAGRAM 16 CAMRY CNG P o w e r S ou rc e K e y R e mind er an d S e at B elt W a rning 1 H orn 4 3 2 B ACC 2 AM1 B B–Y B–R 1 2A IG1 4 4 1B 1 1K 1 SHORT PIN 10A GAUGE W I10 IGNITION SW 25A DOOR 2 1 1 1D 2 1K D L–W C B 7 C B–R B–R 4 A L–W B–R B–R 10 2K 1 1W 7 9 3 1 2F G–W 1 A 2 1 C J1 JUNCTION CONNECTOR C 10 7 1J 3 1M 5 8 6 5 1M 4 1S 7 1S G–B 100A ALT 13 A HORN RELAY G–B 2 F F 9 A , F11 C , F14 F 1 F FUSIBLE LINK BLOCK B–R B 1 C 3 1T I12 A INTEGRATION RELAY 5 R A A 12 2J C10 A , C12 C 1 1B J31 A , J32 B JUNCTION CONNECTOR 1 D SEAT BELT WARNING J3 LIGHT[COMB. METER] JUNCTION CONNECTOR R–L R–L R–W 2 7. 5A DOME 2 1D 40A AM1 10A HORN G–W 6 B–G B5 BUCKLE SW LH 2 W–B 2 A A J9 JUNCTION CONNECTOR Instrument panel brace LH J34 JUNCTION CONNECTOR IF Under the left center pillar BK See Light Auto Turn Off System<6–2> 1 1 W–B U1 UNLOCK WARNING SW BATTERY R–Y L–B W–B W–B FL MAIN 3. 0W 1 1 C14 HORN SW [COMB. SW] H3 HORN (High) H4 HORN (Low) MEMO 1 W F 9 A , F14 F B–R 1 A B–G BATTERY FL MAIN 3. 0W FUSIBLE LINK BLOCK B–R 100A ALT B–R 2 F D 10A GAUGE B–Y D D 2 1D 1 1K 2 Instrument panel brace RH BR R–L J3 JUNCTION CONNECTOR R–L R–L J19 JUNCTION CONNECTOR R–L EC BR IG Intake manifold 3 1 C o mb in atio n M ete r R–L 2 SE 3 1 IG+ SI 4 L D R–L 1 F F F 1 1J J24 JUNCTION CONNECTOR IG1 4 ACC R–L 2 IG2 1 1B I10 IGNITION SW 2 AM1 R–L 1 2 2 1K 40A AM1 P o w er S o urc e 17 CAMRY CNG L P Y–G BR BR R–L F E D C B A (Cont. next page) M OVERALL ELECTRICAL WIRING DIAGRAM V1 VEHICLE SPEED SENSOR (Combination Meter) P W3 WATER TEMP. SENDER Y–G 17 CAMRY CNG (Cont’ d) C om bination M e ter 5 A See Interior Light System<6–4> R–L 7 R–L Y–R To Engine Control Module<2–7> C 3 IH1 Y–G 6 IH1 E 7 IH1 J1 JUNCTION CONNECTOR B B 5 BR 2 Y–G 1 10 A R 8 A P 9 A DOOR 10 B O/D OFF 12 A B FUEL C A WATER TEMP. A B–O 8 C P 6 C L 15 B R–W 7 B 3 A See Electronically Controlled Transmission and A/T Indicator System <3–3><3–4> TACHOMETER (*1) ILLUMINATION 12 C 14 B BRAKE TURN RH REAR LIGHTS 4 B See Electronically Controlled Transmission and A/T Indicator System<3–3> See Illumination System <7–4> 3 IF1 17 IF1 P–L See Engine Control System<2–2> See ABS System<15–2> EB Left radiator side support 2 C OIL HIGH BEAM WASHER LEVEL CRUISE 4 C ABS 4 A SEAT BELT 5 B See Charging System <1–4> W–B Y–B 5 IH1 10 C See Headlight System<4–4> See Cruise Control System<13–2> 12 B SRS C10 A , C11 B , C12 C Y–B 8 B 9 B MALFUNCTION INDICATOR LAMP J15 JUNCTION CONNECTOR See Turn Signal and Hazard Warning Light System<5–3> 1 C B 13 B 1 A A W–B See Key Reminder and Seat Belt Warning System<16–3> 11 C BULB CHECK RELAY B V–W J4 JUNCTION CONNECTOR 2 P–L B–O 2 B B V–W 1 B 13 A CHARGE See Interior Light System<6–4> O1 OIL PRESSURE SW 1 3 IJ2 GR 6 IE1 W–B P3 PARKING BRAKE SW R–W Instrument panel brace LH W1 WASHER LEVEL WARNING SW W–B IF N W–B P–L J9 JUNCTION CONNECTOR 7 A FUEL 16 B 7 IE1 A 3 BR See Charging System<1–4> From Park/Neutral Position SW<1–2> 1 G–W See Taillight System<8–3> R–W B1 BRAKE FLUID LEVEL WARNING SW 2 D 6 B TURN LH 3 IE2 R–W B R–W 1 11 A V–W L 2 V–W P 2 IH1 C TRIP METER ODOMETER F 6 IF1 B–O 6 A To Cruise Control ECU<13–4> From Engine Control Module <2–10> L To Engine Control Module<2–10><3–3> D BR BR 11 B 13 C See Illumination System<7–4> B * 1 : Speedometer 8 7 6 See SRS System <14–4> Left kick panel IE COMBINATION METER M M OVERALL ELECTRICAL WIRING DIAGRAM 18 CAMRY CNG P o w e r S ou rc e R ea r W in do w D e fog ge r a nd M irro r H ea ter 1 R a diato r F a n an d C on de ns e r F a n 4 3 2 B–R B–R B–Y B–Y B–R ACC 2 AM1 IG1 4 4 1B W B–R 1 2 2 M 1 1 2G W–R W–B W–B B–R B–R W–B W–B EB Left radiator side support 3 4 1 5 1 1 1 W–B W–B W–B 2 EA1 2 W–R 1 1 B–R 1 1 R 5 M 1 FAN NO. 2 RELAY 1 2 R1 RADIATOR FAN MOTOR 3 G–W 1 FAN NO. 3 RELAY 2 L L 1 From MG CLT Relay<19–2> Instrument panel brace LH 1 W4 WATER TEMP. SW NO. 1 L–W W–B W–B 2 2 G–W B–W L–W A N2 NOISE FILTER (Rear Window Defogger) 2 2F 7 2G A3 A/C SINGLE PRESSURE SW A IF IG W–B W–B J9 JUNCTION CONNECTOR ID W–B 4 E W–B W–B W–B Cowl side panel LH 2 3 3 1V II 1 2C 1 EA1 5 REAR WINDOW DEFOGGER 3 G–W 1 7 1G Right kick panel 4 2F 8 IB1 D FL MAIN 3. 0W 2 12 1J R4 REAR WINDOW DEFOGGER SW W–B 20 ID1 2 3 B W–B B–G 20 IL1 BATTERY B–R 2 Y–G A 4 FAN NO. 1 RELAY B A 1 4 B–R 2 2C 1 1L J33 JUNCTION CONNECTOR A 2 2H 1 3 2 1 W–B A 2 A1 A/C CONDENSER FAN MOTOR 5 L–B DEFOGGER RELAY 5 2 2B 5 ENGINE MAIN RELAY 1 W–B J35 JUNCTION CONNECTOR 1 A F 9 A , F12 D , F14 F 100A ALT FUSIBLE LINK BLOCK 2 F A 13 1J 3 1 F A L–B R13 MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] 5 A B–Y B–R B–R B–R R14 MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] 1 B–R 5 ID1 B–Y To Diode (Idle–Up)<2–8> B–R B–R B–R B–R 5 IL1 6 2K L–B B–Y 1 1B 30A CDS 6 1A 7 1J J30 JUNCTION CONNECTOR 5 1T 1 30A RDI W–B 4 1D B–Y 1 11 1J 1 2 3 1R B–Y 40A AM1 15A ECU–IG 10A MIRROR– HEATER 2 1K 10A HEATER 1 40A DEF NOISE FILTER I10 IGNITION SW 1 D 1 1K M 19 CAMRY CNG P o w e r S o urc e A ir C o nd ition in g 1 3 2 ACC 2 AM1 IG1 4 L–B 1 1K W L–B G To Engine Control Module<2–10> 1 FACE B/L 9 2C FOOT 2 1W 2 1K 1 5 B R–B D J12 JUNCTION CONNECTOR B L–R B B BR OFF 2 5 1 B IF OFF 6 IG W–B 7 GND A A BR Instrument panel brace LH W–B W–B B4 BLOWER SW J20 JUNCTION CONNECTOR W–B 1 J9 JUNCTION A CONNECTOR A A W–B BR LO 6 IG3 A CONTROL CIRCUIT R–W 4 M1 5 DEF M L–B 8 M2 4 F/D To Engine Control Module<2–10> L–B L–O A 2 R–B A 3 B/L FOOT L–R 1 FACE 3 Left radiator side support B R–B 1 3 J30 JUNCTION CONNECTOR 6 B–W B–G 5 EB J7 JUNCTION CONNECTOR J12 JUNCTION CONNECTOR D D L–B 2 HI BATTERY From Engine Control Module<2–10> To Engine Control Module <2–10> L–R BR W–L 4 To Engine Control Module<2–10> B3 BLOWER RESISTOR FUSIBLE LINK BLOCK FL MAIN 3. 0W L–Y W–B F14 F To FAN NO. 3 Relay<18–3> B–W F 9 A , F13 E , B–W 3 EB1 L–R M 1 1 A 5 1 7 IJ2 L–W 50A HTR 100A ALT 2 B2 BLOWER MOTOR L–R B–W 1 E 6 L–O 1 L–Y L–W B–R B–R 2 F L–R B–R 1 F 2 EB1 7 DEF B–L 1 L–R 1 EB2 8 F/D L–R 1 1 L 1 2 L–W 1 3 B/L FOOT B–W 1 1 1B DEF GND FACE W–B 3 10 IJ2 L–B R–B 2 5 2K L–R 3 1 9 IJ2 F/D L–B 2 1 10A A/C 4 40A AM1 2 1 MG CLT RELAY 5 1 1 HTR RELAY 1 L–B 2 1 3 1R 2 BR L–B A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR 4 W–L L–B 2 IJ2 G H7 HEATER CONTROL SW 10A HEATER I10 IGNITION SW L–B 4 A3 A/C DUAL PRESSURE SW B–Y B–Y 4 B–W 1 L–B ON A15 AIR VENT MODE CONTROL SERVO MOTOR A12 A/C SW Intake manifold EC FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 1999 CAMRY. Applicable models: MCV20 Series SXV20 Series For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals; Manual Name
1999 CAMRY Repair Manual Volume 1 Volume 2
1999 TOYOTA New Car Features Pub. No. RM654U1 RM654U2 NCF160U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. NOTICE When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction. A INTRODUCTION This manual consists of the following 12 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, ”How to use this manual”). The ”System Outline” and ”Service Hints” useful for troubleshooting are also contained in this section. I GROUND POINTS Shows ground positions of all parts described in this manual. J OVERALL ELECTRICAL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. K POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. L PART NUMBER OF CONNECTORS Indicates the part number of the connectors used in this manual. A H HOW TO USE THIS MANUAL B This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Points section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wiring Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from__, to__). When overall connections are required, see the Overall Electrical Wiring Diagram at the end of this manual. B HOW TO USE THIS MANUAL ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. [A] STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 66) ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, ,,,,,,,,,, [C] 15A STOP 7. 5A GAUGE 4 IB 2 1 ,,,, @@@@ €€€€ ÀÀÀÀ @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, @@@@ €€€€ ÀÀÀÀ ,,,, 7 3C [G] 15 3C R–L W–R R (W/G) 3 IB L (S/D) [B] R–L 4 2 C7 REAR LIGHTS WARNING LIGHT [COMB. METER] S6 STOP LIGHT SW 14 [E] IE1 13 1 G–W [D] L (S/D) I5 [F] G–W Y–G G–W TO ABS ECU [H] 7 L4 LIGHT FAILURE SENSOR 8 DELAY CIRCUIT [J] B18 H17 HIGH MOUNTED STOP LIGHT [L] 1 W–B B18 W–B 1 BV1 W–B W–B W–B 3 2 BO 50 [N] [M] BL W–B 4 [K] (SHIELDED) R6 STOP LIGHT RH [REAR COMB. LIGHT LH] R7 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R G–R G–R 1 BV1 3 11 G [I] 4 1 G–R 2 4 B [I] [A] : System Title [B] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B Example : Indicates Relay Block No.1 : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red O = Orange LG = Light Green [C] : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. P Y [D] : Indicates related system. The first letter indicates the basic wire color and the second letter indicates the color of the stripe. [E] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. = Pink = Yellow G = Green Example: L–Y L (Blue) Female Male ( ) GR = Gray Y (Yellow) [J] : Indicates a wiring Splice Point (Codes are ”E” for the Engine Room, ”I” for the Instrument Panel, and ”B” for the Body). The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. [F] : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. [G] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, No.3 ,,,, ,,,, The Location of splice Point I 5 is indicated by the shaded section. [K] : Indicates a shielded cable. [L] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Female Numbered in order from upper right to lower left Male [M] : Indicates a ground point. [H] : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. The first letter of the code for each ground point(s) indicates the component’s location, e.g, ”E” for the Engine Compartment, ”I” for the Instrument Panel and Surrounding area, and ”B” for the Body and Surrounding area. [N] : Page No. B HOW TO USE THIS MANUAL [O] SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on and holds the warning light on until the ignition SW is turned off. [P] SERVICE HINTS S6 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed L4 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : Approx. 12 volts with the stop light SW on 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON position 11–GROUND : Always continuity [Q] : PARTS LOCATION Code See Page See Page Code See Page 34 L4 36 R7 37 H17 36 R6 37 S6 35 [R] : RELAY BLOCKS Code 1 [S] Code C7 See Page 18 Relay Blocks (Relay Block Location) R/B No.1 (Instrument Panel Left) @@@ €€€ ÀÀÀ ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, @@@ €€€ ÀÀÀ ,,, @@@ €€€ ÀÀÀ Code See Page Junction Block and Wire Harness (Connector Location) [T] IB 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 3C 22 Instrument Panel Wire and J/B No.3 (Instrument Panel Left Side) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code [U] See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 42 Floor Wire and Instrument Panel Wire (Left Kick Panel) BV1 50 Luggage Room Wire and Floor Wire (Luggage Compartment Left) : GROUND POINTS Code [V] See Page Ground Points Location BL 50 Under the Left Quarter Pillar BO 50 Back Panel Center : SPLICE POINTS Code [W] I5 See Page 44 Wire Harness with Splice Points Code Cowl Wire B18 C7 H17 See Page 50 Wire Harness with Splice Points Luggage Room Wire L4 R6 R7 1 2
4 X X 7 8
X 11 X X
X

3
3 6
6
S6 GRAY


4 X






13 1 2 [X] 1
2
B [O] : Explains the system outline. [P] : Indicates values or explains the function for reference during troubleshooting. [Q] : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example : Part ”L4” (Light Failure Sensor) is on page 36 of the manual. ∗ The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example : L 4 Á Á Parts is 4th in order Light Failure Sensor [R] : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example : Connector ”1” is described on page 18 of this manual and is installed on the left side of the instrument panel. [S] : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example : Connector ”3C” connects the Instrument Panel Wire and J/B No.3. It is described on page 22 of this manual, and is installed on the instrument panel left side. [T] : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example : Connector ”IE1” connects the floor wire (female) and Instrument panel wire (male). It is described on page 42 of this manual, and is installed on the left side kick panel. [U] : Indicates the reference page showing the position of the ground points on the vehicle. Example : Ground point ”BO” is described on page 50 of this manual and is installed on the back panel center. [V] : Indicates the reference page showing the position of the splice points on the vehicle. Example : Splice point ”I5” is on the Cowl Wire Harness and is described on page 44 of this manual. [W]: Indicates connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. Pins used in the system circuit. Occupied positions, but not applicable to the system circuit. Unoccupied positions. The pins shown [X] : Connector Colorare only for the highest grade, or only include those in the specification. Connectors not indicated are milky white in color. HINT : Junction Connector Same Color Short Terminal Junction connector (code: J1 to J40) in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same position in the short terminal may be connected to a wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. B HOW TO USE THIS MANUAL The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( EA , IB and IC shown below) can also be checked this way. I GROUND POINT FAN MAIN RELAY 5 A/C FAN RELAY NO.2 5 A/C FAN RELAY NO.3 5 E3 O/D MAIN SW E3 CLOCK W–B W–B A A A A E5 E6 W–B FRONT SIDE MARKER LIGHT RH W–B FRONT SIDE MARKER LIGHT LH W–B BRAKE FLUID LEVEL WARNING SW W–B W–B ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, ,,,, W–B I4 W–B 2 IA1 B4 COMBINATION METER W–B 1 3D W–B CRUISE CONTROL MIRROR SW 3 3F W–B REMOTE CONTROL MIRROR SW 13 3G W–B TURN SIGNAL FLASHER 5 W–B 3E I2 REAR WINDOW DEFOGGER SW 6 3E I2 LIGHT CONTROL SW [COMB. SW] WIPER AND WASHER SW [COMB. SW] W–B I5 15 ID1 W–B W–B I5 W–B W–B BLOWER RESISTOR 8 IB1 W–B I8 W–B A/C AMPLIFIER 4 4 POWER WINDOW CONTROL RELAY B5 DOOR KEY LOCK SW LH B5 DOOR LOCK CONTROL SW FUEL CONTROL SW 3 IC3 I5 W–B WOOFER AMPLIFIER BR COMBINATION METER 4 BR BR 4 I3 BR I3 COMBINATION METER BR FUEL SENDER W–B 4 BR BR 5 BA1 W–B AUTO ANTENNA MOTOR B5 (4A–GZE) W–B HEATER RELAY POWER WINDOW MASTER SW I5 4 W–B BR B5 DOOR LOCK MOTOR LH W–B 4 RADIO AND PLAYER UNLOCK WARNING SW W–B W–B HORN SW [COMB. SW] DIMMER SW [COMB. SW] I2 W–B 10 EA2 I4 BLOWER SW I5 W–B B4 W–B I6 W–B EA ELECTRICAL IDLE−UP CUT RELAY (M/T) HEATER SERVO MOTOR AMPLIFIER PARKING BRAKE SW 7 W–B 3C E4 B4 I6 W–B 7 3B W–B DOOR LOCK MOTOR RH A E5 E4 W–B HEATER CONTROL ASSEMBLY J1 JUNCTION CONNECTOR W–B W–B W–B E4 W–B DOOR KEY LOCK SW RH A E2 E4 W–B W–B E3 W–B DOOR LOCK CONTROL SW RH DOOR LOCK CONTROL RELAY CIGARETTE LIGHTER E3 W–B RETRACT MOTOR LH PARKING LIGHT LH W–B W–B RETRACT MOTOR RH FRONT TURN SIGNAL LIGHT LH W–B W–B RETRACT CONTROL RELAY PARKING LIGHT RH W–B W–B RADIATOR FAN MOTOR FRONT TURN SIGNAL LIGHT RH W–B W–B 5 W–B FAN MAIN RELAY IB IC ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. B The ”Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. K POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. 10A ECU–B Short Pin 2 2 7.5A DOME 15A EFI Battery 30A AM2 Fusible Link Block 2 10A HAZARD 6 2 20A RADIO NO.1 Starter S2 10A HORN 100A ALT 60A ABS 6 5 Engine Room R/B (See Page 20) Fuse 20A 10A System Page STOP ABS ABS and Traction Control Cruise Control Electronically Controlled Transmission and A/T Indicator Multiplex Communication System 194 187 180 166 210 DOME Cigarette Lighter and Clock Combination Meter Headlight Interior Light Key Reminder and Seat Belt Warning Light Auto Turn Off Theft Deterrent and Door Lock Control 214 230 112 122 POWER SOURCE 40A DOOR LOCK CB 1.25B FL MAIN W W W 2 2 7 EB1 W W B W B 1 7.5A DOME I2 50A MAIN E7 2 W–L W W W I2 1 1 R W I2 1 B W 1 W B 2 2 4 W–B 2 B 4 B B 2 3 2 4 1 2 1 W–B 2 2 3 B–W 1 3 2 G 15A TAIL 1 20A DEFOG B–Y 1 G W–R 1 B 2 1 4 I8 IGNITION SW B–W STARTER RELAY E7 8 IG1 3 ACC 2 1 IG2 B 2 1 TAIL RELAY INJECTION RELAY B–O E7 2 W 15A HAZ–RADIO AM1 2 6 EB1 W–R W–R 2 AM2 E7 7.5A AM2 B G–W W BATTERY 3 EA2 1 EA1 W–B 1 1 E6 15A RAD CIG B–Y 1 P–L 1 ∗ The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. C TROUBLESHOOTING To Ignition SW IG Terminal Fuse [A] SW 1 Voltmeter [B] VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. Relay [C] Solenoid SW 2 CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Ohmmeter SW If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Ohmmeter Diode (c) Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. Digital Type Analog Type C To Ignition SW IG Terminal Test Light Fuse Case Short [A] SW 1 Short [B] Disconnect Disconnect Light (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: [A] – Ignition SW on [B] – Ignition SW and SW 1 on [C] – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: Relay Short [C] Disconnect SW 2 FINDING A SHORT CIRCUIT (a) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) (b) When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Solenoid DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT : Check to see what kind of connector you are disconnecting before pulling apart. Pull Up Press Down Pull Up Press Down C TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) Reference: 1. PREPARE THE SPECIAL TOOL 10 3 1 HINT : To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 1 0.2 (mm) 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR Example: (Case 1) Up Tool TERMINAL RETAINER. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. Terminal Retainer [A] Terminal Retainer HINT : The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. [Retainer at Full Lock Position] Stopper ”Case 1” Raise the terminal retainer up to the temporary lock position. Terminal Retainer [Retainer at Temporary Lock Position] Example: (Case 2) For Non–Waterproof Type Connector Secondary Locking Device ”Case 2” Open the secondary locking device. C Tool Tab Tab Example: [B] Terminal Retainer Tool Male Access Hole ( Mark) Tool For Waterproof Type Connector HINT : Terminal retainer color is different according to connector body. Example: Terminal Retainer Black or White Black or White Gray or White : Connector Body : Gray : Dark Gray : Black Female ”Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole (
Mark) and pull the terminal retainer up to the temporary lock position. HINT : The needle insertion position varies according to the connector’s shape (Number of terminals etc.), so check the position before inserting it. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] Example: (Case 2) ”Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Terminal Retainer Tool Tool [Male] Press Down Press Down [Female] C TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. Retainer at Full Lock Position Retainer at Temporary Lock Position [Male] [Female] (c) Release the locking lug from terminal and pull the terminal out from rear. Locking Lug Tool 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR ABBREVIATIONS D ABBREVIATIONS The following abbreviations are used in this manual. ABS = Anti–Lock Brake System A/C = Air Conditioning ACIS = Acoustic Control Induction System A/T = Automatic Transaxle COMB. = Combination ECU = Electronic Control Unit EGR = Exhaust Gas Recirculation ESA = Electronic Spark Advance EVAP = Evaporative Emission FL = Fusible Link J/B = Junction Block LH = Left–Hand M/T = Manual Transaxle O/D = Overdrive R/B = Relay Block RH = Right–Hand SFI = Sequential Multiport Fuel Injection SRS = Supplemental Restraint System SW = Switch TEMP. = Temperature VSV = Vacuum Switching Valve w/ = With w/o = Without ∗ The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. E GLOSSARY OF TERMS AND SYMBOLS GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. CIGARETTE LIGHTER An electric resistance heating element. HEADLIGHTS Current flow causes a headlight 1. SINGLE filament to heat up and emit light. A FILAMENT headlight may have either a single (1) filament or a double (2) filament 2. DOUBLE FILAMENT CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. HORN An electric device which sounds a loud audible signal. DIODE A semiconductor which allows current flow in only one direction. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE, ZENER LIGHT Current flow through a filament causes the filament to heat up and emit light. A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. PHOTODIODE The photodiode is a semiconductor which controls the current flow according to the amount of light. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSE METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. FUEL FUSIBLE LINK (for Medium Current Fuse) (for High Current Fuse or Fusible Link) A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the crosssection surface area of the wires. M MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. E RELAY Basically, an electrically operated 1. NORMALLY switch which may be normally CLOSED closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. SPEAKER An electromechanical device which creates sound waves from current flow. 2. NORMALLY OPEN SWITCH, MANUAL 1. NORMALLY OPEN RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. Opens and closes circuits, i it thereby th b stopping (1) or allowing (2) current flow. 2. NORMALLY CLOSED RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at ”base”. (Reed Switch Type) SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always drawn as (1) NOT straight lines on wiring CONNECTED diagrams. Crossed wires (1) without a black dot at the junction are j nott joined; j i d crossed wires (2) with a black dot or octagonal ( ) (2) SPLICED mark at the junction are spliced (joined) connections. F RELAY LOCATIONS [Engine Compartment] [Body] F [Instrument Panel] Fusible Link Block Engine Compartment Left (See Page 18) (Inside Engine Room J/B No.2) F RELAY LOCATIONS ,,, ,,, ,,,: Instrument Panel J/B Lower Finish Panel (See Page 19) F [Instrument Panel J/B Inner Circuit] F RELAY LOCATIONS ,,, ,,, ,,,: Engine Room J/B No.2 Engine Compartment Left (See Page 18) F [Engine Room J/B No.2 Inner Circuit] F RELAY LOCATIONS 1 Engine Compartment Left (See Page 18) : Engine Room R/B No.1 (Inside Engine Room J/B No.2) 2 : Engine Room R/B No.2 Near the Battery (See Page 18) F 3 : Engine Room R/B No.3 Radiator Upper Support RH (See Page 18) (TMMK Made w/ ABS and Traction Control) (TMC Made w/ ABS, w/ ABS and Traction Control) 3 : Fusible Link Block Radiator Upper Support RH (See Page 18) (TMMK Made w/ ABS w/o Traction Control) G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [1MZ–FE] A 1 A/C Condenser Fan Motor A 2 A/C Magnetic Clutch and Lock Sensor A 3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A 4 ABS Actuator A 5 ABS Actuator A 6 ABS Actuator and ECU A 7 ABS and Traction Actuator A 8 ABS and Traction Actuator A 9 ABS Speed Sensor Front LH A 10 ABS Speed Sensor Front RH A 28 Air Fuel Ratio Sensor (Bank 1 Sensor 1) A 29 Air Fuel Ratio Sensor (Bank 2 Sensor 1) A 30 A/C Ambient Temp. Sensor A 31 Airbag Sensor Front LH A 32 Airbag Sensor Front RH B 1 Back–Up Light SW B 2 Brake Fluid Level Warning SW C 1 Camshaft Position Sensor C 2 Crankshaft Position Sensor C 3 Cruise Control Actuator D 1 Data Link Connector 1 D 2 Daytime Running Light Resistor D 3 Diode (A/C) E E E E E 1 2 3 5 6 EGR Gas Temp. Sensor EGR Valve Position Sensor Electronically Controlled Transmission Solenoid Engine Coolant Temp. Sensor Engine Hood Courtesy SW F F F F F F F F F 1 2 3 4 5 6 7 8 9 Front Turn Signal Light and Parking Light LH Front Turn Signal Light and Parking Light RH Front Wiper Motor Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block G 1 Generator G 2 Generator H H H H H H 1 2 3 4 5 6 Headlight LH Headlight RH Heated Oxygen Sensor (Bank 1 Sensor 1) Heated Oxygen Sensor (Bank 2 Sensor 1) Horn (High) Horn (Low) G Position of Parts in Engine Compartment [1MZ–FE] I I I I I I I I I I I 1 2 5 6 7 8 9 10 11 12 13 Idle Air Control Valve Igniter Ignition Coil No.1 Ignition Coil No.2 Ignition Coil No.3 Injector No.1 Injector No.2 Injector No.3 Injector No.4 Injector No.5 Injector No.6 K 1 Knock Sensor 1 K 2 Knock Sensor 2 M 2 Mass Air Flow Meter N 1 Noise Filter (Ignition) O 1 Oil Pressure SW P 1 Park/Neutral Position SW,A/T Indicator Light SW and Back–Up Light SW P 2 Power Steering Oil Pressure SW R 1 Radiator Fan Motor S 1 Starter S 2 Starter T 1 Theft Deterrent Horn T 2 Throttle Position Sensor V 2 Vehicle Speed Sensor (Combination Meter) V 3 Vehicle Speed Sensor (Electronically Controlled Transmission) V 4 VSV (EGR) V 5 VSV (EVAP) V 6 VSV (Intake Air Control) W W W W W 1 2 3 4 5 Washer Level Warning SW Washer Motor Water Temp. Sender Water Temp. SW No.1 Water Temp. SW No.2 G ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [5S–FE] A 1 A/C Condenser Fan Motor A 2 A/C Magnetic Clutch and Lock Sensor A 3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A 4 ABS Actuator A 5 ABS Actuator A 6 ABS Actuator and ECU A 9 ABS Speed Sensor Front LH A 10 ABS Speed Sensor Front RH A 11 Air Fuel Ratio Sensor A 31 Airbag Sensor Front LH A 32 Airbag Sensor Front RH B 1 Back–Up Light SW B 2 Brake Fluid Level Warning SW C 1 Camshaft Position Sensor C 2 Crankshaft Position Sensor C 3 Cruise Control Actuator D 1 Data Link Connector 1 D 2 Daytime Running Light Resistor E E E E 3 4 5 6 Electronically Controlled Transmission Solenoid Electronically Controlled Transmission Solenoid Engine Coolant Temp. Sensor Engine Hood Courtesy SW F F F F F F F F F 1 2 3 4 5 6 7 8 9 Front Turn Signal Light and Parking Light LH Front Turn Signal Light and Parking Light RH Front Wiper Motor Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block Fusible Link Block G 1 Generator G 2 Generator H H H H H 1 2 3 5 6 Headlight LH Headlight RH Heated Oxygen Sensor (Bank 1 Sensor 1) Horn (High) Horn (Low) G Position of Parts in Engine Compartment [5S–FE] I 1 Idle Air Control Valve I 3 Ignition Coil and Igniter No.1 I 4 Ignition Coil and Igniter No.2 I 8 Injector No.1 I 9 Injector No.2 I 10 Injector No.3 I 11 Injector No.4 I 14 Intake Air Temp. Sensor K 1 Knock Sensor 1 R 1 Radiator Fan Motor S 1 Starter S 2 Starter T 1 Theft Deterrent Horn T 2 Throttle Position Sensor V 2 Vehicle Speed Sensor (Combination Meter) V 4 VSV (EGR) V 5 VSV (EVAP) M 1 Manifold Absolute Pressure Sensor N 1 Noise Filter (Ignition) O 1 Oil Pressure SW P 1 Park/Neutral Position SW,A/T Indicator Light SW and Back–Up Light SW P 2 Power Steering Oil Pressure SW W W W W 1 2 3 4 Washer Level Warning SW Washer Motor Water Temp. Sender Water Temp. SW No.1 G ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel A A A A A A A A A A A A A A A A A A A A 12 13 14 15 16 17 18 19 20 22 23 24 33 34 35 36 37 38 39 40 A/C Amplifier A/C Evaporator Temp. Sensor A/C SW ABS and Traction ECU ABS and Traction ECU ABS and Traction ECU ABS ECU ABS ECU Air Vent Mode Control Servo Motor Airbag Squib (Front Passenger Airbag Assembly) Airbag Squib (Steering Wheel Pad) Ashtray Illumination A/C Blower Motor Linear Controller A/C Control Assembly A/C Control Assembly A/C Room Temp. Sensor A/C Solar Sensor Air Inlet Control Servo Motor Air Mix Control Servo Motor Automatic Light Control Sensor B B B B 3 4 5 8 Blower Motor Blower Resistor Blower SW Blower Resistor (Low Speed) C C C C C C C 4 5 6 7 8 9 10 Cigarette Lighter Cigarette Lighter Illumination Clock Clutch Start SW Combination Meter Combination Meter Combination Meter C C C C C C C C 11 12 13 14 15 17 18 19 Combination SW Combination SW Combination SW Cruise Control Clutch SW Cruise Control ECU Center Airbag Sensor Assembly Center Airbag Sensor Assembly Center Airbag Sensor Assembly D D D D D D 4 5 6 7 10 11 Data Link Connector 2 Data Link Connector 3 Daytime Running Light Relay (Main) Diode (Courtesy) Diode (Dome) Diode (Idle–Up) E E E E E 7 8 9 10 11 Engine Control Module Engine Control Module Engine Control Module Engine Control Module Engine Control Module G 3 Glove Box Light and SW H 7 Hazard SW H 8 Heated Oxygen Sensor (Bank 1 Sensor 2) H 9 Heater Control SW I I I I 15 16 17 18 Ignition Key Cylinder Light Ignition SW Integration Relay Integration Relay G Position of Parts in Instrument Panel J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector Junction Connector J J J J 34 35 36 37 Junction Connector Junction Connector Junction Connector Junction Connector K 3 Key Interlock Solenoid O 2 O/D Main SW and A/T Shift Lever Illumination P 3 Parking Brake SW P 4 Power Outlet R R R R R R 2 3 4 5 6 7 Radio and Player Radio and Player Radio and Player Rear Window Defogger SW Remote Control Mirror SW Rheostat S S S S 3 4 5 6 Shift Lock ECU Stereo Component Amplifier Stereo Component Amplifier Stop Light SW T T T T T 3 4 5 6 7 Theft Deterrent ECU Theft Deterrent ECU Traction Off SW Turn Signal Flasher Transponder Key Amplifier U 1 Unlock Warning SW W 6 Wireless Door Lock ECU G ELECTRICAL WIRING ROUTING Position of Parts in Body B 6 Buckle SW LH F 10 F 11 F 12 F 13 F 14 C16 Condenser H10 High Mounted Stop Light D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 I 19 Interior Light A 25 ABS Speed Sensor Rear LH A 26 ABS Speed Sensor Rear RH A 27 Auto Antenna Motor and Relay Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Key Lock and Unlock SW Front LH Door Key Lock and Unlock SW Front RH Door Lock Control SW RH Door Lock Motor and Door Unlock Detection SW Front LH Door Lock Motor and Door Unlock Detection SW Front RH Door Lock Motor and Door Unlock Detection SW Rear LH Door Lock Motor and Door Unlock Detection SW Rear RH Front Door Speaker LH Front Door Speaker RH Front Tweeter (Speaker) LH Front Tweeter (Speaker) RH Fuel Pump and Sender J 38 Junction Connector J 39 Junction Connector J 40 Junction Connector L L L L L L 1 2 3 4 5 6 License Plate Light LH License Plate Light RH Light Failure Sensor Luggage Compartment Key Unlock SW Luggage Compartment Light Luggage Compartment Light SW G Position of Parts in Body M 3 Moon Roof Control SW and Relay M 4 Moon Roof Motor and Limit SW N 2 Noise Filter (Rear Window Defogger) P 5 P 6 P 7 P 8 P 9 P 10 P 11 P 12 P 13 P 24 P 25 Personal Light Power Window Control SW Front RH Power Window Control SW Rear LH Power Window Control SW Rear RH Power Window Master SW and Door Lock Control SW LH Power Window Motor Front LH Power Window Motor Front RH Power Window Motor Rear LH Power Window Motor Rear RH Pretensioner LH Pretensioner RH R 8 R 9 R10 R 11 R12 R13 R14 R15 R16 R17 Rear Combination Light LH Rear Combination Light LH Rear Combination Light RH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Rear Window Defogger Rear Window Defogger Remote Control Mirror LH Remote Control Mirror RH S 7 Side Airbag Sensor LH S 8 Side Airbag Sensor RH V V V V 1 7 8 9 Vapor Pressure Sensor VSV (Vapor Pressure Sensor) Vanity Light LH Vanity Light RH G ELECTRICAL WIRING ROUTING Position of Parts in Seat B 7 Buckle SW LH P 14 P 15 P 16 P 17 P 18 P 19 P 20 Power Seat Control SW (Driver’s Seat) Power Seat Control SW (Front Passenger’s Seat) Power Seat Motor (Driver’s Seat Rear Vertical Control) Power Seat Motor (Driver’s Seat Reclining Control) Power Seat Motor (Driver’s Seat Slide Control) Power Seat Motors (Driver’s Seat) Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) P 21 Power Seat Motor (Front Passenger’s Seat Reclining Control) P 22 Power Seat Motor (Front Passenger’s Seat Slide Control) P 23 Power Seat Motors (Front Passenger’s Seat) S 9 Side Airbag Squib LH S 10 Side Airbag Squib RH MEMO G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [1MZ–FE] : Location of Splice Points G Connector Joining Wire Harness and Wire Harness EA1 DARK GRAY 2 1 1 2 (w/o Daytime Running Light) ES1 EB1 EB1 (w/ Daytime Running Light) 1 2 3 4 4 3 2 1 5 6 7 8 8 7 6 5 GRAY EB2 1 2 3 4 4 3 2 1 5 6 X X X X 6 5 1 BLACK 1 1 Code Joining Wire Harness and Wire Harness (Connector Location) EA1 Engine Room Main Wire and Engine Room Main No.3 Wire (Radiator LH) EB1 EB2 GRAY Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) EC1 Engine Wire and Sensor Wire (Head Cover RH) ES1 Engine Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) GRAY 1 EC1 1 2 3 4 DARK GRAY 2 1 4 3 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [5S–FE] : Location of Splice Points G Connector Joining Wire Harness and Wire Harness EA1 1 2 DARK GRAY (w/ Daytime Running Light) 2 1 (w/o Daytime Running Light) EB1 EB1 1 2 3 4 4 3 2 1 5 6 7 8 8 7 6 5 EB2 GRAY 1 2 3 4 4 3 2 1 5 6 X X X X 6 5 1 Code Joining Wire Harness and Wire Harness (Connector Location) EA1 Engine Room Main Wire and Engine Room Main No.3 Wire (Radiator LH) EB1 EB2 GRAY Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) GRAY 1 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) ID1 Floor Wire and Cowl Wire (Left Kick Panel) IE1 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IE2 Front Door LH Wire and Cowl Wire (Left Kick Panel) IF1 IF2 IG1 IG2 IG3 IH1 IH2 Floor Wire and Instrument Panel Wire (Left Kick Panel) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) Instrument Panel Wire and Cowl Wire (Under the Blower Motor) Instrument Panel Wire and Instrument Panel No.2 No 2 Wire (Instrument Panel Brace RH) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Splice Points G Connector Joining Wire Harness and Wire Harness Code Joining Wire Harness and Wire Harness (Connector Location) II1 II2 II3 Engine Wire and Cowl Wire (Under the Blower Motor) II4 IJ1 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IK1 IK2 Engine g Room Main Wire and Cowl Wire ((Right g Kick Panel)) IK3 IL1 IM1 IM2 IN1 IN2 Floor No.2 Wire and Cowl Wire (Right Kick Panel) Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) Floor No No.2 2 Wire and Instrument Panel Wire (Right Kick Panel) IT1 Cowl Wire and Cowl Wire (Left Kick Panel) IU1 Engine Room Main Wire and Cowl Wire (Right Kick Panel) G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points : Location of Splice Points G Connector Joining Wire Harness and Wire Harness BO1 1 2 3 4 5 6 7 BP1 2 1 7 6 5 4 3 1 2 3 4 5 6 7 Code Joining Wire Harness and Wire Harness (Connector Location) BO1 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) 2 1 7 6 5 4 3 G ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Splice Points G Connector Joining Wire Harness and Wire Harness BQ1 BV1 BR1 YELLOW 1 2 1 2 3 3 2 1 BW1 1 2 2 1 2 1 YELLOW 2 1 1 2 Code Joining Wire Harness and Wire Harness (Connector Location) BQ1 Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) BR1 Floor No.2 Wire and Seat No.2 Wire (Under the Passenger’s Seat) BV1 Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) BW1 Floor No.2 Wire and Seat No.2 Wire (Under the Passenger’s Seat) POWER SOURCE 5 2 G1 GENERATOR B–W 1 2 (* 6) 3 B 2 2 (* 6) W–B 2 GR (* 6) A/F HTR RELAY 60A FL ABS B 1 B–G 1 3 (*7, *2 * 4) R–L ABS SOL RELAY 6 4 3 5 3 2 1 3 60A FL ABS B–G 1 3 2 W–L 3 2 (* 2 * 5) GR–R 3 W–B 3 1 2 4 3 W–R 3 GR–R L (*6) L 3 GR–L 3 3 ABS MOTOR RELAY B–R W–B 1 4 2 3 1 B–R L–R 1 5 (* 3) 1 1 1 100A ALT 25A A/F HTR 1 A 1 C 50A HTR 1 D 4 2F W–B 5 2C W–B 6 2K 15A EFI 10A HAZARD 20A RADIO NO. 1 10A HORN 4 2L 30A AM2 1 B–R B–G SHORT PIN 10A ECU–B 2 W–B 1 W–R (* 6) 1 2A 5A ALT–S 7. 5A DOME R 40A MAIN B BATTERY 3 2B 1 HEAD RELAY 2 1 2 3 5 4 3 2 1 ST RELAY (* 8) 3 2G (*9) FL MAIN 3. 0W B R–B W 5 ENGINE MAIN RELAY B–R 1 FL 1. 25B 2 W–B 1 F7 D , F8 E , F9 F L–B 1 E 3 FUSIBLE LINK BLOCK B–R 2 F 1 2 30A CDS F4 A , F5 B , F6 C , B–R 1 F 1 2 30A RDI 4 2 2B 2 (* 3) HTR RELAY E3 1 B L–R 1 10A A/C L–B 1 2 W–B B–G 1 1 L–W (* 2 * 5) B–G (*7, *2 * 4) B–G (5S–FE W/O ABS) (* 6) L L–B 4 2G R–L (* 8) 15A HEAD (RH)(* 9) 15A HEAD RH(UPR)(* 8) 15A HEAD (LH)(* 9) 15A HEAD LH(UPR)(* 8) EB B–R 4 1B 5 3 1 2 10A TAIL 25A DOOR 7. 5A PANEL 15A STOP TAILLIGHT RELAY 7. 5A OBD 30A POWER 1 POWER RELAY 5 3 2 1 2 NOISE FILTER 1 2 B–R NOISE FILTER 1 2 I1 40A DEF 1 2 7 1J W–B DEFOGGER RELAY 5 3 10A MIRROR–HEATER B–R 1 1B W 2 1K 1 1 2 2 40A AM1 15A CIG 7. 5A RAD–NO. 2 2 AM1 ACC 3 L–R IG1 4 B–Y 6 1K 1 1K 15A POWER–OUTLET 15A ECU–IG 10A HEATER 10A GAUGE 7 AM2 IG2 6 B–R ST2 8 R 25A WIPER 7. 5A TURN 3 1K 4 1K 5 1K 5 1B 6 1A I16 IGNITION SW W–R W–R B–R 5A IGN 5A STARTER 5A DRL NO. 2 R 1 2 (*8) 2 2 W–R 1 2 4 2 DIM RELAY 3 2 2 2 R–B 2 1 2 2 R–G R–L(* 8) R–Y 10A H–LP LH (LWR) 1 3 2 R W–B R 10A H–LP RH (LWR) R–L (*8) A * 1 : TMC MADE * 2 : TMMK MADE * 3 : EXCEPT TAIWAN * 4 : W/ TRACTION CONTROL * 5 : W/O TRACTION CONTROL * 6 : CALIFORNIA * 7 : TMC MADE EXCEPT 5S–FE W/O ABS * 8 : W/ DAYTIME RUNNING LIGHT * 9 : W/O DAYTIME RUNNING LIGHT J11 JUNCTION CONNECTOR IG POWER SOURCE SERVICE HINTS HEAD RELAY [ENGINE ROOM J/B NO.2] 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake pedal released (Parking brake SW off) (w/ Daytime Running Light) TAILLIGHT RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the light control SW at TAIL or HEAD position I16 IGNITION SW 2–3 : Closed with the ignition SW at ACC or ON position 2–4 : Closed with the ignition SW at ON or ST position 7–6 : Closed with the ignition SW at ON or ST position 7–8 : Closed with the ignition SW at ST position : PARTS LOCATION Code F4 See Page 26 (1MZ–FE) A F5 F6 F7 28 (5S–FE) 26 (1MZ–FE) B F8 28 (5S–FE) 26 (1MZ–FE) C Code F9 28 (5S–FE) See Page D E F Code 26 (1MZ–FE) G1 28 (5S–FE) See Page 26 (1MZ–FE) 28 (5S–FE) 26 (1MZ–FE) I16 30 28 (5S–FE) J11 31 26 (1MZ–FE) 28 (5S–FE) : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 1 24 Engine Room R/B No.1 (Engine Compartment Left) 2 24 Engine Room R/B No.2 (Near the Battery) 3 25 Engine Room R/B No.3 (Radiator Upper Support RH) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 1J 20 Cowl Wire and J/B Instrument Panel J/B (Lower Finish Panel) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1K 2A 2B 2C 2F 2G 2K 2L : GROUND POINTS Code EB IG See Page 36 (1MZ–FE) 38 (5S–FE) 40 Ground Points Location Left Radiator Side Support Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Cowl Wire Code I1 See Page 42 Wire Harness with Splice Points Cowl Wire F4 (A) F5 (B) F6 (C) 1 F9 (F) F7 (D) 1 F8 (E) 1 G1 1 I16 1 J11 ORANGE 1 1 A 2 A X 2 3 4 X 6 7 8 A A A A (Hint : See Page 7) STARTING AND IGNITION (1MZ–FE) ACC AM1 IG1 ST1 7 AM2 3 1K B–R IG2 6 ST2 8 8 1C B–R W–R R B–W 4 1K I16 IGNITION SW J29 JUNCTION CONNECTOR B B 5 1K 5A STARTER B–W B B–W 11 2 5 30A AM2 40A MAIN ST RELAY 1 3 2 3 2B 5 2D 9 2K 2 5 P1 PARK/NEUTRAL POSITION SW P 11 2J N 6 GR B–O (* 2 M/T) GR II2 B–G C B B–O GR(*1 A/T) 1 A (*2 A/T) B–R 10 W–B F4 A , F6 C FUSIBLE LINK BLOCK GR(* 1) B–O(* 2) 1 C (* 1 M/T) B B (A/T) 1 2A 1 II2 1 B–W C7 CLUTCH START SW 4 2L (A/T) B–W (M/T) W–R 3 1J (A/T) B–W 5 1B C B J7 A , J8 B JUNCTION CONNECTOR B A B A GR(*1) FL MAIN 3. 0W B–O(*2) 1 A 1 B W–B B–R B–O(*2) M BATTERY S1 B , S2 A STARTER GR(* 1) J11 JUNCTION CONNECTOR A IG * 1 : TMC MADE * 2 : TMMK MADE B–R 12 II3 B–R B–W J18 JUNCTION CONNECTOR A B–R B–R 1 1 2 G 2 Y 2 2 1 10 IGC3 IGC2 I2 IGNITER 9 +B 3 GR GND 7 BR–Y IGT1 6 LG–B IGT2 5 W–R IGT3 B–W IGF 4 BR IGC1 20 B 25 E 13 E 12 E 11 E NSW B–R B–R 1 A B–R A I5 IGNITION COIL NO. 1 A I6 IGNITION COIL NO. 2 A L I7 IGNITION COIL NO. 3 A IGF IGT3 IGT2 IGT1 STA 1 N1 NOISE FILTER (IGNITION) E 7 A , E 8 B , E11 E 7 A B–O(* 2) GR(*1) ENGINE CONTROL MODULE 2 BR GR(*1) B–O(* 2) BR ED STARTING AND IGNITION (1MZ–FE) SERVICE HINTS I16 IGNITION SW 7–6 : Closed with the ignition SW at ON or ST position 7–8 : Closed with the ignition SW at ST position P1 PARK/NEUTRAL POSITION SW 5–6 : Closed with the A/T shift lever in P or N position (A/T) S1 (B), S2 (A) STARTER Points closed with the Park/Neutral position SW at P or N position and the ignition SW at ST position (A/T) Points closed with the clutch start SW on and the ignition SW at ST position (M/T) : PARTS LOCATION Code See Page C7 Code See Page Code See Page 30 I5 27 (1MZ–FE) J18 31 E7 A 30 I6 27 (1MZ–FE) J29 31 E8 B 30 I7 27 (1MZ–FE) N1 27 (1MZ–FE) E11 E 30 I16 30 P1 F4 A 26 (1MZ–FE) J7 A 31 S1 B 27 (1MZ–FE) F6 C 26 (1MZ–FE) J8 B 31 S2 A 27 (1MZ–FE) I2 27 (1MZ–FE) J11 27 (1MZ–FE) 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1K 2A 2B 2D 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code II2 II3 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code See Page Ground Points Location ED 36 (1MZ–FE) Rear Side of the Surge Tank IG 40 Instrument Panel Brace LH E7 (A) C7 E8 (B) E11 (E) (California) 1 2


X X
7 X


X X X





X





X
X



X


X
X X X
11 12 13









20 X

X
25




X X

X
X




E11 (E) F4 (A) F6 (C) (Except California) BLACK 1

1

X




11 12 13








X
25





I2 I5 I6 I7 BLACK BLACK BLACK BLACK 1 1 2 3 4 5 6 7 X I16 2 1 2 1 9 10 J7 (A) J8 (B) GRAY GRAY











B B B





C C C J11 A X


X 6 7 8 A A A A A (Hint : See Page 7) (Hint : See Page 7) J18 (Hint : See Page 7) J29 ORANGE




B B B B












A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) S1 (B) 2 S2 (A) BLACK 1 1 N1 P1 GRAY GRAY 1 2 X
5 6





STARTING AND IGNITION (5S–FE) ACC AM1 IG1 ST1 7 AM2 B–R IG2 6 ST2 8 13 II3 B–R B–W W–R R J29 JUNCTION CONNECTOR B B 4 1K I16 IGNITION SW B–R 5 1K B–W B B–W B–W 4 2L 2 5 30A AM2 40A MAIN 1 II2 B–W C7 CLUTCH START SW 11 1 (A/T) W–R 3 1J (M/T) B–W 5 1B (A/T) 5A STARTER 2 ST RELAY 5 P 1 2A 1 3 2 3 2B 5 2D 9 2K P1 PARK/NEUTRAL POSITION SW N 11 2J GR B–G 1 A C B B–O GR(*3 A/T) II2 (*4 A/T) B–O (* 4 M/T) GR GR(* 3) B–O(* 4) B–R FUSIBLE LINK BLOCK 10 W–B F4 A , F6 C (* 3 M/T) B 1 C (A/T) 6 B C B J7 A , J8 B JUNCTION CONNECTOR B A B A GR(*3) FL MAIN 3. 0W B–O(*4) 1 A 1 B W–B B–R B–O(*4) M BATTERY S1 B , S2 A STARTER GR(*3) J11 JUNCTION CONNECTOR A IG * 1 : W/ ENGINE IMMOBILISER SYSTEM * 2 : W/O ENGINE IMMOBILISER SYSTEM * 3 : TMC MADE * 4 : TMMK MADE J25 JUNCTION CONNECTOR B B B–R B B–R B B–R 1 1 3 4 3 2 W–R Y–R GND 4 B–W 2 BR IGF W–R GND B IGT I4 IGNITION COIL AND IGNITER NO. 2 IGT N1 NOISE FILTER (IGNITION) +B I3 IGNITION COIL AND IGNITER NO. 1 IGF BR +B B–R B–W A A A W–R 22 A 22 A NSW 23 C 20 C 17 C 3 C IGT1 IGF BR W–R I2 22 C (*1) 19 C (*2) IGT2 STA 11 A (*1) 11 A (*2) E7 A , E9 C ENGINE CONTROL MODULE GR(* 3) BR B–O(* 4) EC J19 JUNCTION CONNECTOR 1 STARTING AND IGNITION (5S–FE) SERVICE HINTS I16 IGNITION SW 7–6 : Closed with the ignition SW at ON or ST position 7–8 : Closed with the ignition SW at ST position P1 PARK/NEUTRAL POSITION SW 5–6 : Closed with the A/T shift lever in P or N position (A/T) S1 (B), S2 (A) STARTER Points closed with the Park/Neutral position SW at P or N position and the ignition SW at ST position (A/T) Points closed with the clutch start SW on and the ignition SW at ST position (M/T) : PARTS LOCATION Code See Page C7 Code 30 See Page I16 Code 30 See Page N1 29 (5S–FE) E7 A 30 J7 A 31 E9 C 30 J8 B 31 S1 P1 B 29 (5S–FE) 29 (5S–FE) F4 A 28 (5S–FE) J11 31 S2 A 29 (5S–FE) F6 C 28 (5S–FE) J19 31 I3 29 (5S–FE) J25 31 I4 29 (5S–FE) J29 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1B 1J 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1K 2A 2B 2D 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code II2 II3 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code See Page Ground Points Location EC 38 (5S–FE) Surge Tank RH IG 40 Instrument Panel Brace LH : SPLICE POINTS Code I2 See Page 42 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points E7 (A) E7 (A) (w/ Engine Immobiliser System) (w/o Engine Immobiliser System)









11




X



11



X

















22









22

X 17 X


22 23


C7 1 2 E9 (C) F4 (A) E9 (C) (w/ Engine Immobiliser System) DARK GRAY F6 (C) I3 GRAY (w/o Engine Immobiliser System) 1 1

3









1 2 3 4

X

19 20





I4 I16 BLACK 1 2 3 4 X


X 6 7 8 J11 J19 J7 (A) J8 (B) GRAY GRAY











B B B





C C C (Hint : See Page 7) (Hint : See Page 7) J25 J29 A A A

A A A





B

B B B




B B B B












(Hint : See Page 7) (Hint : See Page 7) GRAY A A A A A A (Hint : See Page 7) (Hint : See Page 7) N1 P1 GRAY GRAY S1 (B) S2 (A) BLACK BLACK 1 1 X X
5 6





1 CHARGING B–G ACC 2 AM1 IG1 4 B–Y ST1 7 AM2 IG2 6 B–R W W–R ST2 2 1K 5 1K 3 1K I16 IGNITION SW 2 1 1K 5A IGN 10A GAUGE * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT 40A AM1 2 1J B–R 8 1T 4 B 5A ALT–S Y 30A AM2 Y C C C Y 100A ALT Y (* 1) (*1) 1 C J1 JUNCTION CONNECTOR B 2 F Y B–R 1 F (* 2) B–R 1 B W B–G 1 2A (*1) 4 IG2 E3 R–L C8 A , C9 B 3 2C B–R 4 2L 13 A TO DAYTIME RUNNING LIGHT RELAY (MAIN) 5 1B W–R 1 1B CHARGE WARNING LIGHT [COMB. METER] 1 6 EB1 4 IK2 F6 C , F9 F R–L FUSIBLE LINK BLOCK G1 B , G2 A 3 A 1 A 2 A FL MAIN 3. 0W B–G F4 A , F5 B , Y B–G 1 A S L IG BATTERY IC REGULATOR 1 B B GENERATOR SERVICE HINTS G2 (A) GENERATOR (A) 3–GROUND : 13.9–15.1 volts with the engine running at 2000 rpm and 25C (77F) 13.5–14.3 volts with the engine running at 5000 rpm and 115C (239F) (A) 1–GROUND : 0–4 volts with the ignition SW at ON position and the engine not running : PARTS LOCATION Code See Page C8 A 30 C9 B 30 F4 F5 F6 26 (1MZ–FE) A F9 28 (5S–FE) 26 (1MZ–FE) B Code G1 28 (5S–FE) See Page C F B Code 26 (1MZ–FE) G2 28 (5S–FE) See Page A 26 (1MZ–FE) 28 (5S–FE) 26 (1MZ–FE) I16 30 28 (5S–FE) J1 31 26 (1MZ–FE) 28 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1B 1J 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1K 1T 2A 2C 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 See Page 36 (1MZ–FE) 38 (5S–FE) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) IG2 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IK2 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) Wire Harness with Splice Points Cowl Wire Code E3 See Page 38 (5S–FE) Wire Harness with Splice Points Cowl Wire CHARGING C8 (A) C8 (A) (TMC Made) BLUE





(TMMK Made) BLUE





13











13 C9 (B) C9 (B) F4 (A) (TMC Made) 1


4



F5 (B)










4



F6 (C) F9 (F)







G1 (B) G2 (A) ORANGE 1 1 1 1 I16 J1 X 2
4 X 6 7
BLACK


C C





C C (Hint : See Page 7) 2 1 2 3 MEMO ENGINE CONTROL (1MZ–FE) B(* 1) R B–R 8 1C (* 1) B–W 5 1 3 2 JUNCTION CONNECTOR 1 2A B–R 3 1 1 5 EB1 4 EB1 I1 7 ID1 L–B J18 JUNCTION CONNECTOR 2 (* 1) II3 B–R 12 W–B 2 30A AM2 5 J35 A , J36 B 2 B–W 4 2L 4 1K 2 A/F HTR RELAY 2 C A B–R 5A IGN L 5A STARTER W–R 5 1B (* 1) 1 1 L–B 7 1W 1 L–B 3 1K I16 IGNITION SW C A 1 CIR OPN RELAY 3 1J A B 2 B–R G–R B (*1) ST2 8 B–R B–W 25A A/F HTR B–R R 5 1K 1 B–R IG2 6 W–R 7 AM2 B–W 7 IK1 G–R 1 ES1 B–R B FROM POWER SOURCE SYSTEM (SEE PAGE 50) (*1) B–W B–W A A B–R B–R B–R B–R B–R B–R 2 2 2 2 2 2 1 1 1 1 1 B–R A 4 F14 FUEL PUMP M 5 G–R W–B I13 INJECTOR NO. 6 A I12 INJECTOR NO. 5 A I11 INJECTOR NO. 4 A I10 INJECTOR NO. 3 A I9 INJECTOR NO. 2 1 A I8 INJECTOR NO. 1 F4 A , F6 C B–R 1 (* 1) G R–L W Y L B–G W–B R FL MAIN 3. 0W G R–L W BATTERY Y R L W–B 1 C FUSIBLE LINK BLOCK B B–W A J40 JUNCTION CONNECTOR BL B(*1) B(* 1) B–W B–Y FROM POWER SOURCE SYSTEM (SEE PAGE 50) B–Y B–W B–Y 9 II3 B–W B–R B–W C7 CLUTCH START SW 2 5 P N C B C B GR (* 5 A/T) 10 II2 J7 A , J8 B V B–W JUNCTION CONNECTOR B–Y (A/T) 6 2 GR(*4 A/T) B–Y 10 ID1 P1 PARK/NEUTRAL POSITION SW (M/T) B–W 1 GR(*4 M/T) B–Y B–Y 1 B–O(* 5 M/T) B B B–Y B–R B–W B–O B–Y J27 A , J28 B B–Y E A V7 VSV (VAPOR PRESSURE SENSOR) B B 4 2F 10 2C W–B W–B E A 2 2J B B 5 2C B A JUNCTION CONNECTOR 3 B A 11 II2 (A/T) J29 JUNCTION CONNECTOR B–Y B–Y B B B–Y 5 EFI RELAY 2 B–W 8 2J 7 2K 1 B (A/T) 15A EFI B A B–W B–O B–Y 1 ID1 (* 5) V B–W GR (*4) 16 A 8 A +B G–R 3 FC A B–R 2 A 9 A MREL TPC 20 B 7 A 1 A BATT STA NSW E7 A , E8 B , E9 C , G TRC– L 20 A (* 2) 13 A (* 2) 21 A LG 14 A (* 2) 4 C B 5 D (* 2) 6 D W 1 E (* 2) 16 B 2 E (* 3) 10 C 3 E (* 3) 5 C BR–W ENGINE CONTROL MODULE NEO EFI+ EFI– TRC+ RXCK L–Y TXCT CODE R–L # 10 (* 3) # 20 G–W # 30 L # 40 R 4 E (*1) # 50 Y # 60 W IGSW R–L W–B E10 D , E11 E G R–L W Y R TO TRANSPONDER KEY AMPLIFIER L B–Y W–B EB FROM ABS AND TRACTION ECU * 1 : CALIFORNIA * 2 : W/ TRACTION CONTROL * 3 : W/ ENGINE IMMOBILISER SYSTEM * 4 : TMC MADE * 5 : TMMK MADE ENGINE CONTROL (1MZ–FE) B(*1) B(* 1) B–Y B–Y J20 JUNCTION CONNECTOR A B–Y A FROM POWER SOURCE SYSTEM (SEE PAGE 50) A A A A B–Y BR 10A MIRROR– HEATER H3 HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) BR (* 6) (* 6) E1 HT OX 1 3 L–B(* 6) (SHIELDED) Y–G R–Y G–W 2 4 +B 7 D 3 D W B–Y 2 1 G–O V5 VSV (EVAP) V4 VSV (EGR) 2 2 (*6) B–Y 1 B–Y B–Y 1 LG B–Y A C B V6 VSV (INTAKE AIR CONTROL) A A S6 STOP LIGHT SW J12 JUNCTION CONNECTOR J27 A , J28 B 2 A 1 5 1R JUNCTION CONNECTOR 4 1R G–W 7 1C G–W 11 1J (* 6) G–O 9 1C 15A STOP W 10A TAIL E7 A , E8 B , E9 C , E10 D , E11 E ENGINE CONTROL MODULE 15 A ELS2 VG E2G THA 19 D L–Y 22 D R–B 10 D 5 3 1 TO IGNITER 18 E ACIS P 25 E W–R IGF 13 E LG–B IGT3 12 E BR–Y IGT2 11 E GR IGT1 17 E STP EGR EVP1 B–Y 2 OXR1 KSW 11 C 8 IG3 L–B L–B M2 MASS AIR FLOW METER 4 11 D HTR B B JUNCTION CONNECTOR 18 A J 9 A , J10 B 19 A ELS B A BR BR 2 1 L–B 5 1M 7 1D L–B W–B 3 1M 7 1J W–B B–Y A IG J11 JUNCTION CONNECTOR U1 UNLOCK WARNING SW B(*1) BR(* 6) BR J20 JUNCTION CONNECTOR B–Y B–Y (SHIELDED) A A BR(* 6) BR A B–Y BR(* 6) BR (*6) OX 3 BR(* 6) 12 D 16 E 4 D OXL1 HTL RSO * * * * P–B Y–B R–W (*6) B (*6) Y–R I2 15 E 3 9 B RSC HTS THG THW 13 D 14 D BR(* 1) 1 B–R(* 1) BR(* 6) (SHIELDED) 4 I2 B–R(* 1 *5) I2 2 R(* 1 * 4) HT 1 (* 1) BR E1 1 : CALIFORNIA 4 : TMC MADE 5 : TMMK MADE 6 : EXCEPT CALIFORNIA 8 B 3 D OXS 11 D 20 D AFR– 3 4 +B BR(* 1 * 5) 1 B G(* 1 *4) HT 1 2 B(* 1) AFR+ OX 3 II1 A28 AIR FUEL RATIO SENSOR (BANK 1 SENSOR 1) B +B 2 2 BR(* 1) B E1 B (SHIELDED) 2 H8 HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) I1 IDLE AIR CONTROL VALVE 4 (* 6) BR (* 6) H4 HEATED OXYGEN SENSOR (SHIELDED) (BANK 2 SENSOR 1) B–Y B–Y (*6) J24 JUNCTION CONNECTOR B B(*1) (SHIELDED) I2 B–Y BR HAFR E 7 A , E 8 B , E 9 C , E10 D , E11 E 1 3 Y 2 3 E2 1 VTA 4 II1 CF G–W J10 B JUNCTION CONNECTOR 2 ID1 VC 6 BR T2 THROTTLE POSITION SENSOR D B D B VCC BR BR I2 Y Y Y 3 II1 Y 5 ID1 II2 IND T 3 THEFT DETERRENT ECU B–L R–Y 2 E2 I2 G–W P 1 PTNK 9 D 1 P2 POWER STEERING OIL PRESSURE SW I2 4 IG3 R–Y 1 6 ID1 PS 29 E 16 C FROM FAN NO. 1 RELAY I2 17 A R–Y BR BR BR 1 Y BR 1 2 IMLD PTNK V1 VAPOR PRESSURE SENSOR 2 BR I2 2 BR Y L BR 3 E2 EGR VALVE POSITION SENSOR G–Y W–G 22 E P EGLS 2 D BR VC 23 D E5 ENGINE COOLANT TEMP. SENSOR VTA1 E1 EGR GAS TEMP. SENSOR E2 18 D G–B ENGINE CONTROL MODULE ENGINE CONTROL (1MZ–FE) BR(* 6) BR(* 6) BR BR B–Y (SHIELDED) (SHIELDED) BR(* 6) BR(* 6) BR(* 6) BR(* 6) BR(* 1) BR(* 1) A29 AIR FUEL RATIO SENSOR (BANK 2 SENSOR 1) B(*1) B(* 1) BR(* 1) BR 4 21 D B–W B–R TE1 8 I2 (SHIELDED) E1 (SHIELDED) I2 L L–W D1 DATA LINK CONNECTOR 1 L(* 1 *5) B–W(*1 * 4) B–W(*1 * 5) 12 D AFL– 4 D HAFL AFL+ L(* 1 *4) (SHIELDED) +B L 3 I2 C1 CAMSHAFT POSITION SENSOR 2 1 BR 12 C2 CRANKSHAFT POSITION SENSOR 1 2 BR 3 BR BR B–Y 1 BR BR(*1) 2 B–W(* 1) BR(* 1) 6 E TC 16 D 24 D NE+ NE– 10 E G22+ E 7 A , E 8 B , E 9 C , E10 D , E11 E ENGINE CONTROL MODULE KNKL KNKR 28 E TW 14 B 27 E ACT A/C 13 B 25 B TACH 27 B BR BR B–O B–O B–O B–Y F A 3 EC1 1 B–O W (SHIELDED) (SHIELDED) K1 KNOCK SENSOR 1 K2 KNOCK SENSOR 2 W (SHIELDED) D B 14 B 1 TW 10 B 7 C ACT 13 B 1 C AC1 J27 A , J28 B 1 EC1 LG–B V(* 8) (SHIELDED) W (SHIELDED) 2 EC1 F A JUNCTION CONNECTOR 4 EC1 (SHIELDED) W (SHIELDED) I2 16 A (*8) 4 C (*7) IGN A12 C A/C AMPLIFIER A34 A , A35 B A/C CONTROL ASSEMBLY BR(* 6) BR(*7) BR BR BR BR I2 (SHIELDED) (SHIELDED) A BR(* 6) BR(*6) A BR(* 6) BR(*6) A BR(* 1) BR(*1) A BR(* 1) BR(*1) A BR BR A BR BR A BR A A BR A A * 1 : CALIFORNIA * 4 : TMC MADE * 5 : TMMK MADE * 6 : EXCEPT CALIFORNIA * 7 : MANUAL A/C * 8 : AUTOMATIC A/C A BR J22 JUNCTION CONNECTOR (* 5 M/T) A BR 6 A SIL W BR (* 6) BR 11 A EOM (* 1) 13 C ADJ2 BR W 24 E E1 V–W BR BR 17 D G–R (*5 M/T) BR W 22 B SPD E 7 A , E 8 B , E 9 C , E10 D , E11 E E01 E02 E03 21 E 31 E 30 E 1 D BR BR BR BR ENGINE CONTROL MODULE E04 E05 8 D BR BR (* 1) (* 1) B–O B B B BR (*1) BR J26 JUNCTION CONNECTOR (* 1) B B–O BR (* 6) EC ENGINE CONTROL (1MZ–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) BR 7. 5A OBD (SHIELDED) 10A GAUGE D F B J4 JUNCTION CONNECTOR J28 B D JUNCTION CONNECTOR F B 5 16 SG BAT SIL CG 7 4 3 IG3 V–W C 9 B , C10 C COMBINATION METER 7 C 14 B 15 B 6 C V–W D5 DATA LINK CONNECTOR 3 (SHIELDED) W B B II2 V–W R–L J15 JUNCTION CONNECTOR SPEEDOMETER 2 V–W TACHOMETER G–R MALFUNCTION INDICATOR LAMP W–B (SHIELDED) W J3 JUNCTION CONNECTOR C C R–L R–L BR I5 BR C A 2 1D BR C A J8 B B B J7 A , B B 1 1J R–L BR BR JUNCTION CONNECTOR 10 1J R–L BR 6 II3 B BR I3 8 C 2 C 5 C 2 IJ1 3 2 SI SE IG+ BR L IJ1 P 7 V2 VEHICLE SPEED SENSOR (COMBINATION METER) W–B R–L 8 1J 7 1J P 10 IG3 L 6 IG3 A W–B A A G–R J24 JUNCTION CONNECTOR G–R A J8 B B–O J7 A , JUNCTION CONNECTOR B–O A B BR R–L 1 B–O A ED IG J11 JUNCTION CONNECTOR IH SYSTEM OUTLINE This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline of the engine control is explained here. 1. INPUT SIGNALS (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the water temp. is input into TERMINAL THW of the engine control module as a control signal. (2) Intake air temp. signal circuit The intake air temp. sensor is installed in the mass air flow meter and detects the intake air temp., which is input as a control signal into TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust gases is detected and input as a control signal into TERMINALS OXL1, OXR1 (Except California) and OXS of the engine control module. To maintain stable detection performance by the heated oxygen sensor, a heater is used for warming the sensor. The heater is also controlled by the engine control module (HTL, HTR (Except California) and HTS). (4) RPM signal circuit Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. The camshaft position is input as a control signal to TERMINAL G22+ of the engine control module, and the engine RPM is input into TERMINAL NE+. (5) Throttle signal circuit The throttle position sensor detects the throttle valve opening angle as a control signal, which is input into TERMINAL VTA1 of the engine control module. (6) Vehicle speed signal circuit The vehicle speed sensor, installed inside the transmission, detects the vehicle speed and inputs a control signal into TERMINAL SPD of the engine control module. (7) Park/Neutral position SW signal circuit The Park/Neutral position SW detects whether the shift position is in neutral, parking or not, and inputs a control signal into TERMINAL STA of the engine control module. (8) A/C SW signal circuit The A/C control assembly (Automatic A/C) or A/C Amplifier (Manual A/C) inputs the A/C operations into TERMINAL A/C of the engine control module as a control signal. (9) Battery signal circuit (California or w/ engine immobiliser and/or traction control) Voltage is always supplies to TERMINAL BATT of the engine control module. If you turn on the ignition SW, the current goes from TERMINAL MREL of the engine control module to the EFI relay and put on the relay, and the voltage related to the engine control module operation is supplied to TERMINAL +B of the engine control module through the EFI relay. (Except California or w/ engine immobiliser and/or traction control) Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, voltage for engine control module start–up power supply is applied to TERMINAL +B of engine control module via EFI relay. (10) Intake air volume signal circuit Intake air volume is detected by the mass air flow meter and a signal is input into TERMINAL VG of the engine control module as a control signal. (11) NSW signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor during cranking is detected and the signal is input into TERMINAL NSW of the engine control module as a control signal. (12) Engine knock signal circuit Engine knocking is detected by the knock sensor 1 and 2, then the signals are input into TERMINALS KNKR and KNKL of the engine control module as a control signal. (13) Air fuel ratio signal circuit (California) The air fuel ratio is detected and input as a control signal into TERMINALS AFL+, AFR+ of the engine control module. ENGINE CONTROL (1MZ–FE) 2. CONTROL SYSTEM ∗ SFI system The SFI system monitors the engine condition through the signals, which are input from each sensor (Input signals (1) to (12) ). The best fuel injection volume is decided based on this data and the program memorized by the engine control module, and the control signal is output to TERMINALS #10, #20, #30, #40, #50 and #60 of the engine control module to operate the injector (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals, which are input to the engine control module from each sensor (Input signals from 1, 3, 4, 12). The best ignition timing is decided according to this data and the memorized data in the engine control module and the control signal is output to TERMINALS IGT1, IGT2 and IGT3. This signal controls the igniter to provide the best ignition timing for the driving conditions. ∗ Heated oxygen sensor heater control system The heated oxygen sensor heater control system turns the heater on when the intake air volume is low (Temp. of exhaust emissions is low), and warms up the heated oxygen sensor to improve detection performance of the sensor. The engine control module evaluates the signals from each sensor (Input signals from 1, 4, 9, 10), current is output to TERMINALS HTL, HTR and HTS, controlling the heater. ∗ Idle air control system The idle air control system (Rotary solenoid type) increases the RPM and provides idle stability for fast idle–up when the engine is cold, and when the idle speed has dropped due to electrical load and so on, the engine control module evaluates the signals from each sensor (Input signals from 1, 4, 5, 8, 9), current is output to TERMINALS RSO and RSC to control idle air control valve. ∗ EGR control system The EGR control system detects the signal from each sensor (Input signals from 1, 4, 9, 10), and outputs current to TERMINAL EGR to control the VSV (EGR). The EGR valve position sensor is mounted on the EGR valve. this sensor converts the EGR valve opening height into a voltage and sends it to the engine control module as the EGR valve position signal. ∗ ACIS ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened and closed in accordance with the driving conditions to control the intake manifold length in two stages for increased engine output in all ranges from low to high speeds. The engine control module judges the engine speed by the signals ( (4), (5) ) from each sensor and outputs signals to the TERMINAL ACIS to control the VSV (Intake air control). 3. DIAGNOSIS SYSTEM With the diagnosis system, when there is a malfunction in the engine control module signal system, the malfunctioning system is recorded in the memory. 4. FAIL–SAFE SYSTEM When a malfunction occurs in any systems, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail–safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. SERVICE HINTS E5 ENGINE COOLANT TEMP. SENSOR 1–2 : Approx. 15.04 kΩ (–20C, –4F) Approx. 5.74 kΩ (0C, 32F) Approx. 2.45 kΩ (20C, 68F) Approx. 1.15 kΩ (40C, 104F) Approx. 0.584 kΩ (60C, 140F) Approx. 0.318 kΩ (80C, 176F) E7 (A), E8 (B), E9 (C), E10 (D), E11 (E) ENGINE CONTROL MODULE Voltage at engine control module wiring connector BATT–E1 : Always 9.0–14.0 volts +B–E1 : 9.0–14.0 volts (Ignition SW at ON position) VC–E2 : Always 4.5–5.5 volts (Ignition SW at ON position) VTA1–E2 : 0.3–0.8 volts (Ignition SW on and throttle valve fully closed) : 3.2–4.9 volts (Ignition SW on and throttle valve fully open) VG–E2G : 1.1–1.5 volts (Engine idling and A/C SW OFF position) THA–E2 : 0.5–3.4 volts (Engine idling and intake air temp. 20°C, 68°F) THW–E2 : 0.2–1.0 volts (Engine idling and engine coolant temp. 80°C, 176°F) IGF–E1 : 4.5–5.5 volts (Ignition SW at ON position) Pulse generation (Engine idling) G22+–NE– : Pulse generation (Engine idling) NE+–NE– : Pulse generation (Engine idling) NSW–E1 : 9.0–14.0 volts (Ignition SW on and other shift position in P or N position) Below 3.0 volts (Ignition SW on and shift position in P or N position) SPD–E1 : Pulse generation (Ignition SW on and rotate driving wheel slowly) TC–E1 : 9.0–14.0 volts (Ignition SW at ON Position) W–E1 : Below 3.0 volts A/C–E1 : Below 2.0 volts (Engine idling and A/C SW on) 9.0–14.0 volts (A/C SW off) ACT–E1 : 9.0–14.0 volts (Engine idling and A/C SW on) Below 2.0 volts (A/C SW off) ACIS–E01 : 9.0–14.0 volts (Ignition SW at ON position) STA–E1 : 6.0 volts or more (Engine cranking) THG–E2 : 4.5–5.5 volts (Ignition SW at ON position) ELS–E1 : 7.5–14.0 volts (Taillight SW at ON position) 0–1.5 volts (Taillight SW at OFF position) ELS2–E1 : 7.5–14.0 volts (Defogger SW at ON position) 0–1.5 volts (Defogger SW at OFF position) EGR–E01 : 9.0–14.0 volts (Ignition SW at ON position) FC–E1 : 9.0–14.0 volts (Ignition SW at ON position) 0–3.0 volts (Engine idling) EVP1–E01 : 9.0–14.0 volts (Ignition SW at ON position) CF–E1 : 9.0–14.0 volts (Electric cooling fan is operating on high speed) 0–2.0 volts (Electric cooling fan is operating on low speed or off) TACH–E1 : Pulse generation (Engine idling) TPC–E1 : 9.0–14.0 volts (Ignition SW on and disconnect the vacuum hose from the vapor pressure sensor) PTNK–E1 : 3.0–3.6 volts (Ignition SW at ON position) 1.3–2.1 volts (Ignition SW on and apply vacuum 2.0 kpa (15.0 mmHg, 0.6 in.Hg) STP–E1 : 7.5–14.0 volts (Ignition SW on and brake pedal depressed) Below 1.5 volts (Ignition SW on and brake pedal released) SIL–E1 : Pulse generation (During transmission) RSC, RSO–E01 : 9.0–14.0 volts (Ignition SW on and disconnect E 7 of engine control module connector) KNKL, KNKR–E1 : Pulse generation (Engine idling) HTS, HTL, HTR–E03 : 9.0–14.0 volts (Ignition SW at ON position) 0–3.0 volts (Engine idling) OXS, OXL, OXR–E1 : Pulse generation (Maintain engine speed at 2500 rpm for two minutes after warning up) IGT1, IGT2, IGT3–E1 : Pulse generation (Engine idling) #10, #20, #30, #40, #50, #60–E01 : 9.0–14.0 volts (Ignition SW at ON position) Pulse generation (Engine idling) ENGINE CONTROL (1MZ–FE) I8, I9, I10, I11, I12, I13 INJECTOR 2–1 : Approx. 13.8 Ω CIR OPN RELAY [R/B NO.1] 3–5 : Closed with starter running EFI RELAY [ENGINE ROOM J/B NO.2] 3–5 : Closed with ignition SW at ON or ST position : PARTS LOCATION Code A12 See Page C Code See Page Code See Page 30 H8 30 A28 26 (1MZ–FE) H3 26 (1MZ–FE) A29 26 (1MZ–FE) H4 26 (1MZ–FE) J27 A 31 J28 B 31 A34 A 30 I1 27 (1MZ–FE) A35 B 30 I8 27 (1MZ–FE) J24 31 J26 31 J29 31 C1 26 (1MZ–FE) I9 27 (1MZ–FE) J35 A 31 C2 26 (1MZ–FE) I10 27 (1MZ–FE) J26 B 31 C7 30 I11 27 (1MZ–FE) J40 32 C9 B 30 I12 27 (1MZ–FE) K1 27 (1MZ–FE) C10 C 30 I13 27 (1MZ–FE) K2 27 (1MZ–FE) D1 26 (1MZ–FE) I16 30 M2 27 (1MZ–FE) D5 30 J3 31 P1 27 (1MZ–FE) E1 26 (1MZ–FE) 31 P2 27 (1MZ–FE) E2 26 (1MZ–FE) J7 A 31 S6 31 E5 26 (1MZ–FE) J8 B 31 T2 27 (1MZ–FE) J4 E7 A 30 J9 A 31 T3 31 E8 B 30 J10 B 31 U1 31 E9 C 30 J11 31 V1 27 (1MZ–FE) E10 D 30 J12 31 V2 27 (1MZ–FE) E11 E 30 J15 31 V4 27 (1MZ–FE) F4 A 26 (1MZ–FE) J18 31 V5 27 (1MZ–FE) F6 C 26 (1MZ–FE) J20 31 V6 27 (1MZ–FE) 32 J22 31 V7 27 (1MZ–FE) F14 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 1 24 Engine Room R/B No.1 (Engine Compartment Left) 2 24 Engine Room R/B No.2 (Near the Battery) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1J 1K 1M 1R 1W 2A 2C 2F 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page EB1 36 (1MZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) EC1 36 (1MZ–FE) Engine Wire and Sensor Wire (Head Cover RH) ES1 36 (1MZ–FE) Engine Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 42 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) IJ1 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IK3 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) II1 II2 II3 : GROUND POINTS Code See Page Ground Points Location EB 36 (1MZ–FE) Left Radiator Side Support EC 36 (1MZ–FE) Surge Tank RH ED 36 (1MZ–FE) Rear Side of the Surge Tank IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH BL 44 Under the Left Center Pillar : SPLICE POINTS Code See Page Wire Harness with Splice Points Code I1 42 Cowl Wire I3 I2 42 Engine Wire I5 See Page 42 Wire Harness with Splice Points Cowl Wire ENGINE CONTROL (1MZ–FE) A12 (C) A28 A29 ORANGE DARK GRAY DARK GRAY 1
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V2 V4 V5 V6 V7 BLACK BROWN BLUE BROWN BLUE 1 2 3 1 2 1 2 1 2 1 2 ENGINE CONTROL (5S–FE) R B–R B–R I1 (* 2) (* 2) B–W B–R B–R R (*1) W–R ST2 8 B–R I3 (* 1) B–R 7 1W B–R 3 1K 7 IK1 B–R I16 IGNITION SW (* 2) B–R IG2 6 (* 2) B–R 7 AM2 (* 1) 5 1K 5A IGN 1 1 5 W–R 5 1B 1 CIR OPN RELAY 8 1C B–R 4 2L 2 4 EB1 B–R B–R 2 2 2 2 L–B 1 I11 INJECTOR NO. 4 1 I10 INJECTOR NO. 3 I9 INJECTOR NO. 2 1 L–B B–R 7 ID1 G–R B (* 1) B B–W B B–R I8 INJECTOR NO. 1 B–G 1 A II4 B B F4 A , F6 C L–B 6 FUSIBLE LINK BLOCK 5 EB1 B 1 2A 1 C 1 G–R (* 1) B–R J21 JUNCTION CONNECTOR (* 1) 1 B–W II3 B–R 12 30A AM2 3 4 M 1 F14 FUEL PUMP W Y W–B FL MAIN 3. 0W R L 5 G–R B–W(*1) B–R(*1) W Y BATTERY R W–B L B–R A BL J40 JUNCTION CONNECTOR R B–Y FROM POWER SOURCE SYSTEM (SEE PAGE 50) 4 1K B–R B–Y 5A STARTER (*2) B–W (A/T) 8 2J 2 B–O (*4 M/T) C B 12 A 12 A (A/T) GR(*3) #40 #30 #20 #10 9 C 24 C 10 C 25 C 11 C 11 C 12 C 12 C 23 C 20 C 17 C 3 C L B W–R STA R NSW Y (*1) B–R (*1) 1 A 11 A (*1) 11 A (*2) ENGINE CONTROL MODULE W BATT IGSW 7 D B–W MREL G–R FC 14 A 14 A E 7 A , E 8 B , E 9 C , E10 D 22 A (*1) 22 A (*2) 2 A 1 A +B C B B A B–Y B–Y W–B B–Y 1 C7 CLUTCH START SW B–W J27 A , J28 B B B B–W (M/T) JUNCTION CONNECTOR B–Y B A E B GR(* 3 M/T) (A/T) B B–O B–Y B A B–W J7 A , B J29 JUNCTION CONNECTOR II2 (*4 A/T) 10 4 2F 10 2C E A (A/T) GR B–Y E3 GR B–Y B–Y W–B N II2 B–O 2 2J 3 E A 11 6 B 5 2C II3 IGT1 IGF G–R IGT2 22 C (*1) 19 C (*2) Y–R B–R EFI RELAY 2 9 3 1J (*3 A/T) 5 P1 PARK/NEUTRAL POSITION SW B–W 1 P (*4) 7 2K 5 J8 B 15A EFI (*1) JUNCTION CONNECTOR B–W 2 IGF IGT +B GND +B GND L 13 II3 B–R 4 J25 JUNCTION CONNECTOR B B 1 4 A J19 JUNCTION CONNECTOR A B A W–B B–R B–Y * 1 : W/ ENGINE IMMOBILISER SYSTEM * 2 : W/O ENGINE IMMOBILISER SYSTEM EB * 3 : TMC MADE * 4 : TMMK MADE BR W–B B–R 1 BR R B–R Y BR IGF I4 IGNITION COIL AND IGNITER NO. 2 W–R 3 IGT B–R W 3 2 I3 IGNITION COIL AND IGNITER NO. 1 B–R(*1) W–R I2 B–W(* 1) EC ENGINE CONTROL (5S–FE) B B–Y B B B J19 JUNCTION CONNECTOR B B–Y B–Y B B–Y(* 6) BR V–W BR AF– 4 (* 5) W(*4) (* 5) L(* 3) (* 5) O(*4) 2 C 2 C (*5) 12 B 13 B I2 V G(*5) P–B 3 C 22 C HT 1 W B–O 15 B 23 C AF+ I2 (SHIELDED) W V 6 C 9 C 3 +B B–W(*3) BR 1 7 C 10 C II4 (*5) B 2 3 2 (SHIELDED) 1 1 1 ID1 5 A11 AIR FUEL RATIO SENSOR B–Y 1 K1 KNOCK SENSOR 1 2 2 2 V5 VSV (EVAP) 1 V4 VSV (EGR) I1 IDLE AIR CONTROL VALVE V7 VSV (VAPOR PRESSURE SENSOR) V B–Y 10 ID1 B–Y B–Y BR 16 B 8 B TPC ISCO ISCC EGR EVP KNK 6 B (* 1) 6 B (* 2) 14 B 14 B HTAF AF– AF+ BR 3 1 PTNK VCC E2 V1 VAPOR PRESSURE SENSOR BR I6 BR 3 II2 T2 THROTTLE POSITION SENSOR Y 2 2 ID1 BR P BR 2 Y I2 BR I2 1 3 VC 1 BR 2 VTA BR 1 E2 E2 3 VC 2 PIM M1 MANIFOLD ABSOLUTE PRESSURE SENSOR 2 1 E5 ENGINE COOLANT TEMP. SENSOR Y G–B 7 II4 4 B (* 1) 4 B (* 2) BR Y THW I14 INTAKE AIR TEMP. SENSOR 5 ID1 3 B 3 B Y–B Y THA 2 B 2 B BR P PIM BR 8 II4 9 B 9 B B–Y P E2 10 B 11 B BR 6 ID1 VTA Y P VC 1 B 1 B BR 8 B 7 B LG PTNK Y E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE I2 BR B–Y B–Y * 1 : W/ ENGINE IMMOBILISER SYSTEM * 2 : W/O ENGINE IMMOBILISER SYSTEM B–Y * 5 : CALIFORNIA * 6 : EXCEPT CALIFORNIA * 3 : TMC MADE * 4 : TMMK MADE BR B–Y(*6) BR BR BR BR BR BR (* 6) TE1 8 2 10A MIRROR– HEATER 10A TAIL 1 2 9 1C 1 11 1J J12 JUNCTION CONNECTOR G–O BR E1 C1 CAMSHAFT POSITION SENSOR HT 1 3 +B BR OX 3 12 C2 CRANKSHAFT POSITION SENSOR E1 B–Y 4 +B D1 DATA LINK CONNECTOR 1 BR (* 6) (* 6) 2 B–Y A G–O B–W L BR B–R I2 (SHIELDED) (SHIELDED) L–W (*6) L–Y (SHIELDED) W A (*6) H3 HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) B–Y FROM POWER SOURCE SYSTEM (SEE PAGE 50) 3 1 I2 L B–R 2 5 B 6 B 1 C 8 C OX1 HT1 7 B 15 B 12 D 4 C 6 D 17 C TE1 NE+ NE– D11 DIODE (IDLE–UP) 13 A (*1) 2 A (*2) 11 D 5 C G+ ELS E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE B–Y 2 IK2 L–R L–B 9 II4 1 A13 A/C EVAPORATOR TEMP. SENSOR 8 IG3 L–B G IK2 TO UNLOCK WARNING SW J10 JUNCTION CONNECTOR 9 W–L R–Y D TO TRANSPONDER KEY AMPLIFIER FROM A/C MAGNETIC CLUTCH AND LOCK SENSOR R–Y D L–Y 6 4 IG3 4 C (* 1) 12 B (* 2) II2 B–L II3 L–W 10 THR PS SW 11 B 10 B 1 2 BR L–Y 4 D W–L G–W KSW LOCK IN 19 C 18 C L–B IK2 TXCT 9 D R–L G 7 CODE 8 D W–L R–Y IND II4 RXCK 3 D P2 POWER STEERING OIL PRESSURE SW BR 2 3 PRS 19 A 13 A FROM A/C DUAL PRESSURE SW A14 A/C SW H9 HEATER CONTROL SW 5 R–B B T3 THEFT DETERRENT ECU B 1 MGC 21 A 21 A R–Y J12 JUNCTION CONNECTOR R–B R–B R–W IMLD 1 D L–Y A/C SW 10 A 10 A FROM MG CLT RELAY LOCK 20 A 15 A 1 B–Y ENGINE CONTROL (5S–FE) BR BR BR BR BR (*6) BR B–Y II2 BR 12 4 +B HT OX H8 HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) G–R 3 (SHIELDED) 13 B 5 B HT2 OX2 8 A 9 A 4 A 5 A SPD W G–R 14 C 21 C V–W II3 B 1 P–B II3 W B P–B 1 2 V–W 2 E1 W 6 A (* 1) 16 A (* 2) SIL E 7 A , E 8 B , E 9 C , E10 D E02 E03 13 C 13 C 26 C 26 C 25 C 16 B 7 A 8 A A BR A BR J23 JUNCTION CONNECTOR A BR A BR A A BR BR B–O STP 9 A (* 1) 4 A (* 2) BR BR A BR BR BR TACH G–W E01 15 C 15 C BR BR A BR A E04 BR E1 24 C 14 C (* 5) EOM 2 D BR ENGINE CONTROL MODULE (*6) B–Y BR EC EC BR BR BR G–W BR I2 B–O FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7. 5A OBD FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A STOP 7 1C 1 1J 2 1D R–L 10 1J 10A GAUGE R–L B W D D 3 IG3 V–W (SHIELDED) 15 B 6 C SPEEDOMETER TACHOMETER MALFUNCTION INDICATOR LAMP R–L BR G–R 5 C P G–R 10 IG3 L B–O 2 C 6 IG3 J21 JUNCTION CONNECTOR A 8 1J 4 1R 7 1J 5 1R R–L BR JUNCTION CONNECTOR 8 C A W–B J8 B B–O A A B B II2 R–L W–B A B 2 G–R BR C A COMBINATION METER 1 G–W CG 4 C A J7 A , 14 B C 9 B , C10 C S6 STOP LIGHT SW BAT J8 B SG 5 7 C 2 16 J7 A , SIL J28 B JUNCTION CONNECTOR F B JUNCTION CONNECTOR 7 F B BR I5 D5 DATA LINK CONNECTOR 3 (SHIELDED) W J3 JUNCTION CONNECTOR C C V–W G–R R–L R–L V–W W J4 JUNCTION CONNECTOR J15 JUNCTION CONNECTOR B B 7 IJ1 2 IJ1 L BR I3 P (SHIELDED) J27 A , J28 B C B JUNCTION CONNECTOR W–B A A BR F A B–O J27 A II3 G–W 6 V2 VEHICLE SPEED SENSOR (COMBINATION METER) JUNCTION CONNECTOR 3 F A 2 SI SE IG+ 1 R–L G–W A J11 JUNCTION CONNECTOR IG * 1 : W/ ENGINE IMMOBILISER SYSTEM * 2 : W/O ENGINE IMMOBILISER SYSTEM * 5 : CALIFORNIA * 6 : EXCEPT CALIFORNIA BR B–O IH ENGINE CONTROL (5S–FE) SYSTEM OUTLINE This system utilizes an engine control module and maintains overall control of the engine, transmission and so on. An outline of the engine control is explained here. 1. INPUT SIGNALS (1) Engine coolant temp. signal circuit The engine coolant temp. sensor detects the engine coolant temp. and has a built–in thermistor with a resistance which varies according to the engine coolant temp. thus the engine coolant temp. is input in the form of a control signal into TERMINAL THW of the engine control module. (2) Intake air temp. signal circuit The intake air temp. sensor detects the intake air temp., which is input as a control signal into TERMINAL THA of the engine control module. (3) Oxygen sensor signal circuit The oxygen density in the exhaust gases is detected and input as a control signal into TERMINAL OX1 (except California) and OX2 of the engine control module. (4) RPM signal circuit Camshaft position and crankshaft position are detected by the camshaft position sensor and crankshaft position sensor. Camshaft position is input as a control signal to TERMINAL G+ of the engine control module, and engine RPM is input into TERMINAL NE+. (5) Throttle signal circuit The throttle position sensor detects the throttle valve opening angle, which is input as a control signal into TERMINAL VTA of the engine control module. (6) Vehicle speed signal circuit The vehicle speed sensor, installed inside the transmission, detects the vehicle speed and inputs a control signal into TERMINAL SPD of the engine control module. (7) Park/Neutral position SW signal circuit (A/T) The Park/Neutral position SW detects whether the shift position are in neutral, parking or not, and inputs a control signal into TERMINAL STA of the engine control module. (8) A/C SW signal circuit The A/C amplifier function is built in the engine control module. The A/C SW signal inputs into the TERMINAL A/C SW of the engine control module. (9) Battery signal circuit Voltage is constantly applied to TERMINAL BATT of the engine control module. When the ignition SW is turned on, the voltage for engine control module start–up power supply is applied to TERMINAL +B of engine control module via EFI relay. (10) Intake air volume signal circuit Intake air volume is detected by the manifold absolute pressure sensor (for manifold pressure) and is input as a control signal into TERMINAL PIN of the engine control module. (11) Starter signal circuit To confirm whether the engine is cranking, the voltage applied to the starter motor during cranking is detected and the signal is input into TERMINAL NSW of the engine control module as a control signal. (12) Engine knock signal circuit Engine knocking is detected by knock sensor 1 and the signal is input into TERMINAL KNK as a control signal. (13) Electrical load signal circuit The signal when systems such as the rear window defogger, headlights, etc. Which cause a high electrical burden are on is input to TERMINAL ELS as a control signal. (14) Air fuel ratio signal circuit (California) The air fuel ratio is detected and input as a control signal into TERMINAL AF+ of the engine control module. 2. CONTROL SYSTEM ∗ SFI system The SFI system monitors the engine condition through the signals, which are input from each sensor (Input signals from (1) to (14) etc.) to the engine control module. The best fuel injection volume is decided based on this data and the program memorized by the engine control module, and the control signal is output to TERMINALS #10, #20, #30 and #40 of the engine control module to operate the injector. (Inject the fuel). The SFI system produces control of fuel injection operation by the engine control module in response to the driving conditions. ∗ ESA system The ESA system monitors the engine condition through the signals, which are input to the engine control module from each sensor (Input signals from (1), (2), (4) to (12) etc.) the best ignition timing is detected according to this data and the memorized data in the engine control module, and the control signal is output to TERMINALS IGT1 and IGT2. This signal controls the igniter to provide the best ignition timing for the driving conditions. ∗ Idle Air Control system The IAC system (Step motor type) increases the RPM and provides idling stability for fast idle–up when the engine is cold and when the idle speed has dropped due to electrical load, etc. The engine control module evaluates the signals from each sensor (Input signals (1), (4) to (8), (13) etc.), outputs current to TERMINALS ISCO and ISCC, and controls the idle air control valve. ∗ Fuel pump control system The engine control module operation outputs to TERMINAL FC and controls the CIR OPN relay. Thus controls the fuel pump drive speed in response to conditions. ∗ EGR control system The EGR cut control system controls the VSV (EGR) by evaluating the signals from each sensor which are input to the engine control module (Input signals (1), (5), (6), (9) etc.) and by sending output to TERMINAL EGR of the engine control module. ∗ A/C conditioning operation system In addition to the conventional A/C cut control, the engine control module performs the air conditioning operation as well since the A/C amplifier function is built in it. 3. DIAGNOSIS SYSTEM With the diagnosis system, when there is a malfunctioning in the engine control module signal system, the malfunction system is recorded in the memory. The malfunctioning system can then be found by reading the display (Code) of the malfunction indicator lamp. 4. FAIL–SAFE SYSTEM When a malfunction occurs in any system, if there is a possibility of engine trouble being caused by continued control based on the signals from that system, the fail–safe system either controls the system by using data (Standard values) recorded in the engine control module memory or else stops the engine. SERVICE HINTS E7 (A), E8 (B), E9 (C), E10 (D) ENGINE CONTROL MODULE Voltage at engine control module wiring connector BATT–E1 : Always 9.0–14.0 volts +B–E1 : 9.0–14.0 volts (Ignition SW at ON position) VC–E2 : 4.5– 5.5 volts (Ignition SW at ON position) VTA–E2 : 0.3– 0.8 volts (Ignition SW on and throttle valve fully closed) 3.2–4.9 volts (Ignition SW on and throttle valve open) PIM–E2 : 3.3– 3.9 volts (Ignition SW at ON position) THA–E2 : 0.5–3.4 volts (Ignition SW on and intake air temp. 20°C, 68°F) THW–E2 : 0.2– 1.0 volts (Ignition SW on and coolant temp. 80°C, 176°F) STA–E1 : 6.0–14.0 volts (Engine cranking) W–E1 : 9.0–14.0 volts (No trouble and engine running) TE1–E1 : 9.0–14.0 volts (Ignition SW at ON position) NSW–E1 : 0– 3.0 volts (Ignition SW on and Park/Neutral position SW position P or N position) 9.0–14.0 volts (Ignition SW on and except Park/Neutral position SW position P or N position) IGT1, IGT2–E1 : Pulse generation (Engine cranking or idling) #10, #20, #30, #40–E01, E02 : 9.0–14.0 volts (Ignition SW at ON position) RESISTANCE AT ENGINE CONTROL MODULE WIRING CONNECTORS (Disconnect wiring connector) VC–E2 : 2.5–5.0 kΩ THA–E2 : 2.21–2.69 kΩ (Intake air temp. 20°C, 68°F) THW–E2 : 0.29–0.354 kΩ (Coolant temp. 80°C, 176°F) ENGINE CONTROL (5S–FE) : PARTS LOCATION Code See Page Code See Page Code See Page A11 28 (5S–FE) H8 30 J21 31 A13 30 H9 30 J23 31 A14 30 I1 29 (5S–FE) J25 C1 28 (5S–FE) I3 29 (5S–FE) J27 A 31 C2 28 (5S–FE) I4 29 (5S–FE) J28 B 31 C7 30 I8 29 (5S–FE) J29 31 31 C9 B 30 I9 29 (5S–FE) J40 32 C10 C 30 I10 29 (5S–FE) K1 29 (5S–FE) D1 28 (5S–FE) I11 29 (5S–FE) M1 29 (5S–FE) D5 30 I14 29 (5S–FE) P1 29 (5S–FE) D11 30 I16 30 P2 29 (5S–FE) E5 28 (5S–FE) J3 31 S6 31 A 30 J4 31 T2 29 (5S–FE) E8 B 30 J7 A 31 T3 31 E9 C 30 J8 B 31 V1 29 (5S–FE) E10 D 30 J10 31 V2 29 (5S–FE) F4 A 28 (5S–FE) J11 31 V4 29 (5S–FE) F6 C 28 (5S–FE) J12 31 V5 29 (5S–FE) F14 32 J15 31 V7 29 (5S–FE) H3 28 (5S–FE) J19 31 E7 : RELAY BLOCKS Code 1 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 1J 1K 1R 1W 2A 2C 2F 2J 2K 2L : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) EB1 38 (5S–FE) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 42 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) II2 II3 II4 IJ1 IK1 IK2 : GROUND POINTS Code See Page Ground Points Location EB 38 (5S–FE) Left Radiator Side Support EC 38 (5S–FE) Intake Manifold IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH BL 44 Under the Left Center Pillar : SPLICE POINTS Code See Page E3 38 (5S–FE) I1 42 I2 42 Wire Harness with Splice Points Cowl Wire I5 Engine Wire A11 A13 3 See Page Wire Harness with Splice Points I3 42 Cowl Wire I6 A14 DARK GRAY 1 Code C1 C2 DARK GRAY DARK GRAY 1 2 1 2 C7 1


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V1 V2 V4 V5 V7 BLACK BLACK BLUE BLACK BLUE 1 2 3 1 2 3 1 2 1 2 1 2 ENGINE IMMOBILISER SYSTEM FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : 1MZ–FE * 2 : 5S–FE 15A EFI 7 2K 5 B–W C (*1) J35 JUNCTION CONNECTOR 1 5 2C 4 2F W–B W–B II4 B–W 6 B–Y (*1) 2 2J B–W 2 B–Y B–W 3 (*2) EFI RELAY (*2) C 8 A (* 1) 7 D (* 2) MREL B A E 7 A , E 9 C , E10 D B A CODE RXCK 4 C 8 D J27 A , J28 B 2 3 (* 2) L–Y II4 (* 2) 2 L–Y (*1) L–Y (* 2) R–L II4 (* 2) 4 R–L (*1) (* 2) II4 (* 2) 1 G–W (*1) G–W G–W JUNCTION CONNECTOR 4 TRANSPONDER KEY COIL 1 T7 TRANSPONDER KEY AMPLIFIER 5 EB W–B W–B B–Y W–B B–Y E B TXCT ENGINE CONTROL MODULE 10 C (* 1) 9 D (* 2) 5 C 3 D R–L E A IE : PARTS LOCATION Code See Page Code E7 A 30 J27 E9 C 30 J28 E10 D 30 J35 See Page A 31 B 31 Code T7 See Page 31 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 2C 2F 2J 2K See Page Junction Block and Wire Harness (Connector Location) 22 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code II4 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code EB IE See Page 36(1MZ–FE) 38(5S–FE) 40 Ground Points Location Left Radiator Side Suport Cowl Side Panel LH E7 (A) E9 (C) (1MZ–FE) (1MZ–FE) E10 (D)

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(Hint : See Page 7) (Hint : See Page 7) HEADLIGHT (w/o DAYTIME RUNNING LIGHT) 2 4 1 40A MAIN 15A HEAD (LH) HEAD RELAY 3 2 8 2K 3 2G 4 2G 6 2G R R–B R–B 8 2C R–W 1 3 2B 15A HEAD (RH) 3 3 J32 JUNCTION CONNECTOR H1 HEADLIGHT LH B 2 1 1 R–L R–B R–B B H2 HEADLIGHT RH 2 R–L B B 3 F B I17 INTEGRATION RELAY D B D B J35 A , J36 B JUNCTION CONNECTOR D A F A F A 4 R–L 1 A F B R–B F4 A , F6 C FUSIBLE LINK BLOCK R–B 1 C R–Y R–B R–L 8 7 17 LOW HIGH FLASH 16 W–B C13 COMBINATION SW 8 9 W–B HEAD R–L 3 IG1 TAIL C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] DIMMER SW B–G LIGHT CONTROL SW 13 OFF A A J7 JUNCTION CONNECTOR A 8 1J BATTERY J5 JUNCTION CONNECTOR A 7 1J A IG W–B W–B FL MAIN 3. 0W W–B J11 JUNCTION CONNECTOR IF SERVICE HINTS HEAD RELAY [ENGINE ROOM J/B NO.2] 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position C13 COMBINATION SW 13–16 : Continuity with the light control SW at HEAD position 8–16 : Continuity with the dimmer SW at FLASH position 7–16 : Continuity with the dimmer SW at HIGH or FLASH position : PARTS LOCATION Code See Page C9 30 C13 30 F4 F6 H1 26 (1MZ–FE) A H2 28 (5S–FE) C Code See Page Code 26 (1MZ–FE) See Page J7 31 28 (5S–FE) J11 31 26 (1MZ–FE) J32 31 28 (5S–FE) J35 A 31 J36 B 31 26 (1MZ–FE) I17 30 28 (5S–FE) J5 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1J See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 2B 2C 2G 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG1 See Page 40 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) : GROUND POINTS Code See Page Ground Points Location IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH HEADLIGHT (w/o DAYTIME RUNNING LIGHT) C9 C9 (TMC Made)






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(Hint : See Page 7) (Hint : See Page 7) 3 8 MEMO HEADLIGHT (w/ DAYTIME RUNNING LIGHT) G–R R–B 2 4 1 R–L HEAD RELAY 40A MAIN 3 2 8 2K 3 2G 4 2G 1 15A HEAD LH (UPR) R–B R 3 2B 15A HEAD RH (UPR) G–R R 2 6 1C 2 2 5 2G 2 2G R R DIM RELAY 1 3 2 R–W 2 2 2 2 1 2 R–L 3 1 D2 DAYTIME RUNNING LIGHT RESISTOR 8 EB1 2 R–B W–R 2 R–Y 3 2 1 DRL NO. 4 RELAY FL MAIN 3. 0W 1 H2 HEADLIGHT RH R–B R–B W–R 1 A F4 A , F6 C , F9 F 100A ALT FUSIBLE LINK BLOCK 1 C B–G 4 2 2 2 R–Y BATTERY R R W–B B–R 2 F 3 R–Y B–R B–R 1 F 2 H1 HEADLIGHT LH 4 1B E3 R–G 4 R–B B R 5A DRL NO. 2 W–B 5 1 1 2 TAILLIGHT RELAY 3 EB 7 EB1 R G–R G–R R–B R–B 2 A J2 JUNCTION CONNECTOR 1 1 A 10A H–LP LH (LWR) 10A H–LP RH (LWR) R–B 3 2 2 2 R G–R R–G D6 DAYTIME RUNNING LIGHT RELAY (MAIN) 16 H–LP H–ON CSB 20 19 2 18 6 R R–B R CSO CSE P–L GR–R 4 IG1 9 IG1 8 IG1 P–L 5 V–Y 15 V–Y B B J1 JUNCTION CONNECTOR 1 4 CLTB CLTS R–Y R R A40 AUTOMATIC LIGHT CONTROL SENSOR GR–R B H DIM R–Y R–B R–B TAIL 3 CLTE HEADLIGHT (w/ DAYTIME RUNNING LIGHT) FROM POWER SOURCE SYSTEM (SEE PAGE 50) R–L 7. 5A DOME R–B D A 3 J27 A , J28 B JUNCTION CONNECTOR I17 INTEGRATION RELAY 2 12 2J F B R R–L 1 R–B 4 R–B R–Y R–Y G G 1 1W R–Y R–W R 7 1V R–L G–Y R–Y T 22 23 +B IG 3 HI PKB BRK 13 14 4 E 12 R–W Y R–W CHG– 21 IND W–B D6 DAYTIME RUNNING LIGHT RELAY (MAIN) 17 C J1 JUNCTION CONNECTOR J2 JUNCTION CONNECTOR 7 IG1 C B B R–W R–W Y B 1 1 R–W W–B 6 EB1 Y P3 PARKING BRAKE SW 1 B2 BRAKE FLUID LEVEL WARNING SW G2 GENERATOR W–B 2 L W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE 1 1J 2 1D R–L R–L R–B R–Y G R–Y R–L R–W 3 IG1 G R–Y R–B D J4 JUNCTION CONNECTOR 14 13 8 R–L R–L D LIGHT CONTROL SW C 9 B , C10 C COMBINATION METER DIMMER SW 9 B OFF TAIL HEAD LOW HIGH FLASH W–B R–W 7 B C13 COMBINATION SW 8 B HIGH BEAM BRAKE 7 C 7 3 IG2 16 R–Y W–B R–W W–B A A J5 JUNCTION CONNECTOR 7 1J 8 1J W–B W–B A A W–B W–B IF J11 JUNCTION CONNECTOR A IG W–B A W–B A J7 JUNCTION CONNECTOR HEADLIGHT (w/ DAYTIME RUNNING LIGHT) SYSTEM OUTLINE The current from the FL MAIN is always flowing from the MAIN fuse to HEAD relay (Coil side) to TERMINAL H–LP of the daytime running light relay (Main), from DOME fuse to TERMINAL +B of the daytime running light relay (Main) and from the ALT fuse to Taillight relay (Coil side) to TERMINAL TAIL (TMMK Made) of the daytime running light relay (Main). When the ignition SW is turned on, the current flowing through the GAUGE fuse flows to TERMINAL IG of the daytime running light relay (Main). 1. DAYTIME RUNNING LIGHT OPERATION When the engine is started, voltage generated at TERMINAL L of the generator is applied to TERMINAL CHG– of the daytime running light relay (Main). If the parking brake lever is pulled up (Parking brake SW on) at this time, the relay is not activated so the daytime running light system does not operate. If the parking brake lever is then released (Parking brake SW off), a signal is input to TERMINAL PKB of the relay. This activates the daytime running light relay (Main) and the HEAD relay is turned to on, so the current flows from the MAIN fuse to the HEAD relay (Point side) to TERMINAL 1 of the DIM relay to TERMINAL 4 to H–LP LH (LWR), H–LP RH (LWR) fuses to TERMINAL 1 of the headlights to TERMINAL 3 to TERMINAL 1 of the daytime running light resistor to TERMINAL 2 to GROUND, causing the headlights to light up (Headlights light up dimmer than normal brightness.). Once the daytime running light system operates and the headlights light up, the headlights remain on even if the parking brake lever is pulled up (Parking brake SW on). If the engine stalls and the ignition SW remains on, the headlights remain light up even through current is no longer output from TERMINAL L of the generator. If the ignition SW is then turned off, the headlights go off. If the engine is started with the parking brake lever released (Parking brake SW off), the daytime running light system operates and headlights light up when the engine starts. 2. HEADLIGHT OPERATION When the light control SW is switched to HEAD position and the dimmer SW is set to LOW position, causing the daytime running light relay (Main) and the HEAD relay to turn on, so the current flows from the MAIN fuse to HEAD relay (Point side) to DRL NO.2 fuse to TERMINAL 3 of the DRL NO.4 relay to TERMINAL 4 to TERMINAL H–ON of the daytime running light relay (Main) to TERMINAL H to TERMINAL 3 of the integration relay to TERMINAL 4 to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND, activating the DRL. NO.4 relay. The current to HEAD relay (Point side) then flows to TERMINAL 1 of the DIM relay to TERMINAL 4 to H–LP LH (LWR), H–LP RH (LWR) fuses to TERMINAL 1 of the headlights to TERMINAL 3 to TERMINAL 1 of the DRL NO.4 relay to TERMINAL 2 to GROUND, causing the headlights to light up at normal intensity. When the light control SW is switched to HEAD position and the dimmer SW is set to HIGH position, the signal from the dimmer SW is input to the daytime running light relay (Main). This activates the daytime running light relay (Main) and the HEAD relay is turned on, so the current flows from the MAIN fuse to HEAD relay (Point side) to TERMINAL 1 of the DIM relay to TERMINAL 3 to TERMINAL DIM of the daytime running light relay (Main), activating the DIM relay. This causes current to flow from TERMINAL 1 of the DIM relay to TERMINAL 2 to HEAD LH (UPR), HEAD RH (UPR) fuses to TERMINAL 2 of the headlights to TERMINAL 3 to TERMINAL 1 of the DRL NO.4 relay to TERMINAL 2 to GROUND, causing the headlights to light up at high beam and the high beam indicator light to light up. When the dimmer SW is switched to FLASH position, the signal from the dimmer SW is input to the daytime running light relay (Main). This activates the daytime running light relay (Main) and the HEAD relay is turned on, so the current flows from the MAIN fuse to HEAD relay (Point side) to DRL NO.2 fuse to TERMINAL 3 of the DRL NO.4 relay to TERMINAL 4 to TERMINAL H–ON of the daytime running light relay (Main) to TERMINAL H to TERMINAL 8 of the dimmer SW to TERMINAL 16 to GROUND, activating the DRL NO.4 relay. At the same time, the current flows from the TERMINAL 1 of the DIM relay to TERMINAL 3 to TERMINAL DIM of the daytime running light relay (Main), activating the DIM relay, and also flows from the HEAD LH (UPR), HEAD RH (UPR) fuses to TERMINAL 2 of the headlights to TERMINAL 3 to TERMINAL 1 of the DRL NO.4 relay to TERMINAL 2 to GROUND, causing the headlights to light up at high beam and the high beam indicator light to light up. 3. AUTOMATIC LIGHT CONTROL OPERATION When the daytime running light is operating and the Automatic control sensor detects a decrease in the ambient light (It continues less than approx. 2500 lux over about 20 seconds, and it is less than 1000 lux.), the automatic light control operation starts. At the same time, daytime running light relay (Main) is activated, so current flows from the ALT fuse to the Taillight relay (Coil side) to TERMINAL TAIL of the daytime running light relay (Main), and the DRL NO.2 fuse to the DRL NO.4 relay (Coil side) to TERMINAL H–ON of the daytime running light relay (Main), activating both the Taillight relay and the DRL NO.4 relay, so that the taillights and headlights light up. When the automatic light control sensor detects an increase in the ambient light (It continues more than approx. 1000 lux over about 20 seconds, and it is more than approx. 2500 lux), the ignition SW is turned to off, the light control SW is turned to HEAD position, and the automatic light control operation stops. SERVICE HINTS HEAD RELAY [ENGINE ROOM J/B NO.2] 1–2 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake lever is released (Parking brake SW off) TAILLIGHT RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the light control SW at TAIL or HEAD position D6 DAYTIME RUNNING LIGHT RELAY (MAIN) 2–GROUND : Approx. 12 volts with the ignition SW at ON position 5, 7,17–GROUND : Approx. 12 volts with the light control SW at HEAD position or the dimmer SW at FLASH position Approx. 12 volts with the engine running and the parking brake lever is released (Parking brake SW off) 6,15–GROUND : Always approx. 12 volts 8–GROUND : Continuity with the parking brake lever pulled up 11–GROUND : 13.9–15.1 volts with the engine running at 2000 rpm 25°C (77°F) 12–GROUND : Approx. 12 volts with the high beam light up 13–GROUND : Always continuity 16–GROUND : Continuity with the dimmer SW at HIGH or FLASH position 18–GROUND : Continuity with the brake fluid level not enough : PARTS LOCATION Code See Page A40 30 26 (1MZ–FE) B2 28 (5S–FE) C9 B 30 C10 C 30 C13 30 26 (1MZ–FE) D2 28 (5S–FE) D6 F4 30 A 26 (1MZ–FE) 28 (5S–FE) Code F6 See Page C F9 F G2 H1 H2 I17 Code See Page 26 (1MZ–FE) J1 31 28 (5S–FE) J2 31 26 (1MZ–FE) J4 31 28 (5S–FE) J5 31 26 (1MZ–FE) J7 31 28 (5S–FE) J11 31 26 (1MZ–FE) J27 A 31 28 (5S–FE) J28 B 31 26 (1MZ–FE) 28 (5S–FE) 30 P3 31 HEADLIGHT (w/ DAYTIME RUNNING LIGHT) : RELAY BLOCKS Code 2 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.2 (Near the Battery) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 1V 1W 2B 2G 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 IG1 IG2 See Page 36 (1MZ–FE) 38 (5S–FE) 40 Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) Wire Harness with Splice Points Cowl Wire Code E3 See Page 38 (5S–FE) Wire Harness with Splice Points Cowl Wire A40 B2 BLACK GRAY 1 1 X 3 4 C9 (B) (TMC Made)





7 8 2 9






C9 (B) C10 (C) (TMMK Made)





7 8 (TMC Made) BROWN





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C10 (C) 7





D2 C13 (TMMK Made) BROWN





GRAY 7








X X X 7 8 1 X X X X 1314 X 16
D6 F4 (A) 2 G2 F6 (C) BLACK 1 X 2 3 4 5 6 1
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12 13 14 15 16 17 18 19 20 21 22 23 X X H1 H2 BLACK BLACK 1 2 I17 J2 J1 BLACK 1 3 2 3 1 2 3 4 A A A B B





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B B B B C C (Hint : See Page 7) (Hint : See Page 7) J4 J5 J7 BLACK ORANGE GRAY A A A A A A A A A A A A A A A A A A A


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DD DX (Hint : See Page 7) J11 A





(Hint : See Page 7) (Hint : See Page 7) A A A A A (Hint : See Page 7) HEADLIGHT (w/ DAYTIME RUNNING LIGHT) J27 (A) J28 (B)











D D







F F (Hint : See Page 7) (Hint : See Page 7) P3 1 MEMO LIGHT AUTO TURN OFF FROM POWER SOURCE SYSTEM (SEE PAGE 50) B 3 2B 1 5 7. 5A DOME 10A GAUGE 1 TAILLIGHT RELAY 40A MAIN 2 12 2J 3 2 6 1C * * * * G–R 3 2 8 2K R G–R T H (* 2 *4) D6 A , (*1) J32 JUNCTION CONNECTOR B (* 2) B B–R G–Y E3 J1 JUNCTION CONNECTOR R–B G–R (EXCEPT * 2 * 4) 5 A (* 3) 2 B (* 4) 17 B B R H–LP B TAIL B (* 1) B–R 6 A (* 3) 19 B (* 4) 16 B R–B (*2) (* 2 * 4) B–R 1 HEAD RELAY A A B 4 R–B J2 JUNCTION CONNECTOR 1 : W/O DAYTIME RUNNING LIGHT 2 : W/ DAYTIME RUNNING LIGHT 3 : TMC MADE 4 : TMMK MADE DAYTIME RUNNING LIGHT RELAY (MAIN) 4 1B R–B 1 1W (*2) 1 C 1 F 2 F 2 C 7 3 C 100A ALT 1 A F4 A , F6 C , F9 F 1 C 10 4 C G W–B W–B FL MAIN 3. 0L I17 C INTEGRATION RELAY 7 1S C13 COMBINATION SW 14 13 OFF TAIL R–G 8 1J LIGHT CONTROL SW 7 1J 6 R–Y B–G FUSIBLE LINK BLOCK HEAD W–B 16 BATTERY 1 A IG J11 JUNCTION CONNECTOR A A J7 JUNCTION CONNECTOR D12 DOOR COURTESY SW FRONT LH 1 SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 7 of the integration relay through GAUGE fuse. Voltage is applied at all times to TERMINAL (C) 2 of the integration relay through the taillight relay coil side, and to TERMINAL (C) 3 through the HEAD relay coil side (w/o daytime running light) or through the daytime running light relay (Main) (w/ daytime running light). 1. NORMAL LIGHTING OPERATION With the light control SW turned to TAIL position, a signal is input into TERMINAL (C) 1 of the integration relay. Due to this signal, the current flowing to TERMINAL (C) 2 of the relay flows to TERMINAL (C) 1 to TERMINAL 14 of the light control SW to TERMINAL 16 to GROUND, and taillight relay causes taillights to turn on. With the light control SW turned to HEAD position, a signal is input into TERMINALS (C) 1 and (C) 4 of the integration relay. Due to this signal, the current flowing to TERMINAL (C) 3 of the relay flows to TERMINAL (C) 4 to TERMINAL 13 of the light control SW to TERMINAL 16 to GROUND in the headlight circuit, and causes taillight and HEAD relay to turn the lights on. The taillight circuit is same as above. 2. LIGHT AUTO TURN OFF OPERATION With light on and ignition SW turned off (Input signal goes to TERMINAL 7 of the relay), when the driver’s door is opened (Input signal goes to TERMINAL 6 of the relay), the relay operates and the current is cut off which flows from TERMINAL (C) 2 of the relay to TERMINAL (C) 1 In taillight circuit and from TERMINAL (C) 3 to TERMINAL (C) 4 in headlight circuit. As a result, all lights are turned off automatically. SERVICE HINTS HEAD RELAY [ENGINE ROOM J/B NO.2] 2–1 : Closed with the light control SW at HEAD position or the dimmer SW at FLASH position Closed with the engine running and the parking brake lever released (w/ daytime running light) TAILLIGHT RELAY [INSTRUMENT PANEL J/B] 3–5 : Closed with the light control SW at TAIL or HEAD position D12 DOOR COURTESY SW FRONT LH 1–GROUND : Continuity with the front LH door open I17 (C) INTEGRATION RELAY 7–GROUND : Approx. 12 volts with the ignition SW at ON position 6–GROUND : Continuity with the front LH door open 1–GROUND : Always approx. 12 volts 10–GROUND : Always continuity (C) 2–GROUND : Always approx. 12 volts (C) 3–GROUND : Always approx. 12 volts (C) 4–GROUND : Continuity with the light control SW at HEAD position (C) 1–GROUND : Continuity with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page C13 D6 30 A 30 B 30 D12 F4 32 A 26 (1MZ–FE) 28 (5S–FE) Code F6 See Page C F9 F I17 C J1 26 (1MZ–FE) Code See Page J2 31 28 (5S–FE) J7 31 26 (1MZ–FE) J11 31 28 (5S–FE) J32 31 30 31 LIGHT AUTO TURN OFF : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1B 1C 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2B 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 2J 2K : GROUND POINTS Code See Page IG Ground Points Location 40 Instrument Panel Brace LH : SPLICE POINTS Code See Page E3 Wire Harness with Splice Points 36 (1MZ–FE) Code Cowl Wire E3 C13 See Page 38 (5S–FE) Wire Harness with Splice Points Cowl Wire D6 (A) D6 (B) (TMC Made) GRAY


X X X

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(TMMK Made) 5 6

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16 17
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X X X X X X 1314 X 16
D12 X X X X X F4 (A) F6 (C) F9 (F) I17 (C) ORANGE 1 1 1 1 J1

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J2 J7 BLACK GRAY A A A








(Hint : See Page 7) 2

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(Hint : See Page 7) (Hint : See Page 7) J32 J11 A A A A A A A (Hint : See Page 7) GRAY 1 2 3 4 MEMO TURN SIGNAL AND HAZARD WARNING LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 2 1L 3 2K W H7 HAZARD SW 10A HAZARD G–R 7. 5A TURN 10 8 C13 TURN SIGNAL SW [COMB. SW] OFF RH HAZARD TURN G–W 6 2 1 3 G–Y 1 5 G–B G–R 9 G–B 7 T6 TURN SIGNAL FLASHER 2 G–Y LH G–B ON C D G–B 3 G–Y D G–B C J15 JUNCTION CONNECTOR G–B W–B G–Y D G–B C 8 1V 1 EB1 6 1S 2 1A 8 1H 6 1H G–B G–Y 1 B 1 C LH RH 16 B W–B C 9 B , C10 C TURN SIGNAL INDICATOR LIGHT [COMB. METER] 2 F2 FRONT TURN SIGNAL LIGHT RH 3 W–B 5 R11 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 5 6 W–B 6 W–B 2 R9 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 3 W–B IG A J5 JUNCTION CONNECTOR E4 EB W–B A W–B A J11 JUNCTION CONNECTOR B11 BP W–B F1 FRONT TURN SIGNAL LIGHT LH G–Y B B J35 A , J36 B G–Y G–B G–B B A JUNCTION CONNECTOR G–Y 11 1S 5 1A 10 1C IF SERVICE HINTS T6 TURN SIGNAL FLASHER 2–GROUND : Approx. 12 volts with the ignition SW on or the hazard SW on 1–GROUND : Changes from 12 to 0 volts with the ignition SW on and the turn signal SW LEFT or RIGHT position, and with the hazard SW on 3–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code B 30 F2 28 (5S–FE) C10 C 30 H7 30 R9 33 30 J5 31 R11 33 26 (1MZ–FE) J11 31 T6 31 28 (5S–FE) J15 31 C13 F1 F2 26 (1MZ–FE) J35 A J36 See Page C9 B 31 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1A See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1H 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1L 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2K 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EB1 See Page 36 (1MZ–FE) 38 (5S–FE) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH BP 44 Back Panel Center : SPLICE POINTS Code E4 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Engine Room Main Wire Code B11 See Page 44 Wire Harness with Splice Points Floor Wire TURN SIGNAL AND HAZARD WARNING LIGHT C9 (B) C9 (B) (TMC Made) (TMMK Made) 1













16 1






C10 (C) C10 (C) (TMC Made) BROWN 1











16 C13 (TMMK Made) BROWN






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F1 F2 H7 J5 GRAY GRAY BLACK ORANGE
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2 3 3 X

X 5 6 7 8 9 10 J35 (A) 2 X X X

X X X X

X

3 J11 A A A A A A A A A A A A A (Hint : See Page 7) J15 1 A A A A A (Hint : See Page 7) J36 (B) R9 R11

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B B



















X 5 6 X 5 6 (Hint : See Page 7) (Hint : See Page 7) BLACK




CCCD D D
(Hint : See Page 7) T6 1 2 3 A MEMO STOP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A STOP 10A GAUGE 1 1S 2 1D W R–L 7 1C D J4 JUNCTION CONNECTOR 2 R–L S6 STOP LIGHT SW R–L D 7 C 1 C 8 A , C10 C G–W REAR LIGHTS WARNING LIGHT [COMB. METER] Y–G 3 A 4 1R 5 IF2 G–W Y–G 2 1S L3 LIGHT FAILURE SENSOR 7 4 8 DELAY HOLD 2 11 G–R 1 5 B11 J40 JUNCTION CONNECTOR A BL W–B W–B A BP W–B G–R 2 W–B 5 R11 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R 2 W–B W–B 1 H10 HIGH MOUNTED STOP LIGHT 2 R9 STOP LIGHT LH [REAR COMB. LIGHT LH] R B7 SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. STOP LIGHT DISCONNECTION WARNING When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current flowing from TERMINAL 7 of the light failure sensor to TERMINAL 2 and 1 changes, so the light failure sensor detects the disconnection and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning circuit on holding and the warning light on until the ignition SW is turned off. SERVICE HINTS S6 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed L3 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : Approx. 12 volts with the stop light SW on 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON position 11–GROUND : Always continuity : PARTS LOCATION Code C8 C10 See Page Code See Page Code See Page A 30 J4 31 R9 33 C 30 J40 32 R11 33 32 L3 32 S6 31 H10 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1R 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF2 See Page 40 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Instrument Panel Wire (Left Kick Panel) : GROUND POINTS Code See Page Ground Points Location BL 44 Under the Left Center Pillar BP 44 Back Panel Center : SPLICE POINTS Code B7 See Page 44 Wire Harness with Splice Points Floor Wire Code B11 See Page 44 Wire Harness with Splice Points Floor Wire STOP LIGHT C8 (A) C8 (A) (TMC Made) BLUE (TMMK Made) BLUE

3











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C10 (C) C10 (C) (TMC Made) BROWN












H10 (TMMK Made) BROWN 1
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J40 2 7





L3 R9 R11
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DD DX A A A A A A (Hint : See Page 7) (Hint : See Page 7) S6 BLUE 1
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1 2
4 X X 7 8
X 11 X MEMO INTERIOR LIGHT B W–B 1 2A 1 SHORT PIN 2 7. 5A DOME 12 2J R R R B1 R 1 2 R B5 R B R 1 C16 CONDENSER L3 LIGHT FAILURE SENSOR R R 2 DOOR I19 INTERIOR LIGHT 1 L5 LUGGAGE COMPARTMENT LIGHT 2 OFF ON R 1 A 2 2 P5 PERSONAL LIGHT V8 VANITY LIGHT LH FUSIBLE LINK BLOCK F4 A , F6 C 1 V9 VANITY LIGHT RH 1 1 C (*1) R B1 1 2 R–W 1 (* 1) W–B W–B W–B B–G W–B (W/ FADE OUT) R–W (W/O FADE OUT) R–Y B 3 : *1 B 2 : *2 BATTERY W–B 3 1F 3 1V W–B A J11 JUNCTION CONNECTOR IG BM IE L6 LUGGAGE COMPARTMENT LIGHT SW W–B FL MAIN 3. 0W 1 * 1 : W/ MOON ROOF * 2 : W/O MOON ROOF W–B * 3 : W/O THEFT DETERRENT SYSTEM * 4 : W/ THEFT DETERRENT SYSTEM 7 1J I18 A , B INTEGRATION RELAY 4 D10 DIODE (DOME) 6 1F 12 1S E R R–G D7 DIODE (COURTESY) R R–W 1 2 R–G 2 J33 A , J34 B 10 1 R–W 11 I15 IGNITION KEY CYLINDER LIGHT C9 OPEN DOOR WARNING LIGHT [COMB. METER] J33 A JUNCTION CONNECTOR G–R R–W E A JUNCTION CONNECTOR J16 JUNCTION CONNECTOR E 7 1S D A D A D A 2 R 4 1G R–G 1 11 1H R–W G–R R R 2 1F R–W 1 1M R–W 2 1M 8 A (*3) 6 B (*4) 6 (W/O FADE OUT) 8 1G R–W 9 1S (W/ FADE OUT) 5 1F R 1 1W R–Y 2 R 1 R–W 10 E A D B R–G R–W (W/ FADE OUT) R–W (W/O FADE OUT) R–G 1 D13 DOOR COURTESY SW FRONT RH 1 D12 DOOR COURTESY SW FRONT LH R–G 6 IN2 R–W 1 D15 DOOR COURTESY SW REAR RH D14 DOOR COURTESY SW REAR LH R–W 8 IN2 1 INTERIOR LIGHT SERVICE HINTS I18 (A), (B) INTEGRATION RELAY 1–GROUND : Always approx. 12 volts 4–GROUND : Continuity with the one of each door (Front LH, RH, rear LH and RH) open 6–GROUND : Continuity with the front LH door open 10–GROUND : Always continuity D12, D13, D14, D15 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1–GROUND : Closed with the door open L6 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : Closed with the luggage compartment door open : PARTS LOCATION Code See Page C9 30 C16 32 D7 30 D10 30 D12 32 D13 32 D14 32 D15 F4 A Code See Page F4 A F6 C Code See Page 28 (5S–FE) J33 A 31 26 (1MZ–FE) J34 B 31 28 (5S–FE) L3 32 30 L5 32 A 30 L6 32 B 30 P5 33 I19 32 V8 33 32 J11 31 V9 33 26 (1MZ–FE) J16 31 I15 I18 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1F See Page Junction Block and Wire Harness (Connector Location) 20 Roof Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2A 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2J 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1G 1H 1J 1M 1S 1V 1W : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IN2 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH BM 44 Roof Left : SPLICE POINTS Code B1 B2 See Page 44 Wire Harness with Splice Points Roof Wire Code See Page Wire Harness with Splice Points B3 44 Roof Wire B5 44 Floor Wire C9 C9 (TMC Made)








10 11




D7 D10 BLACK BLACK 1 2 1 2 C16 (TMMK Made)







1 2
10 11




D12 D13 D14 D15 1 1 1 1 F4 (A) 1 F6 (C) I15 I18 (A) I18 (B) (w/o Theft Deterrent System) ORANGE 1






8




1 2 I19 (w/ Theft Deterrent System) ORANGE
X
X
6
X
X

X X X




X X X X
J11 A A J16 J33 (A) J34 (B) BLACK BLACK BLACK




















E E E D D D E E E D D D


(Hint : See Page 7) (Hint : See Page 7) A A A A (Hint : See Page 7) (Hint : See Page 7) L3 1


X X


X
X 1 2 L6 GRAY 1 2 P5 V9 (TMMK Made) 1 2 V8 V8 (TMC Made) BLUE (TMMK Made) 1 1 1 2 V9 (TMC Made) BLUE L5 GRAY 2 1 2 1 2 ILLUMINATION G 1 5 TAILLIGHT RELAY 7. 5A PANEL 2 4 1B 3 6 1C 4 1J 5 1D G G B–R G–R G A J2 JUNCTION CONNECTOR E3 J13 A , J14 B JUNCTION CONNECTOR B A A B A G–R B G A24 ASHTRAY ILLUMINATION 2 1 2 B G (* 3) 12 (* 3) A34 A/C CONTROL ASSEMBLY G (* 4) (* 4) 7 B B 3 6 G (* 4) 1 FL MAIN 3. 0W G 1 B5 BLOWER SW 2 4 B B (* 4) B–G 2 B I17 INTEGRATION RELAY 1 A 6 B B (* 4) (* 5) 2 B B A14 A/C SW G–Y C5 CIGARETTE LIGHTER ILLUMINATION G B G B B (* 4) D6 DAYTIME RUNNING LIGHT RELAY (MAIN) 17 B B R5 REAR WINDOW DEFOGGER SW 100A ALT (*6) G–R 2 F F4 A , F9 F B–R 1 F 16 FUSIBLE LINK BLOCK B–R (* 5) LIGHT CONTROL SW 14 OFF A B A B A B A B A A A A TAIL HEAD A A 16 J13 A , J14 B W–B A W–B B A J7 JUNCTION CONNECTOR B JUNCTION CONNECTOR B 8 1J 6 1V 7 1J 4 1H W–B BATTERY C13 COMBINATION SW A IG B J11 JUNCTION CONNECTOR G G G G G A A A A A A A A J30 A , J31 B JUNCTION CONNECTOR 12 G G3 GLOVE BOX LIGHT AND SW 3 13 C10 COMBINATION METER ILLUMINATION [COMB. METER] O2 A/T SHIFT LEVER ILLUMINATION [O/D MAIN SW] 1 2 W–B B B (* 2) B W–G R4 C 9 C RADIO AND PLAYER 2 C W–G 5 B (* 1) G R2 B , R3 A 3 RADIO AND PLAYER H7 HAZARD SW 10 A 2 1 (*1) (* 2) 10 IH1 G G G G A B (*1) A B G G J5 JUNCTION CONNECTOR A (* 1) W–G 5 IH2 A E B B G W–B A D A 3 1 E B T W–B D A ILL E B B D A 2 B J16 A , J17 B JUNCTION CONNECTOR * 1 : SEPARATE TYPE AMPLIFIER * 2 : BUILT–IN TYPE AMPLIFIER * 3 : AUTOMATIC A/C * 4 : MANUAL A/C * 5 : TMMK MADE W/ DAYTIME RUNNING LIGHT * 6 : EXCEPT * 5 IF R7 RHEOSTAT ILLUMINATION SERVICE HINTS TAILLIGHT RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the light control SW at TAIL or HEAD position C13 COMBINATION SW 14–16 : Closed with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page A14 30 A24 30 A34 30 Code F9 See Page F Code See Page 28 (5S–FE) J17 B 31 G3 30 J30 A 31 H7 30 J31 B 31 B5 30 I7 30 C5 30 J2 31 R2 B 31 C10 30 J5 31 R3 A 31 C13 30 J7 31 R4 C 31 D6 30 J11 31 R5 31 R7 31 F4 A F9 F 26 (1MZ–FE) J13 A 31 28 (5S–FE) J14 B 31 26 (1MZ–FE) J16 A 31 O2 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D 1H 1J 1V See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IH1 IH2 See Page 40 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel No.2 No 2 Wire (Instrument Panel Brace RH) : GROUND POINTS Code See Page Ground Points Location IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) Wire Harness with Splice Points Cowl Wire Code E3 See Page 38 (5S–FE) Wire Harness with Splice Points Cowl Wire A14 A24 B5 A34 C5 BLACK

3 4
1 2
2

X





12








X X
X X

C10 C10 (TMC Made) BROWN (TMMK Made) BROWN










12 13





D6 1 X

6 7
C13




12 13 F4 (A)

X X X X
14 X 16
F9 (F) G3 ORANGE BLACK
X X X
1 X




X X X X X 1 1 2 2



16 17





X X H7 I17 BLACK X 2





J2 J5 BLACK ORANGE A A A








3 X 1 2

A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) J11 J7 GRAY A A A A A A A A J13 (A) J14 (B) BLUE BLUE A A A A A A A A A A A A B B B B B B B B B B B B (Hint : See Page 7) (Hint : See Page 7) A A A A





(Hint : See Page 7) (Hint : See Page 7) 2 J16 (A) J17 (B) J30 (A) J31 (B) O2 BLACK BLACK GRAY GRAY BLUE











A A A A A A A A A A A A D D D





E E E











1
3
(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7)
ILLUMINATION R2 (B)


X 5
R3 (A)

R4 (C)





X 10
2


9 X







X R5 R7 BLACK BLACK 2


6 1 2 3 MEMO TAILLIGHT 1 5 10A TAIL TAILLIGHT RELAY 2 9 1C J2 JUNCTION CONNECTOR HEAD C13 COMBINATION SW FL MAIN 3. 0W W–B 16 1 2 F2 FRONT PARKING LIGHT RH TAIL G B8 1 G G 14 OFF B8 G (* 3) G–O G–O C B L2 LICENSE PLATE LIGHT RH W–B I17 INTEGRATION RELAY 1 2 1 2 2 1 A W–B A W–B J7 JUNCTION CONNECTOR W–B B–G 1 A JUNCTION CONNECTOR C B F1 FRONT PARKING LIGHT LH 100A ALT LIGHT CONTROL SW 2 F F4 A , F9 F B–R 1 F FUSIBLE LINK BLOCK B–R 2 G J35 A , J36 B A A (* 1) G 17 G–Y L1 LICENSE PLATE LIGHT LH W–B (* 2) 16 G B5 D6 DAYTIME RUNNING LIGHT RELAY (MAIN) B–R (* 1) G–R A G–R G–O A J12 JUNCTION CONNECTOR G A A E3 8 1S G–O 6 1C G–R 4 1B 3 8 1J W–B BATTERY W–B 7 1J E4 B9 W–B A W–B J11 JUNCTION CONNECTOR IG EB W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE * 1 : TMMK MADE W/ DAYTIME RUNNING LIGHT * 2 : EXCEPT *1 * 3 : TMC MADE 2 1D R–L D 1 1S R–L D J4 JUNCTION CONNECTOR 7 C C 8 A , C10 C R–L G REAR LIGHTS WARNING LIGHT [COMB. METER] G Y–G 3 A IF2 Y–G 5 8 4 L3 LIGHT FAILURE SENSOR 3 DELAY G (* 3) 11 G–O 9 G–O (* 3) TAIL TAIL 3 5 B11 W–B W–B 5 1 SIDE MARKER 3 SIDE MARKER R9 REAR COMBINATION LIGHT LH G W–B 3 1 W–B B11 W–B B9 4 (*3) W–B W–B R10 TAILLIGHT RH [REAR COMB. LIGHT RH] 3 W–B R8 TAILLIGHT LH [REAR COMB. LIGHT LH] 4 W–B G–O G B8 R11 REAR COMBINATION LIGHT RH G G–O B7 (* 3) B10 G–O G–O A J40 JUNCTION CONNECTOR A W–B BP BL TAILLIGHT SYSTEM OUTLINE When the light control SW is turned to TAIL or HEAD position. The current flows to TERMINAL 3 of the light failure sensor through the TAIL fuse. When the ignition SW is turned on, the current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows through the rear lights warning light to TERMINAL 4 of the light failure sensor. TAILLIGHT DISCONNECTION WARNING With the ignition SW on and the light control SW turned to TAIL or HEAD position, if the taillight circuit is open, the light failure sensor detects the failure by the change in current flowing from TERMINAL 3 of the light failure sensor to TERMINAL 9, and the warning circuit of the light failure sensor is activated. As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights warning light on, which remains on until the light control SW is turned off SERVICE HINTS TAILLIGHT RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the light control SW at TAIL or HEAD position L3 LIGHT FAILURE SENSOR 4, 8–GROUND : Approx. 12 volts with the ignition SW at ON position 3–GROUND : Approx. 12 volts with the light control SW at TAIL or HEAD position 11–GROUND : Always continuity : PARTS LOCATION Code See Page C8 A 30 C10 C 30 Code F9 See Page F Code See Page 26 (1MZ–FE) J40 32 28 (5S–FE) L1 32 C13 30 I17 30 L2 32 D6 30 J2 31 L3 32 26 (1MZ–FE) J4 31 R8 33 28 (5S–FE) J7 31 L9 33 26 (1MZ–FE) J11 31 R10 33 28 (5S–FE) J12 31 R11 33 F1 F2 F4 A 26 (1MZ–FE) J35 A 31 28 (5S–FE) J36 B 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IF2 See Page 40 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Instrument Panel Wire (Left Kick Panel) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support IG 40 Instrument Panel Brace LH BL 44 Under the Left Center Pillar BP 44 Back Panel Center : SPLICE POINTS Code See Page Wire Harness with Splice Points 36 (1MZ–FE) E3 36 (1MZ–FE) B5 44 B9 44 B11 C8 (A) C8 (A) (TMC Made) BLUE (TMMK Made) BLUE








3









C10 (C) C10 (C) (TMC Made) BROWN (TMMK Made) BROWN





7





Floor Wire B10 Floor Wire

3


Wire Harness with Splice Points B8 Engine Room Main Wire 38 (5S–FE) See Page B7 Cowl Wire 38 (5S–FE) E4 Code





C13 7








X X X

X X X X
14 X 16
D6 F1 F2 GRAY GRAY F4 (A) F9 (F) ORANGE 1 X




X X X X X



16 17





X X I17 J2 1 2

1 2 1 2

J4 1 J11 J7 BLACK BLACK GRAY A A A











X X


DD DX A A A A A A A (Hint : See Page 7) (Hint : See Page 7) A A A A A





(Hint : See Page 7) (Hint : See Page 7) J12 J35 (A) J36 (B) J40 L1 BLACK A A A








(Hint : See Page 7) GRAY A A A







C C











A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) 1 2 2 TAILLIGHT L2 L3 R8 R9 R10 R11
X 3 4 1
3
X 3 4 1
3 GRAY 1 2

3 4 X X
8 9 X 11 X X 5
X 5
MEMO BACK–UP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE R–L 1 1J J28 JUNCTION CONNECTOR 2 II2 3 C J27 JUNCTION CONNECTOR R–B C R–B F R–L F II3 R–L A (5S–FE) (1MZ–FE) R–L 5 1V 13 1S A R–B B8 R–B R10 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] 8 A (A/T) 1 B (M/T) 1 3 W–B 2 A (A/T) 2 B (M/T) W–B B9 W–B R8 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] BACK–UP LIGHT SW(M/T) P1 A BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW](A/T) B1 B R–B R–L (5S–FE) A (1MZ–FE) R–L A R–B J21 JUNCTION CONNECTOR R–B J24 JUNCTION CONNECTOR A J40 JUNCTION CONNECTOR BL 1 3 SERVICE HINTS P1 (A) BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW] (A/T) (A) 2–(A) 8 : Closed with the shift lever at R position B1 (B) BACK–UP LIGHT SW (M/T) (B) 2–(B) 1 : Closed with the shift lever at R position : PARTS LOCATION Code B1 See Page B Code See Page 26 (1MZ–FE) J27 31 Code P1 See Page A 29 (5S–FE) 28 (5S–FE) J28 31 R8 33 J21 31 J40 32 R10 33 J24 31 P1 A 27 (1MZ–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire And Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page II2 42 II3 Joining Wire Harness and Wire Harness (Connector Location) Engine Wire and Cowl Wire (Under the Blower Motor) : GROUND POINTS Code See Page BL 44 Ground Points Location Under the Left Center Pillar : SPLICE POINTS Code See Page B8 44 Wire Harness with Splice Points J21 GRAY GRAY 2 See Page B9 B1 (B) 1 Code Floor Wire 44 J24 Wire Harness with Splice Points Floor Wire J27 A A A

A A A




A
A A


(Hint : See Page 7) (Hint : See Page 7)



C C





(Hint : See Page 7) J28 J40 P1 (A) R8 R10 1 X 3
1 X 3
GRAY A





A A A A A



F F (Hint : See Page 7) (Hint : See Page 7) X


2 8



WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/ INT TIME ADJUST * 2 : W/O INT TIME ADJUST 25A WIPER E B E A L J35 A , J36 B L JUNCTION CONNECTOR 1 1A 4 1C 2 M W2 WASHER MOTOR 1 EW L–W WF WIPER SW WASHER SW OFF 6 11 EW 2 L–W L HI LO INT WF IK1 +1 +1 7 L–B +2 (*2) L–Y +2 8 L–O +B 17 L +S 16 +B (*1) INT1 INT2 B1 OFF ON J15 JUNCTION CONNECTOR +S A A L W–B 3 5 2 1 +2 +1 B S M E 4 W–B F3 FRONT WIPER MOTOR 10 2J A IG J11 JUNCTION CONNECTOR 4 2F W–B C11 WIPER AND WASHER SW [COMB. SW] A EB SYSTEM OUTLINE With the ignition SW turned on, the current flows to TERMINAL 17 of the wiper and washer SW, TERMINAL 2 of the washer motor and TERMINAL 2 of the front wiper motor through the WIPER fuse. 1. LOW SPEED POSITION With the wiper and washer SW turned to LO position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND and causes the front wiper motor to run at low speed. 2. HIGH SPEED POSITION With the wiper and washer SW turned to HI position, the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 8 to TERMINAL 3 of the front wiper motor to TERMINAL 4 to GROUND and causes the front wiper motor to run at high speed. 3. INT POSITION With the wiper and washer SW turned to INT position, the wiper relay operates and current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 2 to GROUND. This activates the intermittent circuit and the current flows from TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND and the wiper operates. Intermittent operation is controlled by a condenser charge and discharge function in the relay. 4. WASHER CONTINUOUS OPERATION With the wiper and washer SW pulled to WASHER position (Washer SW ON position), the current flows from the WIPER fuse to TERMINAL 2 of the washer motor to TERMINAL 1 to TERMINAL 11 of the wiper and washer SW to TERMINAL 2 to GROUND and causes the washer motor to run and the window washer to spray. Simultaneously, current flows from the WIPER fuse to TERMINAL 17 of the wiper and washer SW to TERMINAL 7 to TERMINAL 5 of the front wiper motor to TERMINAL 4 to GROUND, causing the wiper to function. SERVICE HINTS C11 WIPER AND WASHER SW [COMB. SW] 2–GROUND : Always continuity 17–GROUND : Approx. 12 volts with the ignition SW at ON position 7–GROUND : Approx. 12 volts with the ignition SW on and the wiper and washer SW at LO position Approx. 12 volts every approx. 1 to 10 seconds intermittently with the ignition SW on and the wiper and washer SW at INT position 16–GROUND : Approx. 12 volts with the ignition SW on and unless the front wiper motor at STOP position 8–GROUND : Approx. 12 volts with the ignition SW on and the wiper and washer SW at HI position F3 FRONT WIPER MOTOR 1–2 : Closed unless the front wiper motor at STOP position : PARTS LOCATION Code See Page C11 Code 30 26 (1MZ–FE) F3 28 (5S–FE) See Page J11 31 J15 J35 31 A 31 Code J36 See Page B W2 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1A See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2F 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2J 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IK1 See Page 42 Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Cowl Wire (Right Kick Panel) 31 27 (1MZ–FE) 29 (5S–FE) WIPER AND WASHER : GROUND POINTS Code EB IG See Page 36 (1MZ–FE) 38 (5S–FE) 40 Ground Points Location Left Radiator Side Support Instrument Panel Brace LH C11 F3 BLACK GRAY J11 A 1 2 3 X 2 X X X X 7 8 X A A A J36 (B)













E E



E E

(Hint : See Page 7) A A A








A (Hint : See Page 7) (Hint : See Page 7) W2 BLACK (Hint : See Page 7) A 4 5 X 11 X X X X 16 17 X J35 (A) J15 BLACK 1 2 X MEMO POWER WINDOW FROM POWER SOURCE SYSTEM (SEE PAGE 50) 2 P9 POWER WINDOW MASTER SW 10 11 BW 10 IE2 BW FRONT LH 5 DOWN L 1 L L B (* 4) B13 L(* 3) (* 4) 30A POWER B L 10A GAUGE L(* 4) B (* 3) 25A DOOR J38 JUNCTION CONNECTOR 1 L(* 3) POWER RELAY 5 1G 7 1J 3 1S 13 1G W–B L L C B W–B(*3) 10 W–B(*4) (* 1)12 A (*2) 3 B 7 W–B(*3) 13 A (*1) 1 B (*2) DU DD 1 5 R E 4 G E 3 W–B(*4) A A L–W JUNCTION CONNECTOR J33 A , J34 B L–W 1 1D 3 R–B 12 1G 2 6 I18 A , B 8 A (* 1) 6 B (* 2) R–G INTEGRATION RELAY J38 JUNCTION CONNECTOR 7 1S (* 4) W–B B13 L A A A L W–B W–B D B (* 4) R–G R G W–B D13 DOOR COURTESY SW FRONT RH R–G 6 IN2 D12 DOOR COURTESY SW FRONT LH IE1 W–B 1 20 7 1G 1 3 1V A IG J11 JUNCTION CONNECTOR W–B R–G J33 A , J34 B JUNCTION CONNECTOR (* 3) E A IE 1 M 2 P10 POWER WINDOW MOTOR FRONT LH * 1 : W/O THEFT DETERRENT SYSTEM * 2 : W/ THEFT DETERRENT SYSTEM * 3 : TMC MADE * 4 : TMMK MADE P9 POWER WINDOW MASTER SW FRONT RH REAR LH REAR RH WINDOW LOCK SW LOCK NORMAL R–Y 9 IE2 R–Y L RRD 13 6 IE2 12 IE2 R–B G–Y R–L 7 IE2 G–Y G–W 5 IE2 J4 JUNCTION CONNECTOR A A RRU 8 R–L G–W 11 IE2 RLD 12 R–B RLU 9 G–B PD 6 G–B PU 14 5 IN2 7 IN2 L A 5 R–B L L 2 BP1 3 BP1 1 BP1 3 BO1 1 BO1 2 M 1 P11 POWER WINDOW MOTOR FRONT RH 5 2 M 1 P12 POWER WINDOW MOTOR REAR LH 3 B UP 4 SD U D 1 5 2 M 1 P13 POWER WINDOW MOTOR REAR RH DOWN R–B G–B D 2 SU R U 1 DOWN UP 3 B G R G 1 R–B G–B D 4 SD R U 3 2 SU G 4 B P6 POWER WINDOW CONTROL SW FRONT RH 2 SD UP 5 SU DOWN R–L G–W L 2 BO1 P7 POWER WINDOW CONTROL SW REAR LH 6 IM2 L 5 IM2 L L 4 IM2 9 IN2 G–B R–Y IF1 P8 POWER WINDOW CONTROL SW REAR RH IF1 G–Y L R–L G–W 1 POWER WINDOW SYSTEM OUTLINE With the ignition SW turned on, current flows through the GAUGE fuse to TERMINAL 7 of the integration relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to TERMINAL 1 of the power relay to TERMINAL 2 to GROUND, this activates the relay and the current flowing to TERMINAL 5 of the relay from the POWER fuse flows to TERMINAL 3 of the relay to TERMINALS 10 and 11 of the power window master SW. 1. MANUAL OPERATION (DRIVER’S WINDOW) With the ignition SW turned on and with the power window master SW (Driver’s) in UP position, the current flowing from TERMINALS 10 and 11 of the power window master SW flows to TERMINAL 1 of the master SW to TERMINAL 1 of the power window motor to TERMINAL 2 to TERMINAL 5 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor to rotate in the up direction. The window ascends only while the SW is being pushed. In down operation, the flow of current from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 of the master SW causes the flow of current from TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the master SW to TERMINALS 3 and 4 to GROUND, flowing in the opposite detection to manual up operation and causing the motor to rotate in reverse, lowering the window. 2. AUTO DOWN OPERATION (DRIVER’S WINDOW) When the driver’s window SW is pushed strongly to the down side, the current flowing to TERMINALS 10 and 11 of the power window master SW flows to the down contact point and auto down contact point of the driver’s SW. This activates the relay (Down side) inside the power window master SW and the hold circuit also turns on at the same time, so the relay (Down side) remains activated even when the SW is released. Current flows at this time from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the power window master SW to TERMINALS 3 and 4 to GROUND, so the motor continues to operate until the driver’s window is fully down. When the driver’s window finishes down operation and the hold circuit goes off, so the relay (Down side) also turns off. This stops the current flowing from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 is cut off, so the power window motor stops and auto down operation stops. When the driver’s SW is pulled to the up side during auto down operation, the hold circuit is turned off so the current flowing from TERMINALS 10 and 11 of the power window master SW to TERMINAL 5 is cut off and the power window motor stops. If the SW remains pulled up the relay (Up side) is activated, so current flows from TERMINALS 10 and 11 of the power window master SW to TERMINAL 1 to TERMINAL 1 of the power window motor to TERMINAL 2 to TERMINAL 5 to TERMINALS 3 and 4 to GROUND, the power window motor rotates in the up direction and manual up operation occurs while the SW is pulled up. 3. MANUAL OPERATION (FRONT RH WINDOW) With the power window control SW front RH pulled to the up side, the current flowing from TERMINAL 4 of the power window control SW flows to TERMINAL 3 of the power window control SW to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 1 of the power window control SW to TERMINAL 2 to TERMINAL 6 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor front RH to rotate in the up direction. The up operation continues only while the power window control SW is pulled to the up side. When the window descends, the current flowing to the motor flows in the opposite direction, from TERMINAL 1 to TERMINAL 2, and the motor rotates in reverse. When the window lock SW is pushed to the lock side, the ground circuit to the front RH window becomes open. As a result, even if Open/Close operation of the front RH window is tried, the current from TERMINALS 3 and 4 of the power window master SW is not grounded and the motor does not rotate, so the front RH window can not be operated and window lock occurs. 4. MANUAL OPERATION (REAR LH, RH WINDOW) With the power window control SW rear LH, RH pulled to the up side, the current flowing from TERMINAL 3 of the power window control SW flows to TERMINAL 1 of the power control SW to TERMINAL 2 of the power window motor to TERMINAL 1 to TERMINAL 5 of the power window control SW to TERMINAL 4 to TERMINAL 12 or 13 of the master SW to TERMINALS 3 and 4 to GROUND and causes the power window motor rear LH, RH to rotate in the up direction. The up operation continues only while the power window control SW is pulled to the up side. When the window descends, the current flowing to the motor flows in the opposite direction, from TERMINAL 1 to TERMINAL 2, and the motor rotates in reverse. When the window lock SW is pushed to the lock side, the ground circuit to the rear LH, RH window becomes open. As a result, even if Open/Close operation of the rear LH, RH window is tried, the current from TERMINALS 3 and 4 of the power window master SW is not grounded and the motor does not rotate, so the rear LH, RH window can not be operated and window lock occurs. 5. KEY OFF POWER WINDOW OPERATION With the ignition SW turned from on to off, the integration relay operates and current flows from the DOOR fuse to TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to TERMINAL 1 of the power relay to TERMINAL 2 to GROUND for about 43 seconds. The same as normal operation, the current flows from the POWER fuse to TERMINAL 5 of the power relay to TERMINAL 3 to TERMINALS 10 and 11 of the power window master SW and TERMINAL 4 (Front RH) or 3 (Rear LH, RH) of the power window control SW. As a result, for about 43 seconds after the ignition SW is turned off, the functioning of this relay makes it possible to raise and lower the power window. Also, by opening the front doors (Door courtesy SW on) within about 43 seconds after turning the ignition SW to off, a signal is input to TERMINAL 6 or (A) 8 (w/o theft deterrent system), (B) 6 (w/ theft deterrent system) of the integration relay. As a result, the relay turned off, and up and down movement of the power window stops. SERVICE HINTS P9 POWER WINDOW MASTER SW 10, 11–GROUND : Approx. 12 volts with the ignition SW at ON position or key off power window operation 3, 4–GROUND : Always continuity 1–GROUND : Approx. 12 volts with the ignition SW on and the master SW (Driver’s window) at UP position 5–GROUND : Approx. 12 volts with the ignition SW on and the master SW (Driver’s window) at DOWN or AUTO DOWN position WINDOW LOCK SW Open with the window lock SW at LOCK position : PARTS LOCATION Code See Page D12 D13 Code 32 J33 32 J34 See Page Code See Page A 31 P9 33 B 31 P10 33 A 30 J38 32 P11 33 B 30 P6 33 P12 33 J4 31 P7 33 P13 33 J11 31 P8 33 I18 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 IE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF1 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IM2 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH POWER WINDOW : SPLICE POINTS Code See Page B13 44 D12 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Front Door LH Wire D13 I18 (A) I18 (B) (w/o Theft Deterrent System) ORANGE 1 (w/ Theft Deterrent System) ORANGE






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(Hint : See Page 7) (Hint : See Page 7) A A A A (Hint : See Page 7) (Hint : See Page 7) J38 P6 (TMC Made) BLACK A A A B B A A A B B B B P6 P7 P8 12345 12345 (TMMK Made) 1 2 3 4 5 1 2 3 4 5 (Hint : See Page 7) P9 1
3 4 5 6
8 9 1011121314 P10 P11 P12 P13 1 2 1 2 1 2 1 2 MEMO DOOR LOCK CONTROL (TMC MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 TO POWER WINDOW MASTER SW 30A POWER 25A DOOR 10A GAUGE 2 1 1 1D L–W 5 POWER RELAY C B 3 2 12 1G 7 1J L J33 A , J34 B JUNCTION CONNECTOR 5 1G 3 1M 5 1M 3 A 18 B 4 A 19 B 5 A 20 B G L–W R–G L 13 A 1 B I18 A , B INTEGRATION RELAY 7 L–R G 6 5 F L–B 3 A A A A W–B J38 A JUNCTION CONNECTOR A A W–B A W–B W–B J39 JUNCTION CONNECTOR IE2 11 IE1 L–R 8 L–B IE2 L–R 3 D19 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH 1 W–B D18 DOOR LOCK CONTROL SW RH W–B 1 3 UNLOCK 2 UNLOCK 3 3 IM1 LOCK 4 IM1 L IE1 R–G 3 UNLOCK R–G 4 IE1 W–B F (* 1) L(*2) 12 IM1 L–R G 13 IM1 L A LG A LG J37 JUNCTION CONNECTOR J6 JUNCTION CONNECTOR B L–W 2 UNLOCK 7 4 B D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH L–W LOCK 12 IE1 2 B B L–W E G P9 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] LG LOCK IE1 B D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK G E J37 JUNCTION CONNECTOR E G LG LG J6 JUNCTION CONNECTOR D J6 JUNCTION CONNECTOR D D 9 A (* 1) 5 B (* 2) 11 B L–R 2 A 17 B J6 JUNCTION CONNECTOR 1 A 16 B 13 W–B 12 A (*1) 3 B (*2) 5 LG 10 L–R U1 UNLOCK WARNING SW L–B R–B 1 2 3 4 M 1 W–B W–B 2 L–W A A W–B 20 IM1 W–B 20 IE1 J11 JUNCTION CONNECTOR IG W–B 7 1G 3 1V W–B W–B A IE IJ D13 DOOR COURTESY SW FRONT RH 1 R–G R–G 1 D12 DOOR COURTESY SW FRONT LH * 1 : W/O THEFT DETERRENT SYSTEM * 2 : W/ THEFT DETERRENT SYSTEM R–G 6 IN2 D B J33 A , J34 B JUNCTION CONNECTOR R–G E A I18 A , 7 1S B INTEGRATION RELAY L–B L–B(* 1) 6 IF2 L–B L–Y E B M D A D A Y 7 BP1 4 BP1 2 3 1 W–B 3 IM2 2 3 4 M 1 M 4 6 BO1 6 BP1 W–B W–B W–B W–B A J40 JUNCTION CONNECTOR BL B6 W–B W–B JUNCTION CONNECTOR 4 L–Y J 9 A , J10 B D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 5 BP1 7 IM2 IK 3 IN2 L–Y JUNCTION CONNECTOR W–B IF2 D22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 1 11 IM1 L–Y J30 A , J31 B Y L–Y 3 1 IN2 L–B L–B L–B 2 C L–B L–R 4 BO1 C B C B L–Y 7 BO1 L–R 2 5 BO1 J37 JUNCTION CONNECTOR L–Y L–B L–R (* 1) C L–Y L–B L–R L–B L–R 2 IN2 L–R L–B 7 IF2 B B B B L–R L–R L–R L–R 10 A (* 1) 7 B (*2) 11 A 9 B Y L–R C A C A C A B A B A B A L–Y 7 A 25 B D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 6 A 12 B 8 A (* 1) 6 B (* 2) 6 BN DOOR LOCK CONTROL (TMC MADE) SYSTEM OUTLINE Current always flows to TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the integration relay through the DOOR fuse. When the ignition SW is turned on, the current flowing through the GAUGE Fuse flows to TERMINAL 7 of the integration relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to the power relay (Coil side) to GROUND. 1. MANUAL LOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to LOCK position, a lock signal is input to TERMINAL (A) 1 or (A) 3 (w/o theft deterrent system), (B) 16 or (B) 18 (w/ theft deterrent system) of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) to TERMINAL 2 of the door lock motors to TERMINAL 3 to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and the door lock motor causes the door to lock. 2. MANUAL UNLOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to UNLOCK position, an unlock signal is input to TERMINAL (A) 2, (A) 4 or (A) 5 (w/o theft deterrent system), (B) 17, (B) 19 or (B) 20 (w/ theft deterrent system) of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 to TERMINAL (A) 6 (w/o theft Deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and door lock motors causes door to unlock. 3. DOUBLE OPERATION UNLOCK OPERATION When the door key lock and unlock SW front LH is turned to the unlock side, only the driver’s door is mechanically unlocked. Turning the door key lock and unlock SW front LH to the unlock side causes a signal to be input to TERMINAL (A) 4 (w/o theft deterrent system), (B) 19 (w/ theft deterrent system) of the relay, and if the signal is input again within 3 seconds by turning the SW to the unlock side again, current flows from TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) of the integration relay to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND, causing the door lock motors to operate and unlock the doors. 4. IGNITION KEY REMINDER OPERATION ∗ Operating door lock knob (Operation of door lock motors) With ignition key in cylinder (Unlock warning SW on), when the door is opened and locked using door lock knob (Door lock motor), the door is locked once but each door is unlocked soon by the function of the relay. As a result, the current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the integration relay to TERMINAL (A) 7 (w/o theft deterrent system),(B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. ∗ Operating door lock control SW or door key lock and unlock SW With ignition key in cylinder (Unlock warning SW on), when the door is opened and locked using door lock control SW or key SW, the door is locked once but each door is unlock by the function of SW contained in motors, which the signal is input to TERMINAL (A) 9 or (A) 10 (w/o theft deterrent system), (B) 5 or (B) 7 (w/ theft deterrent system) of the relay. According to this input signal, the current in ECU flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. ∗ In case of key less lock With ignition key in cylinder (Unlock warning SW on), when the unlock function is disturbed more than 0.2 seconds, for example pushing the door lock knob etc., the door holds on lock condition. Closing the door after, door courtesy SW inputs the signal into TERMINAL 6 or (A) 8 (w/o theft deterrent system), (B) 6 (w/ theft deterrent system) of the integration relay. By this input signal, the ECU works and current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. SERVICE HINTS I18 (A), (B) INTEGRATION RELAY 10–GROUND : Always continuity 6–GROUND : Continuity with driver’s door open 7–GROUND : Approx. 12 volts with ignition SW at ON position (A)13 or (B) 1–GROUND: Always approx. 12 volts (A) 6 or (B)12–GROUND: Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW locked ∗ Locking driver’s, front passenger’s door cylinder with key (A) 1or (B)16–GROUND : Continuity with door lock control SW locked (A) 8 or (B) 6–GROUND : Continuity with front passenger’s door open (A) 9 or (B) 5–GROUND : Continuity with driver’s door lock knob unlocked (A)10 or (B) 7–GROUND: Continuity with front passenger’s door lock knob unlock (A) 2 or (B)17–GROUND: Continuity with door lock control SW unlocked (A) 5 or (B)20–GROUND: Continuity with front passenger’s door lock cylinder unlocked with key (A) 4 or (B)19–GROUND: Continuity with driver’s door lock cylinder unlocked with key (A) 3 or (B)18–GROUND: Continuity with driver’s, front passenger’s door lock cylinder locked with key (A) 7 or (B)11, (B)25–GROUND : Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW unlocked ∗ Door lock control SW locked with ignition key in cylinder and driver’s door open (Ignition key reminder function) ∗ Door lock knob locked with ignition key in cylinder and driver’s door open (Ignition key reminder function) ∗ Unlocking driver’s, front passenger’s door cylinder with key D12, D13 DOOR COURTESY SW FRONT LH,RH 1–GROUND : Closed with each door open D16, D17 DOOR KEY LOCK AND UNLOCK SW FRONT LH,RH 1–2 : Closed with door lock cylinder locked with key 1–3 : Closed with door lock cylinder unlocked with key D19, D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH,RH 1–4 : Closed with door lock knob UNLOCK position U1 UNLOCK WARNING SW 1–2 : Closed with ignition key in cylinder : PARTS LOCATION Code See Page Code D12 32 D13 32 D16 32 D17 32 J9 D18 32 J10 D19 32 D20 32 J30 D21 32 D22 32 See Page Code A 30 B 30 J37 31 31 J38 32 A 31 J39 32 B 31 J40 32 31 P9 33 A 31 U1 31 J31 B 31 J33 A 31 I18 J6 J11 J34 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G 1J 1M See Page B 31 DOOR LOCK CONTROL (TMC MADE) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page IE1 Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) IE2 IF2 IM1 IM2 : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH 40 Right Kick Panel BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar IJ IK : SPLICE POINTS Code B6 See Page 44 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Floor No.2 Wire D12 D13 D16 D17 D18 D19 BLACK 1 X X 3X5 6 1 1 2 3 1 2 3 1 2 3 4 D20 D21 D22 BLACK BLACK BLACK (w/o Theft Deterrent System) ORANGE I18 (A) 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10111213 J6 I18 (B) (w/ Theft Deterrent System) ORANGE 1 X 3 X 5 6 7 X 9 X 11 12 X X X 16 17 18 19 20 X X X X 25 J9 (A) BLACK




B B B B


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A J30 (A) J31 (B) GRAY GRAY











B B B C C C B B B C C C (Hint : See Page 7) (Hint : See Page 7) A A A A


E E E (Hint : See Page 7) (Hint : See Page 7) J33 (A) J34 (B) BLACK BLACK J37 A A







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(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J39 A A A X X A A A X X X X J40 A A P9 A A A A (Hint : See Page 7) (Hint : See Page 7)
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U1 1 2 DOOR LOCK CONTROL (TMMK MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 TO POWER WINDOW MASTER SW 30A POWER 25A DOOR 10A GAUGE 2 1 1 1D L–W 5 POWER RELAY C B 3 2 12 1G 7 1J L J33 A , J34 B JUNCTION CONNECTOR 5 1G 3 1M 5 1M 3 A 18 B 4 A 19 B 5 A 20 B G L–W R–G L I18 A , B INTEGRATION RELAY 7 L–R J6 JUNCTION CONNECTOR 5 F L–B (* 1) L(*2) G G 6 L–R LG 12 IM1 W–B W–B 7 1G 3 1V W–B UNLOCK W–B W–B IE IE1 L–R 11 L–B IE2 L–R 8 2 3 4 M 1 20 IM1 A IE2 B14 W–B W–B B13 3 3 D19 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH 1 W–B D18 DOOR LOCK CONTROL SW RH W–B 1 3 UNLOCK 2 UNLOCK 3 3 IM1 LOCK 4 IM1 L IE1 R–G 3 20 IE1 J11 JUNCTION CONNECTOR 13 IM1 L A LG A F R–G 4 IE1 W–B J37 JUNCTION CONNECTOR L–W 2 UNLOCK 7 B J6 JUNCTION CONNECTOR B D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH L–W LOCK 12 IE1 4 B B L–W E G P9 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] LG LOCK IE1 B D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK G E J37 JUNCTION CONNECTOR E G LG D LG J6 JUNCTION CONNECTOR D 9 A (* 1) 5 B (* 2) 11 B D 2 IG 13 A 1 B L–R 2 A 17 B J6 JUNCTION CONNECTOR 1 A 16 B 13 W–B 12 A (*1) 3 B (*2) 5 LG 10 L–R U1 UNLOCK WARNING SW L–B R–B 1 IJ W–B W–B 2 L–W A A W–B W–B D13 DOOR COURTESY SW FRONT RH 1 R–G R–G D12 DOOR COURTESY SW FRONT LH 1 * 1 : W/O THEFT DETERRENT SYSTEM * 2 : W/ THEFT DETERRENT SYSTEM R–G 6 IN2 D B J33 A , J34 B JUNCTION CONNECTOR R–G E A I18 A , 7 1S B INTEGRATION RELAY L–B L–B(* 1) 6 IF2 L–B L–Y E B M D A D A Y 7 BP1 4 BP1 2 3 1 W–B 3 IM2 2 3 1 M 4 M 4 6 BO1 6 BP1 W–B W–B W–B W–B A J40 JUNCTION CONNECTOR BL B6 W–B W–B JUNCTION CONNECTOR 4 L–Y J 9 A , J10 B D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH 5 BP1 7 IM2 IK 3 IN2 L–Y JUNCTION CONNECTOR W–B IF2 D22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 1 11 IM1 L–Y J30 A , J31 B Y L–Y 3 1 IN2 L–B L–B L–B 2 C L–B L–R 4 BO1 C B C B L–Y 7 BO1 L–R 2 5 BO1 J37 JUNCTION CONNECTOR L–Y L–B L–R (* 1) C L–Y L–B L–R L–B L–R 2 IN2 L–R L–B 7 IF2 B B B B L–R L–R L–R L–R 10 A (* 1) 7 B (*2) 11 A 9 B Y L–R C A C A C A B A B A B A L–Y 7 A 25 B D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 6 A 12 B 8 A (* 1) 6 B (* 2) 6 BN DOOR LOCK CONTROL (TMMK MADE) SYSTEM OUTLINE Current always flows to TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the integration relay through the DOOR fuse. When the ignition SW is turned on, the current flowing through the GAUGE Fuse flows to TERMINAL 7 of the integration relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to the power relay (Coil side) to GROUND. 1. MANUAL LOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to LOCK position, a lock signal is input to TERMINAL (A) 1 or (A) 3 (w/o theft deterrent system), (B) 16 or (B) 18 (w/ theft deterrent system) of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) to TERMINAL 2 of the door lock motors to TERMINAL 3 to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and the door lock motor causes the door to lock. 2. MANUAL UNLOCK OPERATION When the door lock control SW or door key lock and unlock SW are operated to UNLOCK position, an unlock signal is input to TERMINAL (A) 2, (A) 4 or (A) 5 (w/o theft deterrent system), (B) 17, (B) 19 or (B) 20 (w/ theft deterrent system) of the integration relay and causes the relay to function. Current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 to TERMINAL (A) 6 (w/o theft Deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and door lock motors causes door to unlock. 3. DOUBLE OPERATION UNLOCK OPERATION When the door key lock and unlock SW front LH is turned to the unlock side, only the driver’s door is mechanically unlocked. Turning the door key lock and unlock SW front LH to the unlock side causes a signal to be input to TERMINAL (A) 4 (w/o theft deterrent system), (B) 19 (w/ theft deterrent system) of the relay, and if the signal is input again within 3 seconds by turning the SW to the unlock side again, current flows from TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) of the integration relay to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND, causing the door lock motors to operate and unlock the doors. 4. IGNITION KEY REMINDER OPERATION ∗ Operating door lock knob (Operation of door lock motors) With ignition key in cylinder (Unlock warning SW on), when the door is opened and locked using door lock knob (Door lock motor), the door is locked once but each door is unlocked soon by the function of the relay. As a result, the current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the integration relay to TERMINAL (A) 7 (w/o theft deterrent system),(B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. ∗ Operating door lock control SW or door key lock and unlock SW With ignition key in cylinder (Unlock warning SW on), when the door is opened and locked using door lock control SW or key SW, the door is locked once but each door is unlock by the function of SW contained in motors, which the signal is input to TERMINAL (A) 9 or (A) 10 (w/o theft deterrent system), (B) 5 or (B) 7 (w/ theft deterrent system) of the relay. According to this input signal, the current in ECU flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. ∗ In case of key less lock With ignition key in cylinder (Unlock warning SW on), when the unlock function is disturbed more than 0.2 seconds, for example pushing the door lock knob etc., the door holds on lock condition. Closing the door after, door courtesy SW inputs the signal into TERMINAL 6 or (A) 8 (w/o theft deterrent system), (B) 6 (w/ theft deterrent system) of the integration relay. By this input signal, the ECU works and current flows from TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 7 (w/o theft deterrent system), (B) 11 and (B) 25 (w/ theft deterrent system) to TERMINAL 3 of the door lock motors to TERMINAL 2 of the door lock motors to TERMINAL (A) 6 (w/o theft deterrent system), (B) 12 (w/ theft deterrent system) of the relay to TERMINAL 10 to GROUND and causes all the doors to unlock. SERVICE HINTS I18 (A), (B) INTEGRATION RELAY 10–GROUND : Always continuity 6–GROUND : Continuity with driver’s door open 7–GROUND : Approx. 12 volts with ignition SW at ON position (A)13 or (B) 1–GROUND: Always approx. 12 volts (A) 6 or (B)12–GROUND:Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW locked ∗ Locking driver’s, front passenger’s door cylinder with key (A) 1 or (B)16–GROUND: Continuity with door lock control SW locked (A) 8 or (B) 6–GROUND : Continuity with front passenger’s door open (A) 9 or (B) 5–GROUND : Continuity with driver’s door lock knob unlocked (A)10 or (B) 7–GROUND: Continuity with front passenger’s door lock knob unlock (A) 2 or (B)17–GROUND: Continuity with door lock control SW unlocked (A) 5 or (B)20–GROUND: Continuity with front passenger’s door lock cylinder unlocked with key (A) 4 or (B)19–GROUND: Continuity with driver’s door lock cylinder unlocked with key (A) 3 or (B)18–GROUND: Continuity with driver’s, front passenger’s door lock cylinder locked with key (A) 7 or (B)11, (B)25–GROUND : Approx. 12 volts 0.2 seconds with following operation ∗ Door lock control SW unlocked ∗ Door lock control SW locked with ignition key in cylinder and driver’s door open (Ignition key reminder function) ∗ Door lock knob locked with ignition key in cylinder and driver’s door open (Ignition key reminder function) ∗ Unlocking driver’s, front passenger’s door cylinder with key D12, D13 DOOR COURTESY SW FRONT LH,RH 1–GROUND : Closed with each door open D16, D17 DOOR KEY LOCK AND UNLOCK SW FRONT LH,RH 1–2 : Closed with door lock cylinder locked with key 1–3 : Closed with door lock cylinder unlocked with key D19, D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH,RH 1–4 : Closed with door lock knob UNLOCK position U1 UNLOCK WARNING SW 1–2 : Closed with ignition key in cylinder : PARTS LOCATION Code See Page Code D12 32 D13 32 D16 32 D17 32 D18 32 J9 D19 32 J10 D20 32 D21 32 See Page D22 I18 32 J31 B 31 30 J33 A 31 B 30 J34 B 31 31 J37 31 A 31 J40 32 B 31 P9 33 31 U1 31 J11 A 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G 1J 1M See Page A J6 J30 Code DOOR LOCK CONTROL (TMMK MADE) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page IE1 Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) IE2 IF2 IM1 IM2 : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH 40 Right Kick Panel BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar IJ IK : SPLICE POINTS Code Wire Harness with Splice Points Code B6 44 See Page Floor No.2 Wire B14 B13 44 Front Door LH Wire D12 D13 1 D16 See Page 44 D17 1 1 2 3 Front Door RH Wire D18 D19 BLACK BLACK X 1 2 3 Wire Harness with Splice Points X 1 2 3 4 3 X 5 6 D20 D21 D22 BLACK BLACK BLACK (w/o Theft Deterrent System) ORANGE 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10111213 I18 (B) I18 (A) J6 (w/ Theft Deterrent System) ORANGE 1 X 3 X 5 6 7 X 9 X 11 12 X X X 16 17 18 19 20 X X X X 25 J9 (A) BLACK




B B B B


DD DE E E F F F F (Hint : See Page 7)





D D D


(Hint : See Page 7) J10 (B) J11 BLACK A





A J30 (A) J31 (B) GRAY GRAY











B B B C C C B B B C C C (Hint : See Page 7) (Hint : See Page 7) A A A A


E E E (Hint : See Page 7) (Hint : See Page 7) J33 (A) J34 (B) BLACK BLACK A A







C C


E E E D D D


J37 A A B C C A A B B B B C C (Hint : See Page 7) (Hint : See Page 7) P9
2
4

7






(Hint : See Page 7) U1 1 2 J40 A A A A A A (Hint : See Page 7) 1 D B 8 IN2 6 IN2 1 A A E A E A 1 A BATTERY D B 2 1 D B 1 J16 A , J17 B 10 IG1 R–W 1 E B D A D A D A R–W JUNCTION CONNECTOR J33 A , J34 B R–W E B R–W L–W R–W 2 R–W R R–Y A JUNCTION CONNECTOR R J2 JUNCTION CONNECTOR R–G FL MAIN 3. 0W C B J33 A , J34 B 8 1S JUNCTION CONNECTOR L–W R G–R 7. 5A DOME 25A DOOR D12 DOOR COURTESY SW FRONT LH E A R B B C B R–W B A J33 A , J34 B B A L–W 10A TAIL L–W 1 1D JUNCTION CONNECTOR R–G 6 1C D14 DOOR COURTESY SW REAR LH R–G A R–G G–R G–R 3 J33 A , J34 B G–R G G–O TAILLIGHT RELAY JUNCTION CONNECTOR G–R TO TAILLIGHTS TO FRONT PARKING LIGHTS B–R 5 D13 DOOR COURTESY SW FRONT RH B–R B–R E3 R–W 1 F 9 1C R–W 100A ALT 4 1B D15 DOOR COURTESY SW REAR RH B–G WIRELESS DOOR LOCK CONTROL (TMC MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) G–R 1 L–W R 2 R–W 12 2J 1 1W 8 1G D10 DIODE (DOME) 1 R–W R G–R 2 F F4 A , F9 F L–W FUSIBLE LINK BLOCK R–W R–G D7 DIODE (COURTESY) R–W R–G R–G G–R G–R L–W L–W R R R–W R–W 14 8 4 W6 WIRELESS DOOR LOCK ECU 9 10 L V G–R R R–W L–R R–G L–W L–B 2 R–W R–G L–W INTEGRATION RELAY 11 B 18 B B A B A L–B J 9 A , J10 B L–R 19 B L 12 B I18 B JUNCTION CONNECTOR L–B B B R6 REMOTE CONTROL MIRROR SW 7 1D 5 R 25 B L–B J6 JUNCTION CONNECTOR D D E G–R 1 1G R–G R–G R–W R–W E D R–W G LG G 13 IM1 12 IM1 LG G 7 D18 DOOR LOCK CONTROL SW RH LOCK 5 6 UNLOCK 2 12 IE1 G LG IE1 P9 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] LG LOCK R–G E 2 13 R–W 1 4 3 3 1M 7 1J W–B 7 1S UNLOCK 4 1G 12 1S L–W L–B 17 B 6 U1 UNLOCK WARNING SW W–B 16 B G 4 LG 5 1M 1 B L–B L–B W–B W–B W–B W–B R–G R–G R–G A IG J11 JUNCTION CONNECTOR 20 IE1 IE A J39 JUNCTION CONNECTOR A A 20 IM1 3 1V IJ A A 1 3 IE2 4 2 3 M 11 IM1 7 IM2 3 IM2 L–B 8 IE2 L–R A B C A C A C A F L–R B B B B 4 2 3 JUNCTION CONNECTOR C J30 A , J31 B Y L–R L–R Y J37 JUNCTION CONNECTOR F Y L–R F D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH L–R 11 W–B 7 1G 11 IE1 L 3 IM1 L–R A L–B 2 J37 JUNCTION CONNECTOR B L–R 4 IM1 L–R L–W 15 L–R B J6 JUNCTION CONNECTOR B L–W B D19 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH B L L B L–W A L L–W L 1 UNLOCK R–G 7 W–B W–B 2 W–B 4 IE1 L–W R–G L–W B W–B L–W L–W W–B 3 D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK LOCK 3 IE1 R–G J38 JUNCTION CONNECTOR A A W–B B W–B W–B J6 JUNCTION CONNECTOR R–G R–G W–B W–B D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH R–G UNLOCK L W–B W–B WIRELESS DOOR LOCK CONTROL (TMC MADE) G–R G–R L–W L–W R R R–W R–W W6 WIRELESS DOOR LOCK ECU 12 L–R L–R C C 3 L–R L–B 1 M 1 Y L–R R–G L–B L–W L–B L–B W–B L W–B L–B R–G R–G R–G R–G G–R G–R L–W L–W R R R–W R–W LG L–Y L–R L–R L–B L–B L–Y L–R L–Y L–R 2 L–B 3 6 BO1 7 BO1 6 M 4 3 L–B D22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 1 L–R 5 BP1 6 BP1 7 BP1 W–B B A 4 W–B J30 A , J31 B JUNCTION CONNECTOR B A 2 IN2 4 BP1 M W–B L–B C B D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH L–Y L–B C B 3 IN2 5 BO1 2 L–Y L–R IF2 1 JUNCTION CONNECTOR E B 7 4 BO1 J 9 A , J10 B E B IF2 L–Y 2 L–R D A L–Y D A L–Y L–B L–Y L–R LG IF2 L–B W–B 5 L–Y 1 W–B W–B 13 L–Y W6 WIRELESS DOOR LOCK ECU 1 IN2 W–B L–B B6 L–B L–B Y Y L–R L–R R–G R–G L–W L–W L–B L–B L–B R–G R–G R–G R–G J40 JUNCTION CONNECTOR A BL BN W–B L W–B L IK WIRELESS DOOR LOCK CONTROL (TMC MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) G–R L–W 1 R 15A ECU–IG R–W 10A HORN 40A MAIN LG 2 L–Y 8 1D 1 5 4 1 3 2 W–B B–R HORN RELAY HEAD RELAY 2 3 10 2K 8 2K 12 B SH T3 B , T4 A B 10 B R–B A B C A HEAD 7 IG3 L–R * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT R–G L–W L L–B R–G W–B R–G IF R–B DSWP 5 A J 9 A , J10 B L–B J5 JUNCTION CONNECTOR DSWD 4 A R–G L KSW 6 A L–W UL2 10 A R–G L2 8 A JUNCTION CONNECTOR Y W–B A UL3 9 A W–B A A LSWD 14 A L–R LSWP 15 A Y E 7 B R–G THEFT DETERRENT ECU D6 DAYTIME RUNNING LIGHT RELAY (MAIN) R (*2) R–B B HORN J 1 (*1) , J32 (*2) JUNCTION CONNECTOR 9 B IG 11 IG1 (* 1) 13 A TAIL H 5 R–B 11 B +B2 (* 1) G–B G–B 1 B +B1 6 H–LP G–B 5 IG3 W–L R CTY B–R R–W 11 A PANI G–R LG 1 A LSWR J2 JUNCTION CONNECTOR W–L 4 IK1 L–W L–Y 18 A W–B 16 A C C W–L A B 1 JUNCTION CONNECTOR C A J16 A , J17 B 2 T1 THEFT DETERRENT HORN W 3 2F SYSTEM OUTLINE Door lock control (Lock and unlock) and panic control (Theft alarm and flash) is performed by remote control, without the ignition key inserted in the door key cylinder, using low–power electrical waves emitted by a transmitter. 1. WIRELESS DOOR LOCK OR UNLOCK NORMAL OPERATION With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, when the lock or unlock button (Transmitter) is pushed, the wireless door lock ECU receives the electrical waves from the transmitter, causing it to operate. As a result, the ECU judges whether the door is locked or unlocked based on the signal from the door lock motor and door unlock detection SW, and sends a signal to the theft deterrent ECU and integration relay to switch the condition from lock to unlock or vice versa, causing the door lock motor to operate. 2. VISUAL CONFIRMATION OF LOCK OR UNLOCK If all doors indicate that they are locked after the lock command, parking lights and taillight will flash once. If any door indicates that it is open after the unlock command, parking lights and taillights will flash twice. 3. WIRELESS DOOR UNLOCK OPERATION Pushing the unlock button (Transmitter) once, driver’s door is unlocked. Furthermore, pushing the button again within 3 seconds, the other doors are unlocked. 4. AUTOMATIC LOCK OPERATION With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, after pushing the button (Transmitter) to unlock all the doors, if a door is not opened within 30 seconds, all the doors will be automatically relocked. 5. WIRELESS CONTROL STOP FUNCTION If a door is open (Door courtesy SW on), a signal is input from the door courtesy SW to the wireless door lock ECU, stopping wireless door lock or unlock. If the ignition key is in the ignition key cylinder (Unlock warning SW on), the unlock warning SW inputs a signal to the wireless door lock ECU, stopping wireless door lock or unlock. 6. DOOR LOCK MOTOR PROTECTIVE FUNCTION If the door lock or unlock condition does not change after wireless door lock or unlock operation, 2 seconds later, the integration relay ECU sends current three times to the door lock motor. If the door lock condition still has not changed as a result, the wireless door lock ECU stops reception and stops door lock and unlock function. 7. REMOTE PANIC OPERATION Panic will function when doors are locked or unlocked, open or closed. When the panic button (Transmitter) is pushed once, theft alarm sounds and headlights and taillight flash. Then, the panic or the unlock button (Transmitter) is pushed once more, sounding and flashing will stop. Panic will not function when ignition key is in ignition key cylinder. SERVICE HINTS D12, D13, D14, D15 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1–GROUND : Continuity with the door open U1 UNLOCK WARNING SW 2–1 : Continuity with the ignition key in the cylinder W6 WIRELESS DOOR LOCK ECU 8–GROUND : Always approx. 12 volts 1–GROUND : Always continuity 14–GROUND : Continuity with each of the door open 10–GROUND : Continuity with the ignition key in the cylinder WIRELESS DOOR LOCK CONTROL (TMC MADE) : PARTS LOCATION Code See Page D6 30 D7 30 D10 30 D12 32 D13 32 D14 Code See Page F4 A F9 F I18 B Code 28 (5S–FE) See Page J32 31 26 (1MZ–FE) J33 A 31 28 (5S–FE) J34 B 31 30 J37 31 J1 31 J38 32 32 J2 31 J39 32 D15 32 J5 31 J40 32 D16 32 J6 31 P9 33 D17 32 J9 A 31 R6 31 D18 32 J10 B 31 D19 32 D20 32 J16 A 31 T3 B 31 D21 32 J17 B 31 T4 A 31 32 J30 A 31 U1 31 26 (1MZ–FE) J31 B 31 W6 31 D22 F4 A J11 27 (1MZ–FE) T1 31 29 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D 1G 1J 1M 1S 1V 1W 2F 2J 2K See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 IE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF2 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IG1 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) IK1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IM1 IM2 IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH 40 Right Kick Panel BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar IJ IK : SPLICE POINTS Code See Page 36 (1MZ–FE) E3 Wire Harness with Splice Points Code B6 Cowl Wire 38 (5S–FE) D6 D7 D10 GRAY BLACK BLACK 1 2 1 2 X
X X X X


D15
6 7
X



D16 D17 1 1 2 3 1 2 3 D21 D22 BLACK BLACK 1 2 3 4 1 2 3 4 D18 X X 3X5 6 F4 (A) See Page Wire Harness with Splice Points 44 Floor No.2 Wire D12 D13 D14 1 1 1 D19 D20 BLACK BLACK 1 2 3 4 1 2 3 4 F9 (F) ORANGE 1 1 J1 I18 (B) ORANGE 1 X
X


X
X 11

B



B B B B

12 X X X 16 17 18 19
X X X X 25 (Hint : See Page 7) 2 J2 J5 BLACK ORANGE A A A

CCC



(Hint : See Page 7) A A A A A A A A A A A A A (Hint : See Page 7) WIRELESS DOOR LOCK CONTROL (TMC MADE) J9 (A) J10 (B) BLACK BLACK

B B C C A A B B

D D D





E E E J6




B B B B


DD DE E E F F F F J11 A (Hint : See Page 7) A A A (Hint : See Page 7) J16 (A) J17 (B) J30 (A) J31 (B) BLACK BLACK GRAY GRAY



C C A A


















E E E D D D


B B B C C C B B B C C C (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J32 J33 (A) J34 (B) GRAY BLACK BLACK A A B B



B B C C D D D E E E D D D E E E (Hint : See Page 7) (Hint : See Page 7)

B



B B B

(Hint : See Page 7) J37 A A B C C A A B B B B C C (Hint : See Page 7) J38 J39 A A A

A A A



A A A X X A A A X X X X (Hint : See Page 7) (Hint : See Page 7) J40 A A P9 A A A
2
4

7






A (Hint : See Page 7) T1 R6 T3 (B) T4 (A) 1 X X X X
1

4 5 6
8 9 10 11 7 X 9 10 11 12 X 13 14 15 16 X 18 X X X X BLACK X X


1 2 U1 W6 BLUE 1 2 1 X X 4 8 9 A (Hint : See Page 7) (Hint : See Page 7)
2


A 10 11 12 13 5 X 7 14 15 MEMO 1 D B 8 IN2 6 IN2 1 A A E A E A 1 A BATTERY D B 2 1 D B 1 J16 A , J17 B 10 IG1 R–W 1 E B D A D A D A R–W JUNCTION CONNECTOR J33 A , J34 B R–W E B R–W L–W R–W 2 R–W R R–Y A JUNCTION CONNECTOR R J2 JUNCTION CONNECTOR R–G FL MAIN 3. 0W C B J33 A , J34 B 8 1S JUNCTION CONNECTOR L–W R G–R 7. 5A DOME 25A DOOR D12 DOOR COURTESY SW FRONT LH E A R B B C B R–W B A J33 A , J34 B B A L–W 10A TAIL L–W 1 1D JUNCTION CONNECTOR R–G 6 1C D14 DOOR COURTESY SW REAR LH R–G A R–G G–R G–R 3 J33 A , J34 B G–R G G–O TAILLIGHT RELAY JUNCTION CONNECTOR G–R TO TAILLIGHTS TO FRONT PARKING LIGHTS B–R 5 D13 DOOR COURTESY SW FRONT RH B–R B–R E3 R–W 1 F 9 1C R–W 100A ALT 4 1B D15 DOOR COURTESY SW REAR RH B–G WIRELESS DOOR LOCK CONTROL (TMMK MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) G–R 1 L–W R 2 R–W 12 2J 1 1W 8 1G D10 DIODE (DOME) 1 R–W R G–R 2 F F4 A , F9 F L–W FUSIBLE LINK BLOCK R–W R–G D7 DIODE (COURTESY) R–W R–G R–G G–R G–R L–W L–W R R R–W R–W 14 8 4 W6 WIRELESS DOOR LOCK ECU 9 10 L V G–R R R–W L–R R–G L–W L–B 2 R–W R–G L–W INTEGRATION RELAY 11 B 18 B B A B A L–B J 9 A , J10 B L–R 19 B L 12 B I18 B JUNCTION CONNECTOR L–B B B R6 REMOTE CONTROL MIRROR SW 7 1D 5 R 25 B L–B J6 JUNCTION CONNECTOR D D E G–R 1 1G R–G R–G R–W R–W E D R–W G LG G 13 IM1 12 IM1 LG G 7 D18 DOOR LOCK CONTROL SW RH LOCK 5 6 UNLOCK 2 12 IE1 G LG IE1 P9 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] LG LOCK R–G E 2 13 R–W 1 4 3 3 1M 7 1J W–B 7 1S UNLOCK 4 1G 12 1S L–W L–B 17 B 6 U1 UNLOCK WARNING SW W–B 16 B G 4 LG 5 1M 1 B L–B L–B W–B W–B W–B W–B R–G R–G R–G A IG J11 JUNCTION CONNECTOR 20 IE1 IE B14 20 IM1 3 1V IJ 1 3 IE2 4 2 3 M 11 IM1 7 IM2 3 IM2 L–B 8 IE2 L–R A B C A C A C A F L–R B B B B 1 2 3 JUNCTION CONNECTOR C J30 A , J31 B Y L–R L–R Y J37 JUNCTION CONNECTOR F Y L–R L–R 11 W–B 7 1G F D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 11 IE1 L 3 IM1 L–R A L–B 2 J37 JUNCTION CONNECTOR B L–R 4 IM1 L–R L–W 15 L–R B J6 JUNCTION CONNECTOR B L–W B D19 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH B L L B L–W B13 L L–W L 1 UNLOCK R–G 7 W–B W–B 2 W–B 4 IE1 L–W R–G L–W B W–B L–W L–W W–B 3 D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK LOCK 3 IE1 R–G W–B B W–B W–B J6 JUNCTION CONNECTOR R–G R–G W–B W–B D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH R–G UNLOCK L W–B W–B WIRELESS DOOR LOCK CONTROL (TMMK MADE) G–R G–R L–W L–W R R R–W R–W W6 WIRELESS DOOR LOCK ECU 12 L–R L–R C C 3 L–R L–B 1 M 4 Y L–R R–G L–B L–W L–B L–B W–B L W–B L–B R–G R–G R–G R–G G–R G–R L–W L–W R R R–W R–W LG L–Y L–R L–R L–B L–B L–Y L–R L–Y L–R 2 L–B 3 6 BO1 7 BO1 6 M 4 3 L–B D22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 1 L–R 5 BP1 6 BP1 7 BP1 W–B B A 4 W–B J30 A , J31 B JUNCTION CONNECTOR B A 2 IN2 4 BP1 M W–B L–B C B D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH L–Y L–B C B 3 IN2 5 BO1 2 L–Y L–R IF2 1 JUNCTION CONNECTOR E B 7 4 BO1 J 9 A , J10 B E B IF2 L–Y 2 L–R D A L–Y D A L–Y L–B L–Y L–R LG IF2 L–B W–B 5 L–Y 1 W–B W–B 13 L–Y W6 WIRELESS DOOR LOCK ECU 1 IN2 W–B L–B B6 L–B L–B Y Y L–R L–R R–G R–G L–W L–W L–B L–B L–B R–G R–G R–G R–G J40 JUNCTION CONNECTOR A BL BN W–B L W–B L IK WIRELESS DOOR LOCK CONTROL (TMMK MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) G–R L–W 1 R 15A ECU–IG R–W 10A HORN 40A MAIN LG 2 L–Y 8 1D 1 5 4 1 3 2 W–B B–R HORN RELAY HEAD RELAY 2 3 10 2K 8 2K 12 B SH B HORN T3 B , T4 A B L–R 10 B R–B A B C A HEAD R–B DSWP 5 A J 9 A , J10 B L–B J5 JUNCTION CONNECTOR DSWD 4 A R–G L KSW 6 A L–W UL2 10 A R–G L2 8 A 7 IG3 JUNCTION CONNECTOR Y W–B A UL3 9 A W–B A A LSWD 14 A L–R LSWP 15 A Y E 7 B R–G THEFT DETERRENT ECU * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT R–G L–W L L–B R–G W–B R–G IF D6 DAYTIME RUNNING LIGHT RELAY (MAIN) R (*2) R–B 11 IG1 J 1 (*1) , J32 (*2) JUNCTION CONNECTOR 9 B IG H 2 (* 1) 13 A TAIL H–LP R–B 11 B +B2 (* 1) G–B G–B 1 B +B1 19 G–B 5 IG3 W–L R CTY B–R R–W 11 A PANI G–R LG 1 A LSWR J2 JUNCTION CONNECTOR W–L 4 IK1 L–W L–Y 18 A W–B 16 A C C W–L A B 1 JUNCTION CONNECTOR C A J16 A , J17 B 2 T1 THEFT DETERRENT HORN W 3 2F SYSTEM OUTLINE Door lock control (Lock and unlock) and panic control (Theft alarm and flash) is performed by remote control, without the ignition key inserted in the door key cylinder, using low–power electrical waves emitted by a transmitter. 1. WIRELESS DOOR LOCK OR UNLOCK NORMAL OPERATION With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, when the lock or unlock button (Transmitter) is pushed, the wireless door lock ECU receives the electrical waves from the transmitter, causing it to operate. As a result, the ECU judges whether the door is locked or unlocked based on the signal from the door lock motor and door unlock detection SW, and sends a signal to the theft deterrent ECU and integration relay to switch the condition from lock to unlock or vice versa, causing the door lock motor to operate. 2. VISUAL CONFIRMATION OF LOCK OR UNLOCK If all doors indicate that they are locked after the lock command, parking lights and taillight will flash once. If any door indicates that it is open after the unlock command, parking lights and taillights will flash twice. 3. WIRELESS DOOR UNLOCK OPERATION Pushing the unlock button (Transmitter) once, driver’s door is unlocked. Furthermore, pushing the button again within 3 seconds, the other doors are unlocked. 4. AUTOMATIC LOCK OPERATION With the ignition key not inserted into the ignition key cylinder (Unlock warning SW off) and all the doors completely closed, after pushing the button (Transmitter) to unlock all the doors, if a door is not opened within 30 seconds, all the doors will be automatically relocked. 5. WIRELESS CONTROL STOP FUNCTION If a door is open (Door courtesy SW on), a signal is input from the door courtesy SW to the wireless door lock ECU, stopping wireless door lock or unlock. If the ignition key is in the ignition key cylinder (Unlock warning SW on), the unlock warning SW inputs a signal to the wireless door lock ECU, stopping wireless door lock or unlock. 6. DOOR LOCK MOTOR PROTECTIVE FUNCTION If the door lock or unlock condition does not change after wireless door lock or unlock operation, 2 seconds later, the integration relay ECU sends current three times to the door lock motor. If the door lock condition still has not changed as a result, the wireless door lock ECU stops reception and stops door lock and unlock function. 7. REMOTE PANIC OPERATION Panic will function when doors are locked or unlocked, open or closed. When the panic button (Transmitter) is pushed once, theft alarm sounds and headlights and taillight flash. Then, the panic or the unlock button (Transmitter) is pushed once more, sounding and flashing will stop. Panic will not function when ignition key is in ignition key cylinder. SERVICE HINTS D12, D13, D14, D15 DOOR COURTESY SW FRONT LH, RH, REAR LH, RH 1–GROUND : Continuity with the door open U1 UNLOCK WARNING SW 2–1 : Continuity with the ignition key in the cylinder W6 WIRELESS DOOR LOCK ECU 8–GROUND : Always approx. 12 volts 1–GROUND : Always continuity 14–GROUND : Continuity with each of the door open 10–GROUND : Continuity with the ignition key in the cylinder WIRELESS DOOR LOCK CONTROL (TMMK MADE) : PARTS LOCATION Code See Page D6 30 D7 30 D10 30 D12 32 D13 32 D14 Code See Page F4 A F9 F I18 B Code 28 (5S–FE) See Page J32 31 26 (1MZ–FE) J33 A 31 28 (5S–FE) J34 B 31 30 J37 31 J1 31 J40 32 32 J2 31 P9 33 D15 32 J5 31 R6 31 D16 32 J6 31 D17 32 J9 A 31 D18 32 J10 B 31 T3 B 31 D19 32 31 T4 A 31 D20 32 J16 A 31 U1 31 D21 32 J17 B 31 W6 31 32 J30 A 31 26 (1MZ–FE) J31 B 31 D22 F4 A J11 27 (1MZ–FE) T1 29 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D 1G 1J 1M 1S 1V 1W 2F 2J 2K See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 IE2 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF2 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IG1 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) IK1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IM1 IM2 IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH 40 Right Kick Panel BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar IJ IK : SPLICE POINTS Code E3 B6 See Page 36 (1MZ–FE) 38 (5S–FE) 44 Wire Harness with Splice Points Code Cowl Wire See Page Wire Harness with Splice Points B13 44 Front Door LH Wire B14 44 Front Door RH Wire Floor No.2 Wire D6 X 2



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DD DE E E F F F F J11 A (Hint : See Page 7) A (Hint : See Page 7) J16 (A) J17 (B) J30 (A) J31 (B) BLACK BLACK GRAY GRAY



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4 5 6
8 9 10 11 7 X 9 10 11 12 X 13 14 15 16 X 18 X X X X 1 2 1 X X 4 8 9 1011 1213 5 X 7 14 15 MEMO THEFT DETERRENT (TMC MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 1 TAILLIGHT RELAY 5 40A MAIN 3 2 2 6 1C 1 4 HEAD RELAY A 2 3 A 8 2K G–R J2 JUNCTION CONNECTOR G–R 4 1B J 1 (* 1) J32 (* 2) JUNCTION CONNECTOR B R–B 10 IG1 6 J33 A G–R R–B 5 H–LP H 5 E3 11 B 10 B PANI A B 2 R–W D A D A 6 D A R–G R–W R–W D7 DIODE (COURTESY) 1 2 E A W–B FL MAIN 3. 0W J33 A , J34 B JUNCTION CONNECTOR R–W B–G 1 C A J9 A 7 B E B JUNCTION CONNECTOR U1 UNLOCK WARNING SW R–Y L–B 5 1M 1 A E 5 A W–B B A J 9 A , J10 B B A R–G F4 A , F9 F FUSIBLE LINK BLOCK 7 1D DSWP 1 A R–G L–B L–B 2 F CTY DSWD 4 A R–G KSW 6 A JUNCTION CONNECTOR DSWL 2 A 100A ALT 18 A HEAD T3 B , T4 A THEFT DETERRENT ECU B–R E A J33 A , J34 B JUNCTION CONNECTOR IF1 3 1M 1 1G 4 1G D B 4 R–G IG 1 R–G J5 JUNCTION CONNECTOR A A 1 W–B 1 6 IN2 R–W R–G J11 JUNCTION CONNECTOR 1 8 IN2 D13 DOOR COURTESY SW FRONT RH A 12 1S D14 DOOR COURTESY SW REAR LH 1 INTEGRATION RELAY D15 DOOR COURTESY SW REAR RH 7 1S R–W 7 1J W–B L6 LUGGAGE COMPARTMENT LIGHT SW BATTERY R–Y 6 D12 DOOR COURTESY SW FRONT LH B–R TAIL 1 F LG 7 IG3 D6 DAYTIME RUNNING LIGHT RELAY (MAIN) R–B JUNCTION CONNECTOR W6 WIRELESS DOOR LOCK ECU B A (*1) R B A R–B B (*1) B–R G–R (* 2) IF FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7. 5A DOME 1 1D 8 1D 12 2J 5 HORN RELAY 2 R 1 15A ECU–IG B–R 25A DOOR L–W 10A HORN 1 1W 3 8 1G G–B * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT C G–B C B W–L C B 12 B A C JUNCTION CONNECTOR E B D B D A E A 1 IG3 3 1V J39 JUNCTION CONNECTOR 6 BO1 20 IM1 A IE IJ J40 JUNCTION CONNECTOR BL B L–Y B D22 DOOR UNLOCK DETECTION SW REAR RH 4 6 BP1 5 2 IF1 2 1 1 2 B6 W–B W–B W–B W–B IE1 1 BR W–B A IK1 E6 ENGINE HOOD COURTESY SW W–B A 3 BN IK EB IH J33 A JUNCTION CONNECTOR W–B 4 W–B A 4 BP1 L–Y W–B 1 D21 DOOR UNLOCK DETECTION SW REAR LH W–B 1 9 3 IN2 L–Y 4 BO1 A A IF2 W–B 1 2 L–Y L 4 UNLOCK 3 A 7 1G 20 2 11 IM1 D20 DOOR UNLOCK DETECTION SW FRONT RH W–B Y 1 3 IM1 W–B 2 LOCK 3 4 IM1 D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK L–W 4 IE1 W–B J38 JUNCTION CONNECTOR 1 IE1 W–B 4 3 D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH R–G UNLOCK IE1 D19 DOOR UNLOCK DETECTION SW FRONT LH W–B L–R 11 C A R–Y L–Y L–Y E B Y L L–W R–G L–W B C A BP L4 LUGGAGE COMPARTMENT KEY UNLOCK SW C LUG 7 A G–W A J 9 A , J10 B IND 6 B G–W B J37 JUNCTION CONNECTOR DSWH 3 A G–W B LSWR 16 A W–B L–W F LSWP 15 A J 9 A , J10 B R–G B UL2 10 A +B1 B L–R B L–R J6 JUNCTION CONNECTOR F 11 A IG R–Y L2 8 A L–Y UL3 9 A 13 A +B2 Y LSWD HORN 14 A 1 B T3 B , T4 A THEFT DETERRENT ECU L SH D B R 9 B A B B–R G–B 11 IG1 W–L 5 IG3 E A L–W J34 B JUNCTION CONNECTOR C A JUNCTION CONNECTOR IK1 2 R C C10 THEFT DETERRENT INDICATOR LIGHT [COMB. METER] W–L D10 DIODE (DOME) J2 JUNCTION CONNECTOR 1 4 1 J16 A , J17 B 2 JUNCTION CONNECTOR T1 THEFT DETERRENT HORN R–Y 10 2K W 3 2F THEFT DETERRENT (TMC MADE) SERVICE HINTS D16, D17 DOOR KEY LOCK AND UNLOCK SW FRONT LH, RH 1–3 : Closed with door lock cylinder unlocked with key 1–2 : Closed with door lock cylinder locked with key E6 ENGINE HOOD COURTESY SW 2–1 : Open with engine hood open U1 UNLOCK WARNING SW 2–1 : Closed with ignition key in cylinder L4 LUGGAGE COMPARTMENT KEY UNLOCK SW 2–1 : Closed with luggage compartment door lock cylinder unlock L6 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : Closed with luggage compartment door open T3 (B), T4 (A) THEFT DETERRENT ECU (A) 6–GROUND : Continuity with ignition key in cylinder (A)15–GROUND : Continuity with front RH door unlocked (A)14–GROUND : Continuity with front LH door unlocked (A) 5–GROUND : Continuity with front RH door open (A) 4–GROUND : Continuity with front LH door open (A) 8–GROUND : Continuity with door key lock and unlock SW to LOCK position (B) 7–GROUND : Always continuity (A) 7–GROUND : Continuity with luggage compartment door unlocked (A) 1–GROUND : Continuity with each door opened (A) 3–GROUND : Continuity with engine hood close (A) 2–GROUND : Continuity with luggage compartment door open (A)16–GROUND : Continuity with rear door unlocked (A) 9, (A) 10–GROUND : Continuity with door key lock and unlock SW to UNLOCK position (B) 1, (B) 12, (B) 11, (B) 10, (A) 11–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page C10 30 D6 30 D7 30 D10 30 D12 32 D13 32 D14 32 D15 Code See Page E6 F4 A Code 28 (5S–FE) J33 26 (1MZ–FE) J34 See Page A 31 B 31 28 (5S–FE) J37 31 26 (1MZ–FE) J38 32 28 (5S–FE) J39 32 J1 31 J40 32 J2 31 L4 32 32 J5 31 L6 32 D16 32 J6 31 D17 32 J9 A 31 D19 32 J10 B 31 T3 B 31 D20 32 31 T4 A 31 D21 32 J16 D22 32 J17 E6 26 (1MZ–FE) F9 F J11 J32 27 (1MZ–FE) T1 29 (5S–FE) A 31 U1 31 B 31 W6 31 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D 1G 1J 1M 1S 1V 1W 2F 2J 2K See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IG1 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) IK1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IF1 IF2 IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support IE 40 Cowl Side Panel LH IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH 40 Right Kick Panel IJ IK BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar BP 44 Back Panel Center : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Cowl Wire Code B6 See Page 44 Wire Harness with Splice Points Floor No.2 Wire THEFT DETERRENT (TMC MADE) C10 D6 D7 D10 BROWN GRAY BLACK BLACK 1 2 1 2



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D13 D14 X
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D D D E E E D D D E E E A (Hint : See Page 7) A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J16 (A) J17 (B) J32 J33 (A) BLACK BLACK GRAY BLACK



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C C A A B C C A A B B B BC C D D D E E E (Hint : See Page 7) (Hint : See Page 7) J40 A A L4 A A A 1 2 L6 T1 GRAY BLACK 1 1 2 A T3 (B) 1 X X X X 6 7 X 9 10 11 12 (Hint : See Page 7) T4 (A) U1 W6 BLUE 1 2 3 4 5 6 7 8 9 10 11 X 13 14 15 16 X 18 X X X X 1 2
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5 X


THEFT DETERRENT (TMMK MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 1 TAILLIGHT RELAY 5 40A MAIN 3 2 2 6 1C 1 4 HEAD RELAY A 2 3 A 8 2K G–R J2 JUNCTION CONNECTOR G–R 4 1B J 1 (* 1) J32 (* 2) JUNCTION CONNECTOR B R–B 10 IG1 J33 A G–R H 5 R–B 11 B 10 B 18 A HEAD T3 B , T4 A PANI THEFT DETERRENT ECU A B 2 R–W D A D A 6 D A R–W R–W D7 DIODE (COURTESY) 1 2 E A W–B FL MAIN 3. 0W J33 A , J34 B JUNCTION CONNECTOR R–W B–G 1 C A J9 A E B JUNCTION CONNECTOR U1 UNLOCK WARNING SW R–Y L–B 5 1M 1 A 7 B W–B B A E 5 A R–G B A R–G F4 A , F9 F FUSIBLE LINK BLOCK 7 1D DSWP 1 A J 9 A , J10 B L–B L–B 2 F CTY DSWD 4 A R–G KSW 6 A JUNCTION CONNECTOR DSWL 2 A R–G B–R E A J33 A , J34 B JUNCTION CONNECTOR IF1 3 1M 1 1G 4 1G D B 4 R–G IG 1 R–G J5 JUNCTION CONNECTOR A A 1 W–B 1 6 IN2 R–W R–G J11 JUNCTION CONNECTOR 1 8 IN2 D13 DOOR COURTESY SW FRONT RH A 12 1S D14 DOOR COURTESY SW REAR LH 1 INTEGRATION RELAY D15 DOOR COURTESY SW REAR RH 7 1S R–W 7 1J W–B L6 LUGGAGE COMPARTMENT LIGHT SW BATTERY R–Y 6 D12 DOOR COURTESY SW FRONT LH B–R TAIL 100A ALT LG 7 IG3 D6 DAYTIME RUNNING LIGHT RELAY (MAIN) E3 1 F W6 WIRELESS DOOR LOCK ECU 2 H–LP JUNCTION CONNECTOR R–B 19 (*1) B A R–B B A R B (*1) B–R G–R (* 2) IF FROM POWER SOURCE SYSTEM (SEE PAGE 50) 7. 5A DOME 1 1D 8 1D 12 2J 5 HORN RELAY 2 R 1 15A ECU–IG B–R 25A DOOR L–W 10A HORN 1 1W 3 8 1G G–B C G–B C B W–L C B 12 B A C JUNCTION CONNECTOR E B D B D A E A 1 IG3 7 1G 3 1V 20 IM1 A IE IJ J40 JUNCTION CONNECTOR BL B B 6 BP1 2 IF1 2 1 1 2 B6 W–B W–B W–B IE1 W–B 20 W–B W–B W–B 6 BO1 5 BR B13 4 E6 ENGINE HOOD COURTESY SW W–B B14 IK1 1 D22 DOOR UNLOCK DETECTION SW REAR RH 4 3 BN IK EB IH J33 A JUNCTION CONNECTOR W–B 4 4 BP1 L–Y W–B 1 L–Y L–Y 4 BO1 9 3 IN2 D21 DOOR UNLOCK DETECTION SW REAR LH W–B 1 IF2 L–Y 1 2 W–B 3 UNLOCK 2 11 IM1 D20 DOOR UNLOCK DETECTION SW FRONT RH W–B Y 1 3 IM1 W–B 2 LOCK 3 4 IM1 L L–W 4 IE1 D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L–W LOCK 1 IE1 W–B 4 3 D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH R–G UNLOCK IE1 D19 DOOR UNLOCK DETECTION SW FRONT LH W–B L–R 11 C A R–Y L–Y L–Y E B Y L L–W R–G L–W B C A BP L4 LUGGAGE COMPARTMENT KEY UNLOCK SW C LUG 7 A G–W A J 9 A , J10 B IND 6 B G–W B J37 JUNCTION CONNECTOR DSWH 3 A G–W B LSWR 16 A W–B L–W F LSWP 15 A J 9 A , J10 B R–G B UL2 10 A +B1 B L–R B L–R J6 JUNCTION CONNECTOR F 11 A IG R–Y L2 8 A L–Y UL3 9 A 13 A +B2 Y LSWD HORN 14 A 1 B T3 B , T4 A THEFT DETERRENT ECU L SH D B R 9 B A B B–R G–B 11 IG1 W–L 5 IG3 E A L–W J34 B JUNCTION CONNECTOR C A JUNCTION CONNECTOR IK1 2 R C C10 THEFT DETERRENT INDICATOR LIGHT [COMB. METER] W–L D10 DIODE (DOME) J2 JUNCTION CONNECTOR 1 4 1 * 1 : W/ DAYTIME RUNNING LIGHT * 2 : W/O DAYTIME RUNNING LIGHT J16 A , J17 B 2 JUNCTION CONNECTOR T1 THEFT DETERRENT HORN R–Y 10 2K W 3 2F THEFT DETERRENT (TMMK MADE) SERVICE HINTS D16, D17 DOOR KEY LOCK AND UNLOCK SW FRONT LH, RH 1–3 : Closed with door lock cylinder unlocked with key 1–2 : Closed with door lock cylinder locked with key E6 ENGINE HOOD COURTESY SW 2–1 : Open with engine hood open U1 UNLOCK WARNING SW 2–1 : Closed with ignition key in cylinder L4 LUGGAGE COMPARTMENT KEY UNLOCK SW 2–1 : Closed with luggage compartment door lock cylinder unlock L6 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : Closed with luggage compartment door open T3 (B), T4 (A) THEFT DETERRENT ECU (A) 6–GROUND : Continuity with ignition key in cylinder (A)15–GROUND : Continuity with front RH door unlocked (A)14–GROUND : Continuity with front LH door unlocked (A) 5–GROUND : Continuity with front RH door open (A) 4–GROUND : Continuity with front LH door open (A) 8–GROUND : Continuity with door key lock and unlock SW to LOCK position (B) 7–GROUND : Always continuity (A) 7–GROUND : Continuity with luggage compartment door unlocked (A) 1–GROUND : Continuity with each door opened (A) 3–GROUND : Continuity with engine hood close (A) 2–GROUND : Continuity with luggage compartment door open (A)16–GROUND : Continuity with rear door unlocked (A) 9, (A) 10–GROUND : Continuity with door key lock and unlock SW to UNLOCK position (B) 1, (B) 12, (B) 11, (B) 10, (A) 11–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page Code See Page C10 30 E6 26 (1MZ–FE) D6 30 E6 28 (5S–FE) D7 30 D10 30 D12 32 D13 32 D14 32 J1 D15 32 D16 F4 A Code J17 See Page B J32 31 31 26 (1MZ–FE) J33 A 31 28 (5S–FE) J34 B 31 26 (1MZ–FE) J37 31 28 (5S–FE) J40 32 31 L4 32 J2 31 L6 32 32 J5 31 D17 32 J6 31 D19 32 J9 A 31 T3 B 31 D20 32 J10 B 31 T4 A 31 D21 32 D22 32 F9 F J11 J16 A 27 (1MZ–FE) T1 29 (5S–FE) 31 U1 31 31 W6 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1B 1C 1D 1G 1J 1M 1S 1V 1W 2F 2J 2K See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IE1 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IG1 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) IK1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IF1 IF2 IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support IE 40 Cowl Side Panel LH IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH 40 Right Kick Panel IJ IK BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar BP 44 Back Panel Center : SPLICE POINTS Code E3 B6 See Page 36 (1MZ–FE) 38 (5S–FE) 44 Wire Harness with Splice Points Cowl Wire Floor No.2 Wire Code See Page Wire Harness with Splice Points B13 44 Front Door LH Wire B14 44 Front Door RH Wire THEFT DETERRENT (TMMK MADE) C10 D6 BROWN



5
X 2





9



D7 D10 BLACK BLACK 1 2 1 2 X X X X X






19



X X D12 D13 D14 D15 D16 D17 D19 BLACK 1 1 1 1 1 2 3 1

4 1 2 3 D20 D21 D22 E6 BLACK BLACK BLACK BLACK 1

4 1

4 1

4 F4 (A) 1 J1 F9 (F) ORANGE 1 J2 J5 BLACK ORANGE A A A

CCC





B



B B B B

2 1 2 A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J6




B B B B








F F F F J9 (A) J10 (B) BLACK BLACK J11

B B C C A A



D D D E E E D D D E E E A (Hint : See Page 7) A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J16 (A) J17 (B) J32 J33 (A) BLACK BLACK GRAY BLACK



C C A A A A






E E E D D D


(Hint : See Page 7) (Hint : See Page 7)

B



B B B

(Hint : See Page 7)

B B C C D D D E E E (Hint : See Page 7) J34 (B) J37 J40 L4 A A B C C A A B B B B C C



C C A A A A A 1 2 A D D D E E E (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) T3 (B) T4 (A) U1 1 X X X X 6 1 2 3 4 5 6 7 8 9 10 11 1 2 7 X 9 10 11 12 X 13 14 15 16 X 18 X X X X T1 BLACK 1 2 W6 BLUE
X X






L6 GRAY BLACK 5 X


1 MOON ROOF FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 7. 5A DOME 30A POWER 25A DOOR 10A GAUGE 2 5 12 2J R * * * * 1 : TMC MADE 2 : TMMK MADE 3 : W/O THEFT DETERRENT SYSTEM 4 : W/ THEFT DETERRENT SYSTEM 1 POWER RELAY 3 2 7 1F 7 1J 1 1W 1 1D J33 A , J34 B 5 1F R–B A A L–W R (* 2) L W–B C B M3 MOON ROOF CONTROL SW AND RELAY 4 10 13 A (*3) 1 B (*4) 12 A 3 B 7 TILT UP SLIDE OPEN 6 JUNCTION CONNECTOR L–W 5 1G 2 8 7 3 5 1 6 8 A (*3) 6 B (*4) B INTEGRATION RELAY 1 A 2 B J33 A , J34 B R 5 A 5 B D B NO. 1 NO. 2 M W–B B2 BM 1 W–B A J11 JUNCTION CONNECTOR IG D12 DOOR COURTESY SW FRONT LH (*1) W–B IE W–B W–B W–B 3 1V M4 A , B MOON ROOF MOTOR AND LIMIT SW W–B 3 A (* 1) 3 B (* 2) 4 A 3 1F R–G 6 IN2 D13 DOOR COURTESY SW FRONT RH B2 NO. 3 R–G R–G 2 A (*1) 1 B (*2) E A JUNCTION CONNECTOR G–W 4 B G R–L 6 A 6 B (* 2) P–B W–B R–G 7 1S I18 A , 1 SYSTEM OUTLINE Current is applied at all times through the POWER fuse to TERMINAL 5 of the power relay. With the ignition SW turned on, the current flows through the GAUGE fuse to TERMINAL 7 of the integration relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to TERMINAL 1 of the power relay to TERMINAL 2 to GROUND, as a result, power relay is activated and the current to TERMINAL 5 of the power relay flows from TERMINAL 3 of the power relay to TERMINAL 4 of the moon roof control relay. 1. SLIDE OPEN OPERATION Only when the slide open switch is valid and actuated the moon roof motor continually will operate towards the open direction of the roof panel. Releasing and again depressing the open switch, or depressing another operation switch shall cancel this express open function. The relay shall only operate the moon roof motor continually for approx. 20 seconds per actuation. 2. SLIDE CLOSE OPERATION Only when the tilt up switch is valid and actuated the moon roof motor will operate towards the close direction of the roof panel. When the moon roof reaches about 120 mm short of the fully closed position, the limit switch No.2 is turned from on to off. Thereby signaling the moon roof control relay to stop the motor. The motor can not continue to operate until the close switch is released and again depressed. 3. TILT UP OPERATION Only when the tilt up switch is valid and actuated the moon roof motor will operate towards the closed direction of the roof panel. 4. TILT DOWN OPERATION Only when the slide open switch is valid and actuated the moon roof motor will operate towards the open direction of the roof panel. 5. KEY OFF MOON ROOF OPERATION With the ignition SW turned from on to off, the integration relay operates and current flows from the DOOR fuse to TERMINAL (A) 13 (w/o theft deterrent system), (B) 1 (w/ theft deterrent system) of the relay to TERMINAL (A) 12 (w/o theft deterrent system), (B) 3 (w/ theft deterrent system) to TERMINAL 1 of the power relay to TERMINAL 2 to GROUND for about 43 seconds. In the same way as normal operation, the current flows from the POWER fuse to TERMINAL 5 of the power relay to TERMINAL 3 to TERMINAL 4 of the moon roof control relay. As a result, for about 43 seconds after the ignition SW is turned off, the functioning of this relay makes it possible to open and close the moon roof. Also, by opening the front door (Door courtesy SW on) within about 43 seconds after turning the ignition SW to off, a signal is input to TERMINALS 6 or (A) 8 (w/o theft deterrent system), (B) 6 (w/ theft deterrent system) of the integration relay. As a result, the relay turns off and open close movement of the moon roof stops. SERVICE HINTS POWER RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the ignition SW at ON position or key off moon roof operation M3 MOON ROOF CONTROL SW AND RELAY 2–GROUND : Always continuity 4–GROUND : Approx. 12 volts with the ignition SW at ON position or key off moon roof operation : PARTS LOCATION Code I18 See Page Code See Page D12 32 J11 D13 32 J33 A 31 A 30 J34 B 31 B 30 M3 31 33 Code M4 See Page A 33 B 33 MOON ROOF : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1F 20 Roof Wire and Instrument Panel J/B (Lower Finish Panel) 1G 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1V 1W 2J : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page IN2 Joining Wire Harness and Wire Harness (Connector Location) 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH BM 44 Roof Left : SPLICE POINTS Code See Page B2 Wire Harness with Splice Points 44 Code See Page Wire Harness with Splice Points Roof Wire D12 D13 I18 (A) I18 (B) (w/o Theft Deterrent System) ORANGE 1






8


1213 1 (w/ Theft Deterrent System) ORANGE 1 X 3 X
6
X
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X X X X
J11 A A J33 (A) J34 (B) M3 M3 BLACK BLACK (TMC Made) (TMMK Made) 12 3 45X7X 12 3 456 7 8 A A A A A A







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E E E D D D


(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) M4 (A) M4 (B) (TMC Made) (TMMK Made) 1 2 1 2 3 4 3 4 5 6 5 6 MEMO POWER SEAT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 30A POWER 2 L–W 3 1D L–W A A A A L–W J 9 A , J10 B JUNCTION CONNECTOR IF1 L–W C B L–W 8 L–W 2 BQ1 P14 A , B 11 A (*1) 2 B (*2) M BL J40 JUNCTION CONNECTOR A 1 5 P19 POWER SEAT MOTORS (DRIVER’ S SEAT) 2 P16 POWER SEAT MOTOR (DRIVER’ S SEAT REAR VERTICAL CONTROL) 6 1 4 (*2) R R M (*1) (*1) 1 P17 POWER SEAT MOTOR (DRIVER’ S SEAT RECLINING CONTROL) 2 (*2) L–Y (*2) R–B (*1) R–B (*1) M 3 A (* 1) 8 B (* 2) 2 A 5 B W–B 3 (*2) 2 P18 POWER SEAT MOTOR (DRIVER’ S SEAT SLIDE CONTROL) 1 BQ1 R–G (*2) R–G (*1) 2 REAR VERTICAL 5 A 6 B 1 A 12 B L–B L–B (*1) L L (*2) W–B 4 A 7 B 1 DOWN RECLINING 8 A 11 B L–Y SLIDE 7 A 4 B UP REAR FRONT REAR FRONT POWER SEAT CONTROL SW (DRIVER’ S SEAT) * 1 : TMC MADE * 2 : TMMK MADE L–W L–W 4 IN2 L–W 2 BR1 P15 A , B 11 A (*1) 2 B (*2) SLIDE 4 A 7 B DOWN UP RECLINING 1 A 12 B REAR VERTICAL 5 A 6 B 3 A 8 B 7 A (* 1) 4 B (* 2) 2 A 5 B M 1 2 P20 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT REAR VERTICAL CONTROL) 6 1 (*2) R R (*1) (*1) M 4 B6 W–B 5 L–Y 1 P21 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT RECLINING CONTROL) 2 (*2) L–Y (*2) (*1) R–B R–B (*1) (*2) 2 P22 POWER SEAT MOTOR (FRONT PASSENGER’ S SEAT SLIDE CONTROL) 3 R–G (*2) R–G L–B 2 P23 POWER SEAT MOTORS (FRONT PASSENGER’ S SEAT) IK W–B M 1 BR1 W–B 1 (*1) L–B (*1) L L (*2) W–B 8 A 11 B REAR FRONT REAR FRONT POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) BN POWER SEAT SERVICE HINTS P14 (A), (B) POWER SEAT CONTROL SW (DRIVER’S SEAT) (A) 11, (B) 2–GROUND : Always approx. 12 volts (A) 7, (B) 4–GROUND : Always continuity P15 (A), (B) POWER SEAT CONTROL SW (FRONT PASSENGER’S SEAT) (A) 11, (B) 2–GROUND : Always approx. 12 volts (A) 7, (B) 4–GROUND : Always continuity : PARTS LOCATION Code See Page J9 A 31 J10 B 31 P15 See Page Code See Page A 34 P19 34 B 34 P20 34 32 P16 34 P21 34 A 34 P17 34 P22 34 B 34 P18 34 P23 34 J40 P14 Code : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D See Page 20 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IF1 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IN2 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) BQ1 46 Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) BR1 46 Floor No.2 Wire and Seat No.2 Wire (Under the Passenger’s Seat) : GROUND POINTS Code See Page Ground Points Location IK 40 Right Kick Panel BL 44 Under the Left Center Pillar BN 44 Under the Right Center Pillar : SPLICE POINTS Code B6 See Page 44 Wire Harness with Splice Points Floor No.2 Wire Code See Page Wire Harness with Splice Points J9 (A) J10 (B) BLACK BLACK J40 A A A







C C











P14 (A) (TMC Made) BLACK A A A A 1 2 3 4 5 X 7 8 X X 11 X A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) P14 (B) (TMMK Made) BLACK P15 (A) P15 (B) (TMC Made) BLACK X 2 X 4 5 6 7 8 X X 1112 1 2 3 4 5 X 7 8 X X 11 X P16 P17 1 2 1 2 (TMMK Made) BLACK X 2 X 4 5 6 7 8 X X 1112 P18 P19 P20 P21 P22 P23 1 2 1 2 3 1 2 1 2 1 2 1 2 3 4 5 6 4 5 6 ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A EFI 5A IGN 5A STARTER 7 1C 3 1J S6 STOP LIGHT SW E5 ENGINE COOLANT TEMP. SENSOR BR 3 I2 BR 2 2 B–R 5 EFI RELAY 1 B–W W 7 1W 15A STOP 4 2F 2 2J G–W 5 2C 8 2J 7 2K T2 THROTTLE POSITION SENSOR 1 B–W B–Y W–B W–B 4 1R 2 1 1 3 2 BR 9 E 19 E 20 E W–L SLN+ 2 6 3 2 4 1 S2 S1 SL SLN– SLN+ W–B W–B EB THW NC2– 26 E R J26 JUNCTION CONNECTOR V 14 E 1 G C15 CRUISE CONTROL ECU NC2+ E3 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID V3 VEHICLE SPEED SENSOR (ELECTRONICALLY CONTROLLED TRANSMISSION) ECT R 6 L OD Y 14 A W IDL A L–B 13 A L–B 14 D E2 G SL 7 E B L–B 7 II2 G–B L S1 8 E B–Y Y–B S2 P–L 24 B 18 D VC SLN– NSW L–B 4 B L–R ENGINE CONTROL MODULE 23 D Y J27 A , J28 B J29 JUNCTION CONNECTOR 2 D 20 B VTA1 15 A B–W G–W 2 A STP B–R 1 A BATT B E 7 A , E 8 B , E10 D , E11 E OD1 IDLO MREL B JUNCTION CONNECTOR J35 JUNCTION CONNECTOR 8 A +B C B IGSW 16 A C A A B–Y B–Y B B C B–W B A JUNCTION CONNECTOR J27 A , J28 B G–W 5 1R (1MZ–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) R–L * 1 : CALIFORNIA * 2 : EXCEPT CALIFORNIA * 3 : TMMK MADE * 4 : TMC MADE 10A GAUGE J28 B 1 1J JUNCTION CONNECTOR F B R–L F B R–L 2 1D R–L 2 II2 D D R–L J4 JUNCTION CONNECTOR R–L Y L–W (* 4) J24 JUNCTION CONNECTOR O (* 3) A A A R–L A B R–B C A R–B C A R–B 3 IG3 V–W R–L V–W JUNCTION CONNECTOR V–W R–B 22 B R O (*3) (*4) 2 B Y 3 B 2 L–W J27 A , J28 B J15 JUNCTION CONNECTOR B B 14 B 7 C O/D OFF SPEEDOMETER R–L C IJ1 C O2 O/D MAIN SW 2 A B A 4 BR BR BR (* 2) BR A BR BR (*1) J26 JUNCTION CONNECTOR A B J6 JUNCTION CONNECTOR G–O C 2 G–O IJ1 12 A G–O 3 7 BR G–O J22 JUNCTION CONNECTOR BR SI 5 C P G–O SE 2 11 IG3 6 C P BR 15 B V2 VEHICLE SPEED SENSOR (COMBINATION METER) L 10 B 1 IG+ L 31 E COMBINATION METER ENGINE CONTROL MODULE E02 21 E BR E01 30 E BR OD2 17 D BR E1 E03 L SPD E 7 A , E 8 B , E10 D , E11 E C 8 A , C 9 B , C10 C 12 B BR (*1) ED EC IH W–B ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR R–L R–L 2 P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] * 3 : TMMK MADE * 4 : TMC MADE C DL NL RL PL 3 10 9 8 7 D A D A D (*4) O R–B IJ1 3 II3 4 R R–B 1 II2 G–W R B–R II2 B–R (* 3) O 9 J29 JUNCTION CONNECTOR E L–W II2 L–W E J29 JUNCTION CONNECTOR E Y 6 (* 4) Y II2 Y 5 G–W 2L 4 L–W LL (*3) R–B 14 IG3 10 1H G–W B–R O 5 1V (* 3) Y (* 4) R–B L–W R–B R–B 8 A 16 B C 8 A , C 9 B , C10 C W–B COMBINATION METER A W–B J5 JUNCTION CONNECTOR A A W–B W–B IF 9 A P R 10 A R B–R 7 A N O 11 A D Y 6 A 2 L 13 IG3 G–W 15 IG3 16 IG3 (1MZ–FE) SYSTEM OUTLINE Previous automatic transaxle have selected each gear shift using the mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock–up hydraulic pressure. The electronically controlled transmission, however, electrically controls the line pressure and lock–up pressure etc., through the solenoid valve. Engine control module control of the solenoid valve based on the input signals from each sensor makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module, and also the input signals to TERMINAL NC2+ of the engine control module from the vehicle speed sensor devoted to the O/D direct clutch. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For the 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL 3 of the electronically controlled transmission solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL 6 of the electronically controlled transmission solenoid to GROUND, and continuity to solenoids No.1 and No.2 causes the shift. For the 3rd speed, there is no continuity to No.1 solenoid, only to No.2, causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK–UP OPERATION When the engine control module judges from each signal that lock–up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL 2 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock–up solenoid and causing lock–up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock–up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock–up solenoid is cut. 4. OVERDRIVE CIRCUIT ∗ Overdrive on When the O/D main SW is turned on (O/D off indicator light turns off), a signal is input to TERMINAL OD2 of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. ∗ Overdrive off When the O/D main SW is turned to off (O/D off indicator light turns on), the current flowing through the O/D off indicator light flows through the O/D main SW to GROUND. Causing the indicator light to light up. At the same time, a signal is input to TERMINAL OD2 of the engine control module and engine control module operation prevents shift into overdrive. SERVICE HINTS E7 (A), E8 (B), E10 (D), E11 (E) ENGINE CONTROL MODULE (TURN ON THE IGNITION SW) S1, S2–E1 : 9.0–14.0 volts with the solenoid on 0–1.5 volts with the solenoid off L–E1 : 7.5–14.0 volts with the shift lever at L position 2–E1 : 7.5–14.0 volts with the shift lever at 2 position R–E1 : 7.5–14.0 volts with the shift lever at R position STP–E1 : 7.5–14.0 volts with the brake pedal depressed THW–E2 : 0.2–1.0 volts with the engine coolant temp. 80°C (176°F) VAT1–E2 : 0.3–0.8 volts with the throttle valve fully closed 3.2–4.9 volts with the throttle valve fully opened VC–E2 : 4.5–5.5 volts OD2–E1 : 9.0–14.0 volts with the O/D main SW turned off 0–3.0 volts with the O/D main SW turned on +B–E1 : 9.0–14.0 volts OD1–E1 : 9.0–14.0 volts E3 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 2, 3, 6–GROUND : Each 11–15 Ω O2 O/D MAIN SW 2–4 : Closed with the O/D main SW off, open with the O/D main SW on ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR : PARTS LOCATION Code C8 See Page Code E11 See Page E Code 30 J28 See Page A 30 B 31 C9 B 30 J4 31 J29 31 C10 C 30 J5 31 J35 31 C15 30 J6 31 O2 31 E3 26 (1MZ–FE) J15 31 P1 27 (1MZ–FE) E5 26 (1MZ–FE) J22 31 S6 31 E7 A 30 J24 31 T2 27 (1MZ–FE) E8 B 30 J26 31 V2 27 (1MZ–FE) E10 D 30 31 V3 27 (1MZ–FE) J27 A : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1C 1D 1H See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 No 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 1R 1V 1W 2C 2F 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG3 II2 II3 IJ1 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) : GROUND POINTS Code See Page Ground Points Location EB 36 (1MZ–FE) Left Radiator Side Support EC 36 (1MZ–FE) Surge Tank RH ED 36 (1MZ–FE) Rear Side of the Surge Tank IF 40 Left Kick Panel IH 40 Instrument Panel Brace RH : SPLICE POINTS Code I2 See Page 42 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points (1MZ–FE) C8 (A) C8 (A) (TMC Made) BLUE




6 (TMMK Made) BLUE 7 8 9 10 11 12





6 C9 (B) C9 (B) (TMC Made) (TMMK Made)












14 15 16







C10 (C)



5 6




14 15 16 C10 (C) 7





E3 E5 GRAY DARK GRAY C15 (TMMK Made) BROWN (TMC Made) BROWN



5 6 X



6

7





E7 (A)



13 14

E8 (B) 1 2 1 2 3 4 X 6
2 7 8 9 10 11 12
1 2
X X

X 2 3 4 X X 8
X
X

15 10 X 12

X
X X X 16
20 X 22



X X 24
X
X E10 (D) E10 (D) E11 (E) (California) (Except California) BLACK (California)




X 2 X










X
7 8 9





14 X
X




14 X




14



19 20 21 17 18


17 18
X X
X

26
23

23



30 31 ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR (1MZ–FE) E11 (E) J4 J5 (Except California) BLACK BLACK ORANGE


X X


DD DX



X
7 8 9 A A A A A A A A A A A A A (Hint : See Page 7)



14



19 20 21
X

26

(Hint : See Page 7)
30 31 J15 J6 J22 J24 BLACK


B B





B








CC C









A A A A A A A A A A A A
A A


(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J26 J27 (A) J28 (B) J29 A B A A B B B A A B B C C A A B B C C A A A A A B B B B


DD DE E E













F F (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) O2 P1 S6 T2 BLUE GRAY BLUE BLACK J35
2
4



C C





(Hint : See Page 7) V2 V3 BLACK BLACK 1 2 3 1 2 X 7

2 8 3 4 9 10 1 2 3 1
2
MEMO ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A EFI 5A IGN 7 1C 5 3 1J W–B W–B B–Y B–W B 2 1 2 1 B 1 B 10 B 11 B 9 B 9 B SL 15 C 15 C 24 C (*1) 14 C (*2) P A V A 1 B 3 B 1 A S2 S1 SL A 6 BR L–B 20 C 1 C W ECT A A A BR W–B NO. 2 C15 CRUISE CONTROL ECU LOCK–UP OD J25 JUNCTION CONNECTOR NO. 1 II2 8 C 7 C L–B Y–B 14 7 L–B L–R 13 S1 BR S2 21 C 6 C 18 A 20 A E2 E04 E 7 A , E 8 B , E 9 C , E10 D ENGINE CONTROL MODULE L–B IDL VC E3 A , E4 B EB THW NSW 4 B (* 1) 4 B (* 2) E1 22 A 22 A VTA 9 A 4 A B 3 A 3 A BATT 1 A (CALIFORNIA) MREL OD1 IDLO +B 2 A 1 A J23 JUNCTION CONNECTOR 7 D STP 12 A 12 A IGSW G–W BR 3 LG 1 Y T2 THROTTLE POSITION SENSOR J27 A , J28 B (*1) B–Y C B JUNCTION CONNECTOR A A B–W 5 1R G–W (*1) B–Y B–R (* 1) 4 1R II4 B–W B B JUNCTION CONNECTOR B A 6 8 2J BR 7 2K G–W 2 2J J27 A , J28 B 4 2F E5 ENGINE COOLANT TEMP. SENSOR BR B 1 5 2C G–B 2 I2 J29 JUNCTION CONNECTOR 3 B–W (* 2) B–R S6 STOP LIGHT SW 2 EFI RELAY 1 5A STARTER W 7 1W 15A STOP ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID EC BR (5S–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/ ENGINE IMMOBILISER SYSTEM * 2 : W/O ENGINE IMMOBILISER SYSTEM * 3 : TMC MADE * 4 : TMMK MADE R–L 10A GAUGE 1 1J 2 1D R–L J28 B JUNCTION CONNECTOR F B R–L D D R–L J4 JUNCTION CONNECTOR F B Y L–W (* 3) O R–L (* 4) R–B O (* 4) (* 3) L–W Y R–B 2 J15 JUNCTION CONNECTOR B B V–W II2 JUNCTION CONNECTOR J21 JUNCTION CONNECTOR R–L 7 C O/D OFF 6 C L L IJ1 11 IG3 5 C 2 IJ1 3 2 SI SE J6 JUNCTION CONNECTOR V2 VEHICLE SPEED SENSOR (COMBINATION METER) BR IG+ R–L C C C G–O BR BR BR BR 1 EC 12 A G–O 15 B P A 7 G–O V–W COMBINATION METER G–O BR BR BR 14 B C 8 A , C 9 B , C10 C R–L BR A P OD2 5 A (* 1) 7 A (* 2) R–B A R–L 26 C 26 C C A SPEEDOMETER R 13 C 13 C E 7 A , E 8 B , E 9 C , E10 D 2 SPD ENGINE CONTROL MODULE L 25 C 16 B 8 A (* 1) 9 A (* 2) E02 17 A 17 A E01 16 A 18 A E03 15 A 19 A R–B J27 A , J28 B 3 IG3 R–L V–W A B C A IH G–O ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR R–L R–L 2 * 3 : TMC MADE * 4 : TMMK MADE P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] C DL NL RL PL 3 10 9 8 7 L–W D A D A D (* 3) O R–B 3 R IJ1 II3 4 R–B 1 II2 G–W R B–R II2 B–R (* 4) O 9 J29 JUNCTION CONNECTOR E L–W II2 L–W E J29 JUNCTION CONNECTOR E Y 6 (* 3) Y II2 Y 5 G–W 2L 4 L–W LL B–R G–W Y 5 1V 14 IG3 10 1H 15 IG3 G–W 8 A 9 A 2 16 B C 8 A , C 9 B , C10 C W–B COMBINATION METER A 2 4 O2 O/D MAIN SW W–B J5 JUNCTION CONNECTOR A A W–B G–O IF P R–B 10 A R R 7 A N B–R 11 A D 6 A L O 13 IG3 Y 16 IG3 O R–B (*4) R–B L–W R–B (*3) (* 4) R–B (5S–FE) SYSTEM OUTLINE Previous automatic transaxle have selected each gear shift using mechanically controlled throttle hydraulic pressure, governor hydraulic pressure and lock–up hydraulic pressure. The electronically controlled transmission, however, electrically controls the line pressure and lock–up pressure etc., through the solenoid valve. Engine control module controls of the solenoid valve based on the input signals from each sensor which makes smooth driving possible by shift selection for each gear which is most appropriate to the driving conditions at that time. 1. GEAR SHIFT OPERATION During driving, the engine control module selects the shift for each gear which is most appropriate to the driving conditions, based on input signals from the engine coolant temp. sensor to TERMINAL THW of the engine control module, and also the input signals to TERMINAL SPD of the engine control module from the vehicle speed sensor devoted to the electronically controlled transmission. Current is then output to the electronically controlled transmission solenoid. When shifting to 1st speed, current flows from TERMINAL S1 of the engine control module to TERMINAL (B) 3 of the solenoid to GROUND, and continuity to the No.1 solenoid causes the shift. For 2nd speed, current flows from TERMINAL S1 of the engine control module to TERMINAL (B) 3 of the solenoid to GROUND, and from TERMINAL S2 of the engine control module to TERMINAL (B) 1 of the solenoid to GROUND, and continuity to solenoids No.1 and No.2 causes the shift. For 3rd speed, there is no continuity to No.1 solenoid, only to No.2, causing the shift. Shifting into 4th speed (Overdrive) takes place when there is no continuity to either No.1 or No.2 solenoid. 2. LOCK–UP OPERATION When the engine control module judges from each signal that lock–up operation conditions have been met, current flows from TERMINAL SL of the engine control module to TERMINAL (A) 1 of the electronically controlled transmission solenoid to GROUND, causing continuity to the lock–up solenoid and causing lock–up operation. 3. STOP LIGHT SW CIRCUIT If the brake pedal is depressed (Stop light SW on) when driving in lock–up condition, a signal is input to TERMINAL STP of the engine control module, the engine control module operates and continuity to the lock–up solenoid is cut. 4. OVERDRIVE CIRCUIT ∗ O/D main SW on When the O/D main SW is turned on (O/D off indicator light turns off), a signal is input into TERMINAL OD2 of the engine control module and engine control module operation causes gear shift when the conditions for overdrive are met. ∗ O/D main SW off When the O/D main SW is turned to off, the current through the O/D off indicator light flows through the O/D main SW to GROUND, causing the indicator light to light up. At the same time, a signal is input into TERMINAL OD2 of the engine control module and engine control module operation prevents shift into overdrive. SERVICE HINTS E7 (A), E8 (B), E9 (C) ENGINE CONTROL MODULE (TURN ON THE IGNITION SW) S1, S2–E1 : 9.0–14.0 volts with the solenoid on 0–1.5 volts with the solenoid off L–E1 : 7.5–14.0 volts with the shift lever at L position 2–E1 : 7.5–14.0 volts with the shift lever at 2 position R–E1 : 7.5–14.0 volts with the shift lever at R position STP–E1 : 9.0–14.0 volts with the brake pedal depressed THW–E2 : 0.2–1.0 volts with the engine coolant temp. 60°C (140°F) – 120°C (248°F) VTA–E2 : 0.3–0.8 volts with the throttle valve fully closed 3.2–4.9 volts with the throttle valve fully opened VC–E2 : 4.5–5.5 volts OD2–E1 : 9.0–14.0 volts with the O/D main SW turned on 0–3.0 volts with the O/D main SW turned off +B–E1 : 9.0–14.0 volts E3 (A), E4 (B) ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID (A) 1, (B) 1, (B) 3–GROUND : Each 11–15 Ω O2 O/D MAIN SW 2–4 : Closed with the O/D main SW off, open with the O/D main SW on ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR : PARTS LOCATION Code C8 See Page Code See Page Code 30 E9 C9 B 30 E10 C10 C 30 J4 31 J29 31 30 J5 31 O2 31 C15 C 30 J27 D 30 J28 See Page A A 31 B 31 E3 A 28 (5S–FE) J6 31 P1 29 (5S–FE) E4 B 28 (5S–FE) J15 31 S6 31 28 (5S–FE) J21 31 T2 29 (5S–FE) E7 E5 A 30 J23 31 V2 29 (5S–FE) E8 B 30 J25 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1C 1D 1H See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No.2 No 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 1R 1V 1W 2C 2F 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG3 See Page Joining Wire Harness and Wire Harness (Connector Location) 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 42 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) II2 II3 II4 IJ1 : GROUND POINTS Code See Page Ground Points Location EB 38 (5S–FE) Left Radiator Side Support EC 38 (5S–FE) Intake Manifold IF 40 Left Kick Panel IH 40 Instrument Panel Brace RH : SPLICE POINTS Code I2 See Page 42 Wire Harness with Splice Points Engine Wire Code See Page Wire Harness with Splice Points (5S–FE) ∗ 1 : w/ Engine Immobiliser System ∗ 2 : w/o Engine Immobiliser System C8 (A) C8 (A) (TMC Made) BLUE




6 (TMMK Made) BLUE 7 8 9 10 11 12





6 7 8 9 10 11 12
C9 (B) C9 (B) (TMC Made) (TMMK Made)












14 15 16







C10 (C) C15 C10 (C) (TMC Made) BROWN



5 6




14 15 16 (TMMK Made) BROWN 7









5 6 7





E3 (A) E4 (B) E5 E7 (A) BLACK BLACK GREEN (∗ 1) 1 2 1 2 3
5

8 9

1 X 3 1 X X



6





13 14

12

15 16 17 18


22 E7 (A) E8 (B) E8 (B) E9 (C) (∗ 2) (∗ 1) DARK GRAY (∗ 2) (∗ 1) DARK GRAY 1
3 4
X 7
9

1

4



1

4







X

8



13 12



17 18 19 20
22 9 10





9
11



16
15 X
X
20 21

24 25 26 E9 (C) E10 (D) J4 J5 (∗ 2) (∗ 1) DARK GRAY BLACK ORANGE 1



6 7




13



X
14 15 X








26 7

X




X X


DD DX (Hint : See Page 7) A A A A A A A A A A A A A (Hint : See Page 7) ELECTRONICALLY CONTROLLED TRANSMISSION AND A/T INDICATOR (5S–FE) J6 J15 J21 BLACK GRAY


B B





B








CC C









J23 A A A A A A A A A A A A A A

A A A




(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J25 J27 (A) J28 (B) J29 A
A A


A A B B C C A A B B C C A A A A A B B B B


D D DE E E













F F (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) O2 P1 S6 T2 V2 BLUE GRAY BLUE BLACK BLACK 1 2 3 1 2 3
2
4 X 7

2 8 3 4 9 10 1
2
MEMO CRUISE CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 50) J24 JUNCTION CONNECTOR A A R–L R–L (* 1) 10A GAUGE (* 1 A/T) A J21 JUNCTION CONNECTOR A A R–L R–L (* 2) (* 2 A/T) D A 2 2 D 10 B–R (*1) R–L (*2) R–L R–L (M/T) 1 II2 B–R J29 JUNCTION CONNECTOR A A (A/T) B–R (M/T) R–L 9 (A/T) D J27 A , J28 B F B JUNCTION CONNECTOR F B D P1 D POSITION SW [PARK/NEUTRAL POSITION SW] II2 C14 CRUISE CONTROL CLUTCH SW 2 R–L R–L J4 JUNCTION CONNECTOR 1 1J R–L A 2 1D C 9 B , C10 C COMBINATION METER A C15 CRUISE CONTROL ECU CRUISE BR V–W O TC SPD CMS CCS 5 12 11 10 3 IG3 5 IG2 D P D D 2 B 4 CMS CCS RESUME/ ACCEL IG+ TC V–W (*3) SET/ COAST P–B 4 A/D 11 TC CANCEL EP BR 3 (* 1) R–L (* 2) B 5 II3 LG–R LG–R 10 11 1 R–L B SE O SI B B (*4) L 3 V2 VEHICLE SPEED SENSOR (COMBINATION METER) V–W O LG–R IJ1 J2 JUNCTION CONNECTOR 2 O IJ1 LG–R 4 W P PI W–L 10 C CRUISE 14 B V–W 5 C J15 JUNCTION CONNECTOR 6 C L D 15 B 7 3 J3 JUNCTION CONNECTOR SPEEDOMETER B–R 7 C D4 DATA LINK CONNECTOR 2 D1 DATA LINK CONNECTOR 1 C12 CRUISE CONTROL SW [COMB. SW] W–B IH FROM POWER SOURCE SYSTEM (SEE PAGE 50) E3 A , E4 B E 7 A , E 8 B , E 9 C , E11 E ENGINE CONTROL MODULE S2 S2 8 E (* 1) 21 C (* 5) 6 C (* 6) 6 A (* 1) 1 B (* 2) 7 1C J26 (* 1) , J25 (* 2) JUNCTION CONNECTOR A A W L–B 9 1J (A/T) Y–B (A/T) L–R * 1 : 1MZ–FE * 2 : 5S–FE * 3 : TMMK MADE 1MZ–FE * 4 : EXCEPT *3 * 5 : 5S–FE W/ ENGINE IMMOBILISER * 6 : 5S–FE W/O ENGINE IMMOBILISER 15A STOP B–R 24 B 18 A 20 A L–B 4 B 3 A 3 A OD1 15A ECU–IG (A/T) IDLO ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID L–B (A/T) A C 7 J12 JUNCTION CONNECTOR II2 6 9 OD IDL ECT GND B MO 15 MC L 7 W–B JUNCTION CONNECTOR A A 4 W–B 8 1J 1 2 2 A A R–Y W–B A A W S6 STOP LIGHT SW J8 B R–B J7 A , R–G A B A A 2 G–W 3 A A STP– 8 G–B 16 1 G–W C15 CRUISE CONTROL ECU 14 G–W 13 B–R L–B (A/T) C 3 W–B 7 1J A W–B IG J11 JUNCTION CONNECTOR 5 1R M 4 1R C3 CRUISE CONTROL ACTUATOR W–B 4 J27 A JUNCTION CONNECTOR CRUISE CONTROL SYSTEM OUTLINE Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. With the ignition SW turned to on, current flows through the GAUGE fuse to TERMINAL (C) 7 of the combination meter and the current through the ECU–IG fuse flows to TERMINAL 9 of the cruise control ECU. When the ignition SW is on and the cruise control SW is turned on, a signal is input from TERMINAL 5 of the cruise control SW to TERMINAL 11 of the cruise control ECU. As a result, the cruise control ECU functions and the current flows from the ECU–IG fuse to TERMINAL 9 of the cruise control ECU to TERMINAL 16 to GROUND, and the cruise control system is in a condition ready for operation. At the same time, the current through the GAUGE fuse flows to TERMINAL (C) 7 of the cruise control indicator light to TERMINAL (C) 10 to TERMINAL 4 of the cruise control ECU to TERMINAL 16 to GROUND, causing the cruise control indicator light to light up, indicating that cruise control is ready for operation. 1. SET OPERATION When the cruise control SW is turned on and the set SW is pushed with the vehicle speed within the set limit (Approx. 40 km/h, 25 mph to 200 km/h, 124 mph), a signal is input to TERMINAL 10 of the cruise control ECU and the vehicle speed at the time the set SW is released is memorized in the ECU as the set speed. 2. SET SPEED CONTROL During cruise control driving, the cruise control ECU compares the set speed memorized in the cruise control ECU with the actual vehicle speed input into TERMINAL 12 of the cruise control ECU from the speed sensor, and controls the cruise control actuator to maintain the set speed. When the actual speed is lower than the set speed, the ECU causes the current to the cruise control actuator to flow from TERMINAL 15 of the cruise control ECU to TERMINAL 1 of the cruise control actuator to TERMINAL 2 to TERMINAL 7 of the cruise control ECU. As a result, the motor in the cruise control actuator is rotated to open the than the set speed, the current to the cruise control actuator flows from TERMINAL 7 of the cruise control ECU to TERMINAL 2 of the cruise control actuator to TERMINAL 1 to TERMINAL 15 of the cruise control ECU. This causes the motor in the cruise control actuator to rotate to close the throttle valve and return the throttle cable to decrease the vehicle speed. 3. COAST CONTROL During cruise control driving, while the coast SW is on, the cruise control actuator returns the throttle cable to close the throttle valve and decrease the driving speed. The vehicle speed when the coast SW is turned off is memorized and the vehicle continues at the new set speed. 4. ACCEL CONTROL During cruise control driving, while the accel SW is turned on, the cruise control actuator pulls the throttle cable to open the throttle valve and increase the driving speed. The vehicle speed when the accel SW is turned off is memorized and the vehicle continues at the new set speed. 5. RESUME CONTROL Unless the vehicle speed falls below the minimum speed limit (Approx. 40km/h, 25mph) after canceling the set speed by the cancel SW, pushing the resume SW will cause the vehicle to resume the speed set before cancellation. 6. MANUAL CANCEL MECHANISM If any of the following operations occurs during cruise control operation, the magnetic clutch of the actuator turns off and the motor rotates to close the throttle valve and the cruise control is released. ∗ Placing the shift lever except D position (Park/Neutral position SW except D position). ”Signal is not input to TERMINAL 3 of the cruise control ECU” (A/T) ∗ Depressing the clutch pedal (Cruise control clutch SW off). ”Signal input to TERMINAL 3 of the cruise control ECU” (M/T) ∗ Depressing the brake pedal (Stop light SW on). ”Signal input to TERMINAL 2 of the cruise control ECU” ∗ Pushing the cancel switch (Cancel SW on). ”Signal input to TERMINAL 10 of the cruise control ECU” ∗ Pushing the cruise switch off ”signal input to TERMINAL 11 of the cruise control ECU”. 7. TAP–UP CONTROL FUNCTION When the difference between the actual vehicle speed and the set speed is less than 5 km/h (3 mph), the set speed can be increased 1.6 km/h (1 mph) each time by operation the RESUME/ACCEL SW quickly within 0.6 seconds. 8. TAP–DOWN CONTROL FUNCTION When the difference between the actual vehicle speed and the set speed is less than 5 km/h (3 mph), the set speed can be lowered 1.6 km/h (1 mph) each time by operating the SET/COAST SW quickly within 0.6 seconds. 9. AUTO CANCEL FUNCTION A) If any of the following operating conditions occurs during cruise control operation, the set speed is erased, the current flow to the magnetic clutch is stopped and the cruise control is released. (Cruise SW turns off). When this occurs, the ignition SW must be turned off once before the cruise SW will turn on. ∗ When current continued to flow to the motor inside the actuator in the throttle valve ”OPEN” direction. ∗ The motor does not operate despite the motor drive signal being output. B) If any of the following operating conditions occurs during cruise control operation, the set speed is erased, the current flow to the magnetic clutch is stopped and the cruise control is released. (Cruise SW turn off). When this occurs, the cancel state is cleared as the cruise SW will turn on again. ∗ Over current to transistor driving the motor and/or the magnetic clutch. ∗ Open circuit in the magnetic clutch. ∗ Momentary interruption of vehicle speed signal. ∗ Short circuit in the cruise control SW. ∗ When the vehicle speed falls more than 16 km/h (10 mph) below the set speed, E.G. on an upward slope. C) If any of the following conditions occurs during cruise control operation, the set speed is erased and the cruise control is released. (The power to the magnetic clutch is cut off until the set SW is ON again.) ∗ When the vehicle speed falls below the minimum speed limit, approx. 40 km/h (25 mph). ∗ When power to the cruise control system is momentarily cut off. D) If any of the following conditions occurs during cruise control operation, the cruise control is released. ∗ Open the circuit for TERMINAL 2 of the stop light SW. 10. AUTOMATIC TRANSAXLE CONTROL FUNCTION ∗ In overdrive. If the vehicle speed becomes lower than the overdrive cut speed (Set speed minus approx. 4 km/h, 2.5 mph) during cruise control operation, such as driving up a hill, the overdrive is released and the power increased to prevent a reduction in vehicle speed. ∗ After releasing the overdrive, vehicle speed becomes higher than the overdrive return speed (Set speed minus approx. 2 km/h, 1.2 mph) and the cruise control ECU judges by the signals from the actuator’s potentiometer that the upward slope has finished, the overdrive is resumed after approximately 2 seconds. ∗ During cruise control driving, the cruise control operation signal is output from the cruise control ECU to the engine control module. Upon receiving this signal, the engine control module changes the shift pattern to normal. To maintain smooth cruise control operation (on a downward slope etc.), the lock–up release of the transmission when the idling point of the throttle position is ON is forbidden. SERVICE HINTS C3 CRUISE CONTROL ACTUATOR 3–4 : Approx. 38.5 Ω C12 CRUISE CONTROL SW [COMB. SW] 5–3 : Continuity with the CRUISE SW on 4–3 : Approx. 418 Ω with the CANCEL SW on Approx. 68 Ω with the RESUME/ACCEL SW on Approx. 198 Ω with the SET/COAST SW on C15 CRUISE CONTROL ECU 9–GROUND : 10–14 volts with the ignition SW at ON position 12–GROUND : 4 pulses with 1 rotation of rotor shaft 10–GROUND : Approx. 418 Ω with the CANCEL SW on in the cruise control SW Approx. 198 Ω with the SET/COAST SW on in the cruise control SW Approx. 68 Ω with the RESUME/ACCEL SW on in the cruise control SW 16–GROUND : Always continuity CRUISE CONTROL : PARTS LOCATION Code See Page C3 Code 26 (1MZ–FE) E7 See Page Code See Page A 30 J21 31 28 (5S–FE) E8 B 30 J24 31 C9 B 30 E9 C 30 J25 31 C10 C 30 E11 E 30 J26 31 C12 30 J2 31 J27 A 31 C14 30 J3 31 J28 B 31 C15 30 D1 D4 J4 31 26 (1MZ–FE) J7 A 31 28 (5S–FE) J8 B 31 30 J11 31 E3 A 26 (1MZ–FE) J12 31 E4 B 28 (1S–FE) J15 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IG2 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) II2 II3 IJ1 : GROUND POINTS Code See Page Ground Points Location IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH J29 P1 S6 V2 31 27 (1MZ–FE) 29 (5S–FE) 31 27 (1MZ–FE) 29 (5S–FE) ∗ 1 : 5S–FE w/ Engine Immobiliser System ∗ 2 : 5S–FE w/o Engine Immobiliser System C3 C9 (B) BLACK (TMC Made)







1 2 3 4 C9 (B) (TMMK Made)




14 15













14 15
C10 (C) C10 (C) C12 (TMC Made) BROWN (TMMK Made) BROWN BLACK



5 6 7

10


C14



5 6 C15 7

10


XX3 4 5
D1 D1 (1MZ–FE) BLACK (5S–FE) BLACK X X
X 2 3 4 5 6 7 8 1 2 X X
9 10 11 12 13 14 15 16 X X
X
X X X
X X X 11 X
X X X X
X X
X X X
X X X 11 X
X X

D4 E3 (A) E4 (B) E7 (A) DARK GRAY GRAY BLACK (∗ 1) 1 X


3








X



X 6 X






18



X X X 10 X X X X X 4
X X E7 (A) E8 (B) E9 (C) (∗ 2) (1MZ–FE) (∗ 1) DARK GRAY

3

X












20





X







X

4 X X X


X


X
X X X
X
X 24
X
X

X
X

21




X

CRUISE CONTROL E9 (C) E11 (E) (5S–FE w/o Engine Immobiliser System) E11 (E) (1MZ–FE Except California) BLACK (1MZ–FE California)




6








X











J2

X

8













X



X







J3 J4 J7 (A) BLACK GRAY


X X


DD DX

B



B B B B

(Hint : See Page 7)

X

8












BLACK







DDD




A A A A A A (Hint : See Page 7)





(Hint : See Page 7) (Hint : See Page 7) J8 (B) J11 GRAY A A A A A A A A A A A J12 J15 BLACK BLACK




CCC






B B





B (Hint : See Page 7) (Hint : See Page 7) A





(Hint : See Page 7) (Hint : See Page 7) J21 J24 J25 J26 A A A

A A A




A
A A


A
A A


A
A A


(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) GRAY J27 (A) J28 (B) J29 A A









A A A A A
















D D







F F (Hint : See Page 7) (Hint : See Page 7) X

(Hint : See Page 7) P1 S6 V2 GRAY BLUE BLACK
2



10 1 3 2 4 1 2 3


MEMO ABS AND TRACTION CONTROL FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 3 60A FL ABS 3 2 ABS MOTOR RELAY 1 W–R 3 GR–R 2 4 GR–L 3 3 1 5 4 GR–R 2 ABS SOL RELAY 3 3 3 GR–L 3 6 GR–R 3 R–L R–L GR 1 A 24 A R+ GND3 MR GND2 9 C 10 C W–B SR 11 A W–B W–L W–B A15 A , A16 B , A17 C ABS AND TRACTION ECU SFRH 13 A SFRR 26 A W–R R–B W–R GR 9 A SFRH 3 A SFRR 4 BS B W–L A7 A , A8 B W–B ABS AND TRACTION ACTUATOR W–B E1 EA W–R W–B E1 W–B E1 W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) 9 1J 7 1C W 15A STOP B–R 15A ECU–IG C G–W 2 J12 JUNCTION CONNECTOR A A 5 1R J27 A , J28 B S6 STOP LIGHT SW C JUNCTION CONNECTOR C B 4 1R G–W 1 B–R G–W R–L R–L A15 A , A16 B , A17 C ABS AND TRACTION ECU 8 B 16 B STP 12 A SFLH 6 A SFLR 5 A SRRR 10 A SRLH 4 A SRLR 7 A SRC1 2 A SRC2 8 A SMC1 1 A SMC2 AST MT 10 A 14 A 5 B AST GND1 15 A W–B R–W SMC2 6 C Y–B SMC1 12 C Y–R SRC2 4 C B–Y SRC1 5 C B–R SRLR 12 A LG–B R–G 11 A SRRH SRLH 25 A G–Y SRRR 7 C W–R SRRH 8 C W–L SFLR 1 C L–B SFLH 2 C R IG1 3 B MT M BM 2 B A7 A , A8 B GND 1 B W–R W–R W–B W–B W–B ABS AND TRACTION ACTUATOR E1 ABS AND TRACTION CONTROL D1 DATA LINK CONNECTOR 1 D4 DATA LINK CONNECTOR 2 (SHORT PIN) 11 B C 12 IK2 23 A 4 B R–L BR C L C C R–L BR R–L L 2 IK1 LG–R R–L 12 IG3 G–B LG–R C G–B J29 JUNCTION CONNECTOR C LG–R B R–Y R–L 5 IK2 E1 3 II3 B 8 IK2 TRC 17 L R–L (* 2) (* 1) LG–R II3 ABS 14 LG–R TC 4 J32 JUNCTION CONNECTOR 5 G–B II3 R–Y 8 TC 11 G–B R–Y (* 2) Y–B (* 1) R–L II3 R–L 4 WA 22 P–B TS 16 J3 JUNCTION CONNECTOR LG–R WB 23 9 A 22 A 12 B A15 A , A16 B , A17 C TS FL+ FL– 5 A 4 A WA TC FR+ 17 A D/G FR– RL+ 18 A ABS AND TRACTION ECU WT RL– 2 B RR+ 1 B 9 B RR– 10 B A9 ABS SPEED SENSOR FRONT LH A10 ABS SPEED SENSOR FRONT RH A25 ABS SPEED SENSOR REAR LH 1 2 A26 ABS SPEED SENSOR REAR RH (*2) W–B IL1 (*2) 3 B IL1 (*1) 1 L(* 2) P IL1 (*2) G B W (* 2) W 2 (*1) BR(*2) (*2) 1 2 (* 1) 1 Y (SHIELDED) 2 (* 1) 1 R G R 2 4 ID1 (*2) 9 ID1 (SHIELDED) G 3 ID1 (* 2) W–B R 6 IK2 B G 1 IK2 W R W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) R–L * 1 : TMC MADE * 2 : TMMK MADE 10A GAUGE C 8 A , C10 C COMBINATION METER 7 C ABS 3 C SLIP 4 C R–L TRAC OFF 2 1D 5 A D L R–L L LG 19 IG3 J4 JUNCTION CONNECTOR D R–L 18 IG3 R–L LG BR J7 A , A15 A , A16 B , A17 C ABS AND TRACTION ECU C A J8 B JUNCTION CONNECTOR 3 B B B EFI+ EFI– 6 B 14 B 13 B 5 B B LG L TRC+ TRC– LG NEO 15 B W CSW 11 B BR–W BR IND W–B(* 2) 4 T5 TRACTION OFF SW W–B II3 1 NEO 14 A 21 A EFI+ 13 A EFI– 20 A TRC+ A B TRC– E 7 A , E 8 B , E10 D J7 A , J8 B ENGINE CONTROL MODULE JUNCTION CONNECTOR BR W–B 16 B A A E2 W–B 18 D VTA1 23 D VC 2 D L Y 8 1J BR 2 3 1 7 1J A IG J22 JUNCTION CONNECTOR A A BR (* 2) W–B A B 6 W–B A B (* 2) W–B (* 2) J11 JUNCTION CONNECTOR T2 THROTTLE POSITION SENSOR EC ABS AND TRACTION CONTROL SYSTEM OUTLINE (ABS) ABS is a brake system designed for the purpose to improve the operating ability securing the stability of the vehicle by preventing the looking–up of the vehicle controlling the wheel cylinder pressure of all the four wheels at the time of sudden braking. 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+, and RR+ of the ABS and traction ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the ABS and traction ECU when brake pedal is depressed. 2. SYSTEM OPERATION When the wheels are to be locked–up, the solenoid inside the actuator will be controlled by the signal from the ABS and traction ECU and the brake fluid in the wheel cylinder will flow through the reservoir and reduce the hydraulic pressure. While the ABS is in operation, as the ABS and traction ECU always outputs the operation signal to the pump inside the actuator, brake fluid stored inside the reservoir will be suctioned up by the pump inside the actuator and returned to the master cylinder. When the hydraulic pressure of the wheel cylinder is decompressed or increased until the necessary hydraulic pressure, the solenoid inside the actuator is controlled by the control signal from the ABS and traction ECU and as a result, hydraulic pressure of the wheel cylinder will be closed at both routes of the master cylinder and reservoir sides and the hydraulic pressure of the wheel cylinder will become to be in the holding condition. If the increase of hydraulic pressure volume of the wheel cylinder becomes necessary, with the control signal from the ABS and traction ECU, the solenoid inside the actuator will be controlled and become the same condition as usual and the brake fluid of the master cylinder will be sent to the wheel cylinder and will increase the hydraulic pressure of the wheel cylinder. At this time, in the case that the brake fluid stays left in the reservoir, it will be sucked up by the pump inside the actuator and will be sent to the wheel cylinder. Also, increasing speed of the hydraulic pressure is controlled by outputting the increasing and the said holding one after another. (Traction control) Traction control system is designed to perform the engine output control by the fuel cut and hydraulic pressure control of driving wheel brake and control the spinning of the driving wheels. By doing this, it improves starting acceleration and operating ability of the vehicle securing the driving ability in accordance with the road surface condition. 3. TRACTION CONTROL OPERATION Estimating the vehicle speed from the rear wheel speed, comparing it with the front, driving wheel speed and judging the grip condition of the driving wheels. From the estimated vehicle speed, target speed of the driving speed will be set. When the front, driving wheel speed exceeds the control starting speed, it judges that the tire slip is occurred and performs the fuel cut cylinder number control and brake control and then adjust to make the front wheel speed become the traction control target speed. Controlling of the traction control will be completed when the vehicle move onto the road where the driving wheels will not have a tire slip or when the driver decelerate. SERVICE HINTS ABS MOTOR RELAY [R/B NO.3] 3–4 : Approx. 62 Ω ABS SOL RELAY [R/B NO.3] 4–6 : Approx. 80 Ω A9, A10 ABS SPEED SENSOR FRONT LH, RH 1–2 : 0.6 kΩ–2.5 kΩ A15 (A), A16 (B), A17 (C) ABS AND TRACTION ECU (B) 8–GROUND : Approx. 12 volts with the ignition SW at ON position (B)11–GROUND : Continuity with the ignition SW on and the traction off SW on (Traction control off) (B)16–GROUND : Approx. 12 volts with the brake pedal depressed (A)15, (C) 9, (C) 10–GROUND : Always continuity A25, A26 ABS SPEED SENSOR REAR LH, RH 1–2 : 1.2 kΩ–2.3 kΩ T2 THROTTLE POSITION SENSOR 1–2 : 3.5 kΩ–5.0 kΩ : PARTS LOCATION Code A7 A8 See Page A 26 (1MZ–FE) B Code C10 See Page C Code See Page 30 J11 31 31 26 (1MZ–FE) D1 26 (1MZ–FE) J12 A9 26 (1MZ–FE) D4 30 J22 A10 26 (1MZ–FE) E7 A 30 J27 A 31 J28 B 31 31 A15 A 30 E8 B 30 A16 B 30 E10 D 30 J29 31 C A17 30 J3 31 J32 31 A25 32 J4 31 S6 31 A26 32 J7 A 31 T2 27 (1MZ–FE) 30 J8 B 31 T5 31 C8 A : RELAY BLOCKS Code 3 See Page 25 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Radiator Upper Support RH) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) II3 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) 42 Floor No.2 Wire and Cowl Wire (Right Kick Panel) IK1 IK2 IL1 : GROUND POINTS Code See Page Ground Points Location EA 36 (1MZ–FE) Right Radiator Side Support EC 36 (1MZ–FE) Surge Tank RH IG 40 Instrument Panel Brace LH : SPLICE POINTS Code E1 See Page 36 (1MZ–FE) Wire Harness with Splice Points Engine Room Main Wire Code See Page Wire Harness with Splice Points ABS AND TRACTION CONTROL A7 (A) A8 (B) A9 A10 BLACK GRAY GRAY GRAY 1 1 2 3 4 5 6 7 8 9 10 11 12 3 1 2 4 2 1 2 5 A15 (A) A16 (B) A17 (C) A25 1 X X 4 5 X X X 9 10 11 12 13 1 2 3 4 5 6 X 8 1 2 X 4 5 6 2 1 14 15 X 17 18 X X X 22 23 24 25 26 9 10 11 12 13 14 15 16 7 8 9 10 X 12 C8 (A) C8 (A) (TMC Made) BLUE (TMMK Made) BLUE A26



5
2 1 C10 (C) C10 (C) (TMMK Made) BROWN X X
X
X X




5 (TMC Made) BROWN

3 4

X X







X 7







3 4

D4 DARK GRAY X X 11 X 16 X X X 17 X X 14 X X X
X X X 22 23 7





E7 (A) D1 BLACK
X






X X 4 3 X X


X X



X
X 13 14




20 21 X E10 (D) E8 (B) E10 (D) X


X X
2 X

J3 (Except California) BLACK (California)









X 2
X


X 16 X X X






X
X





X

X

18



18
X X X

X
X
23
J4 J7 (A) J8 (B) BLACK GRAY GRAY A A A A A A A A A A A A


C C C B B B





X X


DDDX (Hint : See Page 7)

B



B B B B

(Hint : See Page 7)
23
J11 A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J27 (A) J28 (B) A A







C C











(Hint : See Page 7) (Hint : See Page 7) J22 J12 BLACK




CCC



A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) J29








CC C









J32 S6 GRAY BLUE


CC




CC (Hint : See Page 7) (Hint : See Page 7) T5 BLACK 1 X X 4 T2 BLACK 1 2 3 1
2
ABS (TMC MADE) BR FROM POWER SOURCE SYSTEM (SEE PAGE 50) 8 IK2 R–L R–L 1 R–L 3 3 3 E1 (SHORT PIN) ABS 6 3 WB 3 TC 14 4 IK1 TS 11 WA 16 22 II3 8 II3 5 II3 B B LG–R G–B R–Y GR–R GR W–L W–R GR–L 1 J3 JUNCTION CONNECTOR LG–R A TC 11 W–B 3 D1 DATA LINK CONNECTOR 1 23 G–B 4 D4 DATA LINK CONNECTOR 2 3 R–Y 2 II3 LG–R 5 LG–R 4 R–L 1 ABS SOL RELAY ABS MOTOR RELAY 3 3 2 J22 (1MZ–FE) J23 (5S–FE) JUNCTION CONNECTOR A 1 3 GR–R J7 A , BR II3 B A18 A , A19 B 1 A A4 A , A5 B ABS ACTUATOR 4 A E M TS SFLR SFLH 11 A 6 A 5 A SFRR IK2 12 G–Y 2 B SRLR SFRH 1 B 8 B SRLH 4 B SRRR 7 B SRRH 3 B SFLR 10 A R–B IK2 11 IK2 5 B SFLH MT 2 B W–R 12 A R–W SRRH 21 B W–R 13 6 B BS TC G–Y 5 IK2 LG–B W–B 2 A SRRR 15 B LG–B W–L W–R W–B BM EA SRLH 14 B D/G ABS ECU L–B W–B SRLR E1 EC R+ 8 B W–L SR 24 B W–R MR 26 B R–B 7 A R–G 1 A BR 6 4 3 BR B B GR–R 2 JUNCTION CONNECTOR C A J8 B 60A FL ABS 1 B SFRR 3 A SFRH MT FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A GAUGE 15A ECU–IG 9 1J 7 1C W R–L 2 1D 15A STOP D 2 S6 STOP LIGHT SW J4 JUNCTION CONNECTOR R–L D 7 A10 ABS SPEED SENSOR FRONT RH 2 1 R G G–W 1 B–R C10 ABS WARNING LIGHT [COMB. METER] A9 ABS SPEED SENSOR FRONT LH 2 1 1 IK2 6 IK2 4 1R R–L 4 5 1R G–B G–W 12 IG3 A A C 13 B STP RL+ FL+ RL– 9 B J11 JUNCTION CONNECTOR A B 3 A 9 A FR+ FR– RR+ RR– 10 B 23 B 1 2 2 B IL1 1 IL1 B G 9 ID1 G 3 ID1 A25 ABS SPEED SENSOR REAR LH IG 2 A FL– W 22 B R W–B GND 12 B W–B GND2 25 B 8 A 5 B IG1 R WA G–W G–B A18 A , A19 B ABS ECU 11 B G C B C C W J27 A , A28 B JUNCTION CONNECTOR W C J12 JUNCTION CONNECTOR B–R G–B J29 JUNCTION CONNECTOR R C 1 2 A26 ABS SPEED SENSOR REAR RH ABS (TMC MADE) SYSTEM OUTLINE This system controls the respective brake fluid pressures acting on the disc brake cylinders of the right front wheel, left front wheel and rear wheels when the brakes are applied in a panic stop so that the wheels do not lock. This results in improved directional stability and steerability during panic braking. 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+ and RR+ of the ABS ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the ABS ECU when the brake pedal is depressed. 2. SYSTEM OPERATION During sudden braking the ABS ECU has signals input from each sensor, which controls the current to the solenoid inside the actuator and lets the hydraulic pressure acting on each wheel cylinder escape to the reservoir. The pump inside the actuator is also operating at this time and it returns the brake fluid from the reservoir to the master cylinder, thus preventing locking of the vehicle wheels. If the ABS ECU judges that the hydraulic pressure acting on the wheel cylinder is insufficient, the current on the solenoid is controlled and the hydraulic pressure is increased. Holding of the hydraulic pressure is also controlled by the ABS ECU, by the same method as above. Pressure reduction, holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking. SERVICE HINTS A9, A10 ABS SPEED SENSOR FRONT LH, RH 2–1 : 0.6 kΩ–2.5 kΩ A25, A26 ABS SPEED SENSOR REAR LH, RH 2–1 : 1.2 kΩ–2.3 kΩ A18 (A), A19 (B) ABS ECU (Connect the ABS ECU connectors) (B)21–GROUND : Approx. 12 volts with the ignition SW at ON position and the data link connector 1 TS–E1, TC–E1 not connected (B) 8–GROUND : Approx. 12 volts with the ignition SW at ON position and the data link connector 1 TS–E1, TC–E1 not connected (B)13–GROUND : Approx. 12 volts with the ignition SW at ON position (B) 5–GROUND : Approx. 12 volts with the brake pedal depressed (B)12, (B) 25–GROUND : Always continuity : PARTS LOCATION Code A4 See Page A A5 Code 26 (1MZ–FE) B 31 28 (5S–FE) A26 32 J12 31 26 (1MZ–FE) C10 30 J22 31 26 (1MZ–FE) J23 D1 28 (5S–FE) J27 J28 B 31 D4 30 J3 31 J29 31 28 (5S–FE) J4 31 S6 31 30 J7 A 31 A19 B 30 J8 B 31 : RELAY BLOCKS See Page 25 31 26 (1MZ–FE) A 3 31 A 28 (5S–FE) A18 Code See Page J11 26 (1MZ–FE) A10 Code 32 28 (5S–FE) A9 See Page A25 Relay Blocks (Relay Block Location) Engine Room R/B No.3 (Radiator Upper Support RH) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) II3 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) 42 Floor No.2 Wire and Cowl Wire (Right Kick Panel) IK1 IK2 IL1 : GROUND POINTS Code See Page 36 (1MZ–FE) EA 38 (5S–FE) EC IG Ground Points Location Right Radiator Side Support 36 (1MZ–FE) Surge Tank RH 38 (5S–FE) Intake Manifold 40 Instrument Panel Brace LH : SPLICE POINTS Code See Page E1 36 (1MZ–FE) Wire Harness with Splice Points Code Engine Room Main Wire E1 See Page 38 (5S–FE) A4 (A) A5 (B) A9 A10 GRAY BLACK GRAY GARY 1 1 1 3 4 2 1 2 3 4 X 5 6 7 8 A19 (B) 1 2 X X 5 X X 8 9 10 11 12 13 14 15 X X X X X 21 22 23 24 25 26 2 Wire Harness with Splice Points Engine Room Main Wire A18 (A) 1 2 3 X 5 6 2 7 8 9 10 11 12 A25 A26 2 1 2 1 C10 BROWN


4

7





ABS (TMC MADE) D1 (1MZ–FE) BLACK X X
X X

X X X
X
X X X X X 16 X X
X X X X
X X X 11 X 16 X X X
X 22 23 X 14 X X X
X X X 22 23 X X 4 3 X X J4 J7 (A) J8 (B) BLACK GRAY GRAY














C C C B B B


(Hint : See Page 7) (Hint : See Page 7) J3

B



B B B B

D4 DARK GRAY X
X X X 11 D1 (5S–FE) BLACK


X X


DDDX (Hint : See Page 7) (Hint : See Page 7) J12 J11 J22 J23 BLACK A A A A A




CCC



A A A A A A A A A A A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J27 (A) J28 (B) J29 S6 BLUE A A







C C











(Hint : See Page 7) (Hint : See Page 7)








CC C









(Hint : See Page 7) 1
2
MEMO ABS (TMMK MADE) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 1 15A STOP 10A GAUGE 15A ECU–IG 60A FL ABS 2 9 1J R–L W D C J4 JUNCTION CONNECTOR J12 JUNCTION CONNECTOR C R–L 4 1 12 IG3 L B–R 5 IK3 R–L J29 JUNCTION CONNECTOR L S6 STOP LIGHT SW 7 B–R C10 ABS WARNING LIGHT [COMB. METER] R–L D 2 G–W 3 B–R 2 1D 7 1C C C R–L R–L 15 C 17 IG1 18 +B +B A6 ABS ACTUATOR AND ECU 4 1R WA STP FL+ FL– FR+ FR– 21 14 7 6 5 4 (SHIELDED) G R G–W R–L R–L 5 1R (SHIELDED) E2 10 IK3 1 IK3 1 IK2 6 IK2 13 IK2 A A B W G (SHIELDED) R G–W G–W (SHIELDED) C B J27 A , J28 B JUNCTION CONNECTOR 2 1 A9 ABS SPEED SENSOR FRONT LH 2 1 A10 ABS SPEED SENSOR FRONT RH W–B D4 DATA LINK CONNECTOR 2 D1 DATA LINK CONNECTOR 1 * 1 : 5S–FE * 2 : 1MZ–FE TC TS 11 II3 (* 2) R–Y (* 1) 16 P–B 11 LG–R BR E1 3 LG–R TC 4 R–L ABS 14 8 II3 C A B B J7 A , LG–R J8 B JUNCTION CONNECTOR BR J3 JUNCTION CONNECTOR R–Y LG–R B B B 6 IK2 BR 5 J22 (1MZ–FE) J23 (5S–FE) JUNCTION CONNECTOR R–Y LG–R 12 IK2 II3 R–L A A 11 TS RL– RR+ RR– 9 8 2 1 L P Y BR RL+ W–B GND2 16 W–B GND1 19 12 TC A6 ABS ACTUATOR AND ECU (SHIELDED) (SHIELDED) (SHIELDED) (SHIELDED) 9 ID1 Y BR 3 ID1 IK3 7 IK3 2 IK3 4 ID1 3 IL1 6 IK3 (SHIELDED) 2 IL1 1 (SHIELDED) 1 EA BR 8 L IK3 IL1 L 9 P IK3 Y 3 P E1 (SHIELDED) E1 W–B (SHIELDED) W–B BR E1 W–B W–B (SHIELDED) 2 A25 ABS SPEED SENSOR REAR LH 1 2 A26 ABS SPEED SENSOR REAR RH EC ABS (TMMK MADE) SYSTEM OUTLINE This system controls the respective brake fluid pressures acting on the disc brake cylinders of the right front wheel, left front wheel and rear wheels when the brakes are applied in a panic stop so that the wheels do not lock. This results in improved directional stability and steerability during panic braking. 1. INPUT SIGNALS (1) Speed sensor signal The speed of the wheels is detected and input to TERMINALS FL+, FR+, RL+ and RR+ of the ABS actuator and ECU. (2) Stop light SW signal A signal is input to TERMINAL STP of the ABS actuator and ECU when the brake pedal is depressed. 2. SYSTEM OPERATION During sudden braking the ABS actuator and ECU has signals input from each sensor, which controls the current to the solenoid inside the actuator and lets the hydraulic pressure acting on each wheel cylinder escape to the reservoir. The pump inside the actuator is also operating at this time and it returns the brake fluid from the reservoir to the master cylinder, thus preventing locking of the vehicle wheels. If the ABS actuator and ECU judges that the hydraulic pressure acting on the wheel cylinder is insufficient, the current on the solenoid is controlled and the hydraulic pressure is increased. Holding of the hydraulic pressure is also controlled by the ABS actuator and ECU, by the same method as above. Pressure reduction, holding and increase are repeated to maintain vehicle stability and to improve steerability during sudden braking. SERVICE HINTS A9, A10 ABS SPEED SENSOR FRONT LH, RH 2–1 : Approx. 1.6 kΩ A25, A26 ABS SPEED SENSOR REAR LH, RH 2–1 : Approx. 1.6 kΩ A6 ABS ACTUATOR AND ECU (Connect the ABS actuator and ECU connectors) 12–GROUND : Approx. 12 volts with the ignition SW at ON position and the data link connector 1 TS–E1, TC–E1 not connected 11–GROUND : Approx. 12 volts with the ignition SW at ON position and the data link connector 1 TS–E1, TC–E1 not connected 16, 19–GROUND : Always continuity 15–GROUND : Approx. 12 volts with the ignition SW at ON position 14–GROUND : Approx. 12 volts with the brake pedal depressed 17, 18–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page Code 26 (1MZ–FE) A6 28 (5S–FE) D1 26 (1MZ–FE) A9 A10 See Page C10 Code See Page 30 J12 31 26 (1MZ–FE) J22 31 28 (5S–FE) J23 31 28 (5S–FE) D4 30 J27 A 31 26 (1MZ–FE) J3 31 J28 B 31 31 J29 31 A25 28 (5S–FE) 32 J7 J4 A 31 S6 31 A26 32 J8 B 31 : RELAY BLOCKS Code 3 See Page 25 Relay Blocks (Relay Block Location) Fusible Link Block (Radiator Upper Support RH) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1C 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1D 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1J 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IG3 40 Instrument Panel Wire and Cowl Wire (Under the Blower Motor) II3 42 Engine Wire and Cowl Wire (Under the Blower Motor) IK2 42 IK3 42 IL1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) Floor No.2 Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code EA EC See Page Ground Points Location 36 (1MZ–FE) Right Radiator Side Support 38 (5S–FE) 36 (1MZ–FE) Surge Tank RH 38 (5S–FE) Intake Manifold : SPLICE POINTS Code E1 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Engine Room Main Wire E2 38 (5S–FE) Wire Harness with Splice Points Engine Room Main Wire A6 A9 A10 GRAY GRAY X X X X X 21 X 19 18 A26 2 1 See Page 36 (1MZ–FE) BLACK 15 14 X 12 11 X 9 8 7 6 5 4 X 2 1 X X X X X Code 17 1 2 2 1 2 16 C10 D1 BROWN


4

1 A25 7





(1MZ–FE) BLACK X X
X X
X
X X X
X X X 11 X 16 X X X

ABS (TMMK MADE) D1 D4 (5S–FE) BLACK DARK GRAY X X
X X
X
X X X
X X X 11 X 16 X X J3

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B B B B

X
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X 14 X X X
X X X (Hint : See Page 7) X X 4 3 X X J4 J7 (A) J8 (B) J12 BLACK GRAY GRAY BLACK


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C C C B B B


(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J22 J23 A A A A A A A A A A A (Hint : See Page 7) A A A A A A A A A A A (Hint : See Page 7) J29 S6 BLUE








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(Hint : See Page 7) 1
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(Hint : See Page 7) J27 (A) J28 (B) A A







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(Hint : See Page 7) (Hint : See Page 7) SRS NOTICE: When inspecting or repairing the SRS, perform the operation in accordance with the following precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model year.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Work must be started after 90 seconds from when the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)
When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back–up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, center airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly directly to hot air or flames.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, center airbag sensor assembly, front airbag sensor assembly and side airbag sensor assembly should be inspected.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, center airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, seat belt pretensioner, center airbag sensor assembly, front airbag sensor assembly or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check.
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section of the Repair Manual. SRS FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A CIG 2 1N 7 2J 26 B 15 B 6 B 20 B 9 B 7 A 3 9 A 4 10 A (* 3) GR–L 2 (* 3) 2 IU1 1 LG–B B–W 1 IU1 B–W IT1 W–R S7 SIDE AIRBAG SENSOR LH (* 3) GR 1 2 1G A BR–W 2 W–R 5 B IT1 BR 1 B 3 1W W–R CONNECTION DETECTION PIN 2 BR–W BR 1 A CONNECTION DETECTION PIN 2 W–R B–O B A32 AIRBAG SENSOR FRONT RH (* 3) A31 AIRBAG SENSOR FRONT LH P–L 4 1N 10A ECU–B L–W 5A IGN 12 A C17 A , C18 B , C19 C Y Y–R Y–G 1 BV1 3 1V SPIRAL CABLE W–B W–B 1 A J11 JUNCTION CONNECTOR IG IE Y–G Y–R 2 A23 AIRBAG SQUIB (STEERING WHEEL PAD) 2 A22 AIRBAG SQUIB (FRONT PASSENGER AIRBAG ASSEMBLY) 1 2 S9 SIDE AIRBAG SQUIB LH (* 2 *3) 3 1N 1 7 1J 2 BV1 (* 2 *3) 1 1N Y–G Y–B 6 A (*2 * 3) W–B 5 A Y–R 11 B (* 1 * 3) 10 B (* 1 * 3) 13 B Y–R 14 B Y–R 28 B (*2 * 3) 27 B W–B CENTER AIRBAG SENSOR ASSEMBLY D1 DATA LINK CONNECTOR 1 AB TC E1 BR (* 4) 3 P–B (* 4) LG–R 11 B–Y LG 5 (* 5) * 4 : TMMK MADE 1MZ–FE * 5 : EXCEPT * 4 (* 5) * 1 : TMC MADE * 2 : TMMK MADE * 3 : W/ SIDE AIRBAG W–R 1 2 3 II3 11 LG LG 13 7 II3 LG–R C9 SRS WARNING LIGHT [COMB. METER] 12 S8 SIDE AIRBAG SENSOR RH 4 2 IG2 J3 JUNCTION CONNECTOR B A B 10 C 9 C 7 C 3 B 19 B LG–R P–B 12 C B B–Y A D4 DATA LINK CONNECTOR 2 GR LG (* 3) LG (* 3) (* 3) L–Y (* 3) P A C17 A , C18 B , C19 C 4 TC E1 3 BR BR B B W Y–G (* 2 * 3) Y–R C (* 2 * 3) J8 B W 2 BW1 6 2 1 2 P24 PRETENSIONER LH S10 SIDE AIRBAG SQUIB RH P25 PRETENSIONER RH II3 7 BR 1 D5 DATA LINK CONNECTOR 3 2 SIL 1 J22 (1MZ–FE) J23 (5S–FE) JUNCTION CONNECTOR BR 1 BW1 C A A A A BR Y L–B(*2) Y–B(* 1) C J7 A , 12 B JUNCTION CONNECTOR 6 C J3 JUNCTION CONNECTOR 5 C Y Y–G (* 2 * 3) Y–G (* 1 * 3) 1 C (* 1 * 3) Y–R 2 C Y–R 1 A (* 2 * 3) 2 A Y–B CENTER AIRBAG SENSOR ASSEMBLY EC SRS SYSTEM OUTLINE The SRS is a driver and front passenger protection device which has a supplemental role to the seat belts. When the ignition SW is turned to ACC or ON, current from the CIG fuse flows to TERMINAL (B) 6 of the center airbag sensor assembly. Only when the ignition SW is on does the current flow from the IGN fuse to TERMINAL (B) 5 of the center airbag sensor assembly. If an accident occurs while driving, when the frontal impact exceeds a set level, current from the CIG or IGN fuse flows to TERMINALS (B) 14, (B) 10, (A) 2 and (C) 5 of the center airbag sensor assembly to TERMINAL 1 of the airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (B) 13, (B) 11, (A) 1 and (C) 6 of the center airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, so that current flows to the front airbag squibs and the pretensioners and causes them to operate. When the side impact also exceeds a set level, current from the CIG or IGN fuse flows to TERMINALS (A) 5, (C) 2, (A) 2 and (C) 5 of the center airbag sensor assembly to TERMINAL 1 of the side airbag squibs and the pretensioners to TERMINAL 2 to TERMINALS (A) 6, (C) 1, (A) 1 and (C) 6 of the center airbag sensor assembly to TERMINAL (B) 27, (B) 28 or BODY GROUND to GROUND, causing side airbag squibs and the pretensioners to operate. The airbag stored inside the steering wheel pad is instantaneously expanded to soften the shock to the driver. The airbag stored inside the passenger’s instrument panel is instantaneously expanded to soften the shock to the front passenger. Side airbags are instantaneously expanded to soften the shock of side to the driver and front passenger. The pretensioners make sure of the seat belt restrainability. : PARTS LOCATION Code See Page Code See Page Code See Page A22 30 D4 30 P24 33 A23 30 D5 30 P25 33 C9 30 J3 31 S7 33 C17 A 30 J7 A 31 S8 33 C18 B 30 J8 B 31 S9 34 C19 C 30 J11 31 S10 34 26 (1MZ–FE) J22 31 28 (5S–FE) J23 31 D1 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1G See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1J 1N 1V 1W 2J : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IG2 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) II3 42 Engine Wire and Cowl Wire (Under the Blower Motor) IT1 42 Cowl Wire and Cowl Wire (Left Kick Panel) IU1 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) BV1 46 Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) BW1 46 Floor No.2 Wire and Seat No.2 Wire (Under the Front Passenger’s Seat) : GROUND POINTS Code See Page Ground Points Location 36 (1MZ–FE) Surge Tank RH 38 (5S–FE) Intake Manifold IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH EC A22 A23 A31 A32 YELLOW YELLOW YELLOW YELLOW 1 1 2 1 2 2 1 2 C9 C9 C17 (A) (TMC Made) (TMMK Made) YELLOW







A


12 13













12 13


B 1 2 XX5 6 7 X 9 10 X 12 C18 (B) C19 (C) D1 YELLOW YELLOW (1MZ–FE) BLACK A A B X X 3 X 5 6 B X X 3 1 2 XX5 6 X X 9 10 11 12 13 14 15 X X 7 X 9 10 X 12
X X D1 D4 (5S–FE) BLACK DARK GRAY X X X 11 X
X X X X 11 X X
X X

D5 X X
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X X 19 20 X X X X X 26 27 28 X X 3 X X J3 A A B C C A A B B B B C C
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C C C B B B


J11 A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) SRS J22 J23 A A A A A A A A A A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) S9 S10 YELLOW YELLOW 1 2 1 2 P24 P25 S7 S8 YELLOW YELLOW YELLOW YELLOW 1 2 1 2 1 2 3 4 1 2 3 4 MEMO SHIFT LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A CIG 15A ECU–IG 8 1D 7 1C W 1 1T 15A STOP P–L B–R 2 S6 STOP LIGHT SW C A C 1 J16 JUNCTION CONNECTOR 4 1R P–L B–R A G–W J6 JUNCTION CONNECTOR G–W 2 1H 1 3 ACC S3 SHIFT LOCK ECU IG 6 SHIFT LOCK CONTROL SW STP P1 P P2 SLS– G–R 3 G 2 G–W 1 L SHIFT LOCK SOLENOID SLS+ KLS+ E 5 W–B L–B 4 L–B 5 IG1 A J5 JUNCTION CONNECTOR 2 K3 KEY INTERLOCK SOLENOID W–B W–B A 8 1J 7 1J W–B W–B 1 A A J11 JUNCTION CONNECTOR A J7 JUNCTION CONNECTOR IG IF L–R 2 1 SYSTEM OUTLINE When the ignition SW is turned to ACC position the current from the CIG fuse flows to TERMINAL 1 of the shift lock ECU, in the ON position, the current from the ECU–IG fuse flows to TERMINAL 3 of the ECU. 1. SHIFT LOCK MECHANISM With the ignition SW on, when a signal that the brake pedal is depressed (Stop light SW on) and a signal that the shift lever is put in P position (Continuity between P1 and P of the shift lock control SW) is input to the shift lock ECU, the ECU operates and current flows from TERMINAL 3 of the ECU to TERMINAL SLS+ of the shift lock solenoid to solenoid to TERMINAL SLS– to TERMINAL 5 of the ECU to GROUND. This causes the shift lock solenoid to turn on (Plate stopper disengages) and the shift lever can shift into position other than the P. 2. KEY INTERLOCK MECHANISM With the ignition SW ON or ACC position, when the shift lever is put in P position (No continuity between P2 and P of shift lock control SW), the current flowing from TERMINAL 4 of the shift lock ECU to the key interlock solenoid is cut off. This causes the key interlock solenoid to turn off (Lock lever disengages from LOCK position) and the ignition key can be turned from ACC to LOCK position. SERVICE HINTS S3 SHIFT LOCK ECU 1–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 3–GROUND : Approx. 12 volts with the ignition SW at ON position 5–GROUND : Always continuity 6–GROUND : Approx. 12 volts with the brake pedal depressed S6 STOP LIGHT SW 2–1 : Closed with the brake pedal depressed : PARTS LOCATION Code See Page Code See Page Code See Page J5 31 J11 31 S3 31 J6 31 J16 31 S6 31 J7 31 K3 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1C 1D 1H 1J 1R 1T See Page Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code IG1 See Page 40 Joining Wire Harness and Wire Harness (Connector Location) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) : GROUND POINTS Code See Page Ground Points Location IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH SHIFT LOCK J5 J6 J7 A A A A A
















A A A A A A A A A A A A A A A A A A A A (Hint : See Page 7) J16 K3 BLACK



C C 1 2 (Hint : See Page 7) S6 S3 BLUE 1X3 4 5 6 A A A A (Hint : See Page 7) (Hint : See Page 7) BLACK A





(Hint : See Page 7)





J11 GRAY ORANGE 1
2
MEMO HORN FROM POWER SOURCE SYSTEM (SEE PAGE 50) 10A HORN 1 5 2 3 10 2K 1 2F G–B G–W HORN RELAY J2 JUNCTION CONNECTOR C G–B G–W C 6 C12 HORN SW [COMB. SW] G–W 1 H5 HORN (HIGH) 1 H6 HORN (LOW) SERVICE HINTS HORN RELAY [ENGINE ROOM J/B NO.2] 5–3 : Closed with the horn SW on : PARTS LOCATION Code See Page Code See Page Code See Page C12 30 H5 28 (5S–FE) H6 28 (5S–FE) H5 26 (1MZ–FE) H6 26 (1MZ–FE) J2 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 2F 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2K 22 Cowl Wire And Engine Room J/B No.2 (Engine Compartment Left) C12 H5 H6 J2 BLACK BLACK BLACK BLACK 1 XX


6 1




CCC



(Hint : See Page 7) CIGARETTE LIGHTER AND CLOCK FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A CIG 7. 5A PANEL 1 1T 5 1D 12 2J G R 6 1J 7. 5A DOME P–L 1 1W A A J30 A , J31 B R–Y P–L A B 8 1G JUNCTION CONNECTOR 1 A D10 DIODE (DOME) J6 JUNCTION CONNECTOR 2 R A D B E A G J16 A , J17 B R JUNCTION CONNECTOR C4 CIGARETTE LIGHTER 1 P–L 2 3 1 C6 CLOCK 2 W–B W–B 4 A J5 JUNCTION CONNECTOR W–B A A J11 JUNCTION CONNECTOR IG IF SERVICE HINTS C4 CIGARETTE LIGHTER 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1–GROUND : Always continuity C6 CLOCK 4–GROUND : 1–GROUND : 2–GROUND : 3–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position Always approx. 12 volts Always continuity Approx. 12 volts with the light control SW at TAIL or HEAD position : PARTS LOCATION Code See Page C4 30 Code See Page J6 J11 Code See Page 31 J30 A 31 31 J31 B 31 C6 30 D10 30 J16 A 31 J5 31 J17 B 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page 1D 1G Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1T 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) : GROUND POINTS Code See Page Ground Points Location IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH C4 C6 D10 J5 BLACK BLACK ORANGE J6 1 1 2 2 1 2 3 4 A A A A A
















A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) J11 A A J16 (A) J17 (B) J30 (A) BLACK BLACK GRAY











A A A A A A


E E E D D D








(Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) A A A A (Hint : See Page 7) J31 (B) GRAY A A A A A A





(Hint : See Page 7) KEY REMINDER AND SEAT BELT WARNING FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : W/ POWER SEAT 10A GAUGE R–L D D R–L 7. 5A DOME 2 1D 12 2J J4 JUNCTION CONNECTOR 7 C C 8 A , C10 C R SEAT BELT WARNING LIGHT [COMB. METER] R–W 4 A 1 1W 3 1T 9 INTEGRATION RELAY 7 1 BUZZER 6 8 7 1S 4 1S W–B R–Y 2 (* 1) R–Y 3 BQ1 1 3 1M 1 1 D12 DOOR COURTESY SW FRONT LH B7 BUCKLE SW LH 2 B6 BUCKLE SW LH 2 W–B (* 1) W–B 7 1J A IG J11 JUNCTION CONNECTOR (* 1) W–B W–B 1 BQ1 A J40 JUNCTION CONNECTOR A BL (W/O POWER SEAT) U1 UNLOCK WARNING SW (W/O POWER SEAT) R–Y R–G 1 (* 1) 5 5 1M L–B 10 SYSTEM OUTLINE Current always flows to TERMINAL 1 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 7 of the integration relay. At the same time, current flows to TERMINAL 9 of the relay from the GAUGE fuse through the seat belt warning light. This current activates the relay and the current flowing through the warning light flows from TERMINAL 9 of the relay to TERMINAL 10 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL 8 of the relay to TERMINAL 10 to GROUND, causing the warning light to light up. A buckle SW off signal is input to TERMINAL 8 of the relay, the current flowing to TERMINAL 1 of the relay flows from TERMINAL 10 to GROUND and the seat belt warning buzzer sounds for approx. 6 seconds. However, if the seat belt is put on during this period (While the buzzer is sounding), signal input to TERMINAL 8 of the relay stops and the current flow from TERMINAL 1 of the relay to TERMINAL 10 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the ignition key inserted in the key cylinder (Unlock warning SW on), the ignition SW still off and driver’s door open (Door courtesy SW on), when a signal is input to TERMINAL 6 of the integration relay, the relay operates, current flows from TERMINAL 1 of the relay to TERMINAL 10 to GROUND and key reminder buzzer sounds. SERVICE HINTS B6, B7 BUCKLE SW LH 1–2 : Closed with driver’s seat belt in use D12 DOOR COURTESY SW FRONT LH 1–GROUND : Closed with front LH door open U1 UNLOCK WARNING SW 1–2 : Closed with ignition key in cylinder INTEGRATION RELAY [INSTRUMENT PANEL J/B] 10–GROUND : Always continuity 6–GROUND : Continuity with the driver’s door open 5–GROUND : Continuity with the ignition key in cylinder 8–GROUND : Continuity with the driver’s seat belt in use 1–GROUND : Always approx. 12 volts : PARTS LOCATION Code See Page B6 32 B7 C8 A Code C10 See Page C 1D 31 34 D12 32 J40 32 30 J4 31 U1 31 See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1S 20 Floor Wire and Instrument Panel J/B (Lower Finish Panel) 1T 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1J 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code BQ1 See Page 46 See Page J11 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code Code 30 Joining Wire Harness and Wire Harness (Connector Location) Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) KEY REMINDER AND SEAT BELT WARNING : GROUND POINTS Code See Page Ground Points Location IG 40 Instrument Panel Brace LH BL 44 Under the Left Center Pillar B6 C8 (A) B7 C8 (A) (TMC Made) BLUE 1 2


4

1 2









4

C10 (C) C10 (C) D12 (TMMK Made) BROWN (TMC Made) BROWN





(TMMK Made) BLUE 1 7











J11 J4 7





J40 U1 BLACK


X X


DDDX A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) 1 2






MEMO POWER OUTLET FROM POWER SOURCE SYSTEM (SEE PAGE 50) 15A POWER– OUTLET V 5 1J 2 P4 POWER OUTLET W–B 1 4 1V W–B 3 1V IE SERVICE HINTS P4 POWER OUTLET 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 1–GROUND : Always continuity : PARTS LOCATION Code See Page P4 Code See Page 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1J 1V See Page 20 Junction Block and Wire Harness (Connector Location) Cowl Wire and Instrument Panel J/B (Lower Finish Panel) : GROUND POINTS Code IE See Page 40 P4 ORANGE 1 2 Ground Points Location Cowl Side Panel LH Code See Page REMOTE CONTROL MIRROR FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : TMMK MADE * 2 : TMC MADE W/ MIRROR HEATER * 3 : TMC MADE W/O MIRROR HEATER 15A CIG P–L 1 1T A J6 JUNCTION CONNECTOR P–L A R6 REMOTE CONTROL MIRROR SW 9 M M LG–R BR–R LG–B LG–R 14 IM1 15 IM1 2 A (*1) 3 B (*2) 2 C (*3) 1 A 4 B 3 C 3 A 2 B 1 C M M R16 A , B , C R17 A , B , C REMOTE CONTROL MIRROR LH REMOTE CONTROL MIRROR RH LG–R 3 A 2 B 1 C 16 IM1 LG–B 1 A 4 B 3 C 15 IE1 BR–R BR–Y IE1 BR–W 14 LG–R BR–Y C OPERATION SW SELECT SW E 6 10 W–B LG–B J4 JUNCTION CONNECTOR C C M+ A J5 JUNCTION CONNECTOR A W–B 7 BR–Y VR 1 BR–R VL 8 BR–W HR 5 16 IE1 RIGHT/ DOWN LEFT/ UP MV LG–R MH HL DOWN UP LEFT RIGHT B 2 A (* 1) 3 B (* 2) 2 C (* 3) IF SERVICE HINTS R6 REMOTE CONTROL MIRROR SW 9–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 6–10 : Continuity with the operation SW at UP or LEFT position 9–6 : Continuity with the operation SW at DOWN or RIGHT position : PARTS LOCATION Code See Page J4 31 J5 31 J6 31 R6 31 Code R16 R17 See Page A 33 B 33 C 33 A 33 Code R17 See Page B 33 C 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page 1T 20 Junction Block and Wire Harness (Connector Location) Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page IF 40 Ground Points Location Left Kick Panel J4 J5 BLACK ORANGE


X X CCC


X (Hint : See Page 7) J6 A A A A A
















A A A A A A A A A A A A A R6 1
5 6 7 X X 8 9 10 (Hint : See Page 7) (Hint : See Page 7) R16 (A), R17 (A) R16 (A), R17 (A) R16 (B), R17 (B) R16 (C), R17 (C) (TMMK Made w/ Mirror Heater) (TMMK Made w/o Mirror Heater) (TMC Made w/ Mirror Heater) (TMC Made w/o Mirror Heater) 3 2 1
X

234
1 2 3 1 2 3 REAR WINDOW DEFOGGER AND MIRROR HEATER FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 3 : AUTOMATIC A/C * 4 : MANUAL A/C * 1 : TMC MADE * 2 : TMMK MADE 1 10A HEATER 40A DEF 10A MIRROR– HEATER 2 1 5 NOISE FILTER 2 DEFOGGER RELAY 4 1D 7 1J W–B B–Y B 5 1T B–Y 1 1L L–B 3 13 1J (*3) Y–G Y–G 12 1J (*4) 3 1R L–B 1 2 5 IE1 5 IM1 A IG (* 1) W–B (*2) R17 A , W–B 7 1G W–B 1 B A J11 JUNCTION CONNECTOR 20 IM1 3 1V W–B N2 NOISE FILTER (REAR WINDOW DEFOGGER) A W–B REAR WINDOW DEFOGGER A (*1) W–B W–B A 20 IE1 B R5 REAR WINDOW DEFOGGER SW J39 JUNCTION CONNECTOR A 1 A (W/ AUTO ANTENNA) (* 4) W–B 3 R14 A , R15 B TIMER CIRCUIT REAR WINDOW DEFOGGER 1 5 A (*1) 4 B (*2) (*2) B R16 A , J38 JUNCTION CONNECTOR B (W/ AUTO ANTENNA) B 5 (W/O AUTO ANTENNA) 4 5 A (*1) 4 B (*2) (* 1) (* 4) L–B A34 A/C CONTROL ASSEMBLY 1 A (*1) 6 B (*2) B 1 A (*1) 6 B (*2) RDFG W–B 8 ID1 23 A MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] W–B B–Y A (*1) J32 JUNCTION CONNECTOR MIRROR HEATER LH [REMOTE CONTROL MIRROR LH] W–B B–Y A W–B BO IE IJ SERVICE HINTS DEFOGGER RELAY [INSTRUMENT PANEL J/B] 5–3 : Closed with the ignition SW on and the rear window defogger SW on R5 REAR WINDOW DEFOGGER SW 4–GROUND : Approx. 12 volts with the ignition SW on 3–GROUND : Always continuity 5–GROUND : Continuity with the rear window defogger SW on and approx. 15 minutes thereafter R16 (A), (B), R17 (A), (B) MIRROR HEATER LH, RH [REMOTE CONTROL MIRROR LH, RH] (A)1, (B) 6–GROUND : Approx. 12 volts with the rear window defogger SW on (A)5, (B) 4–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page A34 30 N2 33 J11 31 R5 31 J32 31 R14 A 33 J38 32 R15 B 33 J39 32 R16 A 33 Code R16 R17 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 1T 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1V 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1G 1J 1L 1R : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) ID1 40 Floor Wire and Cowl Wire (Left Kick Panel) IE1 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location IE 40 Cowl Side Panel LH IG 40 Instrument Panel Brace LH IJ 40 Right Kick Panel BO 44 Right Quarter Pillar See Page B 33 A 33 B 33 REAR WINDOW DEFOGGER AND MIRROR HEATER A34 J11 J32 J38 GRAY A



X







A






X X 23 X X
A A A A A


A A




A A A

A A A



(Hint : See Page 7) (Hint : See Page 7) A (Hint : See Page 7) J39 A A A X X A A A X X X X N2 R5 R14 (A) R15 (B) R16 (A) BLACK BLACK BLACK (TMC Made) 1 1


5 1 X 1 (Hint : See Page 7) 3 4 5
R16 (B) R17 (A) R17 (B) (TMMK Made) (TMC Made) (TMMK Made)


6 X 4 1


5



6 X 4 MEMO AUTO ANTENNA FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 1 : BUILT–IN TYPE AMPLIFIER * 2 : SEPARATE TYPE AMPLIFIER 20A RADIO NO. 1 15A ECU–IG 3 1H 8 1D L–Y 11 2K 7. 5A RAD– NO. 2 5 1W R3 RADIO AND PLAYER L–Y 6 1G 4 (* 1) GR 3 B–R B–R (* 2) 3 IH1 GR (* 2) B A A A A A ANT+B S4 A , S5 B STEREO COMPONENT AMPLIFIER 7 L–Y A +B (* 2) 4 IH1 L–Y B A 8 (* 1) ACC+B GR (* 2) 2 B ACC C A R4 RADIO AND PLAYER J16 A , J17 B JUNCTION CONNECTOR B–R B–R 3 IN1 1 IN1 B–R B–R 2 5 4 ACC IG 8 (* 2) E A27 AUTO ANTENNA MOTOR AND RELAY ANT+B ANT 6 W–B B6 W–B +B R–B (*1) GR 4 IN1 GR (* 2) 5 IN1 3 8 IH1 B–R A B L–Y C B L–Y B B IK W–B GR (*1) GR (*1) L–Y L–Y (* 1) +B BN SERVICE HINTS A27 AUTO ANTENNA MOTOR AND RELAY 3–GROUND : Always approx. 12 volts 5–GROUND : Approx. 12 volts with the ignition SW at ON position 2–GROUND : Approx. 12 volts with the ignition SW at ACC or ON position 6–GROUND : Always continuity : PARTS LOCATION Code See Page A27 Code See Page 32 R3 31 R4 31 J16 A 31 J17 B 31 S4 A Code See Page S5 B 31 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1D 1G 20 Instrument Panel Wire and Instrument Panel J/B (Lower ( Finish Panel)) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2K 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IH1 40 Instrument Panel Wire and Instrument Panel No.2 Wire (Instrument Panel Brace RH) IN1 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location IK 40 Right Kick Panel BN 44 Under the Right Center Pillar : SPLICE POINTS Code See Page B6 44 Wire Harness with Splice Points Code See Page Wire Harness with Splice Points Floor No.2 Wire A27 J16 (A) J17 (B) BLACK BLACK A A B B C C A A B B C C











(Hint : See Page 7) (Hint : See Page 7) R3

X 3 4 2 5 6 R4



8
X


S4 (A)




3 4


8 X
S5 (B)



X X 7



X
X X X
2



X X





RADIO AND PLAYER (SEPARATE TYPE AMPLIFIER) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 20A RADIO NO. 1 7. 5A RAD–NO. 2 B–R 3 1H 1 IN1 5 1W ANT A27 AUTO ANTENNA MOTOR AND RELAY B–R L–Y 11 2K 4 R–B GR 8 IH1 6 1G R4 RADIO AND PLAYER ANT+B GND BEEP RL 13 RR 14 15 G 12 Y 7 12 B 5 B 6 B 11 B 4 B 13 B 14 B I4 1 B AMP+ ACC 3 B 9 B R+B 13 A RACC GND MUTE FLIN FRIN SGND BEEP RLIN RRIN S4 A , S5 B STEREO COMPONENT AMPLIFIER Y R W F10 FRONT DOOR SPEAKER LH IH 3 A R 4 1 2 F11 FRONT DOOR SPEAKER RH 2 R12 REAR SPEAKER LH IF1 W IF1 L 10 R Y IF1 Y 3 10 A W B 2 IF1 1 L V 1 F13 FRONT TWEETER (SPEAKER) RH 2 1 LG P P BR F12 FRONT TWEETER (SPEAKER) LH 2 1 9 B 1 IM1 P 9 IM1 B L 3 IH2 L 1 IH2 LG 6 IH2 LG 2 IH2 V 5 IH1 1 IE1 11 A RR– 1 IH1 IE1 4 A RR+ 6 IH1 9 8 A RL– 2 IH1 7 IH1 1 A RL+ 2 A LG FR– 10 B V 9 A FR+ V FL– P FL+ BR E 1 2 R13 REAR SPEAKER RH GND 11 (SHIELDED) FR 6 R W FL 5 W B MUTE B 3 L 2 B +B ACC 4 GR 7 A +B 1 R 3 IH1 GR 4 IH1 L–Y GR A L–Y B AMP+B BR J16 JUNCTION CONNECTOR A (SHIELDED) J16 JUNCTION CONNECTOR B L–Y 8 SERVICE HINTS S4 (A), S5 (B) STEREO COMPONENT AMPLIFIER (A) 7–GROUND : Always approx. 12 volts (B) 2–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (B)10–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page A27 32 F13 32 R13 33 F10 32 J16 31 S4 A 31 F11 32 R4 31 S5 B 31 F12 32 R12 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1G See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2K 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1H : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF1 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) 40 Instrument Panel Wire and Instrument Panel No.2 No 2 Wire (Instrument Panel Brace RH) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IN1 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) IH1 IH2 : GROUND POINTS Code IH See Page 40 Ground Points Location Instrument Panel Brace RH : SPLICE POINTS Code I4 See Page 42 Wire Harness with Splice Points Instrument Panel No.2 Wire Code See Page Wire Harness with Splice Points RADIO AND PLAYER (SEPARATE TYPE AMPLIFIER) A27 X
4


F10 F11 BLUE BLUE 1 2 1 2 F12 F13 J16 BLACK 1 2 1 2 A A B B







(Hint : See Page 7) R4 1
3 4 8
5 6 7 X 11 12 13 S5 (B) 1 2 3 4 5 6 X X 9 1011121314 14 15 R12 R13 1 2 1 2 S4 (A) 1 2 3 4 X X 7 8 9 10 11 X 13 X X X MEMO RADIO AND PLAYER (BUILT–IN TYPE AMPLIFIER) FROM POWER SOURCE SYSTEM (SEE PAGE 50) 20A RADIO NO. 1 7. 5A RAD–NO. 2 A27 AUTO ANTENNA MOTOR AND RELAY 3 1H L–Y 11 2K GR ANT B–R 5 1W 4 L–Y 6 1G J16 JUNCTION CONNECTOR J16 JUNCTION CONNECTOR A B A 1 IN1 L–Y GR B–R B 4 A 3 A R2 B , R3 A 2 BR F10 FRONT DOOR SPEAKER LH 1 2 F11 FRONT DOOR SPEAKER RH IF1 3 IF1 1 2 R12 REAR SPEAKER LH RR– R W 3 B 10 IF1 4 IF1 W 9 RR+ 1 B Y 1 IM1 B 9 IM1 RL– 6 B R RL+ 2 B Y V 1 IH IE1 FR– 5 A B V BR P 1 P IE1 FR+ 1 A L FL– 6 A L FL+ 2 A 9 ANT+B LG GND 7 A 8 A ACC LG +B RADIO AND PLAYER 1 2 R13 REAR SPEAKER RH SERVICE HINTS R3 (A) RADIO AND PLAYER (A) 4–GROUND : Always approx. 12 volts (A) 3–GROUND : Approx. 12 volts with the ignition SW at ON or ACC position (A) 7–GROUND : Always continuity : PARTS LOCATION Code See Page Code A27 32 F10 32 R2 F11 32 R3 See Page J16 Code See Page 31 R12 33 B 31 R13 33 A 31 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page 1G 1H 1W 2K Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IE1 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF1 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) IN1 42 Floor No.2 Wire and Instrument Panel Wire (Right Kick Panel) : GROUND POINTS Code IH See Page 40 A27 Ground Points Location Instrument Panel Brace RH F10 F11 J16 BLUE BLUE BLACK R2 (B) 1 X
4


1 2 1 2 A A B B







(Hint : See Page 7) R3 (A) 1 2 R12 R13 1 2 1 2 3 4 5 6 7 8 X
2 3 X
6 COMBINATION METER R V–W 8 1G R–Y E V–W E 2 3 IG3 V–W D10 DIODE (DOME) C 8 A , C 9 B , C10 C MALFUNCTION INDICATOR LAMP WATER TEMP. 6 C 10 B 2 A 1 A BR DOOR 15 B R–W 8 C L 6 IG3 10 IG3 3 IH IJ1 G–R 6 Y–G BR IJ1 IG+ 1 1 W3 WATER TEMP. SENDER BR R–L SE 3 R–L IF2 BR 1 J21 (* 2) , J24 (* 1) JUNCTION CONNECTOR A A V2 VEHICLE SPEED SENSOR (COMBINATION METER) FROM ENGINE CONTROL MODULE BR 3 IJ1 2 SI F14 FUEL SENDER 2 BR 2 IJ1 TO DOOR COURTESY SW 1 7 P IF2 L 4 B–O IF2 G–W 3 Y–R II2 R–L 2 2 C TO ENGINE CONTROL MODULE 5 C 11 B P TRIP METER ODOMETER SPEEDOMETER 14 B B–O TACHO FUEL 3 B BR R–L Y–R 6 B COMBINATION METER G–W FUEL 7 C 1 G–R R–L J28 JUNCTION CONNECTOR V–W B D 1 1W Y–G J4 JUNCTION CONNECTOR J15 JUNCTION CONNECTOR B B R F D 12 2J R F 7. 5A DOME J16 JUNCTION CONNECTOR V–W R–L R–L 2 1D R–L 1 1J TO A/C CONTROL ASSEMBLY 10A GAUGE TO CRUISE CONTROL ECU TO ENGINE CONTROL MODULE FROM POWER SOURCE SYSTEM (SEE PAGE 50) ED : * 1 EC : * 2 GR GR B–W (A/T) 10 II2 C7 CLUTCH START SW 1 2 B–W 6 IG1 B–O B R–Y B–O B (*6 A/T) GR B J29 JUNCTION CONNECTOR (A/T) II2 (* 5 A/T) 6 11 C B P1 PARK/NEUTRAL POSITION SW N B–W FROM THEFT DETERRENT ECU P B–O (M/T) (*6) J7 A , 5 3 1J B–O B A (A/T) * 1 : 1MZ–FE * 2 : 5S–FE * 3 : W/O DAYTIME RUNNING LIGHT * 4 : W/ DAYTIME RUNNING LIGHT * 5 : TMC MADE * 6 : TMMK MADE (* 5) B–W J8 B 5A STARTER JUNCTION CONNECTOR FROM POWER SOURCE SYSTEM (SEE PAGE 50) (M/T) C 8 A , C 9 B , C10 C COMBINATION METER O/D OFF LG G–O L 12 A TO O/D MAIN SW R–W TO ABS AND TRACTION ECU B B R–W R–W B R–W 8 A (*1) 14 B (*2) 2 B2 BRAKE FLUID LEVEL WARNING SW B PKB (* 3) BRK D6 A , 18 A (*1) 4 B (*2) DAYTIME RUNNING LIGHT RELAY (MAIN) (* 4) R–W Y–G W1 WASHER LEVEL WARNING SW J2 JUNCTION CONNECTOR P–L P–L TO ABS ECU TO ABS AND TRACTION ECU TO ABS ACTUATOR AND ECU TO INTEGRATION RELAY SLIP 5 A IF2 IK2 1 TRAC OFF BULB CHECK RELAY 3 C 3 IG2 5 3 TO CRUISE CONTROL ECU 7 B R–W 3 A Y–G 17 IG3 O IJ1 BRAKE REAR LIGHTS WASHER LEVEL 11 C P–L 4 C R–L ABS SEAT BELT 4 A R–W CRUISE 10 C 5 IG2 1 2 1 W–B R–W (* 4) TO LIGHT FAILURE SENSOR P3 PARKING BRAKE SW 7 IG1 R–W EB 1 J11 JUNCTION CONNECTOR O1 OIL PRESSURE SW W–B 5 2 B O OIL Y–B 5 B Y–B SECURITY 9 C A IG COMBINATION METER FROM POWER SOURCE SYSTEM (SEE PAGE 50) 5A IGN FROM A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 8 1T 16 B G 13 C ILLUMINATION 6 A L 2 P 4 B Y O 11 A (* 5) B–R 7 A L–W R 10 A (* 6) R–B 8 A D G–W 9 A N B–R 13 A R G–Y 1 C CHARGE G–B G 1 B 12 C C 8 A , C 9 B , C10 C B Y W–B COMBINATION METER B R7 RHEOSTAT 2 D D ILL FROM GENERATOR E T 1 J16 JUNCTION CONNECTOR G 3 G A J5 JUNCTION CONNECTOR A W–B TURN RH TURN LH FROM HAZARD SW OR TURN SIGNAL SW [COMB. SW] IF A W–B A W–B W–B FROM POWER SOURCE SYSTEM (SEE PAGE 50) * 3 : W/O DAYTIME RUNNING LIGHT * 4 : W/ DAYTIME RUNNING LIGHT R–L 7. 5A PANEL 10A ECU–B FROM HEADLIGHT LH, RH (* 3) R–W FROM DAYTIME RUNNING LIGHT RELAY (MAIN) (* 4) 7 2J G W–R 5 1D 3 IG1 G A A A 2 1G W–R J30 JUNCTION CONNECTOR R–L 3 1W W–B W–B G COMBINATION METER C 8 A , C 9 B , C10 C 9 B LG SRS 13 B TO CENTER AIRBAG SENSOR ASSEMBLY G 8 B HIGH BEAM 12 B * 5 : TMC MADE * 6 : TMMK MADE COMBINATION METER SERVICE HINTS B2 BRAKE FLUID LEVEL WARNING SW 1–2 : Closed with the float down C8 (A), C9 (B), C10 (C) COMBINATION METER (B) 2–GROUND : Approx. 12 volts with the ignition SW at ST position and the shift lever at P or N position (A/T) Approx. 12 volts with the ignition SW at ST position and the clutch pedal depressed (M/T) (A) 13, (C) 7–GROUND : Approx. 12 volts with the ignition SW at ON position (B)11, (B) 12–GROUND: Always approx. 12 volts (A) 2, (B) 9, (B) 16, (C) 5–GROUND : Always continuity O1 OIL PRESSURE SW 1–GROUND : Closed with the oil pressure above approx. 20 kpa (2.8 psi, 0.2 kgf/cm2) P3 PARKING BRAKE SW 1–GROUND : Closed with the parking brake lever pulled up W3 WATER TEMP. SENDER 1–GROUND : Approx. 160–240 Ω (50°C, 122°F) Approx. 17.1–21.2 Ω (120°C, 248°F) : PARTS LOCATION Code See Page Code 26 (1MZ–FE) B2 C7 See Page J5 31 28 (5S–FE) J7 A 31 30 J8 B 31 Code O1 P1 See Page 29 (5S–FE) 27 (1MZ–FE) 29 (5S–FE) C8 A 30 J11 31 P3 31 C9 B 30 J15 31 R7 31 C10 C 30 J16 31 A 30 J21 31 B D6 30 J24 31 D10 30 J28 31 F14 32 J29 31 J2 31 J30 31 J4 31 O1 27 (1MZ–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code 1D 1G See Page Junction Block and Wire Harness (Connector Location) 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1J 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 1T 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 1W 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2J 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) IF2 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IG1 40 IG2 40 IG3 40 Instrument Panel Wire and Cowl Wire (Under The Blower Motor) II2 42 Engine Wire and Cowl Wire (Under the Blower Motor) IJ1 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IK2 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) Instrument Panel Wire and Cowl Wire (Lower Finish Panel) V2 W1 W3 27 (1MZ–FE) 29 (5S–FE) 27 (1MZ–FE) 29 (5S–FE) 27 (1MZ–FE) 29 (5S–FE) : GROUND POINTS Code See Page Ground Points Location 36 (1MZ–FE) EB Left Radiator Side Support 38 (5S–FE) EC 38 (5S–FE) Intake Manifold ED 36 (1MZ–FE) Rear Side of the Surge Tank IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH B2 C8 (A) C7 GRAY 1 C8 (A) (TMC Made) BLUE 2 1 2 3 4 5 6 1 2 (TMMK Made) BLUE 7 8 9 10 11 12 13 C9 (B) (TMMK Made) 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 C10 (C) (TMMK Made) BROWN 7 8 9 10 11 12 13 1 2 3 4 5 6 X X X X




X

7 8 9 10 11 12 13 D6 (B) D10 (TMMK Made) BLACK D6 (A) (TMC Made) GRAY X
9 10 11 12 13 14 15 16 C10 (C) (TMC Made) BROWN 1 2 3 4 5 6 7 8 9 10 11 12 13 C9 (B) (TMC Made) 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2
8 X

4


18 F14 1 2 3 X X X X X


14








X X J2 J4 J5 J7 (A) BLACK BLACK ORANGE GRAY


B B





B


X X


DD DX A A A A A A A A A A A A A





(Hint : See Page 7) (Hint : See Page 7) B B B


(Hint : See Page 7) (Hint : See Page 7)
COMBINATION METER J8 (B) J11 GRAY A





A A J16 BLACK


B B





B A A J15 BLACK





A (Hint : See Page 7)


C C C D D D E E E (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J24 J28 J29 A
A A













B B B B












J21 GRAY A A A

A A A




(Hint : See Page 7)



F F (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J30 O1 P1 GRAY GRAY GRAY A A A A A A 1 X






5 6 P3





(Hint : See Page 7) V2 W1 W3 W3 BLACK BLACK (1MZ–FE) DARK GRAY (5S–FE) GRAY 1 1 1 2 3 1 2 R7 BLACK 1 1 2 3 MEMO RADIATOR FAN AND CONDENSER FAN ACC 2 AM1 1 1 IG1 4 30A RDI 30A CDS W 2 B–Y 2 I16 IGNITION SW 1 4 FAN NO. 1 RELAY 1 1K 2 1K 2 40A AM1 15A ECU–IG 1 2C 2 3 2 2F 1 2G 7 2G 2 2C 2 2H W–B W–B EB W–B A1 A/C CONDENSER FAN MOTOR R L B–W FAN NO. 2 RELAY (1MZ–FE) L E4 5 2 1 3 4 1 5 1 B–R W–R B–R W–B (5S–FE) * 1 : AUTOMATIC A/C * 2 : MANUAL A/C 1 1 W–B 1 (1MZ–FE) A34 B 2 EA1 BATTERY 3 1 (1MZ–FE) L W5 WATER TEMP. SW NO. 2 A12 A ENGINE CONTROL MODULE 1 FAN NO. 3 RELAY 1 2 B (*1) 12 A (*2) MGC E11 E W–B FL MAIN 3. 0W (1MZ–FE) L–Y 1 1 II1 A/C CONTROL ASSEMBLY CF A/C AMPLIFIER 29 E W–B B–G F9 F FUSIBLE LINK BLOCK 1 IK1 1 W4 WATER TEMP. SW NO. 1 2 F4 A , F7 D , 5 2 L–W G–W 1 A 7 IK2 1 II2 (1MZ–FE) 1 (1MZ–FE) L–Y A3 A/C SINGLE PRESSURE SW 2 1 EA1 100A ALT 1 L W–B 1 D M 1 D3 DIODE (A/C) L–W 2 F 13 2J G–W B–R W–B B–R 1 F 3 (1MZ–FE) B–R 4 2F 2 (1MZ–FE) 3 2 2B B–R E3 2 (1MZ–FE) G–W ENGINE MAIN RELAY 1 1 5 4 R1 RADIATOR FAN MOTOR G–W M (5S–FE) B–R 2 6 2K 2 L 6 1A 1 1B FROM MG CLT RELAY B–R L 1 B–R G–W SYSTEM OUTLINE FAN MOTOR OPERATION (1MZ–FE) With the ignition SW turned on, the current through the ECU–IG fuse flows to the FAN NO.1 relay (Coil side), FAN NO.2 relay (Coil side) and FAN NO.3 relay (Coil side). Furthermore, the current through the FAN NO.1 relay (Coil side) or the FAN NO.2 relay (Coil side) flows to TERMINAL 3 of the A/C single pressure SW to TERMINAL 2 to TERMINAL 2 of the water temp. SW No.1 to TERMINAL 1 to GROUND, causing the FAN NO.1 relay to turn off and the FAN NO.2 relay to turn on. 1. LOW SPEED OPERATION Only when the A/C system is activated or the water temp. SW No.2 is turned on, the A/C condenser fan motor and the radiator fan motor rotates at low speed. When the A/C system is activated, the current from ECU–IG fuse flows to the FAN NO.3 relay (Coil side) to TERMINAL 1 of the diode (A/C) to TERMINAL 2 to TERMINAL (A)12 of the A/C amplifier (Manual A/C) or (B) 2 of the A/C control assembly (Automatic A/C) causing the FAN NO.3 relay to turn on. As a result, the current through the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 5 to TERMINAL 5 of the FAN NO.3 relay to TERMINAL 3 to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. As this flowing in series for the motors, the motors rotate at low speed. When the water temp. SW No.2 is turned on, the current from ECU–IG fuse flows to the FAN NO.3 relay (Coil side) to TERMINAL 1 of the water temp. SW No.2 to GROUND, causing the FAN NO.3 relay to turn on. As a result, the current through the CDS fuse flows the same route as above, rotating the motors at low speed. 2. HIGH SPEED OPERATION Only when the A/C single pressure SW is turned off or the water temp. SW No.1 is turned off, the A/C condenser fan motor and the radiator fan motor rotate at high speed. When the A/C single pressure SW is turned off, the current from the RDI fuse flows to the FAN NO.1 relay (Point side) to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. At the same time, the current from the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 4 to GROUND. As the current flowing in parallel for the motors as above, the motors rotate at high speed. FAN MOTOR OPERATION (5S–FE) With the ignition SW turned on, the current through the ECU–IG fuse flows to the FAN NO.1 relay (Coil side), FAN NO.2 relay (Coil side). furthermore, the current through the FAN NO.1 relay (Coil side) or the FAN NO.2 relay (Coil side) flows to TERMINAL 3 of the A/C single pressure SW to TERMINAL 2 to TERMINAL 2 of the water temp. SW No.1 to TERMINAL 1 to GROUND, causing the FAN NO.1 relay to turn off and the FAN NO.2 relay to turn on. 1. LOW SPEED OPERATION When the ignition SW is turned on and the A/C system is activated, the A/C condenser fan motor and the radiator fan motor rotates at low speed. When the A/C system is activated, the current from MG CLT relay flows to the FAN NO.3 relay (Coil side) to GROUND, causing the FAN NO.3 relay to turn on. As a result, the current through the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 5 to TERMINAL 5 of the FAN NO.3 relay to TERMINAL 3 to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. As this flowing in series for the motors, the motors rotate at low speed. 2. HIGH SPEED OPERATION Only when the A/C single pressure SW is turned off or the water temp. SW No.1 is turned off, the A/C condenser fan motor and the radiator fan motor rotate at high speed. When the A/C single pressure SW is turned off, the current from the RDI fuse flows to the FAN NO.1 relay (Point side) to TERMINAL 2 of the radiator fan motor to TERMINAL 1 to GROUND. At the same time, the current from the CDS fuse flows to TERMINAL 2 of the A/C condenser fan motor to TERMINAL 1 to TERMINAL 3 of the FAN NO.2 relay to TERMINAL 4 to GROUND. As the current flowing in parallel for the motors as above, the motors rotate at high speed. SERVICE HINTS A3 A/C SINGLE PRESSURE SW 3–2 : Open above approx. 15.5 kgf/cm2 (224 psi, 1520 kpa) Closed below approx. 12.5 kgf/cm2 (181 psi, 1225 kpa) W4 WATER TEMP. SW NO.1 2–1 : Open above approx. 95°C (203° F) W5 WATER TEMP. SW NO.2 (1MZ–FE) 1–GROUND : Closed above approx. 90°C (194°F) RADIATOR FAN AND CONDENSER FAN : PARTS LOCATION Code See Page 26 (1MZ–FE) A1 28 (5S–FE) 26 (1MZ–FE) A3 28 (5S–FE) A12 A 30 A34 B 30 D3 Code E F4 A F7 F9 26 (1MZ–FE) See Page E11 D F Code 30 I16 26 (1MZ–FE) R1 28 (5S–FE) 26 (1MZ–FE) W4 28 (5S–FE) 26 (1MZ–FE) W5 See Page 30 27 (1MZ–FE) 29 (5S–FE) 27 (1MZ–FE) 29 (5S–FE) 27 (1MZ–FE) 28 (5S–FE) : RELAY BLOCKS Code 1 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1A 1B 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Engine g Room Main Wire and Engine g Room J/B No.2 ((Engine g Compartment Left)) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1K 2B 2C 2F 2G 2H 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 II1 II2 IK1 IK2 See Page 36 (1MZ–FE) 38 (5S–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room Main No No.3 3 Wire (Radiator LH) 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code EB See Page 36 (1MZ–FE) 38 (5S–FE) Ground Points Location Left Radiator Side Support : SPLICE POINTS Code E3 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Cowl Wire Code E4 See Page 36 (1MZ–FE) 38 (5S–FE) Wire Harness with Splice Points Engine Room Main Wire ∗ 1 : 1MZ–FE Except California A1 A3 A12 (A) GRAY BLACK ORANGE
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1 2 AIR CONDITIONING (AUTOMATIC A/C) 50A HTR FROM POWER SOURCE SYSTEM (SEE PAGE 50) F8 FUSIBLE LINK BLOCK 10A HEATER 10A ECU–B 1 7 2J W–R 3 1R L–B L–B 2 1W L–B L–B 5 2K 1 1 1 J32 JUNCTION CONNECTOR A 1 10 1V W–R L–B 3 1W A 5 1 HTR RELAY 2 1 A MG CLT RELAY 3 1 9 2C W–R 2 1 3 1 L–B L–B 4 5 L–B 1 1 L–W L–R W–B B–W L–W L–W L–W L–R 1 EB2 2 1 M B–W I8 B–W 3 +B B–W VM SI 2 B–W A33 A/C BLOWER MOTOR LINEAR CONTROLLER 4 GND 6 W–B 1 2 W–B L–R B8 BLOWER RESISTOR (LOW SPEED) I7 B–W L–R B3 BLOWER MOTOR W–B I7 W–B B–W W–B L–B A A A W–B W–B W–B J11 JUNCTION CONNECTOR EB W–B W–B W–B W–B A II IG W–B Y–G FROM DEFOGGER RELAY 23 A RDFG A34 A , A35 B A/C CONTROL ASSEMBLY FOOT F/D DEF 18 A 19 A 20 A L–O 5 B/L 17 A B–L 7 FACE 4 A TO SPEEDOMETER [COMB. METER] L L L–B W–L L–B 11 IK2 2 EB1 9 IK2 L–Y 7 IK2 L–B L–Y V–W 6 SPD 15 A L–R TPI 7 B L AIR 7 A L–W AIF 6 A P–L PSW 9 B R BLW 16 B L–Y LOCK 3 A B–W HR 10 A W–L MGCR 2 B L–W L–B IG+ 26 A W–R B 13 A D3 DIODE (A/C) 2 3 3 W–R M L–W L–W 1 W–R 1 A3 A/C DUAL PRESSURE SW 2 A20 AIR VENT MODE CONTROL SERVO MOTOR L–O B–L L–R L 1 2 3 4 5 FACE B/L FOOT F/D DEF 4 M W–B 4 W–R A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR 1 L–W L–B B–W B–W W–L A38 AIR INLET CONTROL SERVO MOTOR B–W A CONTROL CIRCUIT B W–B L–B L–B 6 IG W–B W–B 7 GND W–R W–B W–B AIR CONDITIONING (AUTOMATIC A/C) A34 A , A35 B A/C CONTROL ASSEMBLY 2 1 A30 A/C AMBIENT TEMP. SENSOR 2 D B I10 F A B–Y 4 3 F F WARM W–R I9 COOL 10 IK2 W–R A39 AIR MIX CONTROL SERVO MOTOR W–B W–B B–Y LG–B V 25 13 14 TACH A/C ACT THWO E8 ENGINE CONTROL MODULE 5 W–R V B–O 27 W–R F W–R L 1 F W–R P 2 J29 JUNCTION CONNECTOR G–R J1 A JUNCTION CONNECTOR W–R W–R W–R A GND 14 A IK3 L A A M TW 14 B L L 4 LG–B B–Y B–O Y 1 2 IG1 ACT 10 B IK1 Y 1 AC1 13 B J27 A , J28 B W–R IGN 16 A JUNCTION CONNECTOR W–R TAM 3 B W–R 1 A13 A/C EVAPORATOR TEMP. SENSOR W–R 2 L 1 A37 A/C SOLAR SENSOR 2 A36 A/C ROOM TEMP. SENSOR W–R W 1 IG1 L TE 6 B L–W TR 4 B G–Y SG 1 A W–R TS 5 B W B–Y TP 8 B L S5 11 A P AMC 8 A G–R AMH 9 A SYSTEM OUTLINE 1. HEATER BLOWER MOTOR OPERATION Current is applied at all times through HTR fuse to TERMINAL 1 of the HTR relay. When the ignition SW is turned on, current flows through the HEATER fuse to TERMINAL 5 of the HTR relay to TERMINAL 3 to TERMINAL HR of the A/C control assembly. At the same time, current also flows from HEATER fuse to TERMINAL IG+ of the A/C control assembly. ∗ Low speed operation When the blower SW (A/C control assembly) is pushed to LOW SPEED position, the current to TERMINAL HR of the A/C control assembly flows to TERMINAL GND of the A/C control assembly to GROUND and turns the HTR relay on. As a result, the current to TERMINAL 1 of the HTR relay flows to TERMINAL 2 of the relay to TERMINAL 2 of the blower motor to TERMINAL 1 to TERMINAL 2 of the blower resistor to TERMINAL 6 to GROUND and causes the blower motor to rotate at low speed. ∗ High speed operation When the blower SW (A/C control assembly) is pushed to HIGH SPEED position, the current to TERMINAL HR of the A/C control assembly flows to TERMINAL GND of the A/C control assembly to GROUND and turns the HTR relay on. As a result, the current to TERMINAL 1 of the HTR relay flows to TERMINAL 2 to TERMINAL 2 of the blower motor to TERMINAL 1 to TERMINAL 4 of the A/C blower motor linear controller to TERMINAL 2 to TERMINAL BLW of the A/C control assembly (Which is activated when the blower SW is pushed to high speed position) to TERMINAL GND to GROUND without passing through the blower resistor, causing the blower motor to rotate at high speed. 2. AIR INLET CONTROL SERVO MOTOR OPERATION (Switching from FRESH to RECIRC) With the ignition SW turned on, the current flows from HEATER fuse to TERMINAL IG+ of the A/C control assembly to TERMINAL AIR to TERMINAL 7 of the air inlet control servo motor to TERMINAL 6 to TERMINAL AIF of the A/C control assembly to TERMINAL GND to GROUND, the motor rotates and the damper moves to the RECIRC side. when the damper operates with the A/C SW at RECIRC position, the damper position signal is input from TERMINAL 5 of the servo motor to TERMINAL TPI of the A/C control assembly. As a result, current to the servo motor circuit is cut off by the A/C control assembly, so the damper stops at that position. (Switching from RECIRC to FRESH) With the ignition SW turned on, when the RECIRC/FRESH SW is switched to the FRESH side, the current flows from TERMINAL IG+ of the A/C control assembly to TERMINAL AIF to TERMINAL 6 of the air inlet control servo motor to TERMINAL 7 to TERMINAL AIR of the A/C control assembly to TERMINAL GND to GROUND, The motor rotates and the damper stops at that position. 3. AIR VENT MODE CONTROL SERVO MOTOR OPERATION When the ignition SW turned on, the current flows from HEATER fuse to TERMINAL IG+ of the A/C control assembly. (Switching from DEF to FACE) The current flows from TERMINAL FACE of the A/C control assembly to TERMINAL 1 of the air vent mode control servo motor to TERMINAL 5 to TERMINAL DEF of the A/C control assembly to TERMINAL GND to GROUND. The motor rotates and the damper moves to the FACE side. When the damper operates with the A/C SW at FACE position, the damper position signal is input from TERMINAL 5 of the servo motor to the TERMINAL DEF of the A/C control assembly. As a result, current to the servo motor circuit is cut off by the A/C control assembly, so the damper stops at that position. (Switching from FACE to DEF) The current flows from TERMINAL DEF of the A/C control assembly to TERMINAL 5 of the air vent control servo motor to TERMINAL 1 to TERMINAL FACE of the A/C control assembly to TERMINAL GND to GROUND, the motor rotates and the damper stops at that position. 4. AIR MIX CONTROL SERVO MOTOR OPERATION When the temperature control SW (A/C control assembly) is turned to the ”COOL” side the current flows from TERMINAL AMC of the A/C control assembly to TERMINAL 1 of the air mix control servo motor to motor to TERMINAL 2 to TERMINAL AMH of the A/C control assembly to GROUND and the motor rotates. The damper opening angle at this time is input from TERMINAL 3 of the servo motor to TERMINAL TP of the A/C control assembly, this is used to determine the DAMPER STOP position and maintain the set temperature. When the temperature control SW (A/C control assembly) is turned to the ”HOT” side, the current flows from servo motor to TERMINAL AMH of the A/C control assembly to TERMINAL 2 of the air mix control servo motor to motor to TERMINAL 1 to TERMINAL AMC of the A/C control assembly, rotating the motor in reverse and switching the damper from ”COOL” to ”HOT” side. AIR CONDITIONING (AUTOMATIC A/C) 5. AIR CONDITIONING OPERATION The A/C control assembly receives various signals, I.E., the engine RPM from the engine control module, out side air temperature signal from the A/C ambient temp. sensor, coolant temperature from the engine control module and the lock signal from the A/C compressor, etc. When the engine is started and the A/C SW (A/C control assembly) is on, a signal is input to the A/C control assembly. As a result, the ground circuit in A/C control assembly is closed and current flows from HEATER fuse to TERMINAL 1 of the MG CLT relay to TERMINAL 2 to TERMINAL 3 of the diode (A/C) to TERMINAL 2 to TERMINAL MGCR of the A/C control assembly to TERMINAL GND to GROUND, turning the MG CLT relay on, so that the magnetic clutch is on and the A/C compressor operates. At the same time, the engine control module. Detects the magnetic clutch is on and the A/C compressor operates. If the A/C control assembly detects the following conditions, it stops the air conditioning: ∗ Evaporator outlet air is too low. ∗ There is a marked difference between the compressor speed and the engine speed. ∗ The refrigerant pressure is abnormally high or abnormally low. ∗ The engine speed is too low. ∗ Rapid acceleration occurs. SERVICE HINTS A3 A/C DUAL PRESSURE SW 4–1 : Open above approx. 2.0 kgf/cm2 (29 psi, 196 kpa) or 32 kgf/cm2 (464 psi, 3138 kpa) A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR 4–GROUND : Approx. 3.7 Ω A34 (A), A35 (B) A/C CONTROL ASSEMBLY B–GROUND : Always approx. 12 volts IG+ –GROUND : Approx. 12 volts with the ignition SW at ON position HR –GROUND : Approx. 12 volts with the ignition SW at ON position and do not turn the blower motor Below 1 volts with the ignition SW at ON position and turn the blower motor PSW–GROUND : Below 1 volts with the ignition SW at ON position AC1–GROUND : Below 1 volts at start the engine, operate the compressor + OR MORE volts at start the engine, do not operate the compressor BLW–GROUND : Below 1.5 volts with the ignition SW on and turn the blower motor S5–SG : 4–6 volts with the ignition SW at ON position SG–GROUND : Always continuity AMH–AMC : 1.3–1.9 volts with the ignition SW off AIF–GROUND : Approx. 12 volts with the FRESH SW on AIR–GROUND : Approx. 12 volts with the RECIRC SW on FACE–GROUND: Approx. 12 volts with the FACE SW on DEF–GROUND : Approx. 12 volts with the DEF SW on GND–GROUND : Always continuity : PARTS LOCATION Code See Page Code See Page Code See Page A2 26 (1MZ–FE) A36 30 F8 26 (1MZ–FE) A3 26 (1MZ–FE) A37 30 J1 31 A13 30 A38 30 A20 30 A39 30 J27 A 31 A30 26 (1MZ–FE) B3 30 J28 B 31 A33 30 B8 30 J29 31 J32 31 A34 A 30 D3 30 A35 B 30 E8 30 : RELAY BLOCKS Code 1 See Page 24 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) J11 31 ,,, : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR ,,, ,,, Code See Page Junction Block and Wire Harness (Connector Location) 1R 1V 20 Cowl Wire and Instrument Panel J/B (Lower ( Finish Panel)) 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1W 2C 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page EB2 36 (1MZ–FE) Joining Wire Harness and Wire Harness (Connector Location) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) IG1 40 Instrument Panel Wire and Cowl Wire (Lower Finish Panel) 42 Engine g Room Main Wire and Cowl Wire ((Right g Kick Panel)) IK1 IK2 IK3 : GROUND POINTS Code See Page Ground Points Location EB 36 (1MZ–FE) Left Radiator Side Support IG 40 Instrument Panel Brace LH II 40 Cowl Side Panel RH : SPLICE POINTS Code See Page I7 42 I8 Wire Harness with Splice Points A2 A3 BLACK
1 4 See Page I9 Cowl Wire GRAY 1 2 X 4 Code 42 I10 A13 Cowl Wire A20 A30 DARK GRAY 1 2
A33 1 2 3 4 5 6 7 A34 (A) 1 2 A35 (B) BLACK 1 2 3 4 Wire Harness with Splice Points 1
3 4 X 6 7 8 9 10 11
13 14 15 16 17 18 19 20 X X 23 X X 26 A36 A37 BLACK BLACK X 2 3 4 5 6 12 1 2 7 8 9 10 X X 13 14 X 16 A38 A39 B3 B8 D3 BLACK 1 X 3 X 5 6 7 ORANGE X 1 2 3 4 5 1 2 X 2 X X 6
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(Hint : See Page 7) (Hint : See Page 7) MEMO AIR CONDITIONING (MANUAL A/C) 50A HTR FROM POWER SOURCE SYSTEM (SEE PAGE 50) F8 FUSIBLE LINK BLOCK 10A HEATER 2 1W 3 1R L–B L–B 1 5 2K A 1 5 1 4 HTR RELAY 2 5 MG CLT RELAY A 1 3 1 L–B 1 L–W L–R L–R B–W W–B J32 JUNCTION CONNECTOR 9 2C 2 3 1 1 L–B 1 1 L–B 1 1 L–B L–B L–B L–B L–B B–W L–Y(* 2) L–Y(* 2) L–W(* 1) L–W(* 1) B–W(*2) TO FAN NO. 3 RELAY 10A A/C 1 1 L–R B4 BLOWER RESISTOR 2 M 3 EB1 L–R 1 2 EB1 L–R 1 EB2 2 3 B3 BLOWER MOTOR 2 6 W–B 1 (* 1) LO (* 1) L–B 4 M1 W–B 8 M2 W–B 5 HI W–B L–W B–W I3 L–O B–W L–B B–W 1 W–B W–B OFF 3 A 1 B5 BLOWER SW W–B A A J11 JUNCTION CONNECTOR A W–B L–B EB A IG W–B * 1 : 1MZ–FE * 2 : 5S–FE H9 HEATER CONTROL SW L–B B–W FACE B/L FOOT F/D DEF 3 GND FACE B/L FOOT F/D DEF 1 8 7 6 5 4 2 L–B B–W L–Y(*2) L–Y(* 1) L–W(* 1) 3 2 7 IK2 L–Y L–O B–L L–R L L–W L–R R–B W–B (*1) L–Y(* 2) D3 DIODE (A/C) D L–R D D L–R J12 JUNCTION CONNECTOR W–B W–B W–B (*1) (* 1) R–W 1 2 3 4 5 FACE B/L FOOT F/D DEF (* 1) R–B CONTROL CIRCUIT 5 (* 2) 1 A B L–B 6 IG OFF W–B 7 GND ON A20 AIR VENT MODE CONTROL SERVO MOTOR R–W (* 1) 2 R–W R–B M L–R R–B A14 A/C SW AIR CONDITIONING (MANUAL A/C) * 1 : 1MZ–FE * 2 : 5S–FE * 3 : 5S–FE W/ ENGINE IMMOBILISER * 4 : 5S–FE W/O ENGINE IMMOBILISER L–B B–W B–W 1 A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR 4 A3 A/C DUAL PRESSURE SW 1 2 W–R(*1) 9 IK2 10 IK2 W–R(*1) IK2 G BR(* 2) W–L 2 W–L G 4 (* 2) TH BR(* 2) (*2) (*1) J29 JUNCTION CONNECTOR B BR (* 2) (*2) W–R J8 JUNCTION CONNECTOR 10 II3 6 II3 (* 2) II2 J23 JUNCTION CONNECTOR BR BR 3 F 2 BR (* 2) II2 L–R (* 1) B–O (* 2) R–B (* 2) L–Y G (* 2) 1 F B BR (* 2) F 1 (* 2) R–W A13 A/C EVAPORATOR TEMP. SENSOR (* 2) F A L–W B (* 1) R–B LG–B B R–B JUNCTION CONNECTOR B J27 A , J28 B J12 JUNCTION CONNECTOR (* 1) W–R 13 (* 1) D B SG 9 (* 2) ACT 7 W–L AC1 1 W–B R–W (* 1) W–L IGN 4 L–W (*1) (*1) R–B 8 (*1) S–A/C B–Y 10 LOCK (*1) L–A/C 5 R–W GND (*1) 14 +B B–O MGC W–B A12 A/C AMPLIFIER 2 (*1) 12 (* 1) G L–Y(* 2) (*1) L–Y(* 1) A 20 A 15 A LOCK 19 A 13 A PRS 21 A 21 A MGC 25 B 13 B 10 A 10 A A/C SW 11 B 10 B TACH A/C E7 A , E8 B , E9 C ENGINE CONTROL MODULE ACT THR 9 B 9 B E2 (*1) 19 C (*3) 18 C (*4) LOCK IN A (* 2) 27 B EC SYSTEM OUTLINE Current always flows from the HTR fuse to TERMINAL 1 of the HTR relay. When the ignition SW is turned on, the current from the HEATER fuse flows to TERMINAL 6 of the air vent mode control servo motor, to the MG CLT relay (Coil side) to TERMINAL MGC of the A/C amplifier (1MZ–FE) or TERMINAL MGC of the engine control module (5S–FE), to TERMINAL 1 of the A/C dual pressure SW to TERMINAL 4 to TERMINAL +B of the A/C amplifier (1MZ–FE) or TERMINAL PRS of the engine control module (5S–FE), current also to the HTR relay (Coil side) to TERMINAL 3 of the blower SW. 1. AIR VENT MODE CONTROL SERVO MOTOR OPERATION When the damper is in FACE position and B/L mode on the heater control SW is selected, current flows from TERMINAL 7 of the heater control SW to TERMINAL 2 of the air vent mode control serve motor so that a signal that the ground circuit is activated is input into TERMINAL B of the control circuit inside the air vent mode control servo motor. Simultaneously, a signal that the ground circuit is not activated is input into TERMINAL A of the control circuit inside the servo motor. These two signals activate the control circuit so that current flows from the HEATER fuse to the servo motor, causing the servo motor to operate and the damper to move to B/L position. When the damper reaches B/L position. A ground cut signal is input into TERMINAL B of the control circuit, the control circuit operates, the servo motor stops rotating and the damper stops at B/L. When another mode position is selected, input of signals into TERMINAL A and TERMINAL B of the control circuit that ground is made or not (as explained above) activates the control circuit and moves the serve motor to the desired position. 2. AIR CONDITIONING OPERATION When the blower SW is on, current flows from the HEATER fuse to the HTR relay (Coil side) to TERMINAL 3 of the blower SW to TERMINAL 1 to GROUND, activating the HTR relay. This causes current to flow from the HTR fuse to the HTR relay (Point side) to A/C fuse to TERMINAL 2 of the A/C SW. If the A/C SW is turned on at this time, a signal is input into the A/C amplifier (1MZ–FE) or engine control module (5S–FE). This activates the A/C amplifier (1MZ–FE) or engine control module (5S–FE) and MG CLT relay so that current flows from the HEATER fuse to the MG CLT relay (Point side) to A/C magnetic clutch. Causing The compressor to operate. When blower SW is on and heater control SW is at DEF position, it causes A/C to run whether A/C SW is on or not. SERVICE HINTS HTR RELAY [R/B NO.1] 1–2 : Closed with the ignition SW on and the blower SW on MG CLT RELAY [R/B NO.1] 5–3 : Closed with the ignition SW on, the blower SW on and the A/C SW on or the heater control SW at DEF position A3 A/C DUAL PRESSURE SW 1–4 : Open with pressure 2.0 kgf/cm2 (29 psi, 196 kpa) or above 32 kgf/cm2 (464 psi, 3138 kpa) B4 BLOWER RESISTOR 6–1 : Approx. 0.62 Ω 1–3 : Approx. 1.46 Ω 2–6 : Approx. 0.38 Ω : PARTS LOCATION Code See Page A2 A3 Code See Page Code See Page 26 (1MZ–FE) B4 30 J8 31 28 (5S–FE) B5 30 J11 31 26 (1MZ–FE) D3 26 (1MZ–FE) J12 31 J23 28 (5S–FE) E7 A 30 A12 30 E8 B 30 J27 A 31 A13 30 E9 C 30 J28 B 31 A14 30 A20 30 B3 30 F8 H9 26 (1MZ–FE) J29 31 28 (5S–FE) J32 31 30 : RELAY BLOCKS Code 1 See Page 24 31 Relay Blocks (Relay Block Location) Engine Room R/B No.1 (Engine Compartment Left) AIR CONDITIONING (MANUAL A/C) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page 1R Junction Block and Wire Harness (Connector Location) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 2C 22 Engine Room Main Wire and Engine Room J/B No.2 (Engine Compartment Left) 2K 22 Cowl Wire and Engine Room J/B No.2 (Engine Compartment Left) 1W : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code See Page Joining Wire Harness and Wire Harness (Connector Location) 36 (1MZ–FE) EB1 38 (5S–FE) Cowl Wire and Engine Room Main Wire (Under the Engine Room J/B No.2) No 2) 36 (1MZ–FE) EB2 38 (5S–FE) II2 II3 IK2 42 Engine Wire and Cowl Wire (Under the Blower Motor) 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) : GROUND POINTS Code See Page Ground Points Location 36 (1MZ–FE) EB Left Radiator Side Support 38 (5S–FE) EC 38 (5S–FE) Intake Manifold IG 40 Instrument Panel Brace LH : SPLICE POINTS Code I3 See Page Wire Harness with Splice Points 42 Code A2 A3 A12 GRAY BLACK ORANGE 1 2 X 4 See Page Wire Harness with Splice Points Cowl Wire
1 4 A20 A13 1 2 X 4 5 X 7 8 9 10 X 1213 14
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5 1 2 B4 B5 D3 ORANGE 1 1 2 3 4 5 6 7 1 2 3 2 X X 6 1 4 X 3 5

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A A




(Hint : See Page 7) (Hint : See Page 7) I GROUND POINT W–B FRONT TURN SIGNAL LIGHT AND PARKING LIGHT LH W–B W–B W–B E1 E4 W–B FRONT TURN SIGNAL LIGHT AND PARKING LIGHT RH W–B WASHER LEVEL WARNING SW W–B E4 E1 W–B W–B 2 EA1 E4 FAN NO. 3 RELAY 1 HTR RELAY 1 DRL NO. 4 RELAY 2 E4 E1 W–B E4 W–B ABS AND TRACTION ECU (GND3) (* 3) W–B ABS AND TRACTION ACTUATOR (* 3) W–B (GND1) (*2 * 4) W–B (GND2) (*2 * 4) W–B ABS ACTUATOR AND ECU ABS ACTUATOR (* 1) W–B (CALIFORNIA) 2 A/F HTR RELAY W–B (5S–FE) (GND2) (* 3) W–B 1 E1 W–B W–B FAN NO. 2 RELAY W–B W–B W–B E1 W–B E4 W–B (GND1) (* 3) E4 W–B WATER TEMP. SW NO. 1 W–B ABS SOL RELAY W–B RADIATOR FAN MOTOR E1 W–B ENGINE HOOD COURTESY SW W–B 3 (*1, * 3) W–B W–B E4 E4 (* 5) W–B (* 5) W–B ENGINE MAIN RELAY W–B DAYTIME RUNNING LIGHT RESISTOR W–B EFI RELAY W–B 10 2J 4 2F W–B FRONT WIPER MOTOR W–B 5 2C (AUTOMATIC A/C) W–B W–B EB EA A/C DUAL PRESSURE SW HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) BR A A BR 2 II1 6 II3 BR J22 JUNCTION CONNECTOR BR BR BR DATA LINK CONNECTOR 1 B B C A BR DATA LINK CONNECTOR 2 B B C A BR DATA LINK CONNECTOR 3 (SG) J7 A , J8 B JUNCTION CONNECTOR (EOM) BR A BR I2 A BR A BR HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) (E1) BR (ADJ2) (* 2 M/T) HEATED OXYGEN SENSOR (BANK 2 SENSOR 1) J26 JUNCTION CONNECTOR B B A BR I2 BR (CALIFORNIA) B BR BR (CALIFORNIA) BR (E05) ENGINE CONTROL MODULE (E04) (E03) BR (E02) BR (E01) BR IGNITER (1MZ–FE) ED COMBINATION METER (EXCEPT CALIFORNIA) BR NOISE FILTER (IGNITION) B (CALIFORNIA) BR (ET) BR 3 IJ1 BR BR COMBINATION METER BR (CALIFORNIA) (ET) EC (1MZ–FE) 3 IJ1 BR * * * * * 1 : TMC MADE 2 : TMMK MADE 3 : W/ TRACTION CONTROL 4 : W/O TRACTION CONTROL 5 : W/ DAYTIME RUNNING LIGHT BR (E04) (CALIFORNIA) (EOM) A (E01) BR (CALIFORNIA) A (E1) BR BR BR IGNITION COIL AND IGNITER NO. 2 BR BR IGNITION COIL AND IGNITER NO. 1 A J19 JUNCTION CONNECTOR BR ENGINE CONTROL MODULE (E02) BR (E03) BR (5S–FE) BR DATA LINK CONNECTOR 1 BR A A A A A BR BR DATA LINK CONNECTOR 2 DATA LINK CONNECTOR 3 (SG) BR C A BR J7 A , J8 B B B BR 6 II3 B B BR 10 IK2 I2 BR (EXCEPT CALIFORNIA) HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) BR J23 A JUNCTION CONNECTOR JUNCTION CONNECTOR C A (5S–FE) BR BR EC BR EC 12 II2 BR BR HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) A/C MAGNETIC CLUTCH AND LOCK SENSOR I GROUND POINT CRUISE CONTROL ECU TRACTION OFF SW A B A A W–B CRUISE CONTROL ACTUATOR W–B A B A A W–B CRUISE CONTROL SW [COMB. SW] A B A A W–B DAYTIME RUNNING LIGHT RELAY (MAIN) A A W–B LIGHT CONTROL AND DIMMER SW [COMB. SW] A A W–B KEY INTERLOCK SOLENOID (* 3) (CG) POWER WINDOW MASTER SW AND DOOR LOCK CONTROL SW LH (E) (E) W–B W–B(*1) A W–B A (* 1) DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH W–B DOOR KEY LOCK AND UNLOCK SW FRONT LH W–B A (* 1) A (* 1) A W–B REMOTE CONTROL MIRROR LH POWER WINDOW MASTER SW AND DOOR LOCK CONTROL SW LH J38 JUNCTION CONNECTOR DATA LINK CONNECTOR 3 W–B A A J7 A , (E) W–B W–B UNLOCK WARNING SW J8 B W–B (E1) CENTER AIRBAG SENSOR ASSEMBLY JUNCTION CONNECTOR A 8 1J (* 1) (E) (* 5) 3 1M 1 1N W–B(*2) POWER RELAY W–B W–B (*1) (* 2) DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH W–B DOOR KEY LOCK AND UNLOCK SW FRONT LH W–B REMOTE CONTROL MIRROR LH W–B INTEGRATION RELAY W–B B13 (* 2) NOISE FILTER (* 2) 20 IE1 W–B W–B (* 6) (* 6) W–B W–B 9 2K B2 W–B(*6) (*9) W–B I7 (* 9) A B3 W–B W–B J11 JUNCTION CONNECTOR A TRANSPONDER KEY AMPLIFIER W–B A/C CONTROL ASSEMBLY W–B W–B (MANUAL A/C) I1 A (* 9) W–B W–B W–B (1MZ–FE MANUAL A/C) W–B A W–B W–B W–B(*1) A W–B (* 1) BM (* 9) (MANUAL A/C) B2 A/C AMPLIFIER W–B (MANUAL A/C) W–B (*1 * 6) BRAKE FLUID LEVEL WARNING SW W–B W–B MOON ROOF MOTOR AND LIMIT SW ST RELAY W–B 3 1V B2 TURN SIGNAL FLASHER W–B W–B PERSONAL LIGHT W–B W–B 3 1F W–B WIPER AND WASHER SW [COMB. SW] W–B W–B A 4 1V W–B W–B MOON ROOF CONTROL SW AND RELAY W–B W–B VANITY LIGHT RH A B 3 : *6 B 2 : *7 VANITY LIGHT LH (E2) 7 1G 3 1N W–B POWER OUTLET (* 2) W–B W–B CENTER AIRBAG SENSOR ASSEMBLY NOISE FILTER 7 1J (* 2) IE II IG BLOWER RESISTOR (LOW SPEED) A/C BLOWER MOTOR LINEAR CONTROLLER HEATER CONTROL SW BLOWER RESISTOR REAR WINDOW DEFOGGER SW BLOWER SW CIGARETTE LIGHTER AIR VENT MODE CONTROL SERVO MOTOR (GND) ABS ECU (GND2) REMOTE CONTROL MIRROR SW O/D MAIN SW SHIFT LOCK ECU A A W–B WIRELESS DOOR LOCK ECU W–B A A W–B THEFT DETERRENT ECU W–B A A W–B DOOR KEY LOCK AND UNLOCK SW FRONT RH (* 1) (–) COMBINATION METER W–B (EP) CLOCK W–B A W–B A W–B A A J39 JUNCTION CONNECTOR J5 JUNCTION CONNECTOR DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH W–B (* 1) A W–B DOOR LOCK CONTROL SW RH (* 1) W–B GLOVE BOX LIGHT AND SW A A W–B REMOTE CONTROL MIRROR RH (* 1) W–B RHEOSTAT A A W–B (*2) RADIO AND PLAYER (*2) W–B W–B (*2) W–B (*2) IF DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH DOOR LOCK CONTROL SW RH REMOTE CONTROL MIRROR RH IJ 7 IH1 1 IF2 BR BR BR BR W–B B14 20 IM1 W–B STEREO COMPONENT AMPLIFIER W–B (* 2) W–B 1 : TMC MADE 2 : TMMK MADE 3 : W/ TRACTION CONTROL 5 : W/ DAYTIME RUNNING LIGHT 6 : W/ MOON ROOF 7 : W/O MOON ROOF 8 : W/O THEFT DETERRENT SYSTEM 9 : AUTOMATIC A/C W–B A * * * * * * * * DOOR KEY LOCK AND UNLOCK SW FRONT RH BR BR BR FUEL SENDER (ES) COMBINATION METER IH W–B 6 BP1 W–B POWER SEAT CONTROL SW (FRONT PASSENGER’ S SEAT) W–B 1 BR1 W–B W–B B6 W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH IK W–B W–B B6 BN AUTO ANTENNA MOTOR AND RELAY I GROUND POINT BUCKLE SW LH W–B (*10) B12 W–B (* 10) 1 BQ1 W–B A A W–B B9 W–B LICENSE PLATE LIGHT RH W–B LICENSE PLATE LIGHT LH W–B REAR COMBINATION LIGHT RH W–B REAR COMBINATION LIGHT LH W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH W–B W–B (*10) A HIGH MOUNTED STOP LIGHT W–B A REAR COMBINATION LIGHT LH W–B REAR COMBINATION LIGHT RH W–B LUGGAGE COMPARTMENT KEY UNLOCK SW W–B W–B A B9 W–B B11 B9 W–B W–B FUEL PUMP BUCKLE SW LH (*11) A POWER SEAT CONTROL SW (DRIVER’ S SEAT) W–B (*10) J40 JUNCTION CONNECTOR W–B B11 W–B B11 * 10 : W/ POWER SEAT * 11 : W/O POWER SEAT W–B W–B 6 BO1 BL B11 W–B LIGHT FAILURE SENSOR A B BP BO REAR WINDOW DEFOGGER : PARTS LOCATION Code See Page J5 Code See Page Code See Page 31 J19 31 J38 32 J7 A 31 J22 31 J39 32 J8 B 31 J23 31 J40 32 31 J26 31 J11 : RELAY BLOCKS Code See Page Relay Blocks (Relay Block Location) 1 24 Engine Room R/B No.1 (Engine Comportment Left) 2 24 Engine Room R/B No.2 (Near The Battery) 3 25 Engine Room R/B No.3 (Radiator Upper Support RH) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR Code See Page Junction Block and Wire Harness (Connector Location) 1F 20 Roof Wire and Instrument Panel J/B (Lower Finish Panel) 1G 20 Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel) 20 Cowl Wire and Instrument Panel J/B (Lower Finish Panel) 22 Engine Room Main Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 22 Cowl Wire and Engine Room J/B No No.2 2 (Engine Compartment Left) 1J 1M 1N 1V 2C 2F 2J 2K : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS Code EA1 See Page 36 (1MZ–FE) 38 (5S–FE) Joining Wire Harness and Wire Harness (Connector Location) Engine Room Main Wire and Engine Room Main No No.3 3 Wire (Radiator LH) IE1 40 Front Door LH Wire and Instrument Panel Wire (Left Kick Panel) IF2 40 Floor Wire and Instrument Panel Wire (Left Kick Panel) IH1 40 Instrument Panel Wire and Instrument Panel No.2 Wire (Instrument Panel Brace RH) 42 Engine g Wire and Cowl Wire (Under ( the Blower Motor)) II1 II2 II3 IJ1 42 Engine Wire and Instrument Panel Wire (Under the Blower Motor) IK2 42 Engine Room Main Wire and Cowl Wire (Right Kick Panel) IM1 42 Front Door RH Wire and Instrument Panel Wire (Right Kick Panel) BO1 44 Rear Door Wire LH and Floor Wire (Under the Left Center Pillar) BP1 44 Rear Door Wire RH and Floor No.2 Wire (Under the Right Center Pillar) BQ1 46 Floor Wire and Seat No.1 Wire (Under the Driver’s Seat) BR1 46 Floor No.2 Wire and Seat No.2 Wire (Under the Passenger’s Seat) I GROUND POINT : GROUND POINTS Code See Page 36 (1MZ–FE) EA 38 (5S–FE) 36 (1MZ–FE) EB 38 (5S–FE) Ground Points Location Right Radiator Side Support Left Radiator Side Support 36 (1MZ–FE) Surge Tank RH 38 (5S–FE) Intake Manifold ED 36 (1MZ–FE) Rear Side of the Surge Tank IE 40 Cowl Side Panel LH IF 40 Left Kick Panel IG 40 Instrument Panel Brace LH IH 40 Instrument Panel Brace RH II 40 Cowl Side Panel RH 40 Right Kick Panel EC IJ IK BL 44 Under the Left Center Pillar BM 44 Roof Left BN 44 Under the Right Center Pillar BO 44 Right Quarter Pillar BP 44 Back Panel Center : SPLICE POINTS Code E1 E4 See Page Wire Harness with Splice Points Code See Page Wire Harness with Splice Points 36 (1MZ–FE) B3 44 Roof Wire 38 (5S–FE) B6 44 Floor No.2 Wire 44 Floor Wire 36 (1MZ–FE) Engine Room Main Wire 38 (5S–FE) B9 B11 I1 42 Cowl Wire B12 46 Seat No.1 Wire I2 42 Engine Wire B13 44 Front Door LH Wire I7 42 Cowl Wire B14 44 Front Door RH Wire B2 44 Roof Wire J5 J7 (A) J8 (B) ORANGE GRAY GRAY A A A A A A A A A A A A A A A A A A A A A A A A A


C C C B B B


A A A A A A (Hint : See Page 7) (Hint : See Page 7) (Hint : See Page 7) J19 J11 (Hint : See Page 7) J22 J23 A A A A A A A A A A A A A A A A A A A A A A (Hint : See Page 7) (Hint : See Page 7) J26 GRAY A A A

A A A




(Hint : See Page 7)
B

B B B (Hint : See Page 7) J38 J39 A A A

A A A



A A A X X A A A X X X X (Hint : See Page 7) (Hint : See Page 7) J40 A A A A A A (Hint : See Page 7) J OVERALL ELECTRICAL WIRING DIAGRAM [A] : System Title [B] : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black W = White BR = Brown L = Blue V SB = Sky Blue = Violet R = Red O = Orange LG = Light Green P Y = Pink = Yellow [F] : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. Example: GR = Gray G = Green The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: ,,,, ,,,, 3C indicates ,,,, that it is inside ,,,, Junction Block ,,,, ,,,,No.3 ,,,, L–Y [G] : Indicates related system. L (Blue) [H] : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). Outside numerals are pin numbers. Y (Yellow) [C] : The position of the parts is the same as shown in the wiring diagram and wire routing. [D] : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example : Numbered in order from upper left to lower right Numbered in order from upper right to lower left Female [I] Male ( ) : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. [J] : Indicates a shielded cable. Female Male The numbering system for the overall wiring diagram is the same as above [E] : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example : [K] : Indicates and located on ground point. [L] : The same code occuring on the next page indicates that the wire harness is continuous. Indicates Relay Block No.1 J SYSTEMS LOCATION SYSTEMS LOCATION ABS TMC Made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19–2 TMMK Made . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–2 Light Auto Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ABS and Traction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–2 Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–3 Air Conditioning Automatic A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29–2 Manual A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27–2 Power Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–2 Auto Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–2 Back–Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 Moon Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–2 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1~29–1 Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–2 Radiator Fan and Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–3 Cigarette Lighter and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–4 Radio and Player Built–In Type Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–3 Separate Type Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23–2 Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–2 Rear Window Defogger and Mirror Heater . . . . . . . . . . . . . . . . . . . . 26–2 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–2 Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–4 Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–2 Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–2 Electronically Controlled Transmission and A/T Indicator 1MZ–FE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 5S–FE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–2 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Engine Control and Engine Immobiliser System 1MZ–FE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 5S–FE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Starting and Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Stop Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2 Theft Deterrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–2 Headlight w/ Daytime Running Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 w/o Daytime Running Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21–4 Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2 Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3 Key Reminder and Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . 21–3 Turn Signal and Hazard Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–2 Wireless Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–5 J OVERALL ELECTRICAL WIRING DIAGRAM SYSTEM INDEX 1 CAMRY ELECTRICAL WIRING DIAGRAM P o w er S o u rc e S ta rting a n d Ig n ition 1 C ha rg in g 3 2 4 B–G W * * * * * ACC 2 AM1 IG1 4 W–R 7 AM2 IG2 6 B–R ST2 8 R W B–Y 1 : 1MZ–FE 2 : 5S–FE 3 : w/ Daytime Running Light 4 : TMC Made 5 : TMMK Made B–R(*2) J25 JUNCTION CONNECTOR B 1 Y (*3) 4 IK2 J1 JUNCTION CONNECTOR C Y (*3) 6 EB1 R–L IGT1 GND 6 7 3 BR–Y (*1) GR (*1) Y IGT2 5 BR (*1) To Engine Control Module<2–8> ED : *1 EC : *2 BR (*2) Rear side of the surge tank(*1) Intake manifold(*2) G1 B , G2 A GENERATOR IGT3 BR (*1) IGF W Y (* 3) C +B 4 To Engine Control Module<3–11> R–L To Daytime Running Light Relay (Main)<7–2> Y N1 NOISE FILTER (Ignition) IGC1 Y (w/o Daytime Running Light) IGC2 I 2 IGNITER J19 A JUNCTION CONNECTOR C BR (*2) IGC3 A 9 B GR(*2 *4) B–O(*2 *5) BR(*2) 10 A N1 NOISE FILTER (Ignition) 1 1 2 G 2 To Engine Control Module<3–11> B–R 2 B–R 2 Y B A 1 4 IG2 BR LG–B (*1) To Bulb Check Relay [Comb. Meter] <25–6> A 1 A W–R (*1) B A 2 L IG C B GR(*1 *4) B–O(*1 *5) GR(*4) B–O(*5) C B To Engine Control Module<2–10> Left kick panel II2 GR(*4) B–O(*5) BATTERY J11 JUNCTION CONNECTOR A J7 A , J8 B W–B 10 JUNCTION CONNECTOR FL MAIN 3. 0W 6 GR(*4) B–O(*5) (A/T) B–G S1 B , S2 A STARTER 11 A B N GR B–R GR(*4) B–O(*5) (M/T) FUSIBLE LINK BLOCK W–B 1 A B–R 100A ALT GR(*4) B–O(*5) F6 C , F9 F 1 I5 IGNITION COIL NO. 1 P 1 A B–R F4 A , F5 B , I6 IGNITION COIL NO. 2 1 C A B–R 2 F I7 IGNITION COIL NO. 3 1 F P1 PARK/NEUTRAL POSITION SW 5 1 B A B–R B B–R B–R A 4 J18 JUNCTION CONNECTOR A 2 B 2 Y–R(*2) 11 II2 C7 CLUTCH START SW 11 2J W–R 9 2K 3 W–R (*2) 5 2D 3 2 B(*2) 3 2B 1 4 B–R (*1) 2 IGF IGT GND B–W (A/T) 3 12 II3 B–W (M/T) 1 GND IGT IGF W–R B–W (A/T) B 1 ST RELAY 40A MAIN 30A AM2 5A ALT–S B–R B–G 1 2A 5 4 B 2 1J B–R (*2) BR(*2) 2 1 1B +B B–G 4 2L 1 +B B–R 3 2C 1 J29 JUNCTION CONNECTOR B 13 II3 8 1C B–R (*1) B 3 1J B–W 40A AM1 W–R B–W 2 1 1K 10A GAUGE 5A IGN 13 A I4 IGNITION COIL AND IGNITER NO. 2 C8 A , C9 B B–R (*2) 5A STARTER W 2 1K I3 IGNITION COIL AND IGNITER NO. 1 B CHARGE WARNING LIGHT[COMB. METER] W To Engine Control Module<2–9><3–10> 5 1B B B–Y B B–R 8 1T B–R 3 1K I16 IGNITION SW B–R B–R 4 1K B–R 5 1K 1 A L B B IG A S A 1 B–G 2 3 W J 1 W B 25A A/F HTR W (*1) B–R B–R B–R B–R B 100A ALT 40A AM1 B–G 7. 5A OBD W FL 1. 25B C10 MALFUNCTION INDICATOR LAMP [COMB. METER] G–R W–B W–B W–B W–B IG A W–B W–B B–Y FUSIBLE LINK BLOCK F4 A , F6 C , F9 F Under the left center pillar J40 JUNCTION CONNECTOR Instrument panel brace LH J11 JUNCTION CONNECTOR J7 A , J8 B JUNCTION CONNECTOR BL A R–L 5 7 1J BR Left radiator side support B (*1) L–B M 4 SIL 7 C C C (Shielded) W EB EFI RELAY W–B (* 1) B (*1) F14 FUEL PUMP 7 ID1 8 1J SG 5 BR C A B B BR J7 A , J8 B JUNCTION CONNECTOR C B BR BR A B 4 E1 3 +B 12 TE1 D1 DATA LINK CONNECTOR 1 8 * 1 : California BR BR B–Y BR L–W W B–W B–R B–Y B–R B–Y G–R G–R B(*1) B–Y BATTERY 30A AM2 L–B FL MAIN 3. 0W 15A EFI 2 A A A B W–B 1 ES1 B–R 7 D D 4 CG BAT D5 DATA LINK CONNECTOR 3 16 W 1 A 2 W–B (*1) 2 4 EB1 CIR OPN RELAY 1 C 2 L–B 3 1 1 G–R 1 2 1 J4 JUNCTION CONNECTOR 2 F 10 2C 3 1 2 1D R–L 5 2C 2 2J A B C A 5 7 IK1 1 1K W–B 4 2F 1 2 C A B–R B–R B–R 3 From Airbag Sensor Assembly<28–4> 1 F 1 2A 3 5 2 L (*1) 2 5 B–W B–R W–R B–W (* 1) B–W B–R B–R 1 7 2K 7 1W 5A IGN 3 1K 8 1C 12 II3 B–R 1 1B B–Y 8 2J B–Y B–R B–R B–Y 10A GAUGE 4 2L ST2 IG2 6 IG1 4 I16 IGNITION SW 7 AM2 2 AM1 2 E ng in e C o n trol an d E n gine Im m ob ilis e r S y s tem (1 M Z – F E ) N M L K J I H G F E D C B A (Cont. next page) L–W 4 1B 1 5 1B 5 1K W–R 2 2 1K W ACC B–Y 1 2 L (*1) 1 1 P o w e r S o ur ce B 10 1J 2 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM BR (Shielded) J3 JUNCTION CONNECTOR W W G–R J35 A , J36 B JUNCTION CONNECTOR A/F HTR RELAY(*1) 2 CAMRY (Cont’ d) (Cont. next page) * 1 : California * 2 : Except California * 3 : w/ Engine Immobiliser System E n g in e C o n trol an d E n gine Im m ob ilis er S y s te m (1 M Z – F E ) 5 A B B–R A A B–R B–W A A To A/C Control Assembly<29–8> From Igniter <1–2><1–3> From ABS and Traction ECU<18–2> 2 To A/C Amplifier <27–4> To A/C Control Assembly <29–8> From A/C Amplifier<27–4> From A/C Control Assembly <29–8> 1 2 To Speedometer [Comb. Meter]<25–8> 2 1 V 1 B–R 1 2 I13 INJECTOR NO. 6 2 A B–R 1 A I12 INJECTOR NO. 5 2 I11 INJECTOR NO. 4 1 I10 INJECTOR NO. 3 I9 INJECTOR NO. 2 I8 INJECTOR NO. 1 B–Y 1 ID1 1 V (*6) GR BR–Y LG–B W–R L (*9) LG (*9) B (*9) W (*9) BR–W (*9) LG–B B–Y V–W V G R–L W Y R L B–R B–Y B–W W L–W B–Y 10 ID1 2 A B–R L–W A B–R W B–R F B–Y(*3) J18 JUNCTION CONNECTOR B–R E 8 B–R B–Y V7 VSV(Vapor Pressure Sensor) D 7 6 B–Y C * 4 : TMC Made * 5 : TMMK Made * 6 : Automatic A/C B–Y 16 A 6 E +B W 1 A 2 A FC HTS 3 A 9 B 6 D # 10 1 E #20 OXS 8 B EOM HAFR AFR+ 13 C AFR– 13 B A/C EGR 16 B ACT 14 A NEO EVP1 18 E 21 A EFI+ RSO 7 D 16 E 13 A EFI– 20 A 25 E TRC+ TRC– RSC 13 E IGF 12 E IGT3 HTR OXR1 3 D 11 D 15 E 14 B 11 E IGT2 TW IGT1 HTL OXL1 4 D 12 D A A B–Y 4 +B 2 B BR BR BR J20 JUNCTION CONNECTOR J24 JUNCTION CONNECTOR B B OX E1 B–Y B–Y B–Y 4 3 HT BR BR 2 II1 (Shielded) A 2 B A E1 1 BR B–Y B–Y +B Y–R A OX H4 HEATED OXYGEN SENSOR (Bank 2 Sensor 1)(*2) B–Y A 3 HT BR A B–Y 1 (Shielded) A W 2 L–B 3 H3 HEATED OXYGEN SENSOR (Bank 1 Sensor 1)(*2) A 1 Y–B R–W 1 B–Y G–R 1 I1 IDLE AIR CONTROL VALVE G–R B 1 LG B (*1) 2 B–Y B B(*1) 2 V5 VSV(EVAP) BR 4 Y–G BR 2 BR B–Y 3 2 V4 VSV(EGR) 4 1 B N 25 B SPD ACIS 17 E (Shielded) 2 BR M AFL– 21 D B–W(*4) L (*5) BR B L 22 B TPC ENGINE CONTROL MODULE L (*4) B–W(*5) 4 BR K # 60 AFL+ 12 D B–W 2 (Shielded) E1 3 A29 AIR FUEL RATIO SENSOR (Bank 2 Sensor 1)(*1) +B 1 R (*4) B–R(*5) OX G(*4) BR(*5) HT B–R 3 A28 AIR FUEL RATIO SENSOR (Bank 1 Sensor 1)(*1) G–R J 4 D 9 A 4 E #50 HAFL 3 D 11 D 20 D BR 5 EB1 B 10 IG3 1 (Shielded) E A P–B E A B–Y G–R B A G–R I 3 E # 40 R–Y E B G–R H 2 E #30 V6 VSV(Intake Air Control) E B H8 HEATED OXYGEN SENSOR (Bank 1 Sensor 2) B B B–Y B–Y G 5 D MREL BATT IGSW B–Y B–Y J27 A , J28 B JUNCTION CONNECTOR B A 8 A E 7 A , E 8 B , E 9 C , E10 D , E11 E 6 A B B SIL B–Y B–Y (*3) 9 II3 11 A TC BR BR BR BR BR B–Y BR BR 6 II3 BR BR D E F G BR BR (*1) C Rear side of surge tank ED J * 4 : TMC Made * 5 : TMMK Made J OVERALL ELECTRICAL WIRING DIAGRAM Cowl side panel LH J26 JUNCTION CONNECTOR B B B BR (*1) BR (*1) P2 POWER STEERING OIL PRESSURE SW 1 B–L To Tachometer [Comb. Meter] <25–5> B–O CF 29 E D B 1 II2 B–W 1 2 L BR NE+ 16 D BR C2 CRANKSHAFT POSITION SENSOR 2 1 B–R (Shielded) 3 EC1 (Shielded) W 1 EC1 From Park/Neutral Start SW(A/T) or Clutch Start SW(M/T) <1–2> W W 2 EC1 STA 7 A GR(*4) B–O(*5) 1 K1 KNOCK SENSOR 1 (Shielded) K2 KNOCK SENSOR 2 W 1 BR 4 EC1 (Shielded) KNKR 27 E ENGINE CONTROL MODULE NE– 24 D G22+ 10 E (Shielded) RXCK CODE BR (* 1) 10 C 5 C 4 C BR BR (*5 M/T) Surge tank RH EC BR A A BR A BR A BR (*2) A BR A G F E J22 JUNCTION CONNECTOR A BR A D C B B–Y A A BR BR BR BR (*1) BR BR A IMLD 16 C L KSW 11 C B–W NSW L–B 20 B 4 IG3 G–W (*3) 8 IG3 3 R–L (*3) R–Y C1 CAMSHAFT POSITION SENSOR E1 E03 E02 E01 17 D 30 E 31 E 21 E 2 1 4 L–Y (*3) 2 T7 TRANSPONDER KEY AMPLIFIER 5 1 A B–Y (*3) 9 THW 14 D 13 D W–B (*3) E1 EGR GAS TEMP. SENSOR THG G–Y E5 ENGINE COOLANT TEMP. SENSOR From ” STARTER” Fuse <1–2> From FAN NO. 1 Relay <26–3> TXCT G–B 2 1 BR E 7 A , E 8 B , E 9 C , E10 D , E11 E 2 D VC VTA1 23 D 15 A STP ELS2 18 A 10 BR ELS G–O 19 A From ” TAIL” Fuse <11–2> B–Y 18 D From ” MIRROR–HEATER” Fuse<26–2> E2 1 VTA VC E2 2 BR 3 G–W From Stop Light SW <11–4> L–B G–W B–W KNKL 28 E Y BR Y L To Unlock Warning SW <21–3> G–W (Shielded) T2 THROTTLE POSITION SENSOR R–Y F A TACH J27 A , J28 B Y Y To Theft Deterrent ECU <15–3> To A/C Amplifier <27–3> To A/C Control Assembly<29–8> B–O JUNCTION CONNECTOR BR BR 27 B PTNK 17 A Y 6 ID1 Y P B–O ADJ2 24 E V1 VAPOR PRESSURE SENSOR 3 II1 2 Y 3 PTNK P VCC 1 E2 BR 5 ID1 4 II1 BR 2 ID1 BR 11 F A 1 Y E2 EGR VALVE POSITION SENSOR BR E n gine C o ntro l a n d E ng in e Im mo b ilise r S y s te m(1 M Z – F E ) B E05 8 D BR (*1) PS 9 D E04 1 D E2G THA 19 D 3 22 E W–G BR 2 VG 10 D 5 2 BR M2 MASS AIR FLOW METER BR (*1) EGLS * 1 : California * 2 : Except California * 3 : w/ Engine Immobiliser System 1 3 4 L–Y 22 D B–Y 12 R–B P BR 2 CAMRY (Cont’ d) IE W–B (*3) MEMO 3 CAMRY B 7. 5A OBD 40A AM1 B–R B–R Left radiator side support 30A AM2 B B–R B–R B–R B–G W–B BL A 5 M 4 L–B W–B EB L–B BATTERY L–B F14 FUEL PUMP CIR OPN RELAY B–Y Under the left center pillar J40 JUNCTION CONNECTOR G–R FL MAIN 3. 0W 5 ID1 6 ID1 P 7 ID1 C10 MALFUNCTION INDICATOR LAMP [COMB. METER] Y F4 A , F6 C , F9 F FUSIBLE LINK BLOCK G–R 1 II2 1 3 VCC 8 II4 7 II4 V1 VAPOR PRESSURE SENSOR 1 A E A L–W 100A ALT G–R 5 EB1 R–L 4 EB1 B–Y E A B A 2 PTNK P 10 IG3 B–R (*1) 1 2 B A BR 1 3 2 2 Y 1 C 4 2F 5 2C E B E2 1 2 ID1 PIM 2 Y 3 VC E2 1 3 II2 BR Y M1 MANIFOLD ABSOLUTE PRESSURE SENSOR BR 2 F 10 2C E B B–Y B B BR BR 4 3 1 2 B B–Y B–Y(*1) G–R G–R L–R P B–Y LG Y BR B–Y B–W(* 1) B–R(*1) B–R B–Y B–Y B–Y T2 THROTTLE POSITION SENSOR BR 1 F 15A EFI 2 2J 7 II3 B–Y B–R 1 2A EFI RELAY 1 1B 1 9 B–Y (*1) 4 1B 5 B–R 1 D R–L 2 1 J4 JUNCTION CONNECTOR D 2 1D 1 1K BR 3 1 5 7 IK1 10A GAUGE B–R (*1) 5A IGN 8 1C 3 * 1 : w/ Engine Immobiliser System * 2 : w/o Engine Immobiliser System BR 1 7 2K B–W(*1) B–R(*2) 7 1W 3 1K B–R (*2) (*2) 2 W–R 8 2J B–R B–Y B–R B–R (*1) 4 2L ST2 IG2 6 IG1 4 2 B–Y 2 1K I16 IGNITION SW 7 AM2 2 AM1 ACC B B–Y E ng ine C on tro l a nd E n g in e Imm o bilis e r S y s tem (5 S – F E ) BR 10 1J W 5 1B 5 1K W–R 1 P ow e r S ou rc e R Q P O N M L K J I H G F E D C B A (Cont. next page) J OVERALL ELECTRICAL WIRING DIAGRAM Y LG Y B–Y A13 A/C EVAPORATOR TEMP. SENSOR L–R JUNCTION CONNECTOR J27 A , J28 B B–Y B–Y B–Y B G–R W–B (Cont. next page) 3 CAMRY (Cont’ d) E ng in e C o n trol an d E ng in e Im m ob ilis e r S y stem (5 S – F E ) A B C B–Y B–R(*1) B–W(*1) 10 ID1 B–Y 1 B–Y 2 V 2 A 7 C 6 C 15 B 3 C (*1) 1 A 10 C 9 C 23 C 22 C (*2) #20 #30 # 40 +B ISCO ISCC B (*3) C EGR EVP ENGINE CONTROL MODULE TXCT 9 D (*1) SIL J3 JUNCTION CONNECTOR C C 2 D5 DATA LINK CONNECTOR 3 II4 7 2 II3 A B B B H8 HEATED OXYGEN SENSOR (Bank 1 Sensor 2) P–B BR 7 1J C A 3 1 OX HT +B 2 E1 4 W–B (*1) B B–Y (*1) B–Y W–B From Airbag Sensor Assembly<28–4> C A J7 A , J8 B A A W–B 5 1 II3 SG 5 W–B 8 1J 1 5 B W B CG 4 16 A HT2 14 C (*1) 21 C (*2) (Shielded) BAT 16 JUNCTION CONNECTOR BR L–Y (* 1) 4 BR G–W (* 1) 2 B R–L (* 1) 3 C W SIL 13 B (Shielded) II4 (Shielded) 1 W OX2 6 A P–B CODE 8 D B RXCK 3 D G–R G–R BATT B V–W 12 A 12 A 4 II4 T7 TRANSPONDER KEY AMPLIFIER L–R 1 From Diode(Idle–Up) <26–1> P P2 POWER STEERING OIL PRESSURE SW B–Y 9 C 24 C 2 A (*2) B–R B–L G–R G–R L–R P Y LG 10 C 25 C #10 A B–Y (*4) 2 P–B 12 B B–O 5 A 14 A W 10 B B–Y 7 B B–Y 2 B W 11 B I11 INJECTOR NO. 4 1 B B–R 3 B ELS Y 4 B PSSW 4 C 13 A I10 INJECTOR NO. 3 FC B–R W 4 A 14 A B–Y 12 II2 B–Y(*1) BR A B–Y B Cowl side panel LH IE IG J11 JUNCTION CONNECTOR Instrument panel brace LH BR R THR 11 B LG P Q PTNK 8 B Y O PIM 2 B Y–B N VTA 10 B G–B M VC 1 B 1 11 C IGSW G–B Y–B L THA 3 B 1 3 11 C L–Y (*1) THW 1 1 12 C E 7 A , E 8 B , E 9 C , E10 D 4 B 2 2 12 C G–W (*1) 2 MREL 1 R TPC 1 A 1 B 2 R–L (*1) E5 ENGINE COOLANT TEMP. SENSOR I14 INTAKE AIR TEMP. SENSOR 2 1 7 D 2 L 8 B B–R (* 1) 16 B B–W (* 1) BR BR 9 B 9 B I9 INJECTOR NO. 2 I8 INJECTOR NO. 1 6 II4 2 B B–R B–R B–W (*1) 5 II4 V BR E2 1 K B V5 VSV(EVAP) B V4 VSV(EGR) B V BR I1 IDLE AIR CONTROL VALVE 2 V BR J21 JUNCTION CONNECTOR B 1 I B 12 II3 1 ID1 J B B–Y B–R B–R V7 VSV(Vapor Pressure Sensor) H B B B–R G 8 J19 JUNCTION CONNECTOR B B–Y F * 3 : California * 4 : Except California B–Y E 7 6 B–Y B–Y D 5 B–Y * 1 : w/ Engine Immobiliser System * 2 : w/o Engine Immobiliser System BR BR D E J B (*3) C A11 AIR FUEL RATIO SENSOR G (*3) L–B R–Y R–Y W B–O J27 A BR A A A A Intake manifold 14 C (*2) 15 C EOM 2 D BR R–Y EC Intake manifold BR BR BR EC A BR A A TE1 E01 E02 E03 13 C 26 C 25 C (*1) 13 C 26 C 16 B (*2) A J23 JUNCTION A CONNECTOR IGT2 BR BR 6 II3 E1 24 C IGF BR BR L BR 1 13 B E04 15 C BR To Tachometer [Comb. Meter] <25–5> 1 5 C KNK IGT1 15 B (*2) BR (*4) 3 E1 1 : w/ Engine Immobiliser System 2 : w/o Engine Immobiliser System 3 : California 4 : Except California D1 DATA LINK CONNECTOR 1 7 B (*1) 8 TE1 +B 12 * * * * BR BR L–B To Unlock Warning SW <21–3> L–B To Theft Deterrent System<15–3> (Shielded) 1 2 17 C L 8 IG3 2 G+ (Shielded) F A NE– 6 D 11 D STA 12 B NSW BR 4 IG3 B–O F A 4 C 12 D NE+ MGC A/C SW LOCK ENGINE CONTROL MODULE PRS BR (*3) 9 II4 LOCK IN E 7 A , E 8 B , E 9 C , E10 D STP 3 C 19 C 23 C 17 C 22 C 20 C BR 3 II4 9 A 8 A V–W 8 A 7 A SPD HT1 H3 HEATED OXYGEN SENSOR (Bank 1 Sensor 1) 4 D (Shielded) TACH OX1 11 A 11 A 22 A 22 A 20 A 10 A 10 A 15 A 21 A L–Y 21 A From MG CLT Relay<27–3> 18 C 13 A R–B 19 C 19 A From A/C SW <27–4> 1 D L(*5) W(*6) (*3) 4 A R–W KSW W (*4) 9 A From A/C SW <27–4> AF+ L–Y (*4) 1 C G–W 8 C From Stop Light SW<11–4> W–L 6 B G 5 B From A/C Dual Pressure SW<27–4> 6 B From ” STARTER” Fuse<1–2> B–W (A/T) GR(*5) B–O(*6) 6 B W–L 10 II3 11 From Ignition Coil and Igniter No. 1, No. 2<1–3><1–4> B AF– 14 B HT 1 W–R HTAF (*3) 14 B B–W(*5) O (*6) 2 C BR 2 C OX 3 E1 4 To A/C Magnetic Clutch and Lock Sensor<27–4> Y–R BR E AF– 4 +B 2 BR BR (*4) 10 From Park/Neutral Position SW(A/T) or Clutch Start SW(M/T)<1–2> L–W IMLD HT 1 AF+ 3 B–Y (* 4) +B 2 9 E n gine C o ntro l a n d E ng in e Im mo bilis er S y s te m (5 S – F E ) B–Y BR D B–Y (*4) B A B–Y 3 CAMRY (Cont’ d) 12 * 5 : TMC Made * 6 : TMMK Made J OVERALL ELECTRICAL WIRING DIAGRAM BR(*4) BR BR BR BR (*3) K1 KNOCK SENSOR 1 (Shielded) B–W C1 CAMSHAFT POSITION SENSOR C2 CRANKSHAFT POSITION SENSOR BR B–R (Shielded) To Speedometer [Comb. Meter] <25–8> JUNCTION CONNECTOR 4 CAMRY 1 2 2 AM1 IG1 4 3 1K B–Y 1 1K 1 1J A 7 5 II2 6 II2 1 IJ1 3 II3 4 II2 A G–W D R–B A D R–B 7 2K 8 2J D R W–R B–Y E L–W(*3) 0 (*4) J29 JUNCTION CONNECTOR B–W J35 JUNCTION CONNECTOR B–R C L–W(* 3) 0 (*4) J29 JUNCTION CONNECTOR C B–W 5 1B 4 2L II2 Y B–R W E Y E Y 2 1K 9 G–W PL 8 R–B RL 9 R–L I16 IGNITION SW 5 1K 2 1D NL 10 R 7 1W DL 3 B–R ST2 2L 4 L–W 2 II2 LL Y B–R P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] J24 JUNCTION CONNECTOR R–L IG2 6 2 C A R–L 10A GAUGE 5A IGN W–R 7 AM2 JUNCTION CONNECTOR F B 1 : California 2 : Except California 3 : TMC Made 4 : TMMK Made 4 R–L J28 B R–L ACC 3 F B R–L B–Y B–R W * * * * E le ctro n ic a lly C on tro lled T ra ns m is s io n a nd A /T Ind ic a tor (1 M Z – F E ) P o w er S ou rc e R–B 1 C A A B 3 16 IG3 8 A 2 A MREL IGSW 12 B 3 B 2 B L 2 R 7 E 8 E 8 A 9 A 16 B C 8 A , C 9 B , C10 C COMBINATION METER G–O A J6 JUNCTION CONNECTOR A C O2 A O/D MAIN SW 2 4 W–B A A B ED BR (*1) B Rear side of surge tank J5 JUNCTION CONNECTOR J26 JUNCTION CONNECTOR W–B EC W–B J22 JUNCTION CONNECTOR A BR (*1) A Surge tank RH C G–O C G–O E3 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 12 A G–O 1 BR Left radiator side support 10 A OD2 11 IG3 BR (*2) From Cruise Control ECU<17–3> W–B EB 7 A 10 B BR B W Y R L W–B BATTERY S2 E1 17 D BR S1 E02 31 E BR SL 6 E01 21 E 2 BR SLN+ 3 E03 30 E R SLN– 2 V3 VEHICLE SPEED SENSOR (Electronically Controlled Transmission) 1 7 II2 L–B 4 L–B A J26 JUNCTION CONNECTOR A L–B NC2+ 14 E G L–B V P–L W–L B A 26 E A ENGINE CONTROL MODULE NC2– 11 A P 9 E IDLO R S2 6 A 4 B OD1 N S1 24 B D 20 E B–Y B B B–Y FL MAIN 3. 0W 19 E SL B–Y B–G J27 A , J28 B JUNCTION CONNECTOR 1 A 16 A F4 A , F6 C , F9 F 100A ALT FUSIBLE LINK BLOCK 1 C SLN+ SPD 2 E 7 A , E 8 B , E 9 C , E10 D , E11 E SLN– 22 B G–W E2 L B–R B–R 2 F THW 15 IG3 R–B VTA1 R VC 10 1H B–R NSW O/D OFF B–Y W–B W–B B 2 D 23 D 14 D 18 D 20 B 14 IG3 O B–R BATT 13 IG3 Y D 7 C 1 A 5 1V D R–L L–R Y–B V–W R–B 5 2C 4 2F 2 2J +B 1 F Y 1 2A B–R B–W B–Y 1 1B B–R 2 Y 1 See Engine Control and Engine Immobiliser System<2–9><2–10><2–11> To Speedometer [Comb. Meter] <25–8> From Cruise Control ECU <17–3> L–W(*3) 0 (*4) 15A EFI C A J4 JUNCTION CONNECTOR EFI RELAY 40A AM1 30A AM2 5 J27 A , J28 B JUNCTION CONNECTOR 2 IF Left kick panel J W B–R 40A AM1 B–R B–R L–B L–B L–B B–G J23 JUNCTION CONNECTOR Intake manifold BR EC 9 A Intake manifold 13 C 26 C 16 B SPD 8 A To Speedometer [Comb. Meter] <25–8> BR LOCK–UP JUNCTION CONNECTOR J27 A , J28 B W–B W–B FUSIBLE LINK BLOCK F4 A , F6 C , F9 F EC A A E02 BR OD2 5 A (*3) 7 A (*4) IDLO 11 IG3 C 4 2 C C 12 A 7 C O2 O/D MAIN SW W–B J6 JUNCTION CONNECTOR 6 A 11 A A IF A A 16 B 7 A W–B B NO. 2 W NO. 1 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID BR (California) A 14 C BR 15 C E01 25 C 13 C 26 C BR S2 E1 24 C OD1 G–O E3 A , E4 B S1 7 II2 J25 JUNCTION CONNECTOR A L–B E04 15 C E03 R 2 L V–W 1 B A A 6 C 21 C S2 IGSW W–B EB SL 3 B P 1 A 7 C 1 C 8 C V B A B B B–Y G–O Left radiator side support 12 A 20 C S1 STP ENGINE CONTROL MODULE TE1 20 A 8 A 9 A 15 IG3 10 1H 5 1V 4 II2 II3 Left kick panel 7 PL C 8 A , C 9 B , C10 C COMBINATION METER 10 A J5 JUNCTION CONNECTOR D BATTERY EFI RELAY 12 A E2 E7 A , E8 B , E9 C THW 3 A (* 3) 3 A (* 4) 18 A O/D OFF FL MAIN 3. 0W W–B SL VTA J27 A , J28 B JUNCTION CONNECTOR 1 A B–Y +B VC 17 A 17 A 16 A 18 A 15 A 19 A N 100A ALT B 1 C B–Y NSW 1 A J4 JUNCTION CONNECTOR R–L BATT MREL 9 A 4 A 7 B 15 B B–R (*3) 9 B Y 9 B R–B 4 B Y–B 4 B L–R 10 B 14 IG3 13 IG3 16 IG3 Y 11 B D D L O 1 B From Cruise Control ECU <17–3> 2 B–R 1 B B–R (*3) 22 A R–B J29 JUNCTION CONNECTOR 22 A C A R 2 F B–W (*3) 7 D A B C A A 3 8 RL R–B 1 A See Engine Control and Engine Immobiliser System <3–5><3–10><3–11> L–W(*1) O (*2) 2 A II4 Y 2 2J 6 Y 5 2C 4 2F 3 5 L–W(*1) O (*2) G–W 1 F 1 2A 2 1 D A B–R 1 1B 15A EFI R–B D L–W(* 1) O (*2) 1 30A AM2 7 2K 8 2J R–L 2 W–R 4 2L J29 JUNCTION CONNECTOR D 1 IJ1 9 II2 9 NL B–R 2 1K E E II2 10 DL R L–W(* 1) O (*2) E 6 3 2L P1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] R–B B–Y Y 5 II2 Y R–L 2 II2 4 LL L–W 5 1B J28 B R–L A A B–R JUNCTION CONNECTOR F B F B J21 JUNCTION CONNECTOR 2 C 4 R G–W B–W (* 3) B–R (* 4) 2 1D 10A GAUGE 1 1J R–L R I16 IGNITION SW 7 1W 5A IGN 1 1K 3 1 : TMC Made 2 : TMMK Made 3 : w/ Engine Immobiliser System 4 : w/o Engine Immobiliser System R–B 5 1K B–R IG2 6 3 1K R–L * * * * G–W ST2 B–Y IG1 4 ACC 2 R–L W–R 7 AM2 2 AM1 B–R E le ctron ic a lly C on tro lle d T ra ns m is s io n a nd A /T Ind ica to r (5 S – F E ) B–Y W 1 P o w er S ou rc e 5 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM P G–O G–O BR From Cruise Control ECU<17–3> B–Y 6 CAMRY H ea d lig ht (w /o D ay time R u nn in g L ig h t) P ow er S ou rc e 1 3 2 2 4 1 HEAD RELAY 40A MAIN 4 15A HEAD (LH) 3 15A HEAD (RH) 2 1 3 2B 8 2K 3 2G 3 B 2 1 1 2 D B D B J35 A , J36 B 8 13 EL F B R–L F B R–Y C13 COMBINATION SW R–L 4 F4 A , F6 C R–B R–B 1 C H T HF HL JUNCTION CONNECTOR HI D A OFF F A F A TAIL R–L HEAD R–L R–B LIGHT DIMMER SW CONTROL SW B–G FL MAIN 3. 0W H2 HEADLIGHT RH R–B I17 INTEGRATION RELAY 1 A 3 H1 HEADLIGHT LH 3 FUSIBLE LINK BLOCK R–W R–B B R–B B 8 2C R To Theft Deterrent ECU<15–3> 6 2G R–B J32 JUNCTION CONNECTOR B R–B B 4 2G LOW HIGH 3 IG1 FLASH 17 R–L 16 7 W–B 8 R–B C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] A A BATTERY R–L 9 W–B W–B J7 JUNCTION CONNECTOR 8 1J A J5 JUNCTION CONNECTOR 7 1J J11 JUNCTION CONNECTOR IG A W–B W–B A Instrument panel brace LH IF Left kick panel J B–R B B B–R B–R W–B IG JUNCTION CONNECTOR R–B R–B B–G 7 1J 8 1J B I17 INTEGRATION RELAY A A A 16 W–B W–B To Theft Deterrent ECU <15–3> IF A A 9 Left kick panel J5 JUNCTION CONNECTOR R LIGHT DIMMER SW CONTROL SW J7 JUNCTION CONNECTOR W–B FLASH HIGH LOW 8 18 8 EB1 20 DIM 2 4 R 2 2 2 7 EB1 4 3 2 2 5 2G 2 2 EB 2 1 3 1 W–B Instrument panel brace LH W–B J1 JUNCTION CONNECTOR B HI R–L A B HF C9 HIGH BEAM INDICATOR LIGHT[COMB. METER] J11 JUNCTION CONNECTOR B T 7 3 IG1 21 H–ON H–LP 2 2 R BATTERY R–B J27 A , J28 B HEAD H 8 R–Y TAIL OFF EL 13 3 R–W 3 4 R–Y R–B D6 DAYTIME RUNNING LIGHT RELAY(Main) IND HEAD RELAY FL MAIN 3. 0W 2 10A GAUGE R–Y F4 A , F6 C , F9 F 12 HI T W–R 3 1 W–R FUSIBLE LINK BLOCK V–Y TAIL 2 2 R 15A HEAD LH(UPR) 1 A V–Y +B 19 2 1 R 4 2G R–B 100A ALT P–L 2 F P–L H R–L E R–W CHG– To Brake Fluid Level Warning SW<25–5> PKB Y BRK R IG R–W CSE G–R CSO From TAILLIGHT Relay <10–1><11–2> 17 G–Y 16 R CSB 22 To Integration Relay <10–1><11–1> 13 3 2G 2 5A DRL NO. 2 14 To Parking Brake SW <25–5> 4 From Generator <1–4> 23 8 2K 3 1 DIM RELAY 5 7 1V 40A MAIN 4 R–L R 15 D A 1 1W 2 1 3 2B 4 2 2G R–B Left radiator side support W–B DRL NO. 4 RELAY R–B H1 HEADLIGHT LH 15A HEAD RH(UPR) 6 8 IG1 GR–R 9 IG1 GR–R 4 IG1 F B R–L 3 CLTE SHORT PIN 4 12 2J 7. 5A DOME R CLTS 2 1 1 2A 3 R–B 1 CLTB 1 1J 1 1K 2 2 1 R–W R 10A H–LP LH(LWR) 1 1B 1 A40 AUTOMATIC LIGHT CONTROL SENSOR IG1 4 ACC I16 IGNITION SW 2 AM1 B–Y B B H ea dlig ht (w / D a y tim e R u n ning L igh t) R–L 2 2 3 1 2 1 2 D2 DAYTIME RUNNING LIGHT RESISTOR R–B H2 HEADLIGHT RH 3 1 2 R–G 1 C 40A AM1 2 2 1K W 1 P o w e r S o ur ce 10A H–LP RH(LWR) 1 F 7 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM R–Y R–Y C13 COMBINATION SW W–B R–B 8 CAMRY P o w er S ou rc e T urn S ign al a nd H a za rd W ar ning L igh t 1 B ac k – U p L igh t 3 2 4 B ACC 2 AM1 IG1 4 B–Y 1 1K R–L R–L 10A GAUGE W 7. 5A TURN I16 IGNITION SW 1 2A 10A HAZARD 2 II2 F 2 1L 1 1J H7 HAZARD SW 2 F 40A AM1 W 10 TB R–L TL 2 B2 TR TL OFF LH ON OFF TB A TR 5 6 G–W G–R 1 3 G–Y B–R G–B 8 1V 6 1H 5 1A 3 8 A (A/T) 1 B (M/T) 1 3 R10 BACK–UP LIGHT RH [REAR COMB. LIGHT RH] W–B W–B 5 1V R–B C W–B Back panel center 3 13 1S R–B 1 3 II3 R8 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] BP 2 B (M/T) R–B 2 W–B W–B IF 2 A (A/T) R–B 3 W–B Left kick panel R–L (5S–FE) R–B W–B A A B B A W–B Left radiator side support B A W–B J5 JUNCTION CONNECTOR F2 FRONT TURN SIGNAL J35 A , J36 B LIGHT RH JUNCTION CONNECTOR G–Y G–Y 5 2 1A R11 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] G–Y 6 W–B EB C 9 B , C10 C TURN SIGNAL INDICATOR LIGHT[COMB. METER] IG G–Y Instrument panel brace LH 16 B W–B J11 JUNCTION CONNECTOR 1 C LH A W–B BATTERY W–B 2 F1 FRONT TURN SIGNAL LIGHT LH G–B 3 1 B RH W–B FL MAIN 3. 0W 5 1 EB1 G–B B–G B C 6 G–B G–B 1 C C R9 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] C J15 JUNCTION CONNECTOR A R–B 6 1S G–B F9 F FUSIBLE LINK BLOCK 10 1C 8 1H 11 1S G–B F4 A , F6 C , G–Y 2 F 100A ALT D G–Y T6 TURN SIGNAL FLASHER B–R B–R 1 F 1 G–B 2 P1 A BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW](A/T) D G–Y B1 B BACK–UP LIGHT SW (M/T) G–Y 1 A J15 JUNCTION CONNECTOR D RH A J21 JUNCTION CONNECTOR R–L (1MZ–FE) 9 G–B 7 J24 JUNCTION CONNECTOR C13 TURN SIGNAL SW [COMB. SW] 1 1 1B R–L (5S–FE) G–B 8 B1 F R–L (1MZ–FE) G–R 2 1K J28 JUNCTION CONNECTOR 3 2K R–L C J27 JUNCTION CONNECTOR Under the left center pillar A J40 JUNCTION CONNECTOR BL J J OVERALL ELECTRICAL WIRING DIAGRAM L6 LUGGAGE COMPARTMENT LIGHT SW R–Y L5 LUGGAGE COMPARTMENT LIGHT 1 2 R–Y 1 R From Theft Deterrent ECU<15–3> R–Y Cowl side panel LH I15 IGNITION KEY CYLINDER LIGHT 2 G–R 1 : w/ Fade Out 2 : w/o Fade Out 3 : w/o Theft Deterrent System 4 : w/ Theft Deterrent System 3 1V W–B W–B BM Roof left 2 R–W (*1) R–W From Wireless Door Lock ECU<14–6> D A From Theft Deterrent ECU <15–2> R–G E A 6 IN2 E A R–G D12 DOOR COURTESY SW FRONT LH R–G 1 7 1S 1 1G W–B JUNCTION CONNECTOR From Theft Deterrent ECU <15–2> A A B J 9 A , J10 B JUNCTION CONNECTOR R–G R–G From Theft Deterrent ECU <15–1> F4 A , F6 C , F9 F 1 F 100A ALT 2 F B–R 1 A B B–R 1 C 1 1B 1 B–R 40A AM1 2 2 1K FUSIBLE LINK BLOCK B–G FL MAIN 3. 0W BATTERY IG J11 JUNCTION CONNECTOR W–B C A 8 A (*3) 6 B (*4) 10 6 3 C 2 C 1 C I16 IGNITION SW ACC IG1 4 2 AM1 B R–G 7 1J 4 C B–Y B 1 W R–G D13 DOOR COURTESY SW FRONT RH R–G 1 E A 2 1 D7 DIODE (Courtesy) I18 A , B I17 C , 7 R–G INTEGRATION RELAY 10A GAUGE R–W D B 4 1G 4 R–W R–G See Taillight System<11–1> 1 R–W 1 R–W J33 A , J34 B See Headlight System<6–2><7–2> D15 DOOR COURTESY SW REAR RH R–W D14 DOOR COURTESY SW REAR LH 1 7. 5A DOME 1 1K 8 IN2 R–W R–W D A 12 1S 9 1S 1 1W 12 2J 2 SHORT PIN R R–W (*2) E B R 8 1G R–Y G–R E B 11 1H 6 1F 1 1M 2 1F 2 1M 2 5 1F R R 1 1 2A R–W (*2) 1 DOOR I19 INTERIOR LIGHT D A R From Light Failure Sensor<11–4> ON OFF R R–W L ig h t A u to T ur n O ff W–B P5 PERSONAL LIGHT C16 CONDENSER 2 1 R 2 W–B (w/ Moon Roof) 1 2 R (w/ Moon Roof) Instrument panel brace LH 1 R D10 DIODE (Dome) 2 * * * * G–R R–W 2 V8 VANITY LIGHT LH R P ow er S ou rc e W–B W–B 1 R R 3 In te rio r L igh t V9 VANITY LIGHT RH R 9 CAMRY W–B 2 W–B 1 R 3 1F 1 R R IE 11 E 10 R–W E J16 JUNCTION CONNECTOR R R 4 C9 OPEN DOOR WARNING LIGHT [COMB. METER] 10 CAMRY P o w er S ou rc e * 1 : Separate Type Amplifier * 2 : Built–In Type Amplifier * 3 : Automatic A/C Illu mina tio n 1 * 4 : Manual A/C * 5 : w/ Daytime Running Light * 6 : w/o Daytime Running Light 3 2 4 G 1 5 TAILLIGHT RELAY 7. 5A PANEL 2 A A 3 A A A A A A J30 A , J31 B JUNCTION CONNECTOR 4 1B 6 1C 4 1J G 1 W–B 2 G3 GLOVE BOX LIGHT AND SW B J5 JUNCTION CONNECTOR C10 COMBINATION METER ILLUMINATION [COMB. METER] R4 C A A A W–B A A B W–B B A 3 D A B 8 1J 6 1V 4 1H B E B D A 1 E D A W–B BATTERY 12 5 IH2 E B J7 JUNCTION CONNECTOR 13 W–G (*1) A A 3 W–G (*1) W–G (*2) W–B A J13 A , J14 B JUNCTION CONNECTOR 1 B A A 16 9 C RADIO AND PLAYER 5 B R2 B , R3 A 3 RADIO AND PLAYER H7 HAZARD SW 2 2 C O2 A/T SHIFT LEVER ILLUMINATION [O/D MAIN SW] B G (*1) G 2 B HEAD FL MAIN 3. 0W 1 10 A B (*3) TAIL C13 COMBINATION SW 2 A24 ASHTRAY ILLUMINATION A B 12 A34 A/C CONTROL ASSEMBLY B (*4) A B G G (*3) B5 BLOWER SW 7 10 IH1 B B G (*4) 3 6 B (*4) A B 4 A14 A/C SW A B 1 B B G (*4) B–G LIGHT CONTROL SW OFF 2 B H C5 CIGARETTE LIGHTER ILLUMINATION T 2 B (*4) EL To Daytime Running Light Relay(Main)<7–3> 14 From Daytime Running Light Relay(Main)<7–3> 1 R5 REAR WINDOW DEFOGGER SW 6 G G (*4) I17 INTEGRATION RELAY B B G B B G B B B A G JUNCTION CONNECTOR G (*2) G–Y (*5) G F4 A , F9 F 1 A B A G–R (*5) 2 FUSIBLE LINK BLOCK 100A ALT G (*1) A G–R (*6) B–R 2 F A B G G–R J2 JUNCTION CONNECTOR A B J13 A , J14 B A B–R B–R 1 F 5 1D T ILL 2 R7 RHEOSTAT B J16 A , J17 B JUNCTION CONNECTOR W–B 7 1J W–B J11 JUNCTION CONNECTOR IG Instrument panel brace LH IF Left kick panel J J OVERALL ELECTRICAL WIRING DIAGRAM 5 2 W–B R10 TAILLIGHT RH [REAR COMB. LIGHT RH] 4 G–O 9 W–B 3 G–O G–O G Back panel center W–B W–B A A J40 JUNCTION CONNECTOR W–B 3 5 1 R9 TAILLIGHT LH [REAR COMB. LIGHT LH] SIDE MARKER G W–B (*6) 1 G L1 LICENSE PLATE LIGHT LH W–B 2 G G (*6) G–O * 1 : TMC Made w/ ABS w/o Traction Control * 2 : TMMK Made w/ ABS w/o Traction Control * 3 : w/ ABS and Traction Control 3 W–B 1 W–B 2 1 C B W–B W–B J7 JUNCTION CONNECTOR To Engine Control Module<2–10> 1 1B A A W–B Instrument panel brace LH BATTERY IG J11 JUNCTION CONNECTOR 8 1J 7 1J HEAD TAIL C13 COMBINATION SW W–B A F4 A , F9 F FUSIBLE LINK BLOCK B–G FL MAIN 3. 0W 100A ALT 1 A B–R 2 F B–R B–R 1 16 EL H T OFF 1 14 2 A B–R 1 F 40A AM1 2 2 1K W W–B LIGHT CONTROL SW B–R 4 1B 7 1C W G–R (*5) I17 INTEGRATION RELAY G To Wireless Door Lock ECU<14–7> To Theft Deterrent ECU<15–3> 15A STOP 2 AM1 1 TAILLIGHT RELAY From Daytime Running Light Relay(Main)<7–3> G–Y (*4) J2 JUNCTION CONNECTOR G–R (*4) A G–R A 6 1C 3 2 1 5 I16 IGNITION SW IG1 4 ACC To Daytime Running Light Relay(Main)<7–3> G–R Left radiator side support 1 W–B 2 G–O EB F1 FRONT PARKING LIGHT LH A A A A G–O (1MZ–FE) G–O C B J12 JUNCTION CONNECTOR F2 FRONT PARKING LIGHT RH G–O A 9 1C 10A TAIL G–O G–O JUNCTION CONNECTOR G 2 G J35 A , J36 B 8 1S G TAIL B–Y 2 G L2 LICENSE PLATE LIGHT RH W–B BL W–B 5 1 W–B G–O 3 11 W–B R11 TAILLIGHT RH [REAR COMB. LIGHT RH] SIDE MARKER W–B G (*6) BP W–B 3 W–B 4 G–O Under the left center pillar 8 R8 TAILLIGHT LH [REAR COMB. LIGHT LH] TAIL T a illig ht Back panel center R9 STOP LIGHT LH [REAR COMB. LIGHT LH] BP W–B W–B G–R 5 2 2 4 5 IF2 Y–G W–B G–O P ow er S ou rc e BL A A 1 2 1 W–B G (*6) 11 CAMRY Under the left center pillar J40 JUNCTION CONNECTOR 2 1H 7 L3 LIGHT FAILURE SENSOR C 8 A , C10 C Y–G R–L 1 1S W–B G–R 7 C D 2 1D 1 1K * 4 : w/ Daytime Running Light * 5 : w/o Daytime Running Light * 6 : TMC Made W 10A GAUGE R–L D R–L 3 5 1R G–W (*3) H10 HIGH MOUNTED STOP LIGHT R R To Condenser <9–3> R11 STOP LIGHT RH [REAR COMB. LIGHT RH] 3 A To ABS and Traction ECU<18–2> G–W To Shift Lock ECU <16–3> REAR LIGHTS WARNING LIGHT [COMB. METER] G–W (*2) G–W G–W J27 A , J28 B JUNCTION CONNECTOR To ABS Actuator and ECU<20–1> C B G–W (*1) C B To ABS ECU <19–3> J4 JUNCTION CONNECTOR G–W A A 1 To Engine Control Module <2–10><3–10> 4 S top L igh t 4 1R G–W 2 W 2 1S S6 STOP LIGHT SW 12 CAMRY P o w e r S o u rc e W ipe r a n d W a s h er 1 R em o te C o n trol M irr or 3 2 4 * 1 : TMMK Made * 2 : TMC Made w/ Mirror Heater * 3 : TMC Made w/o Mirror Heater L–R IG1 4 B–Y L–R ACC 3 2 AM1 1 1K 6 1K I16 IGNITION SW W 25A WIPER 40A AM1 E A +B +2 +1 +S INT1 INT2 B1 EW WF 2 M WF EW WIPER RELAY +2 2 8 +1 7 +S LEFT +B 16 RIGHT UP MH L L–Y L–B L–O W–B HL LEFT/ UP 8 A A VR 7 B 4 2F 15 IM1 LG–R LG–B BR–R 1 A 3 A 2 A 1 A 3 A 2 A (*1) 4 B 2 B 3 B 4 B 2 B 3 B (*2) 3 C 1 C 2 C 3 C 1 C 2 C (*3) A J5 JUNCTION CONNECTOR 4 M M M M W–B Instrument panel brace LH 14 IM1 A W–B IG 16 IM1 LG–R W–B E F3 FRONT WIPER MOTOR A 15 IE1 BR–Y 10 2J J11 JUNCTION CONNECTOR 14 IE1 BR–W W–B M BATTERY 16 IE1 C W–B W–B FL MAIN 3. 0W LG–B S BR–R +1 10 C LG–R 2 BR–Y 1 BR–W B–G +2 5 E 6 C L 3 M+ LG–B J4 JUNCTION CONNECTOR LG–R J15 JUNCTION CONNECTOR A 1 LG–R L VL BR–Y 5 L–W 1 A RIGHT/ DOWN MV HR BR–R F4 A , F9 F FUSIBLE LINK BLOCK 6 IK1 DOWN 17 SELECT SW L–W B–R B–R 11 R6 REMOTE CONTROL MIRROR SW 9 B WASHER OPERATION SW W2 WASHER MOTOR B–R 100A ALT P–L V LO L L 2 1 2 F J6 JUNCTION CONNECTOR A E B HI 1 F A OFF INT 1 1 1B 1 1T P–L 2 C11 WIPER AND WASHER SW [COMB. SW] L J35 A , J36 B JUNCTION CONNECTOR 2 1K 1 1A To Wireless Door Lock ECU<14–7> 4 1C 15A CIG Left radiator side support EB R16 A , B , C R17 A , B , C REMOTE CONTROL MIRROR LH REMOTE CONTROL MIRROR RH IF Left kick panel J B–R B–R B–R B–R 100A ALT J33 A , J34 B JUNCTION CONNECTOR W–B (*3) B–G Cowl side panel LH W–B FUSIBLE LINK BLOCK 2 R UP G L–W See Light Auto Turn Off System<9–1> INTEGRATION RELAY I18 A , B F4 A , F9 F M P11 POWER WINDOW MOTOR FRONT RH 1 2 1 5 D R UP G M P12 POWER WINDOW MOTOR REAR LH 1 U 3 1 U 2 5 D 1 4 SD 2 SU M P13 POWER WINDOW MOTOR REAR RH B 3 BP1 2 BP1 G W–B(*4) G P10 POWER WINDOW MOTOR FRONT LH 2 R 1 B 4 SD 2 SU UP W–B W–B IE M L 3 U D G–W R IG 1 B 3 G–B 2 G–Y SD R–B 5 3 BO1 G–B SU 1 BP1 R–Y 2 BO1 7 IN2 5 IN2 G–B 3 1V 4 1 BO1 5 IM2 4 IM2 DOWN R–L L L DOWN L 5 IF1 12 IE2 6 IE2 13 RRD DOWN Instrument panel brace LH J11 JUNCTION CONNECTOR A 6 IM2 DOWN L L DOWN L 1 IF1 9 IE2 7 IE2 8 RRU DOWN BATTERY L–W R–B 7 1G W–B (*3) R–B FL MAIN 3. 0W UP L 20 IE1 NORMAL WINDOW LOCK SW A UP 9 IN2 11 IE2 G–W W–B (*4) LOCK J4 JUNCTION CONNECTOR A L A 5 IE2 R–L W–B (*4) 5 G–Y A A DD 1 G DU R–Y 1 A W–B W–B (*3) J38 JUNCTION CONNECTOR A 4 E 12 RLD G–B A A L C B 3 E 9 RLU REAR RH R–B 2 F 6 B 13 1G L 3 1S UP 7 1J G–W 7 1S 1 1D R–L 13 A (* 1) 1 B (* 2) 6 PD G–Y 8 A 10 14 PU REAR LH R–Y B–R 10A GAUGE 6 (*2) 3 B 3 FRONT RH P9 POWER WINDOW MASTER SW G–B 1 1B R–B 1 7 2 POWER RELAY BW 4 1 : w/o Theft Deterrent System 2 : w/ Theft Deterrent System 3 : TMC Made 4 : TMMK Made UP (*1)12 A 5 11 3 * * * * R–B 1 F W 40A AM1 1 BW B L(*4) 2 10 B B L(*3) FRONT LH J38 JUNCTION CONNECTOR 10 IE2 L(*3) 2 30A POWER 12 1G L(*4) 2 1K 25A DOOR 1 5 1G 4 1B L L(*3) 1 1K IG1 4 B–Y ACC R–B 2 P o w er W in do w L(*4) I16 IGNITION SW 1 B–R 2 AM1 P o w er S ou rc e 13 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM P8 POWER WINDOW CONTROL SW REAR RH P7 POWER WINDOW CONTROL SW REAR LH P6 POWER WINDOW CONTROL SW FRONT RH DOWN R MEMO L–W B–R SHORT PIN B B–R B–R J33 A , J34 B 25A DOOR W–B (*3) B–G FL MAIN 3. 0W IE Cowl side panel LH W–B (*3) 7 1G W–B (*4) W–B (*4) (*3) 20 IM1 W–B (*3) 20 IE1 W–B (*4) W–B W–B IJ W–B (*4) W–B (*3) Right kick panel W–B (*4) Instrument panel brace LH A W–B (*4) 3 1V W–B (*3) W–B D18 DOOR LOCK CONTROL SW RH G UNLOCK W–B(*3) LOCK J38 JUNCTION CONNECTOR A W–B (*3) 2 W–B(*4) M 3 J40 JUNCTION CONNECTOR 1 4 11 IE1 8 IE2 3 IE2 L–R From Theft Deterrent ECU<15–2> L–R BL D19 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH IG P9 DOOR LOCK CONTROL SW LH [POWER WINDOW MASTER SW] G W–B UNLOCK (*4) W–B (*3) LG LOCK J11 JUNCTION CONNECTOR LG A F F F 7 A W–B 6 BO1 M 3 Under the left center pillar A 2 4 1 4 BO1 7 BO1 L–Y 5 BO1 6 IF2 7 IF2 L–B L–B (*1) L–B L–R L–R L–R 2 IF2 25 B 6 A 12 B B B C A C B B A L–Y JUNCTION CONNECTOR J30 A , J31 B C B B A B A B B L–B L–B L–R L–R 4 1 IN2 2 IN2 7 B 10 A 1 : w/o Theft Deterrent System 2 : w/ Theft Deterrent System 3 : TMC Made 4 : TMMK Made C A C A * * * * W–B(* 4) W–B(* 3) L–Y L–B L–B L–R L–R Y L–Y L–R L–W R–G 11 A (*1) 9 B (*2) R–Y M L K J I H G F E D C B A (Cont. next page) L–Y BATTERY A UNLOCK W–B (*3) L–R F9 F From Theft Deterrent ECU<15–2> W–B (*4) J39 JUNCTION A W–BCONNECTOR D16 DOOR KEY LOCK AND UNLOCK SW FRONT LH L–W LOCK A L–W A L–R A 1 3 L(*2) L–B A 2 L(*2) L–R FUSIBLE LINK BLOCK R–G W–B (*4) 1 2 F 7 1S 6 B 8 A See Light Auto Turn Off System<9–1> 6 9 A (*1) 5 B (*2) 3 L–R L–R F4 A , F6 C , 3 3 4 IM1 L–B(*1) L–B 100A ALT LG D17 DOOR KEY LOCK AND UNLOCK SW FRONT RH L UNLOCK 2 F 4 LG 5 From Theft Deterrent ECU<15–2> 6 3 IM1 L–W 7 R–G 4 IE1 L–W 3 IE1 A L 2 12 IM1 B L–W J37 JUNCTION ACONNECTOR B 11 B J6 JUNCTION CONNECTOR 1 F JUNCTION CONNECTOR G 13 IM1 B B B A R–G From Theft Deterrent ECU<15–2> 4 1B LG G 12 IE1 B J6 JUNCTION CONNECTOR 13 IE1 E B B 5 A 20 B L L–R L–Y 1 A 7. 5A DOME D B R–G 3 A 18 B L–W D R–G 1 1D E G J6 JUNCTION CONNECTOR E 4 A 19 B I18 A , B INTEGRATION RELAY R–Y L–B 1 C L–W See Key Reminder and Seat Belt Warning System<21–3> 5 1M 5 2 L–W L 1 2A D 2 A (*1) 17 B (*2) R–G C B 1 A 16 B 8 1G L–R A A 7 1J 10 1 1W L–R 1 13 A (*1) 1 B (*2) 1 D o o r L o c k C o n trol L–B 2 12 2J R P ow e r S o urc e 14 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM Y D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR LH W–B W–B (*4) W–B LOCK 14 CAMRY (Cont’ d) W ire le s s D oo r L o ck C on trol 5 A R–Y 1 2 E A From Remote Control Mirror SW<12–3> V 1 G–R E B E B D A B A J33 A , J34 B D A G–R L–R D A JUNCTION CONNECTOR J 9 A , J10 B JUNCTION CONNECTOR L–Y C 4 L–Y Y C L–R 9 B B J37 JUNCTION CONNECTOR C Y 10 13 L–Y From Theft Deterrent ECU <15–2> G 5 12 L–Y C F L–B 11 14 LG W6 WIRELESS DOOR LOCK ECU 8 R–W 7 Y E L–R To Theft Deterrent ECU<15–4> To Door Courtesy SW Front RH, Rear RH <9–2> L–W 15 D 8 R R–G To Unlock Warning SW <21–3> J16 A , J17 B JUNCTION CONNECTOR D B C 7 6 R D10 DIODE (Dome) B * 3 : TMC Made * 4 : TMMK Made L–Y H M 4 From TAILLIGHT Relay<11–1> 1 From Theft Deterrent ECU<15–3> D22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW REAR RH 1 (*3) 4 (*4) 3 L–Y M 2 4 BP1 L–B 4 (*3) 1 (*4) 7 BP1 L–R 3 D20 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 2 5 BP1 Y L–B L–R L–Y 11 IM1 W–B 3 IM2 3 IN2 L–Y G–R 7 IM2 K 10 IG1 L–B L–B Y J L–B L–Y I L–R A W–B J5 JUNCTION CONNECTOR W–B(*4) W–B Right kick panel IK W–B M A 6 BP1 W–B(*3) W–B L BN Under the right center pillar Left kick panel IF J 1 2 2 IF1 Back panel center BP J33 JUNCTION CONNECTOR C C LUG 7 A Left radiator side support IF A A 6 IF1 To Door Unlock Detection SW Rear LH, RH<14–6> Y To Door Unlock Detection SW Front RH<14–5> L To Door Key Lock and Unlock SW Front RH <14–3> L–W To Door Key Lock and Unlock SW Front LH, RH<14–2> R–G To Door Key Lock and Unlock SW Front LH <14–2> L–R To Door Unlock Detection SW Front LH<14–3> R–G To Door Courtesy SW Front RH<9–1> R–W To Door Courtesy SW Front RH, Rear RH <9–2> R–G To Door Courtesy SW Front LH<9–1> L–B To Unlock Warning SW<21–3> 2 F B FL MAIN 3. 0W 1 A 25A DOOR B–G BATTERY 100A ALT 1 F B–R 1 C L–W EB Left kick panel 5 9 E A D B D B L–Y B–R B–R B–R IH Instrument panel brace RH 2 3 IK1 JUNCTION CONNECTOR 1 1 IG3 From Engine Control Module <2–9><3–9> R–Y J 9 A , J10 B 3 A DSWH IND E 7 B 2 A DSWL LSWR 16 A LSWP To Luggage Compartment Light SW<9–4> 15 A UL2 R–Y 10 A L2 R–Y 8 A UL3 W–B 9 A LSWD KSW W–B 14 A DSWD IG 13 A A B 1 1B B–R 4 1B 1 2 2 1K BR R–Y F4 A , F6 C , F9 F FUSIBLE LINK BLOCK 40A AM1 I16 IGNITION SW IG1 4 W B–R J16 A , J17 B JUNCTION CONNECTOR 1 1D 1 2 AM1 ACC 15A ECU–IG C A 8 1D 1 1K B–Y CTY DSWP L–W +B2 L–W 1 B C C J34 JUNCTION CONNECTOR 8 1G 1 1W 12 2J 2 1 1 2A B 2 7. 5A DOME B–R C10 THEFT DETERRENT INDICATOR LIGHT [COMB. METER] 5 A JUNCTION CONNECTOR R–Y SHORT PIN R R–Y W–B 1 A J16 A , J17 B T 3 B , T 4 A THEFT DETERRENT ECU 9 B SH +B1 R 11 A W–L D B E A 2 D10 DIODE (Dome) 1 5 IG3 4 IK1 1 2 3 2F W–L B 4 A TAIL G–R 11 B G–R W–L B J5 JUNCTION CONNECTOR 10A HORN W B J33 JUNCTION CONNECTOR B B 10 IG1 G–R From TAILLIGHT Relay<11–1> 6 B R–B 3 T h eft D e te rren t G–W 6 A R–B PANI 18 A From HEAD Relay(*1)<6–2> From Daytime Running Light Relay(Main)(*2)<7–1> HORN 12 B G–B T1 THEFT DETERRENT HORN R P o w e r S o ur ce G–W E6 ENGINE HOOD COURTESY SW HEAD 11 IG1 G–B 7 IG3 From HORN Relay <21–4> 10 B LG From Wireless Door Lock ECU<14–6> 15 CAMRY L4 LUGGAGE COMPARTMENT KEY UNLOCK SW G–W W–B 4 * 1 : w/o Daytime Running Light * 2 : w/ Daytime Running Light J OVERALL ELECTRICAL WIRING DIAGRAM 16 CAMRY P ow er S ou rc e Power O u tlet S h ift L o c k 1 2 C ig are tte L ig h te r an d C loc k 3 G 4 R L–R IG1 4 B–Y R ACC 3 1 1K G L–R 2 AM1 W 1 1W 6 1K I16 IGNITION SW W R 2 1K 12 2J 15A POWER– OUTLET 8 1D G–W C SLS– SHIFT LOCK SOLENOID 1 2 L V 1 1 1B 1 2A L–B 1 2 1 D B 3 1 4 2 C6 CLOCK S3 SHIFT LOCK ECU 4 W–B W–B W–B W–B 8 1J W–B 5 IG1 4 1V L–B A 2 A 7 1J IG J11 JUNCTION CONNECTOR Instrument panel brace LH W–B A W–B Left kick panel J5 JUNCTION CONNECTOR A W–B IF A J7 JUNCTION CONNECTOR BATTERY 3 1V A 1 W–B A W–B J5 JUNCTION CONNECTOR K3 KEY INTERLOCK SOLENOID B–G FL MAIN 3. 0W 2 KLS+ 5 F4 A , F6 C , F9 F FUSIBLE LINK BLOCK 1 A 1 C 2 G E A R G P G–R 3 C4 CIGARETTE LIGHTER B B–R B–R See Taillight System<11–1> 100A ALT A B G–W 1 P4 POWER OUTLET P1 2 F A P–L P2 E 1 F A A A SHIFT LOCK CONTROL SW B–R B–R B–R A J16 A , J17 B SHORT PIN P–L 40A AM1 4 1B 2 JUNCTION CONNECTOR STP SLS+ J6 JUNCTION CONNECTOR TAILLIGHT RELAY 6 1C ACC 5 1 1 1T L–R 2 1 6 1J J30 A , J31 B IG 2 1 6 JUNCTION CONNECTOR 3 5 1J 1 P–L 2 From Stop Light SW <11–4> R 3 8 1G 15A CIG D10 DIODE (Dome) C P–L 7. 5A DOME B–R B–R 7. 5A PANEL J16 JUNCTION CONNECTOR R–Y G 5 1D 15A ECU–IG IE A Cowl side panel LH IG J11 JUNCTION CONNECTOR Instrument panel brace LH IF Left kick panel J W 15A STOP B–R B–R B–R B–R R–L O F4 A , F9 F FUSIBLE LINK BLOCK D B–G D D 4 J2 JUNCTION CONNECTOR O J7 A , J8 B JUNCTION CONNECTOR W CRUISE LG–R O W–B 3 C12 CRUISE CONTROL SW [COMB. SW] W–B IG A 7 1J 8 1J W–B CANCEL A A Instrument panel brace LH J11 JUNCTION CONNECTOR A A To Engine Control Module <4–3><5–3> SET/ COAST A A W–B M 1 15 MO R–G RESUME/ ACCEL CMS CCS A B 16 GND 2 7 MC 4 3 SPD 12 R–Y L 2 STP– 8 4 1 2 5 1R 4 1R A A JUNCTION CONNECTOR J27 A A A R–Y EP 5 10 CCS OD 14 3 G–W BATTERY C10 CRUISE CONTROL INDICATOR LIGHT[COMB. METER] O W–L FL MAIN 3. 0W 11 CMS IDL 13 W–B 5 IG2 5 B–R 4 TC 6 L–R ECT G–B G–W 10 PI C15 CRUISE CONTROL ECU V–W D 3 P1 D POSITION SW [PARK/NEUTRAL POSITION SW] 4 * 1 : 1MZ–FE A/T * 2 : 5S–FE A/T W 1 A R–L 7 J4 JUNCTION CONNECTOR 100A ALT J12 JUNCTION CONNECTOR B–R B A B–R C14 CRUISE CONTROL CLUTCH SW A 9 II2 10 2 L–B (A/T) 9 B–R J29 JUNCTION CONNECTOR B–R (M/T) A D Y–B (A/T) 2 F 2 A A A A J21 JUNCTION CONNECTOR B–R C R–L (M/T) 1 2 II2 R–L (*2) C 9 1J 15A ECU–IG D A F B To Electronically Controlled Transmission Solenoid<4–2><5–2> D 10A GAUGE 1 1J F B J24 JUNCTION CONNECTOR D 2 1D 1 1K J27 A , J28 B JUNCTION CONNECTOR 3 To Speedometer [Comb. Meter]<25–8> 1 F B–Y R–L (*1) 1 1B 40A AM1 I16 IGNITION SW IG1 4 ACC R–L (A/T) R–L (*2) 1 2 2 1K 2 AM1 R–L 2W C ru is e C on trol R–L (*1) 4 1B 7 1C W 1 P ow e r S o urc e 17 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM S6 STOP LIGHT SW G–W C3 CRUISE CONTROL ACTUATOR R–B W–B To Data Link Connector 1, 2 <18–4><19–3><20–3> To Data Link Connector 2 <18–4><19–3><20–2> 18 CAMRY P ow e r S o urc e A B S an d T rac tion C on tro l 1 * 1 : TMC Made * 2 : TMMK Made 3 2 4 R–L 8 IK2 GR–L IG1 4 B–Y 3 O BR 2 IK1 B B MR 23 A 9 A TS TC SR R–L 24 A 11 A R+ LG–R R–Y GR GR–L 1 A MT 22 A D/G W–B 1 IL1 II3 A A W–B BR 1 J22 JUNCTION CONNECTOR A26 ABS SPEED SENSOR REAR RH 2 BR (Shielded) B(*1) L(*2) W(*1) P(*2) 1 (*2) 2 2 A25 ABS SPEED SENSOR REAR LH 1 BR 3 IL1 (Shielded) G(*1) BR(*2) J8 B 2 9 ID1 R(*1) Y(*2) J7 A , 1 A10 ABS SPEED SENSOR FRONT RH A A (*2) A B 2 IL1 W–B 3 ID1 6 G W–B (*2) A B A9 ABS SPEED SENSOR R FRONT LH W–B (*2) W–B 1 4 ID1 6 IK2 W–B 1 IK2 W–B W–B (*2) RR– GND3 GND2 GND1 10 B 9 C 10 C 15 A B 4 RR+ 9 B W RL– 1 B G B W G R RL+ 2 B R FL– FR+ FR– 4 A 17 A 18 A W–B (*2) W–B Instrument panel brace LH A GR–R R–W R LG–B 14 A AST LG T5 TRACTION OFF SW From Stop Light SW<11–4> 8 1J W–B J32 JUNCTION CONNECTOR J11 JUNCTION CONNECTOR W–B C 10 A FL+ 5 A 7 1J C L C 12 A CSW 11 B A B L BATTERY 25 A ABS AND TRACTION ECU G–W To Engine Control Module<2–8> G–B 7 C SFLR SRRH SRRR SRLH SRLR L LG B W BR–W L G–B G–B L B–G C 8 C G–Y 1 C R–G 2 C W–R W–L L–B W–R R–B Y–B Y–R B–Y 6 C 13 A 26 A WA WT NEO EFI+ EFI– TRC+ TRC– STP 4 B 12 B 15 B 6 B 14 B 13 B 5 B 16 B LG 18 IG3 4 C 12 C J8 B 12 IK2 C A J7 A , J3 B JUNCTION CONNECTOR JUNCTION CONNECTOR B L 3 B 17 R–L 5 B B 3 ABS TRC 14 LG–R 4 A B LG–R 10 A MT P–B 5 A LG–R 11 A II3 B 4 LG–R 6 A 11 R–Y 12 A From Airbag Sensor Assembly<28–4> 8 II3 LG–R(*1) P–B(*2) R–Y 3 A A15 A , A16 B , A17 C IND 3 B C EA LG(* 1) B–Y(*2) 9 A SRRH SRRR SRLH SRLR AST TC 11 5 II3 G–B 1 A SRC1 SRC2 SMC1 SMC2 SFRH SFRR SFLH J29 JUNCTION CONNECTOR Right radiator side support BM E1 TC 16 G–B 8 A G–B LG 12 IG3 5 C IG1 5 A 19 IG3 B–R B–R 8 B C FL MAIN 3. 0W W–R W–L W–B 2 A SFLR F9 F FUSIBLE LINK BLOCK TS 22 M SRC1 SRC2 SMC1 SMC2 SFRH SFRR SFLH SLIP 4 C R–L F4 A , F5 B , ABS 1 A BS 10 A/D D1 DATA LINK CONNECTOR 1 WA 2 B D4 DATA LINK CONNECTOR 2 5 IK2 L 100A ALT 3 C GR–R 4 B GND 7 C TRAC OFF 2 F 3 5 AB R–L B–R B–R 1 F A7 A , A8 B C B–G 1 B 3 C 7 A C 8 A , C10 C COMBINATION METER 3 GR–R ABS AND TRACTION ACTUATOR 1 B B–R B–R D 3 W–B 9 1J D 3 (Short Pin) W–B J12 JUNCTION CONNECTOR 1 1B 2 4 23 R–L(*1) Y–B(*2) 3 R–L J4 JUNCTION CONNECTOR 3 4 II3 WB 2 1D 1 4 ABS MOTOR RELAY 3 15A ECU–IG 10A GAUGE 60A FL ABS 40A AM1 1 ABS SOL RELAY W 1 1K 2 1 6 2 I16 IGNITION SW 2 1K 2 5 From Cruise Control ECU<17–2> 1 From Cruise Control ECU<17–2> 3 R–L 2 AM1 3 From Airbag Sensor Assembly<28–4> GR ACC EA EC JUNCTION CONNECTOR IG Right radiator side support Surge tank RH J W B–R GR–L W–B GR–L W–R B–R B–G B–R W–R R–B 60A FL ABS B–G SFRR SFLH R–B SFRH W–R SRLH 4 A 6 B BS SRLR MT 3 A A4 A , A5 B E W–B W–R Right radiator side support 1 A W–B IG 2 W–B Instrument panel brace LH J11 JUNCTION CONNECTOR A25 ABS SPEED SENSOR REAR LH 1 2 A26 ABS SPEED SENSOR REAR RH 1 2 IL1 1 IL1 3 ID1 9 ID1 10 B 23 B RR+ FR+ 3 A 22 B RR– FR– 9 A C A II3 Surge tank RH (1MZ–FE) Intake manifold (5S–FE) EC J22(1MZ–FE) A J23(5S–FE) JUNCTION CONNECTOR A 6 J7 A , J8 B JUNCTION CONNECTOR B B BR EA A W–B 2 A RL+ FL+ 8 A 9 B RL– FL– 2 A STP 5 B G BM M ABS ACTUATOR 12 B GND ABS ECU W–B 25 B GND2 D/G 24 B R W–R 2 B SRRH SRRR 8 B TC 8 B A10 ABS SPEED SENSOR FRONT RH 1 2 B W–B W–L SFLR 4 B L–B 7 B W–L 3 B G–Y 5 B 10 A MT R–W 1 B 5 IK2 LG–B 13 IK2 14 B 15 B G–Y 12 IK2 11 A W–R 6 A SRLR LG–B 11 IK2 12 A R–G 5 A SRLH TS LG–R W BATTERY ABS MOTOR RELAY W–L BR FL MAIN 3. 0W GR G F9 F GR R FUSIBLE LINK BLOCK ABS SOL RELAY B F4 A , F5 B , GR–R W 1 A R–L 1 B C10 ABS WARNING LIGHT [COMB. METER] 2 B G–B 100A ALT J4 JUNCTION CONNECTOR R–L R–L SFLR SRRH SRRR G–B SFRR SFLH R–Y SFRH J29 JUNCTION CONNECTOR G–B 21 B G–W WA LG–R 11 B A18 A , A19 B 1 IK2 6 IK2 G IG1 LG–R 1 B B–R 13 B P–B LG–R R R+ R–L 26 B B B From Cruise Control ECU<17–2> From Airbag Sensor Assembly<28–4> SR B–R J3 JUNCTION B CONNECTOR B B From Stop Light SW<11–4> 7 A C C ABS 14 G 12 IG3 C 11 II3 8 II3 TC 4 A9 ABS SPEED SENSOR FRONT LH 1 2 B MR 4 7 5 II3 TC 11 3 A/D E1 10 BR W 1 A J12 JUNCTION CONNECTOR 1 IK1 D D TS 16 D4 DATA LINK CONNECTOR 2 R 2 F 3 10A GAUGE 3 C C G–B 3 5 22 WA R–Y 3 6 4 2 1D AB 5 LG–R 3 3 1 9 1J D1 DATA LINK CONNECTOR 1 From Cruise Control ECU<17–2> 4 BR 1 F 3 4 2 15A ECU–IG 2 3 R–L 3 (Short Pin) 1 1 3 R–L 1 1B 2 3 WB 23 4 II3 From Airbag Sensor Assembly<28–4> 3 BR 1 40A AM1 GR–R 1 1K 2 R–L LG 2 GR–R B–Y 8 IK2 A B S (T M C M a de ) O 2 1K IG1 4 1 B–Y I16 IGNITION SW 2 AM1 ACC P o w er S ou rc e 19 CAMRY J OVERALL ELECTRICAL WIRING DIAGRAM 20 CAMRY A B S (T M M K M a d e) P o w e r S o u rc e 1 3 2 4 From Cruise Control ECU<17–2> O ACC B–Y D4 DATA LINK CONNECTOR 2 1 1K B–G A/D 1 W ABS 5 TS 16 II3 R–Y J3 JUNCTION CONNECTOR J7 A , J8 B JUNCTION CONNECTOR C B BR A B From Airbag Sensor Assembly<28–4> 8 LG B–Y(1MZ–FE) LG(5S–FE) II3 5 IK2 BR R–Y LG–R 11 TC TS A6 ABS ACTUATOR AND ECU 2 F FL+ FL– FR+ FR– GND1 GND2 RL+ RL– RR+ RR– 7 6 5 4 19 16 9 8 2 1 1 IK2 6 IK2 13 IK2 3 IK3 (Shielded) 9 IK3 7 IK3 2 IK3 6 IK3 BR L P (Shielded) J22(1MZ–FE) J23(5S–FE) JUNCTION CONNECTOR (Shielded) B W G R (Shielded) 8 IK3 BR Y FL MAIN 3. 0W W–B B–G F9 F 6 II3 L W–B P (Shielded) BR Y W–B W–B (Shielded) W–B G R (Shielded) F4 A , F5 B , FUSIBLE LINK BLOCK 11 BR 12 TC 11 LG–R 12 IK2 WA AB LG–R B 21 IG1 P–B B 10 IK3 15 +B B LG–R C B R–L 17 B J29 JUNCTION CONNECTOR R–L 12 IG3 R–L 100A ALT 1 A 5 IK3 R–L B–R B–R +B 4 C R–L 18 STP 7 C C B–R B–G 14 1 F L B–R G–W 1 1B L 1 IK3 C10 ABS WARNING LIGHT [COMB. METER] 1 D C J12 JUNCTION CONNECTOR B–R B–R 3 G–W 40A AM1 1 B D From Stop Light SW<11–4> J4 JUNCTION CONNECTOR R–L R–L 2 9 1J LG–R BR 2 1D 2 4 3 R–L 60A FL ABS 2 1K TC E1 14 D1 DATA LINK CONNECTOR 1 P–B(1MZ–FE) LG–R(5S–FE) 15A ECU–IG 10A GAUGE 3 I16 IGNITION SW 10 From Cruise Control ECU<17–2> IG1 4 From Airbag sensor Assembly<28–4> 2 AM1 (Shielded) A 3 ID1 9 ID1 4 ID1 3 IL1 2 IL1 1 IL1 A L (Shielded) P Y W–B BR BATTERY (Shielded) BR 2 1 A9 ABS SPEED SENSOR FRONT LH 2 1 1 A10 ABS SPEED SENSOR FRONT RH 2 A25 ABS SPEED SENSOR REAR LH Right radiator side support EA 1 2 A26 ABS SPEED SENSOR REAR RH Surge tank RH (1MZ–FE) Intake Manifold (5S–FE) EC J 21 CAMRY W 1 1B B–R B–R B B–G W–B W–B L–B W–B W–B From Wireless Door Lock ECU<14–6> J 9 A , J10 B L W–B (*3) W–B W–B From Engine Control Module <2–9><3–9> 2 W–B (*1) Under the left center pillar 1 BQ1 W–B (*1) IG JUNCTION CONNECTOR L–B B B B A A BL A 2 1 J40 JUNCTION CONNECTOR W–B (*2) Instrument panel brace LH B B B A B7 BUCKLE SW LH Roof left POWER RELAY J11 JUNCTION CONNECTOR W–B A W–B 2 1 L–B 1 B6 BUCKLE SW LH BM W–B A , B 3 BQ1 R–Y(*1) 4 1S 8 6 1 7 1S 1 1 1W To Theft Deterrent ECU <15–3> IE 3 1F M4 From Theft Deterrent ECU <15–1> L–B Cowl side panel LH 3 1V NO. 3 R–Y (*1) 3 B (* 4) 7 1D L–B 5 1M 7 R–Y (*2) MOON ROOF MOTOR AND LIMIT SW NO. 2 3 A (* 3) 3 1M J33 A , J34 B 7 1J INTEGRATION RELAY 5 1F C 6 C C 3 5 H5 HORN (High) 1 1 2F HORN RELAY H o rn G–W BATTERY B–R 7 1F 9 I18 A , B G–B 4 A G 1 B (*4) 5 6 B (*6) 3 1T 7. 5A DOME M 6 B 10 1 B 8 A (*5) 4 A 10 2K 2 1 10A HORN 4 J2 JUNCTION CONNECTOR FL MAIN 3. 0W 2 B 5 B NO. 1 4 B 2 3 B 13 A L–W 3 30A POWER 1 R–B 12 A See Light Auto Turn Off System<9–1> 5 2 10A GAUGE 2 A (*3) 1 MTR– 12 2J 2 1 1 2A G–B 1 A 1 A P–B (*4) G–W 5 A R–L R 6 A 5 7 C SEAT BELT WARNING J4 LIGHT[COMB. METER] JUNCTION CONNECTOR R–L R–L R–W 100A ALT 3 LS#1 MTR+ A A C B C 8 A , C10 C 2 F 7 LS#2 1 5 1G D D 2 1D R (*4) 1 F 8 LS#3 IG 4 1 1D 25A DOOR 1 1K R 1 C 2 G B L 4 1B JUNCTION CONNECTOR B–R B–R 6 R (*4) L–W 1 40A AM1 1 : w/ Power Seat 2 : w/o Power Seat 3 : TMC Made 4 : TMMK Made 5 : w/o Theft Deterrent System 6 : w/ Theft Deterrent System M3 MOON ROOF CONTROL SW AND RELAY * * * * * * 3 K e y R e m ind e r a nd S e a t B e lt W a rning SHORT PIN 2 2 1K B–R R(*4) 2 B–R I16 IGNITION SW IG1 4 ACC B B–Y M oon Roof B 2 AM1 1 P ow e r S ou rc e 1 H6 HORN (Low) G–W J OVERALL ELECTRICAL WIRING DIAGRAM C12 HORN SW [COMB. SW] G–B D12 DOOR COURTESY SW FRONT LH R–G U1 UNLOCK WARNING SW W–B FUSIBLE LINK BLOCK F4 A , F6 C , F9 F 22 CAMRY P o w er S ou rc e P o w er S ea t 1 * 1 : TMC Made * 2 : TMMK Made 3 2 4 L–W L–W L–W A A A A J 9 A , J10 B JUNCTION CONNECTOR 8 IF1 C B 4 IN2 L–W L–W 3 1D L–W 2 2 BQ1 2 BR1 30A POWER L–W L–W 1 4 1B P14 A , B POWER SEAT CONTROL SW (Driver’ s Seat) 11 A (*1) 2 B (*2) P15 A , B POWER SEAT CONTROL SW (Front Passenger’ s Seat) 11 A (*1) 2 B (*2) B–R DOWN UP 3 A 2 A 6 B 8 B 5 B R–B (*1) L–Y (*1) W–B 2 M R (*2) 2 P20 POWER SEAT MOTOR (Front Passenger’ s Seat Rear Vertical Control) M L–Y (*2) 1 1 R–B (*2) M P21 POWER SEAT MOTOR (Front Passenger’ s Seat Reclining Control) 2 7 A (*1) 4 B (*2) R (*1) 5 A 12 B R–G (*2) 1 REAR 1 A 7 B R–G (*1) 4 A L–B (*2) L (*2) M 8 A P22 POWER SEAT MOTOR (Front Passenger’ s Seat Slide Control) 2 R (*2) 2 P16 POWER SEAT MOTOR (Driver’ s Seat Rear Vertical Control) L–Y (*2) M R–B (*2) P17 POWER SEAT MOTOR (Driver’ s Seat Reclining Control) R–G (*2) L–B (*2) 1 1 FRONT L–Y (*1) L–B (*1) L (*2) B–G P18 POWER SEAT MOTOR (Driver’ s Seat Slide Control) W–B M REAR VERTICAL RECLINING 11 B L–B (*1) 5 B REAR 2 A 6 B SLIDE L (*1) 5 A 12 B 2 FRONT 1 A 7 B R (*1) 4 A R–G (*1) 8 A 11 B R–B (*1) 3 A (*1) 8 B (*2) 4 B 1 A DOWN UP REAR FRONT REAR VERTICAL RECLINING 7 A L (*1) F4 A , F9 B 100A ALT FUSIBLE LINK BLOCK 2 F REAR FRONT B–R B–R 1 F SLIDE 1 FL MAIN 3. 0W 1 BQ1 1 BR1 2 5 6 1 4 3 2 5 6 1 4 W–B 3 W–B BATTERY P19 POWER SEAT MOTORS (Driver’ s Seat) A P23 POWER SEAT MOTORS (Front Passenger’ s Seat) BL Under the left center pillar W–B Right kick panel IK Under the right center pillar W–B J40 JUNCTION CONNECTOR BN J L–Y 20A RADIO NO. 1 B–R B–R B Instrument panel brace RH 7 IH1 100A ALT B–G 1 1 BR IH B R12 REAR SPEAKER LH R13 REAR SPEAKER RH 2 Y 2 4 IF1 10 IF1 3 IF1 B R 9 IF1 3 IH2 1 IH2 6 IH2 2 IH2 BR Y W BATTERY RR– 10 A RR+ 3 A RL– 11 A B R FL MAIN 3. 0W 40A AM1 Y W 1 A GR R 4 A 7. 5A RAD–NO. 2 W 10 B RL+ L–Y E V 2 F RRIN 14 B RLIN 13 B STEREO COMPONENT AMPLIFIER S4 A , S5 B LG 1 F P FR+ G 1 A Y FR– 11 B BEEP SGND 4 B R 8 A W FL+ FRIN 6 B B 2 A FR 7 FL FLIN 5 B 6 L FL– GND 12 MUTE 12 B 5 MUTE BR 9 A BEEP 13 GND GND 13 A 11 GR +B RL 14 R4 RADIO AND PLAYER (Shielded) 7 A 1 IH1 5 IH1 2 IH1 15 RR ANT+B 8 1 B 1 RACC AMP+ 9 B 3 ACC AMP+B W 1 C GR L 6 IH1 L–Y LG 4 IH1 9 IM1 1 IM1 8 IH1 R ACC 2 3 +B R+B 3 B 4 B 2 B 1 V 3 IH1 J16 JUNCTION CONNECTOR 1 F13 FRONT TWEETER (Speaker)RH 2 P 1 1B J16 JUNCTION CONNECTOR GR 1 L–Y L 9 IE1 2 P LG 1 IE1 V B B 1 P A A 1 F11 FRONT DOOR SPEAKER RH L 1 2A W LG 2 2 F12 FRONT TWEETER (Speaker)LH V R–B (*1) 2 1K 6 1G 5 1W F10 FRONT DOOR SPEAKER LH L 3 1H 6 1K L–R L–Y B–R (* 1) 11 2K IG1 ACC 3 2 R ad io a nd P la y e r (S ep ar ate T yp e A m plifie r) To Auto Antenna Motor and Relay <24–2> I16 IGNITION SW 2 AM1 1 P o w er S ou rc e 23 CAMRY 4 * 1 : w/ Auto Antenna J OVERALL ELECTRICAL WIRING DIAGRAM (Shielded) FUSIBLE LINK BLOCK F4 A , F6 C , F9 F 24 CAMRY P o w e r S o u rce 1 2 AM1 R ad io an d P lay e r (B u ilt– In T y pe A m p lifier ) A u to A n te n na 3 2 ACC 3 L–R IG1 4 B–Y 4 * 1 : Separate Type Amplifier * 2 : Built–In Type Amplifier * 3 : w/ Auto Antenna B W I16 IGNITION SW 1 2A 6 1K 20A RADIO NO. 1 2 1K 1 1K 7. 5A RAD–NO. 2 15A ECU–IG 2 3 1H 8 1D GR B–R (*3) B 11 2K L–Y 40A AM1 L–Y(*2) 1 5 1W GR(*2) 1 1B ANT+B C A J16 A , J17 B JUNCTION CONNECTOR B B F4 A , F6 B , FR+ FR– 1 A 5 A RL+ RL– 2 B 6 B RR+ RR– 1 B 3 B GND 7 A BR R W 3 IF1 10 IF1 4 IF1 R B 9 IF1 Y L Y 1 IM1 1 IE1 B L 9 IM1 9 IE1 LG LG 3 IN1 FL– 6 A V 4 IN1 RADIO AND PLAYER +B V 5 IN1 ACC P B–R (* 3) 1 A GR (* 3) F9 F FUSIBLE LINK BLOCK FL+ 2 A A B L–Y (* 3) 100A ALT C B 4 A B–R (*2 *3) A A B–R (*1 *3) A A L–Y (*2) B–R (*3) GR (*2) GR L–Y (*2) L–Y B–R B–R B A 2 F 3 A R2 B , R3 A 8 A B A 1 F B–R(*2 *3) GR (*2) From Radio and Player <23–3> B–R 6 1G 1 IN1 1 C 2 5 ACC IG B–R (*3) B–R (*3) +B GR (*3) L–Y (*3) B B–G 3 4 ANT W P FL MAIN 3. 0W E A27 AUTO ANTENNA MOTOR AND RELAY 6 2 W–B F10 FRONT DOOR SPEAKER LH BATTERY W–B IK BN 1 2 F11 FRONT DOOR SPEAKER RH 1 2 R12 REAR SPEAKER LH 1 2 R13 REAR SPEAKER RH BR W–B Right kick panel 1 Under the right center pillar Instrument panel brace RH IH J 1 1W R B–R B–R B F4 A , F6 B , F9 C B–G J21 JUNCTION CONNECTOR R–L (*2) R–L (* 2) A R–L (* 1) A J24 JUNCTION CONNECTOR R–L (*1) BATTERY FL MAIN 3. 0W FUSIBLE LINK BLOCK A D D 2 1D Instrument panel brace RH F14 FUEL SENDER 1 1 IF2 3 2 4 IF2 3 IF2 BR 1 A 100A ALT A II2 R–L 2 F 2 F F R–L 1 F J28 JUNCTION CONNECTOR 1 1J 10A GAUGE 1 1K J4 JUNCTION CONNECTOR R–L R–L 1 C IG1 4 ACC Y–R 4 1B I16 IGNITION SW 2 AM1 B–Y R G–W 1 2A 1 1 40A AM1 E 2 Y–R 2 2 1K W 2 E 1 G–W SHORT PIN 12 2J R P ow er S ou rc e J16 JUNCTION CONNECTOR 7. 5A DOME 1 2 R–Y 8 1G D10 DIODE (Dome) 25 CAMRY BR IH BR R–L ED : *1 EC : *2 Rear side of surge tank(* 1) Intake manifold(*2) 3 1 C o m bina tio n M ete r R–L (*2) R–L (*1) 1 IG+ 3 SI 2 P SE 4 L P Y–G BR BR G–W Y–R R–L R * 1 : 1MZ–FE * 2 : 5S–FE I H G F E D C B A (Cont. next page) J OVERALL ELECTRICAL WIRING DIAGRAM V2 VEHICLE SPEED SENSOR (Combination Meter) L Y–G W3 WATER TEMP. SENDER BR 25 CAMRY (Cont’ d) * 3 : Except * 4 * 4 : TMMK Made, TMC Made USA w/ Traction Control * 5 : Speedometer C om b in ation M ete r 5 A B 7 6 R R R–L R–L 7 D E BR From Engine Control Module <2–12><3–9> BR 2 Y–G 1 P 9 A A WATER TEMP. A TACHOMETER 8 C 6 C L 15 B 7 B 3 A 9 C SLIP 5 A TRAC OFF 3 C DOOR 10 B O/D OFF 12 A (*5) ILLUMINATION 12 C 14 B TURN LH 1 B TURN RH 1 C BRAKE REAR LIGHTS 4 B 13 A CHARGE See Theft Deterrent System<15–3> See ABS and Traction Control System<18–1> See Interior Light System<9–4> See Electronically Controlled Transmission and A/T Indicator System<4–3><5–3> GR(*3) B–O(*4) 17 IG3 6 IG1 P–L 11 C 2 C WASHER LEVEL HIGH BEAM MALFUNCTION INDICATOR LAMP See Turn Signal and Hazard Warning Light System<8–2><8–3> See Charging System <1–4> ABS 4 A SEAT BELT W–B Y–B 5 IJ1 10 C See Headlight System<6–3><7–3> See Cruise Control System<17–2> 12 B SRS C 8 A , C 9 B , C10 C Y–B 8 B 9 B CRUISE 4 C 5 B B V–W 13 B 1 A A W–B See ABS(TMC Made) System<19–2> See ABS(TMMK Made) System<20–2> See ABS and Traction Control System<18–1> 2 B OIL B J5 JUNCTION CONNECTOR See Engine Control and Immobiliser System<2–3><3–2> B–O BULB CHECK RELAY B J15 JUNCTION CONNECTOR See Illumination System <10–4> 3 V–W IG3 W–B Left radiator side support 8 A FUEL C P R–W See Key Reminder and Seat Belt Warning System<21–3> EB R B See Electronically Controlled Transmission and A/T Indicator System <4–4><5–4> O1 OIL PRESSURE SW 2 W–B Instrument panel brace LH P3 PARKING BRAKE SW R–W IG 1 10 A 16 B From Park/Neutral Position SW(A/T) or Clutch Start SW(M/T) <1–2> 3 P–L IK2 W1 WASHER LEVEL WARNING SW W–B A 5 See Charging System<1–4> From Daytime Running Light Relay(Main) <7–2> R–W (*6) P–L J11 JUNCTION CONNECTOR 3 IG2 R–W 7 IG1 1 3 BR See Taillight System<11–4> R–W (* 7) B2 BRAKE FLUID LEVEL WARNING SW 2 G–W B–O B R–W 1 N V–W From Daytime Running Light Relay(Main)<7–2> R–W (*6) J2 JUNCTION CONNECTOR B B 7 A FUEL V–W L 7 IJ1 D 6 B TRIP METER ODOMETER I P 11 A V–W H 2 IJ1 2 SECURITY 6 IG3 B–O C From Engine Control Module <2–7><3–9><4–3><5–3> Y–G 6 IJ1 6 A From A/C Control Assembly<29–5> G G–W 3 IJ1 L From Cruise Control ECU<17–4> F Y–R Y–R BR 8 11 B 13 C See Illumination System<10–4> C * 6 : w/ Daytime Running Light * 7 : w/o Daytime Running Light See SRS System <28–4> Left kick panel IF COMBINATION METER J 26 CAMRY B–R B–R B–R B–R B–R B–R See Taillight System<11–1> W–B (*5) 100A ALT B–G Cowl side panel LH W–B F4 A , F7 D , F9 F FUSIBLE LINK BLOCK IE W–B(*6) J38 JUNCTION CONNECTOR R16 A , B W–B J39 JUNCTION CONNECTOR W–B (*5) 1 B R14 A , R15 B Right quarter pillar REAR WINDOW DEFOGGER B (*3) W–B W–B BO W–B EB W–B Instrument panel brace LH A B (*3) IG A To A/C Control Assembly<29–5> B–R W–B W–B (*2) IJ W–B W4 WATER TEMP. SW NO. 1 L–W W–B N2 NOISE FILTER (Rear Window Defogger) W–B (*8) To Diode(A/C) <27–2><29–3> To Engine Control Module<2–11> 1 L (*1) 2 EA1 1 From MG CLT Relay<27–2> 3 1V E 2 1 5 3 1 1 Left radiator side support 1 1 B–R W–B W–B W–R 1 M 2 B–R(*1) FAN NO. 2 RELAY 1 A 3 IG 4 1 II1 2 G–W 1 2 4 1 1 1 5 3 1 1 1 M 2 2 2H 2 B–R Right kick panel B–R (*2) W–B (*5) W–R BATTERY To Engine Control Module<2–10> D Y–G(*8) W–B 20 IM1 NOISE FILTER REAR WINDOW DEFOGGER 5 5 IK1 L(*1) L(*1) 1 2G 7 2G 2 2F R1 RADIATOR FAN MOTOR 7 1G Y–G (*7) 20 IE1 L–B (*5) L–W 1 EA1 2 A3 A/C SINGLE PRESSURE SW W–B (*6) 1 B L (* 1) W–B DEFOGGER RELAY 8 ID1 B (*4) 12 1J G–W (*1) 4 B (*6) 5 A (*5) A 1 1L 1 2C G–W B–W (*2) A R17 A , B W–B (*5) A MIRROR HEATER RH [REMOTE CONTROL MIRROR LH] 6 B (*6) 13 2J 4 3 1 2 FAN NO. 1 RELAY L MIRROR HEATER RH [REMOTE CONTROL MIRROR RH] To Engine Control Module<3–6> B–Y 1 A (*5) 3 2 4 FAN NO. 3 RELAY L A 2 2 2 2C 4 2F 3 1 2 2B 2 30A CDS 1 1 : 1MZ–FE 2 : 5S–FE 3 : w/ Auto Antenna 4 : w/o Auto Antenna 5 : TMC Made 6 : TMMK Made 7 : Automatic A/C 8 : Manual A/C G–W FL MAIN 3. 0W G–O (*2) 3 1 5 6 2K 30A RDI * * * * * * * * R 1 A TAILLIGHT RELAY 4 B (*6) 5 13 1J A 6 1A 1 4 R ad ia tor F a n a nd C on d en s er F a n A1 A/C CONDENSER FAN MOTOR 2 F B–Y (*1) 5 A (*5) NOISE FILTER 6 B (*6) 40A DEF 1 F B–Y 1 A (*5) A A 3 1R J32 JUNCTION CONNECTOR D11 DIODE (Idle–Up) 5 IM1 7 1J 2 L–B (*2) B–Y 1 5 IE1 4 1D 2 ENGINE MAIN RELAY 3 5 1T B–Y B–Y J12 JUNCTION CONNECTOR 11 1J 2 1 L–B A A G–O 9 1C 10A MIRROR– HEATER 1 15A ECU–IG B–R 6 1C 3 10A TAIL 1 1 1K 10A HEATER 1 1B 40A AM1 2 5 4 1B B–Y 3 B–R 1 2 1 2 B–R B–R 1 D W 2 1K I16 IGNITION SW IG1 4 ACC B–Y B–R B–R R ea r W ind ow D e fog g er an d M irror H ea ter B–R 2 AM1 1 P o w er S ou rc e J OVERALL ELECTRICAL WIRING DIAGRAM W5 WATER TEMP. SW NO. 2 W–B B–R R5 REAR WINDOW DEFOGGER SW W–B (*8) J11 JUNCTION CONNECTOR W–B (*6) 27 CAMRY A ir C o nd ition in g (M an ua l A /C ) P o w e r S o u rce 1 3 2 4 B–W 1 L–B 4 G A3 A/C DUAL PRESSURE SW ACC 2 AM1 * 1 : 1MZ–FE * 2 : 5S–FE IG1 4 2 IK2 B–Y 1 B J8 JUNCTION CONNECTOR 2 6 A 5 1 7 GND A BR (*2) J23 JUNCTION CONNECTOR OFF II3 BR (*2) 2 B To Engine Control Module<3–10> IG B BR(*2) DEF BR(*2) F/D F F R–W (*2) Instrument panel brace LH W–B W–R (*1) B/L FOOT W–B (*1) F W–R(*1) 5 1 10 W–R(*1) B 13 L–A/C R–W (*1) W–B Left radiator side support A W–L (*1) B SG J29 JUNCTION CONNECTOR 4 9 B 6 IG A LOCK TH L–W (*1) W–B BATTERY G (*1) 7 IK2 R–B 3 CONTROL CIRCUIT 10 IK2 14 +B 8 5 L–R M A12 A/C AMPLIFIER S–A/C 1 B5 BLOWER SW EB D FACE 2 A13 A/C EVAPORATOR J12 TEMP. SENSOR JUNCTION CONNECTOR R–B To Engine Control Module<3–10> (*2) 3 A GND R–B 2 W–L (* 2) R–B (*1) OFF ACT L–R LO AC1 To Engine Control Module<3–10> 4 M1 A IGN L–Y (*2) 8 M2 A W–B (*1) J11 JUNCTION CONNECTOR B–G 5 HI A A J32 JUNCTION CONNECTOR L–B L–B 1 L–O L–B B–W FUSIBLE LINK BLOCK FL MAIN 3. 0W 6 B–W F9 F 2 W–B 1 3 7 W–B(*1) L–Y (*1) 1 W–B B4 BLOWER RESISTOR M F4 A , F8 E , L–R 1 12 2 J12 JUNCTION CONNECTOR D D To FAN NO. 3 Relay<26–4> 3 EB1 L–R L–W 50A HTR 100A ALT 2 2 EB1 B3 BLOWER MOTOR L–R B–W 1 E B–W (*2) 4 MGC 3 LG–B(*1) 4 L–Y (*1) L–W L–R 1 EB2 B–R B–R 2 F 1 A L–W(*1) DEF 5 L–Y(*2) B–R 1 F L (*1) 1 F/D B–Y(*1) 1 6 9 IK2 L–O 1 L–R 7 B–L 1 B/L FOOT 8 L–R 1 1 L 1 1 1B D3 DIODE (A/C) 1 B–W 1 2 L–W 3 GND FACE 3 From FAN NO. 3 Relay<26–3> W–B 2 DEF L–B R–B 3 5 2K L–R 40A AM1 5 F/D L–B 2 1 2 10A A/C 4 1 B–O(*1) 5 1 MG CLT RELAY HTR RELAY L–B 1 1 2 W–R(*1) BR(*2) 1 1 W–L FOOT 2 1W 3 1R From Engine Control Module<3–10> To Engine Control Module<3–10> B/L 9 2C From Engine Control Module<2–7> FACE To Engine Control Module<2–7> L–B From Engine Control Module<2–11> L–B H9 HEATER CONTROL SW 10A HEATER W L–B L–B G (*2) L–B 1 1K I16 IGNITION SW 2 1K A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR 4 A ON A20 AIR VENT MODE CONTROL SERVO MOTOR A14 A/C SW Intake manifold EC J 28 CAMRY W B–R 40A AM1 B–R B–R W–B B–G IG Y–R (*2 *3) S9 SIDE AIRBAG SQUIB LH 2 P24 PRETENSIONER LH 1 Y–B(*1) L–B(*2) A22 AIRBAG SQUIB (Front Passenger Airbag Assembly) 2 Y–G (*2 *3) A23 AIRBAG SQUIB (Steering Wheel Pad) 1 2 S10 SIDE AIRBAG SQUIB RH 1 E2 2 P25 PRETENSIONER RH 1 3 1V 3 1N 28 B PR– 6 C 5 C PR+ LA 3 B W–B IE 12 B SIL TC 19 B Cowl side panel LH To Data Link Connector 3 <2–3><3–8> F4 A , F6 C , F9 F FUSIBLE LINK BLOCK Instrument panel brace LH A 2 Y BATTERY J11 JUNCTION CONNECTOR 1 W–B SPIRAL CABLE Y–R (*2 *3) Y–R (*2 *3) FL MAIN 3. 0W Y–B 2 Y 1 Y–R (*1 *3) 7 1J Y–G (*2 *3) 2 BW1 Y–R (*2 *3) Y–G (*2 *3) 1 BW1 Y–R (*1 *3) 1 A SFR– 1 C SFR+ Y–G (*1 *3) 2 C Y–G (*2 *3) 2 BV1 1 A ESR 7 C A A Y–B 1 BV1 2 A CENTER AIRBAG SENSOR ASSEMBLY PL+ PL– FSR 9 C VUPR SSR+ 12 C 10 C 12 A 10 A 9 A VUPL SSL+ FSL ESL C17 A , C18 B , C19 C 7 A A Y 1 1N +SR 9 B LG 7 II3 W–B 100A ALT 1 C B 2 F SFL– 6 A SFL+ Y–G (*1 *3) 5 A –SR 20 B 2 IG2 13 W 1 F P– 11 B P+ 10 B 13 B D– Y–R 14 B D+ Y–G 27 B E1 B–O +SL P–L (*3) 1 2A GR 15 B L–W (*3) –SL LG–B (*3) 1 1B BR 26 B 4 GR–L (*3) ACC W–R 6 B 1 P (*3) IG2 BR–W 5 B 2 L–Y (*3) 3 12 To Data Link Connector 1, 2 <18–4><19–3><20–3><20–4> P–B 1 30A AM2 4 3 LG (*3) 2 S8 SIDE AIRBAG SENSOR RH GR (*3) 1 S7 SIDE AIRBAG SENSOR LH 4 J3 JUNCTION CONNECTOR B–Y 1 10A ECU–B SHORT PIN W–R 4 2L 2 2 IU1 W–R 1 IU1 1 BR–W B–W 2 IT1 2 B–W 2 1N BR 1 IT1 1 A B CONNECTION DETECTION PIN LG 4 1N 15A CIG 6 1K A B CONNECTION DETECTION PIN 2 1G 3 1W C9 SRS WARNING LIGHT [COMB. METER] 2 5A IGN 3 1K B–R A32 AIRBAG SENSOR FRONT RH W–R 1 : TMC Made 2 : TMMK Made 3 : w/ Side Airbag 4 : TMMK Made 1MZ–FE P–B 2 IG2 6 ST2 L–R A31 AIRBAG SENSOR FRONT LH 3 * * * * LG 2 1K W–R I16 IGNITION SW 7 AM2 W–R IG1 2 W–R 5 1B 5 1K 2 AM1 W ACC 3 W–R SRS B–Y(*4) LG(Except *4) 7 2J 1 P ow er S ou rc e J OVERALL ELECTRICAL WIRING DIAGRAM MEMO W–R 3 1W 10 1V W–R B F4 A , F6 C , F8 E , F9 F B–G Left radiator side support W–B BATTERY W–B EB B–W 6 M 2 L–R II W–B 1 FUSIBLE LINK BLOCK IG W–B 2 A A Instrument panel brace LH SI W–B W–B B–W L–W From FAN NO. 3 Relay<26–3> 2 1 1 1 L 3 5 1 D3 DIODE(A/C) 1 3 2 EB A Left radiator side support W–B B–W 5 2K 9 2C A 3 1R 2 1W L–B Cowl side panel RH J11 JUNCTION CONNECTOR A A W–B A33 A/C BLOWER MOTOR LINEAR CONTROLLER +B VM GND 3 4 B–W FL MAIN 3. 0W 2 1 B3 BLOWER MOTOR B–W L–R L–R 1 A B–R 50A HTR 1 E L–B 100A ALT 2 F B–R B–R 1 F W–B 1 C L–R 1 2A L–W 2 EB1 MG CLT RELAY 1 L–B L–W 1 EB2 HTR RELAY L–B B–W 1 3 5 1 2 1 1 1 4 1 L–W 1 L–B 10A HEATER 1 1K L–B SHORT PIN 1 IG1 4 ACC 3 L–B 1 1B 40A AM1 I16 IGNITION SW 2 AM1 B–Y 2 A ir C o n ditio ning (A u tom a tic A /C ) L–B 2 2 2 1K W 1 P o w er S ou rc e W 7 2J 10A ECU–B 29 CAMRY L–Y A 4 7 IK2 J32 JUNCTION CONNECTOR W–B W–B L–B W–B B–W B–W L–Y L–W L–B W–R J I H G F E D C B A (Cont. next page) J OVERALL ELECTRICAL WIRING DIAGRAM B8 BLOWER RESISTOR (Low Speed) W–B 29 CAMRY (Cont’ d) A ir C on ditio n in g (A u to ma tic A /C ) 5 A W–R 7 6 Y–G 8 From Defogger Relay <26–3> A34 A , A35 B 13 A B IG+ A/C CONTROL ASSEMBLY 23 A RDFG HR 26 A 10 A MGCR LOCK 2 B 3 A BLW 16 B PSW 9 B SPD 15 A AIF 6 A AIR 7 A TPI FACE 7 B 4 A B/L 17 A FOOT 18 A F/D 19 A DEF 20 A AMH 9 A AMC 8 A S5 TS TP 11 A 5 B 8 B IGN 16 A GND 14 A B–Y B–O To Engine Control Module<2–7> From Engine Control Module<2–11> LG–B V F W–B From Engine Control Module<2–7><2–8> J29 JUNCTION CONNECTOR W–R W–R 5 DEF W–R 4 F/D Y 3 FOOT F W–R F W–R 2 B/L 6 IG W–B W–B 7 GND M W–R L–B 3 5 A39 AIR MIX CONTROL SERVO MOTOR WARM L–B 4 W–R 1 W–B B–Y 2 CONTROL CIRCUIT B B–W L A P M COOL J 1 FACE G–R I L–O H B–L G AC1 13 B 10 IK2 2 F L–R 4 L 1 A3 A/C DUAL PRESSURE SW 4 A2 A/C MAGNETIC CLUTCH AND LOCK SENSOR L–W L–B B–W W–L 1 A20 AIR VENT MODE CONTROL SERVO MOTOR 1 W–R L L F B–W ACT 10 B 2 4 IK3 1 W–R E TW 14 B Y 2 W–R W–R 2 IG1 A38 AIR INLET CONTROL SERVO MOTOR 11 IK2 9 IK2 1 A30 A/C AMBIENT TEMP. SENSOR 1 A13 A/C EVAPORATOR TEMP. SENSOR W–R A36 A/C ROOM TEMP. SENSOR A B–Y A 1 2 L–W L–Y L–W G–Y W–R B–Y A 2 L A A37 A/C SOLAR SENSOR L L L–B W–R D TAM 3 B 1 IK1 W 3 J1 JUNCTION CONNECTOR C TE 6 B P–L R L–Y 5 M B W L P G–R L–O B–L L–R L L–W V–W L–B To Speedometer [Comb. Meter]<25–8> B–W W–L L–Y L–W L–B 7 TR 4 B 1 IG1 L 6 SG 1 A W–B W–R W–B J K POWER SOURCE (Current Flow Chart) K K POWER SOURCE (Current Flow Chart) Fusible Link Block (See Page 19) Fuse 50A 100A HTR ALT System Page Air Conditioning (Automatic A/C) Air Conditioning (Manual A/C) 292 300 Charging Headlight (w/ Daytime Running Light) Illumination Light Auto Turn Off 62 100 126 110 Radiator Fan and Condenser Fan Taillight Theft Deterrent (TMC Made) Theft Deterrent (TMMK Made) 288 132 182 188 Wireless Door Lock Control (TMC Made) Wireless Door Lock Control (TMMK Made) 162 172 Instrument Panel J/B (See Page 20) Fuse System Page Charging Combination Meter Electronically Controlled Transmission and A/T Indicator (1MZ–FE) Electronically Controlled Transmission and A/T Indicator (5S–FE) 62 280 202 210 Engine Control (1MZ–FE) Engine Control (5S–FE) SRS 66 82 245 Combination Meter Electronically Controlled Transmission and A/T Indicator (1MZ–FE) Electronically Controlled Transmission and A/T Indicator (5S–FE) Engine Control (1MZ–FE) 280 202 210 66 Engine Control (5S–FE) Starting and Ignition (1MZ–FE) Starting and Ignition (5S–FE) 82 54 58 OBD Engine Control (1MZ–FE) Engine Control (5S–FE) 66 82 7.5A PANEL Cigarette Lighter and Clock Combination Meter Illumination 258 280 126 7.5A RAD–NO.2 Auto Antenna Radio and Player (Built–In Type Amplifier) Radio and Player (Separate Type Amplifier) 272 278 274 7.5A TURN Turn Signal and Hazard Warning Light 114 ABS (TMC Made) ABS (TMMK Made) ABS and Traction Control Back–Up Light 234 240 226 138 Charging 62 5A 5A 7.5A 10A IGN STARTER GAUGE ∗ These are the page numbers of the first page on which the related system is shown. K Fuse 10A 10A 10A 10A 15A 15A 15A System Page Combination Meter Cruise Control Door Lock Control (TMC Made) Door Lock Control (TMMK Made) 280 218 150 156 Electronically Controlled Transmission and A/T Indicator (1MZ–FE) Electronically Controlled Transmission and A/T Indicator (5S–FE) Engine Control (1MZ–FE) Engine Control (5S–FE) 202 210 66 82 Headlight (w/ Daytime Running Light) Key Reminder and Seat Belt Warning Light Auto Turn Off Moon Roof 100 260 110 194 Power Window Stop Light Taillight 144 118 132 HEATER Air Conditioning (Automatic A/C) Air Conditioning (Manual A/C) Rear Window Defogger and Mirror Heater 292 300 268 MIRROR–HEATER Engine Control (1MZ–FE) Engine Control (5S–FE) Rear Window Defogger and Mirror Heater 66 82 268 Engine Control (1MZ–FE) Engine Control (5S–FE) Taillight Wireless Door Lock Control (TMC Made) 66 82 132 162 Wireless Door Lock Control (TMMK Made) 172 Cigarette Lighter and Clock Remote Control Mirror Shift Lock SRS 258 266 252 245 ABS (TMC Made) ABS (TMMK Made) ABS and Traction Control Auto Antenna 234 240 226 272 Cruise Control Radiator Fan and Condenser Fan Shift Lock Theft Deterrent (TMC Made) 218 288 252 182 Theft Deterrent (TMMK Made) Wireless Door Lock Control (TMC Made) Wireless Door Lock Control (TMMK Made) 188 162 172 Power Outlet 264 GAUGE TAIL CIG ECU–IG POWER–OUTLET ∗ These are the page numbers of the first page on which the related system is shown. K POWER SOURCE (Current Flow Chart) Fuse 15A 25A 25A 30A STOP WIPER DOOR POWER System Page ABS (TMC Made) ABS (TMMK Made) ABS and Traction Control Cruise Control 234 240 226 218 Electronically Controlled Transmission and A/T Indicator (1MZ–FE) Electronically Controlled Transmission and A/T Indicator (5S–FE) Engine Control (1MZ–FE) Engine Control (5S–FE) 202 210 66 82 Shift Lock Stop Light 252 118 Wiper and Washer 140 Door Lock Control (TMC Made) Door Lock Control (TMMK Made) Moon Roof Power Window 150 156 194 144 Theft Deterrent (TMC Made) Theft Deterrent (TMMK Made) Wireless Door Lock Control (TMC Made) Wireless Door Lock Control (TMMK Made) 182 188 162 172 Door Lock Control (TMC Made) Door Lock Control (TMMK Made) Moon Roof Power Seat 150 156 194 198 Power Window 144 40A AM1 Charging Radiator Fan and Condenser Fan 62 288 40A DEF Rear Window Defogger and Mirror Heater 268 Engine Room J/B No.2 (See Page 22) Fuse 5A 7.5A ALT–S DOME System Page Charging 62 Cigarette Lighter and Clock Combination Meter Headlight (w/ Daytime Running Light) Interior Light 258 280 100 122 Key Reminder and Seat Belt Warning Light Auto Turn Off Moon Roof Theft Deterrent (TMC Made) 260 110 194 182 Theft Deterrent (TMMK Made) Wireless Door Lock Control (TMC Made) Wireless Door Lock Control (TMMK Made) 188 162 172 ∗ These are the page numbers of the first page on which the related system is shown. K Fuse System Page 10A ECU–B Air Conditioning (Automatic A/C) Combination Meter SRS 10A HAZARD Turn Signal and Hazard Warning Light 114 Horn Theft Deterrent (TMC Made) Theft Deterrent (TMMK Made) Wireless Door Lock Control (TMC Made) 256 182 188 162 Wireless Door Lock Control (TMMK Made) 172 Electronically Controlled Transmission and A/T Indicator (1MZ–FE) Electronically Controlled Transmission and A/T Indicator (5S–FE) Engine Control (1MZ–FE) Engine Control (5S–FE) 202 210 66 82 Engine Immobiliser System 94 10A 15A HORN EFI 292 280 245 15A HEAD (LH) Headlight (w/o Daytime Running Light) 96 15A HEAD (RH) Headlight (w/o Daytime Running Light) 96 15A HEAD LH (UPR) Headlight (w/ Daytime Running Light) 100 15A HEAD RH (UPR) Headlight (w/ Daytime Running Light) 100 RADIO NO.1 Auto Antenna Radio and Player (Built–In Type Amplifier) Radio and Player (Separate Type Amplifier) 272 278 274 Charging Engine Control (1MZ–FE) Engine Control (5S–FE) Starting and Ignition (1MZ–FE) 62 66 82 54 Starting and Ignition (5S–FE) 58 20A 30A AM2 30A CDS Radiator Fan and Condenser Fan 288 30A RDI Radiator Fan and Condenser Fan 288 Headlight (w/ Daytime Running Light) Headlight (w/o Daytime Running Light) Light Auto Turn Off Starting and Ignition (1MZ–FE) 100 96 110 54 Starting and Ignition (5S–FE) Theft Deterrent (TMC Made) Theft Deterrent (TMMK Made) Wireless Door Lock Control (TMC Made) 58 182 188 162 Wireless Door Lock Control (TMMK Made) 172 40A MAIN Engine Room R/B No.1 (See Page 24) Fuse System Page 10A A/C Air Conditioning (Manual A/C) 300 25A A/F HTR Engine Control (1MZ–FE) 66 ∗ These are the page numbers of the first page on which the related system is shown. K POWER SOURCE (Current Flow Chart) Engine Room R/B No.2 (See Page 24) Fuse System Page 5A DRL NO.2 Headlight (w/ Daytime Running Light) 100 10A H–LP LH (LWR) Headlight (w/ Daytime Running Light) 100 10A H–LP RH (LWR) Headlight (w/ Daytime Running Light) 100 Engine Room R/B No.3 (TMMK Made w/ ABS and Traction Control) (TMC Made w/ ABS, w/ ABS and Traction Control) or Fusible Link Block (TMMK Made w/ ABS w/o Traction Control) (See Page 25) Fuse 60A FL ABS System ABS (TMC Made) ABS (TMMK Made) ABS and Traction Control ∗ These are the page numbers of the first page on which the related system is shown. Page 234 240 226 MEMO L PART NUMBER OF CONNECTORS Code Part Name Part Number Code Part Name Part Number A1 A/C Condenser Fan Motor 90980–10928 B4 Blower Resistor 90980–10976 A2 A/C Magnetic Clutch and Lock Sensor 90980–10942 B5 Blower SW 90980–10877 A3 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 90980–10943 B6 Buckle SW LH B7 Buckle SW LH B8 Blower Resistor (Low Speed) C1 Camshaft Position Sensor C2 Crankshaft Position Sensor C3 Cruise Control Actuator 90980–11150 C4 Cigarette Lighter 90980–10760 C5 Cigarette Lighter Illumination 90980–11148 C6 Clock 90980–11013 C7 Clutch Start SW 90980–10825 A4 ABS Actuator 90980–11413 A5 ABS Actuator 90980–10891 A6 ABS Actuator and ECU 90080–98070 A7 ABS and Traction Actuator 90980–11698 A8 ABS and Traction Actuator 90980–11413 A9 ABS Speed Sensor Front LH A10 ABS Speed Sensor Front RH A11 Air Fuel Ratio Sensor 90980–11178 A12 A/C Amplifier 90980–10807 A13 A/C Evaporator Temp. Sensor 90980–10825 A14 A/C SW 90980–10631 A15 ABS and Traction ECU 90980–11390 A16 ABS and Traction ECU 90980–11391 A17 ABS and Traction ECU A18 ABS ECU A19 ABS ECU 90980–11390 A20 Air Vent Mode Control Servo Motor 90980–11165 A22 Airbag Squib (Front Passenger Airbag Assembly) 90980–11884 A23 Airbag Squib (Steering Wheel Pad) 90980–10850 A24 Ashtray Illumination 81945–33010 A25 A26 ABS Speed Sensor Rear RH Auto Antenna Motor and Relay A28 Air Fuel Ratio Sensor (Bank 1 Sensor 1) Air Fuel Ratio Sensor (Bank 2 Sensor 1) A30 A/C Ambient Temp. Sensor A31 Airbag Sensor Front LH 90980–11060 90980–11697 90980–11178 90980–11070 90980–11856 Airbag Sensor Front RH A33 A/C Blower Motor Linear Controller 90980–11676 A34 A/C Control Assembly 90980–11390 A35 A/C Control Assembly 90980–11391 A36 A/C Room Temp. Sensor 90980–10825 A37 A/C Solar Sensor 90980–11918 A38 Air Inlet Control Servo Motor 90980–11165 A39 Air Mix Control Servo Motor 90980–11319 A40 Automatic Light Control Sensor 90980–11107 B1 Back–Up Light SW 90980–11250 B2 Brake Fluid Level Warning SW 90980–11207 Blower Motor C9 90980–10903 90980–10976 90980–10947 Combination Meter (TMC Made) 90980–11114 Combination Meter (TMMK Made) 90980–98048 Combination Meter (TMC Made) 90980–11113 Combination Meter (TMMK Made) 90980–98046 Combination Meter (TMC Made) 90980–11115 Combination Meter (TMMK Made) 90980–98047 C11 Combination SW 90980–11594 C12 Combination SW 90980–11616 C13 Combination SW 90980–11672 C14 Cruise Control Clutch SW 90980–10906 C15 Cruise Control ECU 90980–11391 C16 Condenser 90980–10860 C17 Center Airbag Sensor Assembly 90980–11869 C18 Center Airbag Sensor Assembly 90980–11872 C19 Center Airbag Sensor Assembly 90980–11867 Data Link Connector 1 (1MZ–FE) 90980–11195 90980–11424 A32 B3 C8 C10 ABS Speed Sensor Rear LH A27 A29 90980–11075 90980–10825 D1 Data Link Connector 1 (5S–FE) 90980–11323 D2 Daytime Running Light Resistor 90980–10928 D3 Diode (A/C) 90980–11071 D4 Data Link Connector 2 90980–11417 D5 Data Link Connector 3 90980–11665 D6 Daytime Running Light Relay (Main) 90980–11058 D7 Di d (Courtesy) Diode (C t ) D10 Diode (Dome) D11 Diode (Idle–Up) D12 Door Courtesy SW Front LH D13 Door Courtesy SW Front RH D14 Door Courtesy SW Rear LH D15 Door Courtesy SW Rear RH D16 Door Key Lock and Unlock SW Front LH D17 Door Key Lock and Unlock SW Front RH 90980–10962 90980–11071 90980–10871 90980–11490 Note: Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). L Code D18 D19 D20 Part Name Part Number Code Door Lock Control SW RH (TMC Made) 90980–11326 H1 Headlight LH Door Lock Control SW RH (TMMK Made) 90980–10797 H2 Headlight RH H3 Heated Oxygen Sensor (Bank 1 Sensor 1) H4 Heated Oxygen Sensor (Bank 2 Sensor 1) H5 Horn (High) H6 Horn (Low) H7 Hazard SW H8 Heated Oxygen Sensor (Bank 1 Sensor 2) 90980–11028 H9 Heater Control SW 90980–10799 H10 High Mounted Stop Light 90980–11148 Door Lock Motor and Door Unlock Detection SW Front LH Door Lock Motor and Door Unlock Detection SW Front RH D21 Door Lock Motor and Door Unlock Detection SW Rear LH D22 Door Lock Motor and Door Unlock Detection SW Rear RH 90980–11150 E1 EGR Gas Temp. Sensor 90980–10899 E2 EGR Valve Position Sensor 90980–11143 Electronically Controlled Transmission Solenoid (1MZ–FE) 90980–10854 Electronically Controlled Transmission Solenoid (5S–FE) 90980–11156 E4 Electronically Controlled Transmission Solenoid 90980–11143 E5 Engine Coolant Temp. Sensor 90980–10737 E6 Engine Hood Courtesy SW 90980–11189 Engine Control Module (1MZ–FE) 90980–11638 Engine Control Module (5S–FE) 90980–11392 Engine Control Module (1MZ–FE) 90980–11637 Engine Control Module (5S–FE) 90980–11391 Engine Control Module (1MZ–FE) 90980–11586 Engine Control Module (5S–FE) 90980–11390 Engine Control Module (1MZ–FE) 90980–11476 Engine Control Module (5S–FE) 90980–11408 E11 Engine Control Module 90980–11421 F1 Front Turn Signal Light and Parking Light LH E3 E7 E8 E9 E10 90980–11020 Part Name Part Number 90980–11314 90980–11028 90980–10619 90980–10801 I1 Idle Air Control Valve 90980–11145 I2 Igniter 90980–11653 I3 Ignition Coil and Igniter No.1 I4 Ignition Coil and Igniter No.2 I5 Ignition Coil No.1 I6 Ignition Coil No.2 I7 Ignition Coil No.3 I8 Injector No.1 I9 Injector No.2 I10 Injector No.3 I11 Injector No.4 I12 Injector No.5 I13 Injector No.6 I14 Intake Air Temp. Sensor 90980–11163 I15 Ignition Key Cylinder Light 90980–10906 I16 Ignition SW 90980–11615 I17 Integration Relay 90980–11107 Integration Relay (w/ Theft Deterrent) 90980–11058 Integration Relay (w/o Theft Deterrent) 90980–11542 I19 Interior Light 90980–10121 I18 90980–11150 90980–11246 90980–11153 F2 Front Turn Signal Light and Parking Light RH F3 Front Wiper Motor J1 Junction Connector 90980–11542 F4 Fusible Link Block J2 Junction Connector 90980–10803 F5 Fusible Link Block J3 Junction Connector 90980–11542 F6 Fusible Link Block J4 Junction Connector 90980–10803 F7 Fusible Link Block J5 Junction Connector 90980–11542 F8 Fusible Link Block J6 Junction Connector 90980–11502 F9 Fusible Link Block J7 Junction Connector F10 Front Door Speaker LH J8 Junction Connector F11 Front Door Speaker RH J9 Junction Connector F12 Front Tweeter (Speaker) LH J10 Junction Connector 90980–11599 – 90980–11579 90980–10825 90980–10916 90980–11661 F13 Front Tweeter (Speaker) RH J11 Junction Connector 90980–10976 F14 Fuel Pump and Sender 90980–11077 J12 Junction Connector 90980–10803 G1 Generator 90980–09213 J13 Junction Connector G2 Generator 90980–11349 J14 Junction Connector G3 Glove Box Light and SW 90980–11098 90980–11661 L PART NUMBER OF CONNECTORS Code Part Name J15 Junction Connector J16 Junction Connector J17 Junction Connector J18 Junction Connector J19 Junction Connector Part Number Code Part Name Part Number P1 Park/Neutral Position SW,A/T Indicator Light SW and Back–Up Light SW 90980–11332 P2 Power Steering Oil Pressure SW 90980–11428 P3 Parking Brake SW 90980–10871 P4 Power Outlet 90980–10760 P5 Personal Light 90980–10825 P6 Power Window Control SW Front RH 90980–10789 P7 Power Window Control SW Rear LH P8 Power Window Control SW Rear RH P9 Power Window Master SW and Door Lock Control SW LH P10 Power Window Motor Front LH P11 Power Window Motor Front RH P12 Power Window Motor Rear LH P13 Power Window Motor Rear RH P14 Power Seat Control SW (Driver’s Seat) P15 Power Seat Control SW (Front Passenger’s Seat) P16 Power Seat Motor (Driver’s Seat Rear Vertical Control) P17 Power Seat Motor (Driver’s Seat Reclining Control) P18 Power Seat Motor (Driver’s Seat Slide Control) P19 Power Seat Motors (Driver’s Seat) 90980–10803 P20 Power Seat Motor (Front Passenger’s Seat Rear Vertical Control) 90980–10976 P21 Power Seat Motor (Front Passenger’s Seat Reclining Control) 90980–11166 P22 Power Seat Motor (Front Passenger’s Seat Slide Control) P23 Power Seat Motors (Front Passenger’s Seat) P24 Pretensioner LH P25 Pretensioner RH R1 Radiator Fan Motor 90980–10928 R2 Radio and Player 90980–10996 R3 Radio and Player 90980–10997 R4 Radio and Player 90980–11264 R5 Rear Window Defogger SW 90980–11280 R6 Remote Control Mirror SW 90980–11450 R7 Rheostat 90980–10908 R8 Rear Combination Light LH 90980–10795 90980–10803 90980–11661 90980–11542 J20 Junction Connector 90980–11539 J21 Junction Connector 90980–11542 J22 Junction Connector J23 Junction Connector J24 Junction Connector J25 Junction Connector J26 Junction Connector J27 Junction Connector J28 Junction Connector J29 Junction Connector J30 Junction Connector J31 Junction Connector J32 Junction Connector J33 Junction Connector J34 Junction Connector 90980–11539 90980–11529 90980–11661 90980–11502 90980–11661 90980–10803 90980–11661 J35 Junction Connector J36 Junction Connector J37 Junction Connector J38 Junction Connector J39 Junction Connector J40 Junction Connector K1 Knock Sensor 1 K2 Knock Sensor 2 K3 Key Interlock Solenoid L1 License Plate Light LH L2 License Plate Light RH L3 Light Failure Sensor 90980–10803 L4 Luggage Compartment Key Unlock SW 90980–11212 90980–11542 90980–10825 90980–11148 L5 Luggage Compartment Light 90980–11148 L6 Luggage Compartment Light SW 90980–11097 M1 Manifold Absolute Pressure Sensor 90980–10845 M2 Mass Air Flow Meter 90980–11317 M3 Moon Roof Control SW and Relay 90980–10799 M4 Moon Roof Motor and Limit SW 90980–11011 N1 Noise Filter (Ignition) 90980–10843 N2 Noise Filter (Rear Window Defogger) 90980–11259 O1 Oil Pressure SW 90980–11363 O2 O/D Main SW and A/T Shift Lever Illumination 90980–10795 90980–10631 90980–10807 90980–10860 90980–10803 90980–10825 90980–11001 90980–10825 90980–11001 90980–11862 R9 Rear Combination Light LH 90980–11001 R10 Rear Combination Light RH 90980–10795 R11 Rear Combination Light RH 90980–11001 Note: Not all of the above part numbers of the connector are established for the supply. In case of ordering a connector or terminal with wire, please confirm in advance if there is supply for it using “Parts Catalog News” (published by Parts Engineering Administration Dept.). L Code Part Name R12 Rear Speaker LH R13 Rear Speaker RH R14 Rear Window Defogger R15 Rear Window Defogger R16 R17 Part Number 90980–10860 90980–10792 Remote Control Mirror LH (TMC Made w/ Mirror Heater) 90980–10558 Remote Control Mirror LH (TMC Made w/o Mirror Heater) 90980–10395 Remote Control Mirror LH (TMMK Made w/ Mirror Heater) 90980–11487 Remote Control Mirror LH (TMMK Made w/o Mirror Heater) 90980–11489 Remote Control Mirror RH (TMC Made w/ Mirror Heater) 90980–10558 Remote Control Mirror RH (TMC Made w/o Mirror Heater) 90980–10395 Remote Control Mirror RH (TMMK Made w/ Mirror Heater) 90980–11487 Remote Control Mirror RH (TMMK Made w/o Mirror Heater) 90980–11489 S1 Starter 90980–09689 S2 Starter 90980–11400 S3 Shift Lock ECU 90980–11488 S4 Stereo Component Amplifier 90980–10848 S5 Stereo Component Amplifier 90980–10807 S6 Stop Light SW 90980–11118 S7 Side Airbag Sensor LH S8 Side Airbag Sensor RH S9 Side Airbag Squib LH S10 Side Airbag Squib RH 90980–11857 90980–11864 Code Part Name Part Number T1 Theft Deterrent Horn 90980–11235 T2 Throttle Position Sensor 90980–11261 T3 Theft Deterrent ECU 90980–11424 T4 Theft Deterrent ECU 90980–11392 T5 Traction Off SW 90980–11013 T6 Turn Signal Flasher 82751–50010 T7 Transponder Key Amplifier 90980–10789 U1 Unlock Warning SW 90980–10860 V1 Vapor Pressure Sensor 90980–11860 V2 Vehicle Speed Sensor (Combination Meter) 90980–11143 V3 Vehicle Speed Sensor (Electronically Controlled Transmission) 90980–11156 VSV (EGR)(1MZ–FE) 90980–11149 V4 VSV (EGR)(5S–FE) 90980–11156 V5 VSV (EVAP) V6 VSV (Intake Air Control) 90980–11149 V7 VSV (Vapor Pressure Sensor) 90980–11859 V8 Vanity Light LH V9 Vanity Light RH W1 Washer Level Warning SW 90980–11068 W2 Washer Motor 90980–10981 W3 Water Temp. Sender 90980–11428 W4 Water Temp. SW No.1 90980–11235 W5 Water Temp. SW No.2 90980–11243 W6 Wireless Door Lock ECU 90980–11264 90980–10621 EM–1 ENGINE MECHANICAL (5S–FE) – CO/HC CO/HC EM07X–05 INSPECTION HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing checked correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand CO/HC Meter S04994 2. 3. START ENGINE RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. Author: Date: 1173 EM–2 ENGINE MECHANICAL (5S–FE) – CO/HC If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. (1) Check oxygen sensor operation. (See page DI–66) (2) See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO HC Symptom Causes Normal High Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
O Open en or crossed high–tension cords 2. Incorrect valve clearance 3. Leaky EGR valve 4. Leaky intake and exhaust valves 5. Leaky cylinder Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks:
PCV hose
EGR valve
Intake manifold
Throttle body
IAC valve
Brake booster line 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system
Faulty pressure regulator
Defective ECT sensor
Defective IAT sensor
Faulty ECM
Faulty injector
Faulty throttle position sensor
MAP sensor Author: Date: 1174 EM–3 ENGINE MECHANICAL (5S–FE) – COMPRESSION COMPRESSION EM07Y–05 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. DISCONNECT IGNITION COIL CONNECTORS 3. REMOVE SPARK PLUGS (See page IG–1) Compression Gauge S05312 4. (a) (b) (c) INSPECT CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,226 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. REINSTALL SPARK PLUGS (See page IG–1) 6. RECONNECT IGNITION COIL CONNECTORS Author: Date: 1175 EM–4 ENGINE MECHANICAL (5S–FE) – VALVE CLEARANCE VALVE CLEARANCE EM07Z–03 INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE CYLINDER HEAD COVER (a) Disconnect the 4 high–tension cords from the clamps on the cylinder head cover. (b) Disconnect the 4 high–tension cords from the spark plugs. (c) (d) (e) (c) (f) Disconnect the PCV hose from the intake manifold. Disconnect the PCV hose from the cylinder head cover. Disconnect the engine wire clamp from the mounting bolt of the No.2 timing belt cover. Remove the cylinder head cover. (See page EM–33) (e) (d) S05289 2. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark ”0” of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No.4 are tight. If not, turn the crankshaft one revolution (360°) and align the mark as above. Turn S05590 1 1 1 1 3. (a) 2 2 3 3 P03443 (b) INSPECT VALVE CLEARANCE Check only the valves indicated. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record the out–of–specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.19 – 0.29 mm (0.007 – 0.011 in.) Exhaust 0.28 – 0.38 mm (0.011 – 0.015 in.) Turn the crankshaft one revolution (360°) and align the mark as above. Author: Date: 1176 EM–5 ENGINE MECHANICAL (5S–FE) 3 2 2 3 4 4 4 4 – VALVE CLEARANCE (c) Check only the valves indicated as shown. Measure the valve clearance. (See step (a)) 4. (a) ADJUST VALVE CLEARANCE Remove the adjusting shim. (1) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve points upward. (2) Position the notch of the valve lifter facing the spark plug side. P03442 Upward Cam Lobe Notch Spark Plug Side P13927 (3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248–55040 (09248–05410, 09248–05420) SST (A) SST (B) HINT: Apply SST (B) at slight angle on the side marked with ”9”, at the position shown in the illustration. Spark Plug Side P13988 (4) Remove the adjusting shim with a small screwdriver and magnetic finger. Magnetic Finger P13926 (b) EM0494 Determine the replacement adjusting shim size by following the Formula or Charts: (1) Using a micrometer, measure the thickness of the removed shim. (2) Calculate the thickness of a new shim so that the valve clearance comes within specified value. T ........... Thickness of removed shim A ........... Measured valve clearance N ........... Thickness of new shim Intake: N = T + (A – 0.24 mm (0.009 in.)) Author: Date: 1177 EM–6 ENGINE MECHANICAL (5S–FE) – VALVE CLEARANCE Exhaust: N = T + (A – 0.33 mm (0.013 in.)) (3) Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). (c) SST (A) SST (B) (d) Install a new adjusting shim. (1) Place a new adjusting shim on the valve lifter. (2) Using SST (A), press down the valve lifter and remove SST (B). SST 09248–55040 (09248–05410, 09248–05420) Recheck the valve clearance. P13989 5. (a) (b) (c) (d) (b) (d) (e) (c) S05289 (f) REINSTALL CYLINDER HEAD COVER Install the cylinder head cover. (See page EM–53) Connect the PCV hose to the intake manifold. Connect the PCV hose to the cylinder head cover. Install the engine wire clamp to the mounting bolt of the No.2 timing belt cover. Install the 4 high–tension cords to the clamps on the cylinder head cover. Connect the 4 high–tension cords to the spark plugs. Author: Date: 1178 Adjusting Shim Selection Chart (Intake) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (5S–FE) – Date: Intake valve clearance (Cold): 0.19 – 0.29 mm (0.007 – 0.011 in.) Shim No. Thickness Shim No. Thickness 1 2.500 (0.0984) 10 2.950 (0.1161) 2 2.550 (0.1004) 11 3.000 (0.1181) 3 2.600 (0.1024) 12 3.050 (0.1201) 4 2.650 (0.1043) 13 3.100 (0.1220) 5 2.700 (0.1063) 14 3.150 (0.1240) 6 2.750 (0.1083) 15 3.200 (0.1260) 7 2.800 (0.1102) 16 3.250 (0.1280) 8 2.850 (0.1122) 17 3.300 (0.1299) 9 2.900 (0.1142) HINT: New shims have the thickness in millimeters imprinted on the face. EM–7 V00867 1179 EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.11 shim. mm (in.) VALVE CLEARANCE Author: New shim thickness EM–8 Adjusting Shim Selection Chart (Exhaust) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (5S–FE) – mm (in.) Shim No. Thickness Shim No. Thickness 1 2.500 (0.0984) 10 2.950 (0.1161) 2 2.550 (0.1004) 11 3.000 (0.1181) 3 2.600 (0.1024) 12 3.050 (0.1201) 4 2.650 (0.1043) 13 3.100 (0.1220) Date: 1180 V00868 5 2.700 (0.1063) 14 3.150 (0.1240) Exhaust valve clearance (Cold): 0.28 – 0.38 mm (0.011 – 0.015 in.) 6 2.750 (0.1083) 15 3.200 (0.1260) 7 2.800 (0.1102) 16 3.250 (0.1280) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.9 shim. 8 2.850 (0.1122) 17 3.300 (0.1299) 9 2.900 (0.1142) HINT: New shims have the thickness in millimeters imprinted on the face. VALVE CLEARANCE Author: New shim thickness EM–9 ENGINE MECHANICAL (5S–FE) – IGNITION TIMING IGNITION TIMING EM080–03 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. (a) (b) (c) 3. CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Remove the fuse cover on the instrument panel. Connect a TOYOTA hand–held tester or OBDII scan tool to the DLC3. Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. CONNECT TIMING LIGHT TO ENGINE S05331 TE1 4. (a) E1 INSPECT IGNITION TIMING Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 HINT: After engine rpm is kept at 1,000 – 1,300 rpm for 5 seconds, check that it returns to idle speed. SST A07370 (b) (c) 5. S05309 Using a timing light, check the ignition timing. Ignition timing: 8 – 12° BTDC @ idle (Transmission in neutral position) Remove the SST from the DLC1. SST 09843–18020 FURTHER CHECK IGNITION TIMING Ignition timing: 0 – 10° BTDC @ idle (Transmission in neutral position) HINT: The timing mark moves in a range between 0° and 10°. 6. DISCONNECT TIMING LIGHT FROM ENGINE 7. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Author: Date: 1181 EM–10 ENGINE MECHANICAL (5S–FE) – IDLE SPEED IDLE SPEED EM081–05 INSPECTION 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All vacuum lines properly connected SFI system wiring connectors fully plugged All operating accessories switched OFF Ignition timing check correctly Transmission in neutral position Air conditioning switched OFF 2. S05331 CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL (a) Remove the fuse cover on the instrument panel. (b) Connect a TOYOTA hand–held tester or OBDII scan tool to the DLC3. (c) Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooling fan OFF): 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Author: Date: 1182 EM–11 ENGINE MECHANICAL (5S–FE) – BALANCE SHAFT BACKLASH BALANCE SHAFT BACKLASH EM082–04 ON–VEHICLE INSPECTION 1. Crankshaft Gear TDC 30° 1 100° 2 A 3 210° B 4 No.1 Balance Shaft Gear 280° B A C Z19417 REMOVE OIL PAN AND OIL STRAINER (See page LU–7) 2. INSPECT BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR NOTICE: Backlash between the crankshaft gear and No.1 balance shaft gear varies with the rotation of the balance shaft and the deviation of the crankshaft gear. Accordingly, it is necessary to measure the backlash at the 4 points shown in the illustration on the left. (a) Turn the crankshaft 2 or 3 times to settle the crankshaft gear and No.1 balance shaft gear. (b) When No.1 piston is at TDC, check that the punch marks C shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing. C P06121 (c) Check that punch marks A and B are at the positions on the No.1 balance shaft indicated in the illustration. (d) First turn the crankshaft clockwise, and align the groove of the No.2 balance shaft housing with punch mark A of the No.1 balance shaft. Mark B Mark A No.1 Balance Shaft No.2 Housing Z19411 Mark B No.1 Balance Shaft No.2 Housing Mark A Z19413 Author: Date: 1183 EM–12 ENGINE MECHANICAL (5S–FE) (e) – BALANCE SHAFT BACKLASH Set SST and a dial indicator as shown in the illustration. SST 09224–74010 HINT: Make sure that the stem of the dial indicator is perpendicular to the SST and that it is placed in the middle of the 3rd indentation. SST Measuring Point for Dial Indicator P25734 (f) Lightly turn the No.1 balance shaft by hand until resistance is felt, and measure the backlash. HINT:
SST P06039 Turn the No.1 balance shaft 4 or 5 times to provide a steady backlash reading.
To prevent excessive backlash due to thrust clearance, measure the backlash while pressing on the rear of the No.1 balance shaft. Standard backlash (at punch mark A): 0.025 – 0.065 mm (0.0010 – 0.0026 in.) NOTICE: Do not turn the No.1 balance shaft strongly. (g) Remove the dial indicator and SST. (h) Mark A (i) (j) No.2 Housing No.1 Balance Shaft (k) Turn the crankshaft clockwise to align the groove of the No.2 housing with punch mark B. Set the dial indicator. (See step (e)) Measure the backlash. (See step (f)) Standard backlash (at punch mark B): 0.025 – 0.085 mm (0.0010 – 0.0033 in.) Remove the dial indicator. Mark B Z19415 (l) Mark B (m) (n) No.2 Housing No.1 Balance Shaft (o) Mark A Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark A. Set the dial indicator. (See step (e)) Measure the backlash. (See step (f)) Standard backlash (at punch mark A): 0.025 – 0.065 mm (0.0010 – 0.0026 in.) Remove the dial indicator. Z19413 Author: Date: 1184 EM–13 ENGINE MECHANICAL (5S–FE) – BALANCE SHAFT BACKLASH (p) Mark A No.2 Housing No.1 Balance Shaft Mark B Z19415 Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark B. (q) Set the dial indicator. (See step (e)) (r) Measure the backlash. (See step (f)) Standard backlash (at punch mark B): 0.025 – 0.085 mm (0.0010 – 0.0033 in.) (s) Remove the dial indicator. If even one of the 4 points measured above exceeds the backlash specification, adjust the backlash with new spacers. NOTICE: Use the same size spacers for both the left and right sides. HINT:
Varying the spacer thickness by 0.02 mm (0.0008 in.) changes the backlash by about 0.014 mm (0.0006 in.).
If the backlash is greater than the permitted maximum, select a thinner shim.
If the backlash is less than the specification, select a thicker shim. 3. (a) (b) 3 5 REPLACE NEW SPACERS Uniformly loosen the 6 bolts in the sequence shown. Replace the spacers with new ones. 1 2 6 4 Z19408 4 Pull 6 2 5 1 3 Z19409 4. TIGHTEN BALANCE SHAFT ASSEMBLY While pulling the center part of the engine balancer in the direction of the arrow, uniformly tighten the 6 bolts in several passes, in the sequence shown. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 5. INSPECT AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR (See step 2) 6. REINSTALL OIL STRAINER AND OIL PAN (See page LU–13) Author: Date: 1185 EM–14 Adjusting Spacer Selection Chart (On–Vehicle) Measured backlash Installed spacer No. mm (in.) ENGINE MECHANICAL (5S–FE) – BALANCE SHAFT BACKLASH Author: Date: Standard backlash (at punch mark A): 0.025 – 0.065 mm (0.0010 – 0.0026 in.) EXAMPLE: The No.25 spacers are installed, and the measured backlash is 0.110 mm (0.0043 in.). Replace the No.25 spacers with new No.15 spacers. New spacer thickness No. A01918 1186 01 03 05 07 09 Thickness No. Thickness 1.74 (0.0685) 11 1.84 (0.0724) 1.76 (0.0693) 13 1.86 (0.0732) 1.78 (0.0701) 15 1.88 (0.0740) 1.80 (0.0709) 17 1.90 (0.0748) 1.82 (0.0717) 19 1.92 (0.0756) No. Thickness 21 1.94 (0.0764) 23 1.96 (0.0772) 25 1.98 (0.0780) 27 2.00 (0.0787) 29 2.02 (0.0795) mm (in.) No. Thickness 31 2.04 (0.0803) 33 2.06 (0.0811) 35 2.08 (0.0819) 37 2.10 (0.0827) 39 2.12 (0.0835) EM–15 ENGINE MECHANICAL (5S–FE) – TIMING BELT TIMING BELT EM083–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt PS Pump Drive Belt RH Front Fender Apron Seal N·m (kgf·cm, ft·lbf) : Specified torque S05284 Author: Date: 1187 EM–16 ENGINE MECHANICAL (5S–FE) – TIMING BELT Generator Wire Generator Connector Generator *1 Gasket Wire Clamp Wire Clamp No.2 Timing Belt Cover Timing Belt No.1 Timing Belt Cover Timing Belt Guide Crankshaft Pulley *1 Gasket High–Tension Cord 108 (1,100, 80) Spark Plug Wire Clamp 18 (180, 13) Wire Clamp Wire Clamp Tension Spring Camshaft Timing Pulley 54 (550, 40) *2 37 (380, 27) No.1 Idler Pulley 42 (425, 31) No.2 Idler Pulley 42 (425, 31) 24 (245, 18) Oil Pump Pulley Crankshaft Timing Pulley N·m (kgf·cm, ft·lbf) : Specified torque *1 Replace only if damaged *2 For use with SST S05937 Author: Date: 1188 EM–17 ENGINE MECHANICAL (5S–FE) – TIMING BELT EM084–04 REMOVAL 1. 2. 3. REMOVE GENERATOR (See page CH–6) REMOVE RH FRONT WHEEL REMOVE RH FRONT FENDER APRON SEAL 4. REMOVE PS PUMP DRIVE BELT Loosen the 2 bolts, and remove the drive belt. 5. DISCONNECT GROUND STRAP CONNECTOR S05609 6. REMOVE ENGINE MOVING CONTROL ROD Remove the 3 bolts and control rod. S05249 7. REMOVE NO.2 RH ENGINE MOUNTING BRACKET Remove the 3 bolts and mounting bracket. 8. REMOVE SPARK PLUGS (a) Disconnect the 4 high–tension cords from the clamps on the cylinder head cover. (b) Disconnect the 4 high–tension cords from the spark plug. (c) Remove the 4 spark plugs. S05296 9. (a) (b) REMOVE NO.2 TIMING BELT COVER Disconnect the 2 engine wire clamps from the timing belt cover. Remove the 4 bolts and timing belt cover. S05597 Author: Date: 1189 EM–18 ENGINE MECHANICAL (5S–FE) 10. (a) – TIMING BELT SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark ”0” of the No.1 timing belt cover. Turn S05587 (b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crankshaft 1 revolution (360°). S05580 11. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEY HINT: When re–using timing belt: Affix the matching marks on the timing belt and the camshaft timing pulley, and the timing belt and the No. 1 timing belt cover. A02585 (a) Pry (b) Loosen the mounting bolt of the No.1 idler pulley, and shift the pulley toward the left as far as it will go, and temporarily tighten it. Remove the timing belt from the camshaft timing pulley. Move S05583 12. (a) SST (b) REMOVE CAMSHAFT TIMING PULLEY Using SST, loosen the pulley bolt. SST 09249–63010, 09960–10010 (09962–01000, 09963–01000) Remove the bolt and timing pulley. SST S05593 Author: Date: 1190 EM–19 ENGINE MECHANICAL (5S–FE) 13. (a) SST – TIMING BELT REMOVE CRANKSHAFT PULLEY Using SST (and bolt), loosen the pulley bolt. SST 09213–54015 (91651–60855), 09330–00021 HINT:

S05589 Either of 2 types of pulley may be used, each with its own bolt size, type A (91651–60885) and type B (part No. 91121–40665). When using bolt type B, a plate washer must be inserted between the bolt and SST. HINT: When re–using timing belt: After loosing the crankshaft pulley bolt and matching the ditch of the crankshaft pulley with the ”0” of the timing mark of No.1 timing belt cover, check that matching mark meets. A02586 When matchmark is misaligned clockwise: If the matchmark does not align, align as follows: (1) Align the matchmark by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise. Pull Turn A02587 (2) Hold After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley clockwise, and align its groove with timing mark ”0” of the No.1 timing belt cover. Turn A02588 When matchmark is misaligned counterclockwise: If the matchmark does not align, align as follows: (1) Align the matchmark by pulling the timing belt up on the No.1 idler pulley side while turning the crankshaft pulley clockwise. Pull Turn A02589 Author: Date: 1191 EM–20 ENGINE MECHANICAL (5S–FE) – TIMING BELT (2) Hold (b) Turn After aligning the matchmark, hold the timing belt. And turn the crankshaft pulley counterclockwise, and align its groove with timing mark ”0” of the No.1 timing belt cover. Remove the pulley bolt. A02590 (c) SST Using SST, remove the pulley. SST 09950–50012 (09951–05010, 09952–05010, 09953–05010, 09953–05020, 09954–05020, 09954–05010) HINT:
S05612
14. (a) (b) (c) 15. Either of 2 types of pulley may be used, each with its own bolt size, type A(09954–05020) and type B (09954–05010). When re–using timing belt: Remove the pulley without turning it. REMOVE NO.1 TIMING BELT COVER Disconnect the crankshaft position sensor wire from the clamp on the timing belt cover. Disconnect the clamp of the crankshaft position sensor wire from the timing belt cover. Remove the 4 bolts and timing belt cover. REMOVE TIMING BELT GUIDE S05591 16. REMOVE TIMING BELT HINT: When re–using timing belt: Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft timing pulley. S05944 17. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING Remove the bolt, pulley and tension spring. 18. REMOVE NO.2 IDLER PULLEY Remove the bolt and pulley. S05614 Author: Date: 1192 EM–21 ENGINE MECHANICAL (5S–FE) – TIMING BELT 19. REMOVE CRANKSHAFT TIMING PULLEY If the pulley cannot be removed by hand, use SST to remove the timing pulley. SST 09950–50012 (09951–05010, 09952–05010, 09953–05010, 09953–05020, 09954–05010) NOTICE: Do not scratch the angle sensor of the timing pulley. SST S05579 20. (a) SST (b) REMOVE OIL PUMP PULLEY Using SST, loosen the pulley nut. SST 09960–10010 (09962–01000, 09963–00500) Remove the nut and pulley. S05575 Author: Date: 1193 EM–22 ENGINE MECHANICAL (5S–FE) – TIMING BELT EM085–03 INSPECTION No! EM3336 Turn 1. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley. If there are any defects as shown in the illustration, check these points: (a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft or water pump is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check the timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. (a) INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. Seal S01519 3. (a) Free Length P15243 INSPECT TENSION SPRING Measure the free length of tension spring. Free length: 42.0 mm (1.654 in.) If the free length is not as specified, replace the tension spring. (b) Measure the tension of the tension spring at the specified installed length. Installed tension (at 50.5 mm (1.988 in.)): 32 – 37 N (3.25 – 3.75 kgf, 7.2 – 8.3 lbf) If the installed tension is not as specified, replace the tension spring. Author: Date: 1194 EM–23 ENGINE MECHANICAL (5S–FE) – TIMING BELT EM086–04 INSTALLATION 1. (a) SST (b) INSTALL OIL PUMP PULLEY Align the cutouts of the pulley and shaft, and slide on the pulley. Using SST, install the pulley nut. SST 09960–10010 (09962–01000, 09963–00500) Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) S05576 2. (a) Angle Sensor Inward INSTALL CRANKSHAFT TIMING PULLEY Align the timing pulley set key with the key groove of the pulley. (b) Slide on the timing pulley, facing the angle sensor inward. NOTICE: Do not scratch the angle sensor of the timing pulley. S05577 3. (a) 35 mm INSTALL NO.2 IDLER PULLEY Install the pulley with the bolt. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) HINT: Use the 35 mm (1.38 in.) long bolt. (b) Check that the idler pulley moves smoothly. S05571 4. 42 mm TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING Align the bracket pin hole with the pivot pin. Install the pulley with the bolt. Do not tighten the bolt yet. (a) (b) HINT: Use the 42 mm (1.65 in.) long bolt. (c) Install the tension spring. S05616 (d) Pry (e) Pry the pulley toward the left as far as it will go, and tighten the bolt. Check that the idler pulley moves smoothly. Move S05926 Author: Date: 1195 EM–24 ENGINE MECHANICAL (5S–FE) – TIMING BELT 5. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Using the crankshaft pulley bolt, turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body. S05574 (b) (c) S05944 Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No.1 idler pulley and No.2 idler pulley, and keep them clean. Install the timing belt on the crankshaft timing pulley, oil pump pulley, No.1 idler pulley, water pump pulley and No.2 idler pulley. HINT: When re–using timing belt: Align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution. 6. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. S05578 7. (a) Length = 660 mm (25.98 in.) P25230 INSTALL NO.1 TIMING BELT COVER Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. (4) After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. Author: Date: 1196 EM–25 ENGINE MECHANICAL (5S–FE) (b) (c) (d) – TIMING BELT Install the timing belt cover with the 4 bolts. Install the clamp of the crankshaft position sensor wire to the timing belt cover. Install the crankshaft position sensor wire to the clamp on the timing belt cover. A02591 8. (a) SST (b) SST S05588 SST Fulcrum Length SST S05592 INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST (and bolt), install the pulley bolt. SST 09213–54015 (91651–60855),09330–00021 Torque: 108 N·m (1,100 kgf·cm, 80 ft·lbf) HINT: Either of 2 types of pulley may be used, each with its own bolt size, type A (91651–60855) and type B (part No. 91121–40665). 9. INSTALL CAMSHAFT TIMING PULLEY (a) Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley. (b) Using SST, install the pulley bolt. SST 09249–63010, 09960–10010 (09962–01000, 09963–01000) Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) 37 N·m (380 kgf·cm, 27 ft·lbf) for use with SST HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.). 10. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark ”0” of the No.1 timing belt cover. Turn S05587 Author: Date: 1197 EM–26 ENGINE MECHANICAL (5S–FE) – TIMING BELT (b) Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap. SST 09960–10010 (09962–01000, 09963–01000) 11. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEY SST S05594 HINT:
A02592 When re–using timing belt: Check that the matching marks of the timing belt and the No.1 timing belt cover meet. If the matchmark does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align. (See page EM–17)
When re–using timing belt: Align the matchmarks of the timing belt and camshaft timing pulley. (a) (b) Remove any oil or water on the camshaft timing pulley, and keep it clean. Connect the timing belt to the camshaft timing pulley, and checking the tension between the crankshaft timing pulley and camshaft timing pulley. 12. (a) CHECK VALVE TIMING Loosen the No.1 idler pulley bolt 1/2 turn. S05582 S05931 Loosen S05581 Author: Date: 1198 EM–27 ENGINE MECHANICAL (5S–FE) – TIMING BELT (b) Slowly turn the crankshaft pulley 2 revolutions TDC to TDC. NOTICE: Always turn the crankshaft pulley clockwise. Turn S05587 (c) Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks do not align, remove the timing belt and reinstall it. S05598 (d) Slowly turn the crankshaft pulley 1 and 7/8 revolutions, and align its groove with the mark at 45° BTDC (for No.1 cylinder) of the No.1 timing belt cover. NOTICE: Always turn the crankshaft pulley clockwise. Turn S05586 (e) Tighten the mounting bolt of the No.1 idler pulley. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) S05585 13. (a) Length = 735 mm (28.94 in.) Length = 230 mm (9.06 in.) S01710 INSTALL NO.2 TIMING BELT COVER Check that the timing belt cover gaskets have no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps: (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. Author: Date: 1199 EM–28 ENGINE MECHANICAL (5S–FE) (3) (4) – TIMING BELT Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. (b) (c) 14. (a) (b) (c) Install the belt cover with the 4 bolts. Install the engine wire clamp. INSTALL SPARK PLUGS Install the 4 spark plugs. Connect the 4 high–tension cords to the spark plugs. Install the 4 high–tension cords to the clamps on the cylinder head cover. 15. (a) (b) INSTALL NO.2 RH ENGINE MOUNTING BRACKET Install the mounting bracket with the 3 bolts. Alternately tighten the 3 bolts in several passes. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) 16. (a) (b) INSTALL ENGINE MOVING CONTROL ROD Temporarily install the control rod with the 3 bolt. Alternately tighten the 3 bolts in several passes. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) CONNECT GROUND STRAP CONNECTOR S05596 S05296 17. S05249 18. INSTALL PS PUMP DRIVE BELT Install the drive belt with the 2 bolts. 19. INSTALL RH FRONT FENDER APRON SEAL 20. INSTALL RH FRONT WHEEL 21. INSTALL GENERATOR (See page CH–16) S05609 Author: Date: 1200 EM–29 ENGINE MECHANICAL (5S–FE)    – CYLINDER HEAD  EM087–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod Ground Strap Connector 52 (530, 38) Accelerator Cable No.2 RH Engine Mounting Bracket Throttle Cable (A/T) PCV Hose EVAP Hose EVAP Hose Generator Drive Belt EVAP Hose VSV Connector for EVAP IAT Sensor Connector PS Drive Belt Gasket Air Cleaner Cap RH Front Fender Apron Seal 64 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part A02194 Author: Date: 1201 EM–30 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD Ignition Coil and No.2 Intake Manifold Assembly (with High–Tension Cord) Wire Clamp Ignition Coil Connector (TMMK Made) (TMC Made) 19 (195, 14) Generator Wire Generator Connector Throttle Position Sensor Connector Wire Clamp Throttle Body Gasket ECT Sender Gauge Connector IAC Valve Connector ECT Sensor Connector Heater Water Hose Generator Radiator Hose Water Outlet Gasket Noise Filter Connector Oil Pressure Switch Connector A/F Sensor Connector (California) or Heated Oxygen Sensor (Bank 1 Sensor 1) Connector (Except California) No.1 Exhaust Manifold Heat Insulator (California) Gasket No.1 Exhaust Manifold Stay Except California No.1 Exhaust Manifold Heat Insulator x6 49 (500, 36) Exhaust Manifold, No.2 and no.3 Exhaust Manifold Heat Insulator Assenbly (California) Exhaust Manifold, No.2 and No.3 Exhaust Manifold Heat Insulator Assembly 49 (500, 36) No.2 Exhaust Manifold Stay (TMC Made) (TMMK Made) N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part A01562 Author: Date: 1202 EM–31 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EGR Valve and Vacuum Modulator Ground Wire MAP Sensor Vacuum Hose Gasket VSV Connector for EGR Brake Booster Vacuum Hose VSV for EGR Intake Manifold Gasket x6 Fuel Inlet Hose 19 (195, 14) Fuel Pulsation Damper Air Hose for Air Assist System (California) 34 (350, 25) * 29 (300, 21) 13 (130, 9) Gasket Spacer Injector Connector O–Ring Grommet Intake Manifold Stay Engine Wire Spacer Injector (California) Insulator O–Ring PCV Hose Injector (Except California) Insulator Knock Sensor 1 Connector N·m (kgf·cm, ft·lbf) : Specified torque Non–reusable part * For use with SST A07358 Author: Date: 1203 EM–32 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD Spark Plug 18 (180, 13) Adjusting Shim 44 (450, 33) Valve Lifter Grommet Keeper Spring Retainer Valve Spring Cylinder Head Cover Oil Seal Spring Seat Valve Guide Bushing Gasket 19 (190, 14) Intake Camshaft Exhaust Camshaft Valve Camshaft Bearing Cap x 10 Camshaft Oil Seal See page EM–53 1st 49 (500, 36) 2nd Turn 90° Camshaft Timing Pulley Camshaft Gear Spring Camshaft Sub–Gear Semi–Circular Plug 54 (550, 40) (380, 27) *237 Snap Ring Wave Washer Camshaft Position Sensor Connector Camshaft Position Sensor Assembly Wire Clamp No. 3 Timing Belt Cover LH Engine Hanger Semi–Circular Plug Oil Pressure Switch Cylinder Head 42 (425, 31) Wire Clamp Cylinder Head Gasket Tension Spring Timing Belt No.1 Idler Pulley *1 Gasket Wire Clamp No.2 Timing Belt Cover Generator Bracket and RH Engine Hanger Assembly N·m (kgf·cm, ft·lbf) : Specified torque *1 Replace only if damaged *2 For use with SST Non–reusable part A07368 Author: Date: 1204 EM–33 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM0YL–01 REMOVAL 1. 2. 3. DRAIN ENGINE COOLANT REMOVE AIR CLEANER CAP (See page EM–69) REMOVE GENERATOR (See page CH–6) 4. (a) REMOVE EXHAUST MANIFOLD Remove the 3 nuts holding the front exhaust pipe to the exhaust manifold. Remove the 3 (California) or 5 (Except California) bolts and No.1 exhaust manifold heat insulator. (b) S05282 (c) Remove the 2 bolts and No.1 exhaust manifold stay. (d) TMC Made: Remove the 2 nuts and No.2 exhaust manifold stay. TMMK Made: Remove the bolt, nut and No.2 exhaust manifold stay. S05281 (e) TMC Made TMMK Made S05300 (f) (g) (h) Sensor Connector (i) Clamp Remove the wire clamp. California: Disconnect the A/F sensor connector. Except California: Disconnect the oxygen sensor (bank 1 sensor 1) connector. Remove the 6 nuts, the exhaust manifold, No.2 and No.3 exhaust manifold heat insulators assembly. S05297 Author: Date: 1205 EM–34 ENGINE MECHANICAL (5S–FE) (j) (k) 5. Wire Clamp 6. (a) (b) (c) S05548 (d) (e) (f) 7. 8. – CYLINDER HEAD California: Disconnect the A/F sensor connector for the wiring side from the bracket on the LH engine hanger. Except California: Disconnect the heated oxygen sensor (bank 1 sensor 1) connector for the wiring side from the bracket on the LH engine hanger. REMOVE THROTTLE BODY (See page SF–32) REMOVE IGNITION COILS, NO.2 INTAKE MANIFOLD STAY AND HIGH–TENSION CORDS ASSEMBLY Disconnect the 2 ignition coil connectors. Disconnect the 4 high–tension cords from the 2 clamps on the cylinder head cover. Disconnect the 4 high–tension cords from the spark plugs. Disconnect the wire clamp from the manifold stay. TMC Made: Remove the 2 nuts, 2 bolts, 2 ignition coils, manifold stay and 4 high–tension cords assembly. TMMK Made: Remove the nut, 3 bolts, 2 ignition coils, manifold stay and 4 high–tension cords assembly. DISCONNECT OIL PRESSURE SWITCH CONNECTOR DISCONNECT NOISE FILTER CONNECTOR 9. (a) (b) (c) (d) (c) Clamp (d) (e) A01564 Connector REMOVE WATER OUTLET Disconnect the ECT sensor connector. Disconnect the ECT sender gauge connector. Disconnect the radiator hose from the water outlet. Disconnect the water bypass pipe hose from the water outlet. (e) Disconnect the heater water hose from the water outlet. (f) Remove the 2 nuts, water outlet and gasket. 10. REMOVE INTAKE MANIFOLD STAY Remove the bolt, nut and intake manifold stay. 11. REMOVE EGR VALVE AND VACUUM MODULATOR (a) Disconnect the VSV connector for the EGR. (b) Disconnect the hose clamp from the bracket on the intake manifold. (c) Remove the bolt, and disconnect the VSV for EGR from the intake manifold. A07364 Author: Date: 1206 EM–35 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (d) Loosen the union nut of the EGR pipe, and remove the bolt, 2 nuts, the EGR valve, vacuum modulator, vacuum hoses assembly and gasket. 12. DISCONNECT ENGINE WIRE FROM INTAKE MANIFOLD Disconnect the engine wire clamp from the bracket on the LH side of the intake manifold. Disconnect the 2 engine wire clamps from the 2 brackets on the front side of the intake manifold. A07363 (a) (b) A07365 13. (a) SST (b) DISCONNECT FUEL INLET HOSE FROM DELIVERY PIPE Using SST, loosen the fuel pulsation damper. SST 09612–24014 (09617–24011) Remove the fuel pulsation damper and 2 gaskets, and disconnect the fuel inlet hose from the delivery pipe. S05981 (a) 14. (a) (c) (b) (b) (c) REMOVE INTAKE MANIFOLD Disconnect the MAP sensor vacuum hose from the gas filter. Disconnect the brake booster vacuum hose from the intake manifold. Disconnect the PCV hose from the intake manifold. S05990 (d) (d) (e) Remove the 2 bolts, and disconnect the 2 ground wires from the intake manifold. Disconnect the knock sensor 1 connector. (e) A07360 Author: Date: 1207 EM–36 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (f) 15. Remove the 6 bolts, 2 nuts, intake manifold and gasket. California: REMOVE AIR HOSE FOR AIR ASSIST SYSTEM Disconnect the air hose from the cylinder head port, and remove the air hose. A07359 16. (a) (b) S06000 REMOVE DELIVERY PIPE AND INJECTORS Disconnect the 4 injector connectors. Remove the 2 bolts and delivery pipe together with the 4 injectors. NOTICE: Be careful not to drop the injectors when removing the delivery pipe. (c) Remove the 4 insulators (except California) and 2 spacers from the cylinder head. (d) Pull out the 4 injectors from the delivery pipe. (e) California: Remove the 2 O–rings, insulator and grommet from each injector. (f) Except California: Remove the O–ring and grommet from each injector. 17. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEY (See page EM–17) 18. REMOVE CAMSHAFT TIMING PULLEY (See page EM–17) 19. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING Remove the bolt, pulley and tension spring. 20. REMOVE NO.3 TIMING BELT COVER Remove the 3 bolts and timing and cover. S05962 Author: Date: 1208 EM–37 ENGINE MECHANICAL (5S–FE) A02593 S05933 Knock Pin CYLINDER HEAD NOTICE:
Support the timing belt, so the meshing of the crankshaft timing pulley and timing belt does not shift.
Be careful not to drop anything inside the timing belt cover.
Do not allow the belt to come into contact with oil, water or dust. 21. REMOVE ENGINE HANGERS AND GENERATOR BRACKET (a) Remove the 3 bolts, the generator bracket and RH engine hanger assembly. (b) Remove the bolt and LH engine hanger. 22. REMOVE OIL PRESSURE SWITCH 23. REMOVE CYLINDER HEAD COVER Remove the 4 nuts, grommets, head cover and gasket. HINT: Arrange the grommets in the correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of the grommets in different positions. 24. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) 10 – 45° – Remove the exhaust camshaft. (1) Set the knock pin of the intake camshaft at 10 – 45° BTDC of camshaft angle. HINT: The above angle allows No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly. P03355 Author: Date: 1209 EM–38 ENGINE MECHANICAL (5S–FE) CYLINDER HEAD (2) Secure the exhaust camshaft sub–gear to drive gear with a service bolt. Recommended service bolt: Drive Gear Service Bolt Sub–Gear – Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 – 20 mm (0.63 – 0.79 in.) P03445 HINT: When removing the camshaft, make sure that the torsional spring force of the sub–gear has been eliminated by the above operation. (3) Remove the 2 bolts and rear bearing cap. P03356 (4) 3 NOTICE: Do not remove the No.3 bearing cap bolts at this stage. (5) Remove the No.1, No.2 and No.4 bearing caps. 4 5 6 1 Uniformly loosen and remove the 6 bolts on the No.1, No.2 and No.4 bearing caps in several passes, in the sequence shown. 2 P03241 (6) Alternately loosen and remove the 2 bolts on the No.3 bearing cap. HINT:
P03357 As the 2 No.3 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, retighten the 2 No.3 bearing cap bolts. Then reverse the order of above steps from (6) to (1) and reset the knock pin of the intake camshaft at 10 – 45° BTDC, and repeat steps from (2) to (6) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (7) Remove the No.3 bearing cap and exhaust camshaft. Author: Date: 1210 EM–39 ENGINE MECHANICAL (5S–FE) (b) 80 – 115° – CYLINDER HEAD Remove the intake camshaft. (1) Set the knock pin of the intake camshaft at 80 – 115° BTDC of camshaft angle. HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of intake camshaft to push their valve lifters evenly. Knock Pin P03358 (2) Remove the 2 bolts, front bearing cap and oil seal. (3) Uniformly loosen and remove the 6 bolts on the No.1, No.3 and No.4 bearing caps in several passes, in the sequence shown. P03359 2 6 1 5 NOTICE: Do not remove the No.2 bearing cap bolts at this stage. (4) Remove the No.1, No.3 and No.4 bearing caps. 4 3 P03360 (5) Alternately loosen and remove the 2 bolts on the No.2 bearing cap. HINT:
P03361 As the 2 No.2 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level, after breaking adhesion on the front bearing cap.
If the camshaft is not being lifted out straight and level, retighten the 2 No.2 bearing cap bolts. Reverse the order of above steps from (5) to (1) and reset the knock pin of the intake camshaft at 80 – 115° BTDC, and repeat steps from (2) to (5) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (6) Remove the No.2 bearing cap and camshaft. Author: Date: 1211 EM–40 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD 25. DISASSEMBLE EXHAUST CAMSHAFT (a) Mount the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P05613 SST (b) Using SST, turn the sub–gear clockwise, and remove the service bolt. SST 09960–10010 (09962–01000, 09963–00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub–gear and gear spring. Service Bolt S01665 S01666 3 5 10 8 2 1 7 9 6 4 26. (a) (b) EM7558 REMOVE CYLINDER HEAD Disconnect the camshaft position sensor connector. Remove the 2 bolts holding the water bypass pipe to the cylinder head. (c) Uniformly loosen and remove the 10 cylinder head bolts in several passes, in the sequence shown. NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. (d) Pry S05971 Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. Author: Date: 1212 EM–41 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM089–03 DISASSEMBLY 1. REMOVE CAMSHAFT POSITION SENSOR ASSEMBLY Remove the bolt and sensor assembly. 2. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in the correct order. SST 3. (a) (b) P03265 REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202–70020 (09202–00010) Remove the spring retainer, valve spring, valve and spring seat. HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. (c) Using needle–nose pliers, remove the oil seal. P03266 Author: Date: 1213 EM–42 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM08A–04 INSPECTION 1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. A07356 (b) A07357 Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high–pressure compressed air. 2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS (See page EM–97) 3. (a) CLEAN CYLINDER HEAD Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. P03267 (b) Using a wire brush, remove all the carbon from the combustion chamber. NOTICE: Be careful not to scratch the cylinder block contact surface. P03268 (c) Using a valve guide bushing brush and solvent, clean all the guide bushings. P03149 Author: Date: 1214 EM–43 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (d) Using a soft brush and solvent, thoroughly clean the cylinder head. 4. (a) INSPECT CYLINDER HEAD Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: P03363 Cylinder Block Side Cylinder block side 0.05 mm (0.0020 in.) Manifold side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the cylinder head. Intake Manifold Side Exhaust Manifold Side Z02749 (b) Inspect for cracks. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. P03269 5. (a) (b) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 Author: Date: 1215 EM–44 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD 6. (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 6.010 – 6.030 mm (0.2366 – 0.2374 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Z02754 (c) Intake 5.970 – 5.985 mm (0.2350 – 0.2356 in.) Exhaust 5.965 – 5.980 mm (0.2348 – 0.2354 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Z00052 Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. (See page EM–50) 7. (a) (b) INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° 44.5° Z00054 (c) Check the valve head margin thickness. Standard margin thickness: 0.8 – 1.2 mm (0.031 – 0.047 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 Author: Date: 1216 EM–45 ENGINE MECHANICAL (5S–FE) (d) Overall Length – CYLINDER HEAD Check the valve overall length. Standard overall length: Intake 97.40 – 97.80 mm (3.8346 – 3.8504 in.) Exhaust 98.25 – 98.65 mm (3.8681 – 3.8839 in.) Minimum overall length: EM2534 Intake 97.1 mm (3.823 in.) Exhaust 98.0 mm (3.858 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than the minimum length. EM0255 45° Carbide Cutter 8. (a) INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. (b) Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
Check that the seat contact is in the middle of the valve face with the following width: 1.0 – 1.4 mm (0.039 – 0.055 in.) P03272 (c) Width Z00055 Author: Date: 1217 EM–46 ENGINE MECHANICAL (5S–FE) 45° 30° – CYLINDER HEAD If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. 1.0 – 1.4 mm Z02852 (2) 75° If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. 45° 1.0 – 1.4 mm Z02853 (d) (e) Hand–lap the valve and valve seat with an abrasive compound. After hand–lapping, clean the valve and valve seat. P03273 9. (a) INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Deviation EM0988 (b) Using a vernier caliper, measure the free length of the valve spring. Free length: 40.95 – 42.80 mm (1.6122 – 1.6850 in.) If the free length is not as specified, replace the valve spring. EM0801 Author: Date: 1218 EM–47 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 164 – 189 N (16.7 – 19.3 kgf, 36.8 – 42.5 lbf) at 34.7 mm (1.366 in.) If the installed tension is not as specified, replace the valve spring. EM0281 10. (a) INSPECT CAMSHAFTS Inspect the circle runout. (1) Place the camshaft on V–blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than maximum, replace the camshaft. EM1628 (b) Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.01 – 42.11 mm (1.6539 – 1.6579 in.) Exhaust 40.06 – 40.16 mm (1.5772 – 1.5811 in.) Minimum cam lobe height: EM2011 Intake 41.90 mm (1.6496 in.) Exhaust 39.95 mm (1.5728 in.) If the cam lobe height is less than minimum, replace the camshaft. (c) Using a micrometer, measure the journal diameter. Journal diameter: 26.959 – 26.975 mm (1.0614 – 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. EM2538 (d) Using vernier calipers, measure the free distance between the gear spring ends. Free distance: 22.5 – 22.9 mm (0.886 – 0.902 in.) If the free distance is not as specified, replace the gear spring. Free Distance EM3322 Author: Date: 1219 EM–48 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (e) Inspect the journal oil clearance. (1) Clean the bearing caps and camshaft journals. (2) Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. (3) Place the camshafts on the cylinder head. (4) Lay a strip of Plastigage across each of the camshaft journals. Plastigage EM3371 (5) Install the bearing caps. (See page EM–53) NOTICE: Do not turn the camshaft. (6) Remove the bearing caps. P00259 (7) Measure the Plastigage at its widest point. Standard oil clearance: 0.025 – 0.062 mm (0.0010 – 0.0024 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (8) Completely remove the Plastigage. EM3310 (f) Inspect the camshaft thrust clearance. (1) Install the camshaft. (See page EM–53) (2) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.045 – 0.100 mm (0.0018 – 0.0039 in.) Exhaust 0.030 – 0.085 mm (0.0012 – 0.0033 in.) Maximum thrust clearance: P00263 Intake 0.12 mm (0.0047 in.) Exhaust 0.10 mm (0.0039 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Author: Date: 1220 EM–49 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD (g) EM3308 Inspect the camshaft gear backlash. (1) Install the camshafts without installing the exhaust cam sub–gear. (See page EM–53) (2) Using a dial indicator, measure the backlash. Standard backlash: 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater then maximum, replace the camshafts. 11. (a) INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 – 31.018 mm (1.2205 – 1.2212 in.) P03368 (b) EM2196 Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.2191 – 1.2195 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 – 0.052 mm (0.0009 – 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 12. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. S06013 13. INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. S05606 Author: Date: 1221 EM–50 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM08B–03 REPLACEMENT 80 – 100°C REPLACE VALVE GUIDE BUSHINGS (a) Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). P03270 (b) Using SST and a hammer, tap out the guide bushing. SST 09201–10000 (09201–01060), 09950–70010 (09951–07100) (c) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. SST SST P13987 P03365 Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 10.985 – 11.012 (0.4325 – 0.4335) Use STD 11.035 – 11.062 (0.4344 – 0.4355) Use O/S 0.05 Intake HINT: Different the bushings are used for the intake and exhaust. (e) Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). Exhaust 38.5 mm (1.516 in.) (d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 11.012 mm (0.4335 in.), machine the bushing bore to the following dimension: 11.035 – 11.062 mm (0.4344 – 0.4355 in.) If the bushing bore diameter of the cylinder head is greater than 11.062 mm (0.4355 in.), replace the cylinder head. 40.5 mm (1.594 in.) P03156 Author: Date: 1222 EM–51 ENGINE MECHANICAL (5S–FE) SST – CYLINDER HEAD (f) Using SST and a hammer, tap in a new guide bushing until there is 8.0 – 8.8 mm (0.315 – 0.346 in.) protruding from the cylinder head. SST 09201–10000 (09201–01060), 09950–70010 (09951–07100) (g) Using a sharp 6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM–42) between the guide bushing and valve stem. 8.0 – 8.8 mm SST S07360 Sharp 6 mm Reamer P03367 Author: Date: 1223 EM–52 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM0YM–01 REASSEMBLY HINT:


1. (a) Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. INSTALL VALVES Using SST, push in a new oil seal. SST 09201–41020 SST P03274 Intake Exhaust Gray Black HINT: The intake valve oil seal is gray and the exhaust valve oil seal is black. (b) Install the valve, spring seat, valve spring and spring retainer. Z02903 (c) SST Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202–70020 (09202–00010) P03265 (d) P03276 Using a plastic–faced hammer, lightly tap the valve stem tip to assure a proper fit. 2. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. 3. INSTALL CAMSHAFT POSITION SENSOR ASSEMBLY Install the sensor assembly with the bolt. Torque: 9.5 N·m (97 kgf·cm, 84 in.·lbf) Author: Date: 1224 EM–53 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD EM08D–04 INSTALLATION 1. PLACE CYLINDER HEAD ON CYLINDER BLOCK (a) Place a new cylinder head gasket on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the cylinder head on the cylinder head gasket. A07355 8 6 1 3 9 10 4 2 5 7 2. INSTALL CYLINDER HEAD BOLTS HINT:
The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)).
If any cylinder head bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes, in the sequence shown. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. Z02750 90° (c) (d) 90° Front (e) Painted Mark (f) S01690 (g) 3. (a) (b) (c) P03279 Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. Install the 2 bolts holding the water bypass pipe to the cylinder head. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Connect the camshaft position sensor connector. INSTALL SPARK PLUG TUBES Clean the cylinder head tube holes of any residual adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline. Screw the threads of the spark plug tube coated with adhesive into the cylinder head. Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Author: Date: 1225 EM–54 ENGINE MECHANICAL (5S–FE) – CYLINDER HEAD 4. ASSEMBLE EXHAUST CAMSHAFT (a) Mount the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P05617 (b) Wave Washer Install the camshaft gear spring, camshaft sub–gear and wave washer. HINT: Align the pins on the gears with the spring ends. Sub–Gear Gear Spring Z02838 (c) Using snap ring pliers, install the snap ring. S01666 (d) SST Sub–Gear Main Gear Turn Service Bolt S01664 Using SST, align the holes of the camshaft drive gear and sub–gear by turning camshaft sub–gear clockwise, and install a service bolt. SST 09960–10010 (09962–01000, 09963–00500) (e) Align the gear teeth of the drive gear and sub–gear, and tighten the service bolt. 5. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Author: Date: 1226 EM–55 ENGINE MECHANICAL (5S–FE) (a) 80 –115° Knoc k Pin – CYLINDER HEAD Install the intake camshaft. (1) Apply MP grease to the thrust portion of the camshaft. (2) Place the intake camshaft at 80 – 115° BTDC of camshaft angle on the cylinder head. HINT: The above angle arrows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. P03369 (3) Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent 2 – 3 mm (0.08 – 0.12 in.) Seal Packing EM3373 (4) Install the bearing caps in their proper locations. P03370 (5) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (6) Install and uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown. Torque: 19 N·m (190 kgf·cm, 14 ft·lbf) 7 8 1 2 5 6 3 4 9 10 P03371 (7) Apply MP grease to a new oil seal lip. (8) Using SST and a hammer, tap in the oil seal. SST 09223–46011 SST P03372 Author: Date: 1227 EM–56 ENGINE MECHANICAL (5S–FE) (b) 10 – 45° – CYLINDER HEAD Install the exhaust camshaft. (1) Set the knock pin of the intake camshaft at 10 – 45° BTDC of camshaft angle. HINT: The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly. Knock Pin P03281 (2) Assembly Reference Mark (3) Timing Mark P03373 (4) Apply MP grease to the thrust portion of the camshaft. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. NOTICE: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks. (5) Turn the intake camshaft clockwise or counterclockwise a little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals. NOTICE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps. (6) Install the bearing caps in their proper locations. P03374 (7) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (8) Install and uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown. Torque: 19 N·m (190 kgf·cm, 14 ft·lbf) 10 6 2 9 5 1 4 3 8 7 P03375 Author: Date: 1228 EM–57 ENGINE MECHANICAL (5S–FE) Drive Gear – CYLINDER HEAD (9) Remove the service bolt. 6. CHECK AND ADJUST VALVE CLEARANCE (See page EM–4) Turn the camshaft and position the cam lobe upward, and inspect and adjust the valve clearance. Service Bolt Sub–Gear P03445 7. (a) (b) INSTALL SEMI–CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi–circular plug grooves. Seal packing: Part No. 08826–00080 or equivalent (c) Install the 2 semi–circular plugs to the cylinder head. 8. (a) (b) INSTALL CYLINDER HEAD COVER Remove any old packing (FIPG) material. Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent (c) (d) Install the gasket to the head cover. Install the head cover with the 4 grommets and nuts. Uniformly tighten the nuts in several passes. Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) Seal Packing EM7797 P03282 : Seal Packing P03283 Marking 15° 15° HINT: Install the grommets so that their markings are as shown in the illustration. S05932 Author: Date: 1229 EM–58 ENGINE MECHANICAL (5S–FE) 9. (a) Adhesive (b) 10. P13638 (a) (b) S05962 California (b) New O–Ring New O–Ring (c) New Grommet (d) Except California CYLINDER HEAD INSTALL OIL PRESSURE SWITCH Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833–00080, THREE BOND 1324 or equivalent Install the oil pressure switch. INSTALL ENGINE HANGERS AND GENERATOR BRACKET Install the generator bracket and RH engine hanger assembly with the 3 bolts. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) Install the LH engine hanger with the bolt. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 11. INSTALL NO.3 TIMING BELT COVER Install the timing belt cover with the 3 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 12. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING (See page EM–23) 13. INSTALL CAMSHAFT TIMING PULLEY (See page EM–23) 14. CONNECT TIMING BELT TO CAMSHAFT TIMING PULLEY (See page EM–23) 15. (a) New Insulator – INSTALL INJECTORS AND DELIVERY PIPE California: Install a new insulator and grommet to each injector. Except California: Install a new grommet to each injector. California: Apply a light coat of gasoline onto 2 new O–rings, and install them to each injector. Except California: Apply a light coat of gasoline onto a new O–ring, and install it to each injector. New O–Ring New Grommet Z09141 Author: Date: 1230 EM–59 ENGINE MECHANICAL (5S–FE) (e) Upward (f) – CYLINDER HEAD While turning the injector clockwise and counterclockwise, push it to the delivery pipe. Install the 6 injectors. Position the injector connector upward. Turn Connector Push S06009 (g) Install the 2 spacers and 4 new insulators (Except California) to the cylinder head. (h) Attach the 4 injectors together with the delivery pipe to the cylinder head. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. Spacer New Insulator S05935 (i) S06002 (j) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (k) Position the injector connector upward. Turn Upward Connector S06003 (l) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) S06001 Author: Date: 1231 EM–60 ENGINE MECHANICAL (5S–FE) CYLINDER HEAD (m) Connect the 4 injector connectors. HINT: The No.1 and No.3 injector connectors are brown, and the No.2 and No.4 injector connectors are gray. No.1 Gray – No.2 No.4 No.3 Brown A07362 16. California: INSTALL AIR HOSE FOR AIR ASSIST SYSTEM Connect the air hose to the cylinder head port. California A07361 17. (a) INSTALL INTAKE MANIFOLD Install a new gasket and the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (b) (c) Connect the MAP sensor vacuum hose to the gas filter. Connect the brake booster vacuum hose to the intake manifold. Connect the PCV hose to the intake manifold. A07359 (b) (d) (d) (c) S05990 (e) (e) (f) Connect the 2 ground wires to the intake manifold with the 2 bolts. Connect the knock sensor 1 connector. (f) A07360 Author: Date: 1232 EM–61 ENGINE MECHANICAL (5S–FE) 18. (a) (b) SST Fulcrum Length S05982 – CYLINDER HEAD CONNECT FUEL INLET HOSE TO DELIVERY PIPE Temporarily connect the fuel inlet hose with 2 new gaskets and fuel pulsation damper. Using SST, tighten the fuel pulsation damper. SST 09612–24014 (09617–24011) Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 29 N·m (300 kgf·cm, 21 ft·lbf) for use with SST HINT: Use a torque wrench with a fulcrum length of 30 cm (1.181 in.). 19. INSTALL ENGINE WIRE (a) Install the 2 engine wire clamps to the 2 brackets on the front side of the intake manifold. (b) Install the engine wire clamp to the bracket on the LH side of the intake manifold. A07365 20. (a) INSTALL EGR VALVE AND VACUUM MODULATOR Install a new gasket, the EGR valve, EGR pipe and vacuum modulator assembly with the union nut, 2 nuts and bolt. Torque: 13.3 N·m (136 kgf·cm, 10 ft·lbf) for nut 61.2 N·m (624 kgf·cm, 45 ft·lbf) for union nut A07363 (b) Clamp Connector Install the hose clamp to the bracket on the intake manifold. (c) Install the VSV for the EGR with the bolt. (d) Connect the VSV connector for the EGR. 21. INSTALL INTAKE MANIFOLD STAY Install the intake manifold stay with the bolt and nut. Torque: 39 N·m (398 kgf·cm, 29 ft·lbf) A07364 22. (a) (b) (c) (d) A01564 (b) (c) (d) (e) (f) 23. 24. INSTALL WATER OUTLET Install a new gasket and the water outlet with the 2 nuts. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Connect the radiator hose to the water outlet. Connect the water bypass pipe hose to the water outlet. Connect the heater water hose to the water outlet. Connect the ECT sensor connector. Connect the ECT sender gauge connector. CONNECT OIL PRESSURE SWITCH CONNECTOR CONNECT NOISE FILTER CONNECTOR Author: Date: 1233 EM–62 ENGINE MECHANICAL (5S–FE) 25. Wire Clamp S05548 (a) (b) (c) (d) (e) (f) 26. 27. (a) Sensor Connector (b) Clamp S05297 (c) (d) (e) (f) (g) (h) – CYLINDER HEAD INSTALL IGNITION COILS AND NO.2 INTAKE MANIFOLD STAY ASSEMBLY TMC Made: Install the 2 ignition coils and manifold stay assembly with the 2 nuts and 2 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) for 12 mm head 42 N·m (428 kgf·cm, 31 ft·lbf) for 14 mm head TMMK Made: Install the 2 ignition coils and manifold stay assembly with the nut and 3 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) for 12 mm head 42 N·m (428 kgf·cm, 31 ft·lbf) for 14 mm head Install the wire clamp to the manifold stay. Connect the 4 high–tension cords to the spark plugs. Install the 4 high–tension cords to the 2 clamps on the cylinder head cover. Connect the 2 ignition coil connectors. INSTALL THROTTLE BODY (See page SF–34) INSTALL EXHAUST MANIFOLD California: Install the A/F sensor connector for the wiring side to the bracket to the LH engine hanger. Except California: Install the heated oxygen sensor for the wiring side to the bracket to the LH engine hanger. Attach the exhaust manifold to the front exhaust pipe. Install a new gasket, the exhaust manifold, No.2 and No.3 exhaust manifold heat insulators assembly with the 6 nuts. Uniformly tighten the nuts in several passes. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Install the wire clamp. California: Connect the A/F sensor connector. Except California: Connect the heated oxygen sensor (bank 1 sensor 1) connector. Install the No.1 exhaust manifold stay with the 2 bolts. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) S05281 Author: Date: 1234 EM–63 ENGINE MECHANICAL (5S–FE) (i) TMC Made TMMK Made (j) S05300 (k) (l) 28. 29. 30. 31. 32. S05282 – CYLINDER HEAD TMC Made: Install the No.2 exhaust manifold stay with the 2 nuts. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) for manifold side 58 N·m (591 kgf·cm, 43 ft·lbf) for block side TMMK Made: Install the No.2 exhaust manifold stay with the bolt and nut. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) for manifold side 41.5 N·m (423 kgf·cm, 31 ft·lbf) for block side Install the No.1 exhaust manifold heat insulator with the 3 (California) or 5 (Except California) bolts. Install 3 new nuts holding the front exhaust pipe to the exhaust manifold. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) INSTALL GENERATOR (See page CH–16) INSTALL AIR CLEANER CASE (See page EM–75) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL Author: Date: 1235 EM–64 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT ENGINE UNIT EM0YV–01 COMPONENTS Upper Radiator Support Radiator Reservoir Hose Upper Radiator Support No.2 Electric Cooling Fan Connector Hood EVAP Hose Upper Radiator Hose EVAP Hose Radiator Assembly Washer Hose for Windshield No.1 Electric Cooling Fan Connector VSV Connector for EVAP PCV Hose Air Cleaner Cap EVAP Hose ECT Switch Connector Lower Radiator Support IAT Sensor Connector Lower Radiator Hose Generator Drive Belt Air Filter A/C Compressor Connector Air Cleaner Case A/C Compressor Battery Hold–Down Clamp Cylinder Block Insulator Oil Cooler Hose (A/T) Cruise Control Actuator Connector Cruise Control Actuator Battery Clamp RH Front Fender Aplon Seal Battery Tray PS Oil Pressure Switch Connector LH Front Fender Apron Seal PS Pump Drive Belt PS Pump 56 (570, 41)  Gasket Support Bracket   Gasket Front Exhaust Pipe   62 (630, 46) Support Bracket Support Stay N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A02195 Author: Date: 1236 EM–65 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT Engine Wire No.2 Instrument Panel Under Cover Front Door Inside Scuff Plate Cowl Side Trim A01658 Engine Wire Clamp MAP Sensor Connector Brake Booster Vacuum Hose DLC1 MAP Sensor Vacuum Hose Fuel Inlet Hose Wire Clamp Engine Wire Ground Cable (M/T) Ground Strap Connector Generator Wire Ground Strap Connector Wire Clamp Generator Connector Starter Connector Heater Hose Ground Cable (A/T) Starter Cable Engine Wire Protector A01565 Author: Date: 1237 EM–66 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT M/T Transaxle Shift Control Cable Engine Wire Engine Moving Control Rod 64 (650, 47) Starter 64 (650, 47) 64 (650, 47) Clutch Release Cylinder and Tube Rear Engine mounting Insulator No.2 RH Engine Mounting Bracket 52 (530, 38) 64 (650, 47) Engine and Transaxle Assembly 64 (650, 47) Transaxle Shift Control Cable (A/T) 66 (670, 49) Front Engine Mounting Insulator 64 (650, 47) Tie Rod End RH Drive Shaft 294 (3,000, 217) TMC Made 80 (820, 59) TMMK Made 44 (450, 32) for Silver Color 66 (670, 49) for Green Color Lock Cap LH Drive Shaft  49 (500, 36) Lower Suspension Arm 127 (1,300, 94)  N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A02188 Author: Date: 1238 EM–67 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT M/T RH Stiffener Plate Intake Manifold Stay Engine No.1 Rear End Plate
No.2 Exhaust Manifold Stay 88 (900, 65) Flywheel (TMMK Made) x8 LH Stiffener Plate (TMC Made) Clutch Disk Exhaust Pipe Bracket Clutch Cover x6 19 (195, 14) Oil Pan Insulator No.2 Rear End Plate Engine Wire Back–Up Light Switch Connector VSS Connector 64(650, 47) Wire Clamp 64(650, 47) Ground Strap No.1 Exhaust Manifold Stay 64(650, 47) Transaxle 64(650, 47) N·m (kgf·cm, ft·lbf) : Specified torque
Precoated part S05316 Author: Date: 1239 EM–68 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT A/T RH Stiffener Plate Intake Manifold Stay Engine No.1 Rear End Plate No.2 Exhaust Manifold Stay Drive Plate Front Spacer (TMMK Made) Rear Spacer LH Stiffener Plate (TMC Made) x8

27 (280, 20) 83 (850, 61) x6 Exhaust Pipe Bracket Throttle Cable Oil Pan Insulator Engine Wire 66 (670, 48) No.2 Rear End Plate Wire Clamp 66 (670, 48) VSS Connector Ground Strap 66 (670, 48) Solenoid Connector No.1 Exhaust Manifold Stay Transaxle 66 (670, 20) Solenoid Connector PNP Switch Connector Starter Throttle Cable Clamp N·m (kgf·cm, ft·lbf) : Specified torque
Precoated part A02187 Author: Date: 1240 EM–69 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT EM08F–04 REMOVAL 1. 2. 3. 4. 5. 6. (a) (b) (c) (d) (e) (f) (g) (h) 7. (a) (b) 8. 9. 10. 11. (a) (b) (c) (d) S05251 (e) (f) 12. (a) (b) (c) (d) (e) (f) REMOVE HOOD REMOVE FRONT FENDER APRON SEALS DRAIN ENGINE COOLANT DRAIN ENGINE OIL DISCONNECT ACCELERATOR CABLE REMOVE AIR CLEANER CAP Disconnect the IAT sensor connector. Disconnect the VSV connector for the EVAP Disconnect the PCV hose from the cylinder head cover. Disconnect the EVAP hose from the throttle body. Disconnect the EVAP hose from the VSV. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case. Loosen hose clamp, and disconnect the air cleaner hose from the throttle body. Remove the air cleaner cap and hose assembly. REMOVE AIR CLEANER CASE Remove the air filter. Remove the 3 bolts and air cleaner case. REMOVE BATTERY AND TRAY REMOVE CRUISE CONTROL ACTUATOR REMOVE RADIATOR (See page CO–18) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts holding the support stay to the support bracket. Remove the 2 bolts holding the support bracket to the front frame. Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe. Remove the 3 nuts holding the front exhaust pipe to the exhaust manifold. Remove the front exhaust pipe and 2 gaskets. Remove the nut and support bracket. DISCONNECT CONNECTORS, WIRES, CABLES, CLAMPS AND HOSES Disconnect the generator wire. Disconnect the generator connector. Disconnect the wire clamp from the generator. Disconnect the starter cable. Disconnect the starter connector. Disconnect the DLC1 from the bracket. Author: Date: 1241 EM–70 ENGINE MECHANICAL (5S–FE) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) 13. (a) (b) (c) (d) S05253 14. 15. 16. 17. – ENGINE UNIT Disconnect the engine wire clamp from the bracket on the RH fender apron. Disconnect the MAP sensor connector. Disconnect the wire clamp from the bracket for the MAP sensor. Disconnect the 2 ground strap connectors from the RH fender apron. Disconnect the 2 ground strap connectors from the LH fender apron. Disconnect the engine wire protector clamp from the battery bracket. Disconnect the engine wire from the clamp on the fuel filter. Disconnect the ground cable from the transaxle. Disconnect the brake booster vacuum hose from the intake manifold. Disconnect the heater hose from the water outlet. Disconnect the heater hose from the water bypass pipe. Disconnect the fuel inlet hose from the fuel filter. Disconnect the MAP sensor vacuum hose from the gas filter on the intake manifold. DISCONNECT ENGINE WIRE FROM CABIN Remove the under cover. Disconnect the 3 ECM connectors. Disconnect the 3 cowl wire connectors from the connectors on the bracket. Disconnect the grommet from the cowl panel, and pull out the engine wire. REMOVE DRIVE SHAFTS (See page SA–17) DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE M/T: REMOVE STARTER (See page ST–5) M/T: DISCONNECT CLUTCH RELEASE CYLINDER AND TUBE FROM TRANSAXLE Author: Date: 1242 EM–71 ENGINE MECHANICAL (5S–FE) 18. (a) (b) (c) (d) – ENGINE UNIT DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the drive belt. Remove the 3 bolts, and disconnect the A/C compressor from the engine. Remove the cylinder block insulator. Connector S05250 19. (a) (b) (c) DISCONNECT PS PUMP FROM ENGINE Disconnect the PS oil pressure switch connector. Loosen the 2 bolts, and remove the drive belt. Remove the 2 bolts, and disconnect the PS pump from the engine. 20. REMOVE BOLTS HOLDING TRANSAXLE TO LH ENGINE MOUNTING INSULATOR S05246 M/T M/T: Remove the 3 bolts. S05254 A/T: Remove the 4 bolts. A/T S04616 21. (a) (b) REMOVE NUTS HOLDING REAR ENGINE MOUNTING BRACKET TO FRONT FRAME Remove the 2 hole plugs. Remove the 3 nuts. S05247 Author: Date: 1243 EM–72 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT 22. REMOVE BOLTS HOLDING FRONT ENGINE MOUNTING INSULATOR TO FRONT FRAME Remove the 3 bolts. S05248 23. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. S05323 24. REMOVE ENGINE MOVING CONTROL ROD Remove the 3 bolts and control rod. S05249 25. Lift A06578 REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE: Make sure the engine is clear of all wiring, hoses and cables. (b) Place the engine and transaxle assembly onto the stand. 26. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE Remove the 4 bolts and mounting insulator. 27. REMOVE REAR ENGINE MOUNTING INSULATOR FROM ENGINE Remove the 4 bolts, the mounting insulator. 28. REMOVE NO.2 RH ENGINE MOUNTING BRACKET FROM ENGINE Remove the 3 bolts and mounting bracket. 29. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY Author: Date: 1244 EM–73 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT 30. TMMK Made TMC Made S05526 A/T: REMOVE STARTER (See page ST–5) 31. DISCONNECT CONNECTORS (a) Disconnect the VSS connector. (b) M/T: Disconnect the back–up light switch connector. (c) A/T: Disconnect the PNP switch connector. (d) A/T: Disconnect the 2 solenoid connectors. 32. REMOVE NO.1 EXHAUST MANIFOLD STAY Remove the 2 bolts and manifold stay. 33. REMOVE NO.2 EXHAUST MANIFOLD STAY AND LH STIFFENER PLATE (a) TMC Made: Remove the 2 nuts and manifold stay. (b) TMMK Made: Remove the bolt, nut and manifold stay. (c) Remove the 2 bolts and stiffener plate. 34. REMOVE INTAKE MANIFOLD STAY Remove the 2 bolts and intake manifold stay. 35. REMOVE RH STIFFENER PLATE Remove the 4 bolts and stiffener plate. A02198 36. (a) (b) REMOVE EXHAUST PIPE BRACKET, OIL PAN INSULATOR AND NO.2 REAR END PLATE Remove the 2 bolts and exhaust pipe bracket. Remove the 2 bolts, oil pan insulator and rear end plate. S05530 37. (a) (b) A/T: REMOVE TORQUE CONVERTER CLUTCH BOLTS Turn the crankshaft pulley bolt to gain access to each bolt. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts. Turn S05529 Author: Date: 1245 EM–74 ENGINE MECHANICAL (5S–FE) Wire Bracket 38. (a) (b) 39. – ENGINE UNIT REMOVE TRANSAXLE Remove the 4 bolts, ground strap and wire bracket. Remove the transaxle together with the torque converter clutch (A/T) from the engine. M/T: REMOVE CLUTCH COVER AND DISC Ground Strap S05531 40. M/T: REMOVE FLYWHEEL Remove the 8 bolts and flywheel. 41. A/T: REMOVE DRIVE PLATE Remove the 8 bolts, front spacer, drive plate and rear spacer. 42. REMOVE NO.1 REAR END PLATE Remove the bolt and end plate. M/T S05314 Author: Date: 1246 EM–75 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT EM08G–04 INSTALLATION 1. INSTALL NO.1 REAR END PLATE Install the end plate with the bolt. Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) 2. (a) M/T: INSTALL FLYWHEEL Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent EM7333 (b) (c) M/T 1 7 3 6 3. 5 4 8 2 4. Z18989 5. Wire Bracket 6. (a) (b) Install the flywheel on the crankshaft. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown. Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) A/T: INSTALL DRIVE PLATE (See step 2) Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) M/T: INSTALL CLUTCH DISC AND COVER A/T: CHECK TORQUE CONVERTER CLUTCH INSTALLATION (A140E: See page AX–25) INSTALL TRANSAXLE TO ENGINE Attach the transaxle to the engine. Install the ground strap, wire bracket and 4 bolts. Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) for 14 mm head 64 N·m (650 kgf·cm, 47 ft·lbf) for 17 mm head Ground Strap S05531 Author: Date: 1247 EM–76 ENGINE MECHANICAL (5S–FE) 7. A/T (a) Black Colored Bolt (b) Turn Z19014 – ENGINE UNIT A/T: INSTALL TORQUE CONVERTER CLUTCH BOLTS Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) HINT: First tighten the black colored bolt, install the other bolts. 8. (a) (b) INSTALL NO.2 REAR END PLATE, OIL PAN INSULATOR AND EXHAUST PIPE BRACKET Install the oil pan insulator to the rear end plate. Install the rear end plate and exhaust pipe bracket with the 4 bolts. Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) for 10 mm head 19 N·m (195 kgf·cm, 14 ft·lbf) for 12 mm head S05530 9. INSTALL RH STIFFENER PLATE Install the stiffener plate with the 4 bolts. Torque: 39 N·m (398 kgf·cm, 29 ft·lbf) 10. INSTALL INTAKE MANIFOLD STAY Install the manifold stay with the 2 bolts. Torque: 39 N·m (398 kgf·cm, 29 ft·lbf) A02198 11. TMMK Made (a) (b) TMC Made S05526 (c) INSTALL LH STIFFENER PLATE AND NO.2 EXHAUST MANIFOLD STAY TMC Made: Temporarily install the stiffener plate and manifold stay with the 2 bolts and 2 nuts. TMMK Made: Temporarily install the stiffener plate and manifold stay with the 3 bolts and nut. Tighten the 2 bolts holding the stiffener plate to the transaxle. Author: Date: 1248 EM–77 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT Torque: 37 N·m (380 kgf·cm, 27 ft·lbf) for M/T 42 N·m (430 kgf·cm, 31 ft·lbf) for A/T (d) TMC Made: Tighten the nut holding the manifold stay to the cylinder block. Torque: 58 N·m (591 kgf·cm, 43 ft·lbf) (e) TMMK Made: Tighten the bolt holding the manifold stay to the cylinder block. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) (f) Tighten the nut holding the manifold stay to the exhaust manifold. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) 12. INSTALL NO.1 EXHAUST MANIFOLD STAY Install the manifold stay with the 2 bolts. Torque: 42 N·m (425 kgf·cm, 31 ft·lbf) 13. CONNECT CONNECTORS (a) Connect the VSS connector. (b) M/T: Connect the back–up light switch connector. (c) A/T: Connect the PNP switch connector. (d) A/T: Connect the 2 solenoid connectors. 14. A/T: INSTALL STARTER (See page ST–19) 15. A/T: INSTALL THROTTLE CABLE TO THROTTLE BODY 16. INSTALL NO.2 RH ENGINE MOUNTING BRACKET TO ENGINE Install the mounting insulator with the 3 bolts. Torque: 52 N·m (530 kgf·cm, 38 ft·lbf) 17. INSTALL REAR ENGINE MOUNTING INSULATOR TO ENGINE Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 18. INSTALL FRONT ENGINE MOUNTING INSULATOR TO ENGINE Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) Author: Date: 1249 EM–78 ENGINE MECHANICAL (5S–FE) 19. Lower (a) (b) (c) – ENGINE UNIT INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE Attach the engine sling device to the engine hangers. Lower the engine into the engine compartment. Tilt the transaxle downward, and lower the engine. Keep the engine level, and attach front and rear mountings to the front frame. A06577 20. INSTALL ENGINE MOVING CONTROL ROD Install the control rod with the 3 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) S05249 21. S05248 INSTALL BOLTS HOLDING FRONT ENGINE MOUNTING INSULATOR TO FRONT FRAME Install the 3 bolts. Torque: TMC made 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK made 44 N·m (450 kgf·cm, 32 ft·lbf) for silver color 66 N·m (670 kgf·cm, 49 ft·lbf) for green color 22. (a) (b) INSTALL NUTS HOLDING REAR ENGINE MOUNTING INSULATOR TO FRONT FRAME Install the 3 nuts. Torque: 66 N·m (670 kgf·cm, 49 ft·lbf) Install the 2 hole plugs. S05247 23. M/T INSTALL BOLTS HOLDING LH ENGINE MOUNTING INSULATOR TO FRONT FRAME M/T: Install the 3 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) S05254 Author: Date: 1250 EM–79 ENGINE MECHANICAL (5S–FE) – ENGINE UNIT A/T: Install the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 24. REMOVE ENGINE SLING DEVICE 25. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE A/T S04616 26. (a) (b) (c) INSTALL PS PUMP Install the PS pump with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) Install the drive belt. Connect the PS oil pressure switch connector. S05246 27. (a) (b) (c) 28. Connector S05250 29. 30. 31. (a) (b) (c) (d) 32. S05253 (a) INSTALL A/C COMPRESSOR Install the cylinder block insulator and A/C compressor with the 3 bolts. Torque: 25.5 N·m (260 kgf·cm, 19 ft·lbf) Install the drive belt. Connect the A/C compressor connector. M/T: INSTALL CLUTCH RELEASE CYLINDER AND TUBE TO TRANSAXLE M/T: INSTALL STARTER (See page ST–19) INSTALL DRIVE SHAFTS (See page SA–24) CONNECT ENGINE WIRE TO CABIN Push in the engine wire through the cowl panel. Install the grommet. Connect the 3 engine ECM connectors. Connect the 3 cowl wire connectors to the connectors on the bracket. Install the under cover. CONNECT CONNECTORS, WIRES, CABLES, CLAMPS AND HOSES Connect the generator wire. Author: Date: 1251 EM–80 ENGINE MECHANICAL (5S–FE) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) – ENGINE UNIT Connect the generator connector. Install the wire clamp to the generator. Connect the starter cable. Connect the starter connector. Install the DLC1 to the bracket. Install the engine wire clamp to the bracket on the RH fender apron. Connect the MAP sensor connector. Install the wire clamp to the bracket for the MAP sensor. Connect the VSV connector for the vapor pressure sensor. Connect the 2 ground strap connectors to the RH fender apron. Connect the 2 ground strap connectors to the LH fender apron. Install the engine wire protector clamp to the battery bracket. Install the engine wire to the clamp on the fuel filter. Connect the ground cable to the transaxle. Connect the brake booster vacuum hose to the intake manifold. Connect the heater hose to the water outlet. Connect the heater hose to the water bypass pipe. Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) Connect the MAP sensor vacuum hose to the gas filter on the intake manifold. 33. (a) S05251 INSTALL FRONT EXHAUST PIPE Install the support bracket with the nut. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) (b) Temporarily install 2 new gaskets and the front exhaust pipe with the 2 bolts and 5 nuts. (c) Tighten the 3 nuts holding the exhaust manifold to the front exhaust pipe. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) (d) Tighten the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) (e) Install the bracket with the 2 bolts. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) (f) Install the support stay with the 2 bolts. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) 34. INSTALL RADIATOR (See page CO–23) 35. INSTALL CRUISE CONTROL ACTUATOR 36. INSTALL BATTERY TRAY AND BATTERY 37. INSTALL AIR CLEANER CASE Install the air cleaner case with the 3 bolts. Author: Date: 1252 EM–81 ENGINE MECHANICAL (5S–FE) 38. (a) (b) (c) (d) (e) (f) (g) (h) 39. 40. 41. 42. 43. 44. 45. – ENGINE UNIT INSTALL AIR CLEANER CAP Connect the air cleaner hose to the throttle body. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps. Tighten the air cleaner hose clamp. Connect the PCV hose to the cylinder head cover. Connect the EVAP hose to the throttle body. Connect the EVAP hose to the VSV. Connect the IAT sensor connector. Connect the VSV connector for the EVAP. CONNECT ACCELERATOR CABLE INSTALL ENGINE FENDER APRON SEALS INSTALL HOOD FILL ENGINE WITH OIL FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE COOLANT AND OIL LEVELS Author: Date: 1253 EM–82 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK CYLINDER BLOCK EM08H–03 COMPONENTS Generator * Gasket Wire Clamp No.2 Timing Belt Cover Timing Belt No.1 Timing Belt Cover Timing Belt Guide * Gasket Crankshaft Pulley High–Tension Cord 108 (1,100, 80) Spark Plug 18 (180, 13) Wire Clamp Wire Clamp Wire Clamp Tension Spring Camshaft Timing Pulley 54 (550, 40) No.1 Idler Pulley 42 (425, 31) No.2 Idler Pulley 42 (425, 31) N·m (kgf·cm, ft·lbf) : Specified torque * Replace only if damaged Crankshaft Timing Pulley A07366 Author: Date: 1254 EM–83 ENGINE MECHANICAL (5S–FE) – PCV Hose CYLINDER BLOCK 19 (190, 14) Intake Camshaft 44 (450, 33) Grommet Camshaft Bearing Cap Cylinder Head Cover x 10 Gasket
Camshaft Oil Seal Exhaust Camshaft See page EM–53 1st 49 (500, 36) 2nd Turn 90° Cylinder Head Assembly No.3 Timing Belt Cover VSV for EGR
Cylinder Head Gasket IAC Valve Water Bypass Hose Water Bypass Hose Knock Sensor 1 Connector Wire Clamp Crankshaft Position Sensor Connector N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A07354 Author: Date: 1255 EM–84 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK w/ Oil Cooler Water Pump, Water Bypass Pipe and Oil Cooler Assembly Water Pump and Water Bypass Pipe Assembly (w/o Oil Cooler) Union Bolt 78.5 (800, 58)
O–Ring Oil Filter Generator Drive Belt Adjusting Bar Knock Sensor 1 Oil Dipstick PS Pump Bracket
O–Ring Crankshaft Position Sensor Connector Oil Pump x 10
Gasket
Gasket 8.8 (90, 78 in.·lbf) 5.4 (55, 48 in.·lbf)
Crankshaft Front Oil Seal Oil Strainer x 17 Oil Pan
Gasket 5.4 (55, 48 in.·lbf) Drain Plug N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A07367 Author: Date: 1256 EM–85 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK No.1 Piston Ring No.2 Piston Ring Oil Ring (Expander) Oil Ring (Side Rail) Piston
Snap Ring
Snap Ring Piston Pin
Connecting Rod Bushing Connecting Rod Connecting Rod Bearing Rear Oil Seal Retainer Connecting Rod Cap
Crankshaft Rear Oil Seal See page EM–107 1st 25 (250, 18) 2nd Turn 90° x6 Cylinder Block
Gasket Upper Crankshaft Thrust Washer Upper Main Bearing Crankshaft Lower Main Bearing Lower Crankshaft Thrust Washer Main Bearing Cap 59 (600, 43) Adjusting Spacer Engine Balancer x6 49 (500, 36) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A07353 Author: Date: 1257 EM–86 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK EM0YW–01 DISASSEMBLY 1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 2. REMOVE TIMING BELT AND PULLEYS (See page EM–17) 3. REMOVE CYLINDER HEAD ASSEMBLY (a) Remove the 3 bolts and No.3 timing belt cover. (b) Remove the cylinder head cover. (1) Disconnect the PCV hose from the intake manifold. (2) Remove the 4 nuts, 4 grommets, head cover and gasket. (c) Remove the camshafts. (See page EM–33) (d) Disconnect the knock sensor 1 connector. (e) Disconnect the crankshaft position sensor connector. (f) Disconnect the wire clamp from the generator drive belt adjusting bar. (g) Disconnect the IAC valve water bypass hose from the water bypass pipe. (h) Disconnect the water bypass hose (from the water bypass pipe) from the water outlet. (i) Remove the bolt holding the VSV for EGR to the intake manifold. (j) Remove the 2 bolts holding the water bypass pipe to the cylinder head. (k) Remove the cylinder head assembly. (See page EM–33) 4. REMOVE OIL DIPSTICK 5. REMOVE OIL PAN AND OIL PUMP (a) Disconnect the crankshaft position sensor connector from the generator drive belt adjusting bar. (b) Remove the oil pan and oil pump. (See page LU–7) 6. REMOVE PS PUMP BRACKET Remove the 3 bolts and pump bracket. 7. REMOVE KNOCK SENSOR 1 (See page SF–57) 8. REMOVE OIL FILTER (See page LU–2) 9. 1 3 (a) 2 (b) (c) S06011 REMOVE WATER PUMP, WATER BYPASS PIPE AND OIL COOLER (w/ OIL COOLER) ASSEMBLY w/ Oil Cooler: Remove the nut and union bolt, and disconnect the oil cooler. Remove the O–ring. Remove the bolt and generator drive belt adjusting bar. Remove the 3 bolts in the sequence shown, remove the water pump, water bypass pipe, oil cooler (w/ oil cooler) assembly and O–ring. Author: Date: 1258 EM–87 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK 10. REMOVE REAR OIL SEAL RETAINER Remove the 6 bolts, retainer and gasket. P05527 11. P00717 A B 280° 4 210° B No.1 Balance Shaft Gear Crankshaft Gear 100° 3 A 2 1 30° TDC CHECK THRUST CLEARANCES OF NO.1 AND NO.2 BALANCE SHAFTS OF ENGINE BALANCER Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth. Standard thrust clearance: 0.060 – 0.110 mm (0.0024 – 0.0043 in.) Maximum clearance: 0.11 mm (0.0043 in.) If the clearance is greater than maximum, replace the balance shaft housings and bearings. If necessary, replace the balance shafts. 12. CHECK AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR NOTICE: Backlash between the crankshaft gear and No.1 balance shaft gear varies with the rotation of the balance shaft and the deviation of the crankshaft gear. Accordingly, it is necessary to measure the backlash at the 4 points shown in the illustration on the left. Z19418 (a) (b) Turn the crankshaft 2 or 3 times to settle the crankshaft gear and No.1 balance shaft gear. When the No.1 piston is at TDC, check that the punch marks shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing. P01477 No.1 Balance Shaft (c) Check that punch marks A and B are at the positions on the No.1 balance shaft indicated in the illustration. Mark A Mark B Z19410 Author: Date: 1259 EM–88 ENGINE MECHANICAL (5S–FE) No.1 Balance Shaft Mark A CYLINDER BLOCK (d) First turn the crankshaft clockwise, and align the groove of the No.2 balance shaft housing with punch mark A of the No.1 balance shaft. (e) Set SST and a dial indicator as shown in the illustration. SST 09224–74010 No.2 Housing Mark B – Z19412 Measuring Point for Dial Indicator HINT: Make sure that the needle of the dial indicator is perpendicular to the SST and that it is placed in the middle of the 3rd indention. SST S05942 (f) Lightly turn the No.1 balance shaft by hand and measure the backlash. HINT:
S05943 Mark B No.2 Housing No.1 Balance Shaft Turn the No.1 balance shaft 4 or 5 times to provide a steady backlash reading.
To prevent excessive backlash due to thrust clearance, measure the backlash while pressing on the rear of the No.1 balance shaft. Standard backlash (at punch mark A): 0.005 – 0.040 mm (0.0002 – 0.0016 in.) NOTICE: Do not turn the No.1 balance shaft strongly. (g) (h) (i) (j) (k) Mark A Remove the dial indicator and SST. Turn the crankshaft clockwise to align the groove of the No.2 housing with punch mark B. Set the dial indicator. (See step (e)) Measure the backlash. (See step (f)) Standard backlash (at punch mark B): 0.005 – 0.060 mm (0.0002 – 0.0024 in.) Remove the dial indicator. Z19414 Author: Date: 1260 EM–89 ENGINE MECHANICAL (5S–FE) No.1 Balance Shaft Mark A No.2 Housing (l) (m) (n) (o) Mark B CYLINDER BLOCK Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark A. Set the dial indicator. (See step (e)) Measure the backlash. (See step (f)) Standard backlash (at punch mark A): 0.005 – 0.040 mm (0.0002 – 0.0016 in.) Remove the dial indicator. Z19412 (p) Mark B No.2 Housing – No.1 Balance Shaft Mark A Z19414 Turn the crankshaft clockwise again to align the groove of the No.2 housing with punch mark B. (q) Set the dial indicator. (See step (e)) (r) Measure the backlash. (See step (f)) Standard backlash (at punch mark B): 0.005 – 0.060 mm (0.0002 – 0.0024 in.) (s) Remove the dial indicator. If even one of the 4 points measured above exceeds the backlash specification, adjust the backlash with new spacers. NOTICE: Use the same size spacers for both the left and right sides. HINT:
Varying the spacer thickness by 0.02 mm (0.0008 in.) change the backlash by about 0.014 mm (0.0006 in.).
If the backlash is greater than permitted maximum, select a thinner shim.
If the backlash is less than the specification, select a thicker shim. Author: Date: 1261 EM–90 Adjusting Spacer Selection Chart (Off–Vehicle) Measured backlash Installed spacer No. mm (in.) ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK Author: Date: Standard backlash (at punch mark A): 0.005 – 0.40 mm (0.0002 – 0.0016 in.) EXAMPLE: The No.26 spacers are installed, and the measured backlash is 0.120 mm (0.0047 in.). Replace the No. 26 spacers with new No.11 spacers. New spacer thickness No. A01917 1262 01 03 05 07 09 Thickness 1.74 (0.0685) 1.76 (0.0693) 1.78 (0.0701) 1.80 (0.0709) 1.82 (0.0717) No. 11 13 15 17 19 Thickness 1.84 (0.0724) 1.86 (0.0732) 1.88 (0.0740) 1.90 (0.0748) 1.92 (0.0756) No. 21 23 25 27 29 mm (in.) Thickness 1.94 (0.0764) 1.96 (0.0772) 1.98 (0.0780) 2.00 (0.0787) 2.02 (0.0975) No. Thickness 31 33 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 35 37 39 EM–91 ENGINE MECHANICAL (5S–FE) 13. (a) 4 6 2 (b) – CYLINDER BLOCK REMOVE ENGINE BALANCER Uniformly loosen and remove the 6 bolts in several passes, in the sequence shown. Remove the engine balancer and spacers. 1 5 3 S03789 14. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 – 0.312 mm (0.0063 – 0.0123 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly. If necessary, replace the crankshaft. N00991 15. (a) (b) REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap to ensure correct reassembly. Remove the 2 connecting rod cap nuts. P03166 (c) Using a plastic–faced hammer, lightly tap the connecting rod bolts and lift off the connecting rod cap. HINT: Keep the lower bearing inserted with the connecting rod cap. N00924 (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing. (f) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. N00993 Author: Date: 1263 EM–92 ENGINE MECHANICAL (5S–FE) (g) Plastigage – CYLINDER BLOCK Lay a strip of Plastigage across the crank pin. N00999 (h) Install the connecting rod cap.(See page EM–107) NOTICE: Do not turn the crankshaft. (i) Remove the connecting rod cap. (See steps (b) and (c)) Z19381 (j) Measure the Plastigage at its widest point. Standard oil clearance: STD 0.024 – 0.055 mm (0.0009 – 0.0022 in.) U/S 0.25 0.023 – 0.069 mm (0.0009 – 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. N00920 Mark 1, 2 or 3 Mark 1, 2 or 3 HINT: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked ”1”, ”2” and ”3” accordingly. Reference Standard sized bearing center wall thickness: N00932 (k) Mark ”1” 1.484 – 1.488 mm (0.0584 – 0.0586 in.) Mark ”2” 1.488 – 1.492 mm (0.0586 – 0.0587 in.) Mark ”3” 1.492 – 1.496 mm (0.0587 – 0.0589 in.) Completely remove the Plastigage. Author: Date: 1264 EM–93 ENGINE MECHANICAL (5S–FE) 16. (a) – CYLINDER BLOCK REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. S05989 (b) (c) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT:

Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. N00993 P00598 6 8 10 4 2 1 17. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 – 0.220 mm (0.0008 – 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washer as a set. Thrust washer thickness: 2.440 – 2.490 mm (0.0961 – 0.0980 in.) 18. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 10 main bearing cap bolts in several passes, in the sequence shown. 5 9 7 3 P00105 (b) Using 2 screwdrivers, pry out the main bearing cap, and remove the 5 main bearing caps, 5 lower bearings and 2 lower thrust washers (No.3 main bearing cap only). HINT:

(c) Keep the lower bearing and main bearing cap together. Arrange the main bearing caps and lower thrust washers in the correct order. Lift out the crankshaft. S06014 Author: Date: 1265 EM–94 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK HINT: Keep the upper bearing and upper thrust washers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (f) (g) Plastigage Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. N01000 1 3 9 5 10 7 2 8 (h) Install the main bearing caps. (See page EM–107) NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps. (See steps (a) and (b)) 6 4 P00104 (j) N00988 Measure the Plastigage at its widest point. Standard clearance: No.3 STD U/S 0.25 0.025 – 0.044 mm (0.0010 – 0.0017 in.) 0.027 – 0.067 mm (0.0011 – 0.0026 in.) Others STD U/S 0.25 0.015 – 0.034 mm (0.0006 – 0.0013 in.) 0.019 – 0.059 mm (0.0007 – 0.0023 in.) Maximum clearance: 0.08 mm (0.0031 in.) HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be: No.3 0.027 – 0.054 mm (0.0001 – 0.0021 in.) Others 0.017 – 0.044 mm (0.0007 – 0.0017 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. Author: Date: 1266 EM–95 ENGINE MECHANICAL (5S–FE) No.1 No.2 No.3 No.4 No.5 No.5 No.4 No.3 No.2 No.1 Mark 1, 2 or 3 Mark 0, 1 or 2 – CYLINDER BLOCK HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly. Number marked Cylinder block Mark 1, 2, 3, 4, or 5 1 2 3 Crankshaft 0 1 2 0 1 2 0 1 2 Use bearing 1 2 3 2 3 4 3 4 5 EXAMPLE: Cylinder block ”2” + Crankshaft ”1” = Total number 3 (Use bearing ”3”) Reference Cylinder block main journal bore diameter: Z00060 Mark ”1” 59.020 – 59.026 mm (2.3236 – 2.3239 in.) Mark ”2” 59.026 – 59.032 mm (2.3239 – 2.3241 in.) Mark ”3” 59.032 – 59.038 mm (2.3241 – 2.3243 in.) Crankshaft main journal diameter: Mark ”0” 54.998 – 55.003 mm (2.1653 – 2.1655 in.) Mark ”1” 54.993 – 54.998 mm (2.1651 – 2.1653 in.) Mark ”2” 54.988 – 54.993 mm (2.1649 – 2.1651 in.) Standard sized bearing center wall thickness: No.3 Mark ”1” 1.992 – 1.995 mm (0.0784 – 0.0785 in.) Mark ”2” 1.995 – 1.998 mm (0.0785 – 0.0787 in.) Mark ”3” 1.998 – 2.001 mm (0.0787 – 0.0788 in.) Mark ”4” 2.001 – 2.004 mm (0.0788 – 0.0789 in.) Mark ”5” 2.004 – 2.007 mm (0.0789 – 0.0790 in.) Others (k) 19. (a) (b) Mark ”1” 1.997 – 2.000 mm (0.0786 – 0.0787 in.) Mark ”2” 2.000 – 2.003 mm (0.0787 – 0.0789 in.) Mark ”3” 2.003 – 2.006 mm (0.0789 – 0.0790 in.) Mark ”4” 2.006 – 2.009 mm (0.0790 – 0.0791 in.) Mark ”5” 2.009 – 2.012 mm (0.0791 – 0.0792 in.) Complately remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 5 upper bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. Author: Date: 1267 EM–96 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK 20. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. A06590 21. (a) REMOVE PISTON RINGS Using a piston ring expander, remove the No.1 and No.2 piston rings. Remove the 2 side rails and oil ring expander by hand. (b) HINT: Arrange the piston rings in correct order only. A06589 22. (a) DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. (b) Gradually heat the piston to 80 – 90°C (176 – 194°F). (c) Using a plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. A06587 A01774 HINT:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. A01775 Author: Date: 1268 EM–97 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK EM08J–03 INSPECTION 1. (a) (b) CLEAN CYLINDER BLOCK Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. S05970 2. (a) INSPECT CYLINDER BLOCK Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cylinder block. Z19127 (b) Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylinders and replace all the 4 pistons. (See page EM–104) If necessary, replace the cylinder block. S05987 (c) Inspect the cylinder bore diameter. HINT: There are 3 sizes of the standard cylinder bore diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the top of the cylinder block. Mark 1, 2 or 3 No.1 No.2 No.3 No.4 S05569 Author: Date: 1269 EM–98 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: Mark ”1” 87.000 – 87.010 mm (3.4252 – 3.4256 in.) Mark ”2” 87.010 – 87.020 mm (3.4256 – 3.4262 in.) Mark ”3” 87.020 – 87.030 mm (3.4260 – 3.4264 in.) Maximum diameter: Front 2 1 Thrust 1 Direction A Axial 2 Direction 10 mm (0.39 in.) STD 87.23 mm (3.4342 in.) O/S 0.50 87.73 mm (3.4350 in.) If the diameter is greater than maximum, rebore all the 4 cylinders and replace all the 4 pistons. (See page EM–104) If necessary, replace the cylinder block. B C 10 mm (0.39 in.) Z19307 Ridge Reamer (d) Remove the cylinder ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. S05989 3. (a) CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. A06591 A06592 Author: Date: 1270 EM–99 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. A06593 4. INSPECT PISTON AND CONNECTING ROD (a) Inspect the piston oil clearance. HINT: There are 3 sizes of the standard piston diameter, marked ”1”, ”2” and ”3” accordingly. The mark is stamped on the piston top. Mark 1, 2 or 3 Front Mark (Cavity) A07350 (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 20.5 mm (0.807 in.) from the piston head. Piston diameter: STD 20.5 mm A07352 Mark ”1” Mark ”2” Mark ”3” 86.815 – 86.825 mm (3.4179 – 3.4183 in.) 86.825 – 86.835 mm (3.4183 – 3.4186 in.) 86.835 – 86.845 mm (3.4186 – 3.4190 in.) O/S 0.50 87.315 – 87.345 mm (3.4375 – 3.4387 in.) (2) Measure the cylinder bore diameter in the thrust directions. (See step 2) (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.175 – 0.195 mm (0.0068 – 0.0076 in.) Maximum oil clearance: 0.215 mm (0.0085 in.) If the oil clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. (See page EM–104) If necessary, replace the cylinder block. Author: Date: 1271 EM–100 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK HINT: Use new cylinder block: Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block. Mark 1, 2 or 3 No.1 No.2 No.3 No.4 Mark 1, 2 or 3 S05569 A07350 A07397 (b) Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance (No.1, No.2): 0.030 – 0.070 mm (0.0012 – 0.0028 in.) If the clearance is not as specified, replace the piston. A07348 (c) Inspect the piston ring end gap. (1) Insert the piston ring into the cylinder bore. (2) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block. 110 mm A01916 (3) Using a feeler gauge, measure the end gap. Standard end gap: No.1 0.270 – 0.490 mm (0.0106 – 0.0192 in.) No.2 0.450 – 0.670 mm (0.0177 – 0.0263 in.) Oil (Side rail) 0.100 – 0.470 mm (0.0039 – 0.0185 in.) Maximum end gap: EM7639 No.1 1.09 mm (0.0429 in.) No.2 1.27 mm (0.0499 in.) Oil (Side rail) 1.07 mm (0.0421 in.) Author: Date: 1272 EM–101 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 4 cylinders (see page EM–104) or replace the cylinder block. (d) Inspect the piston pin fit. At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. A06594 (e) Using a rod aligner and feeler gauge, check the connecting rod alignment. (1) Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Z00064 (2) Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Z00065 (f) Inspect the piston pin oil clearance. (1) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 – 22.017 mm (0.8663 – 0.8668 in.) EM7538 Author: Date: 1273 EM–102 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK (2) EM0227 Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 – 22.009 mm (0.8660 – 0.8665 in.) (3) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 – 0.011 mm (0.0002 – 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. (See page EM–104) If necessary, replace the piston and piston pin as a set. (g) Inspect the connecting rod bolts. (1) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. P13428 (2) If the cap nut cannot be turned easily, measure the outside diameter of the connecting rod bolt with a vernier caliper. Standard diameter: 7.860 – 8.000 mm (0.3094 – 0.3150 in.) Minimum diameter: 7.60 mm (0.2992 in.) 15 mm (0.59 in.) A02826 HINT: If the location of this area cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration. If the outside diameter is less than minimum, replace the connecting rod bolt and nut as a set. Author: Date: 1274 EM–103 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK 5. (a) INSPECT CRANKSHAFT Inspect for circle runout. (1) Place the crankshaft on V–blocks. (2) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. P00118 (b) Inspect the main journals and crank pins. (1) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD 54.988 – 55.003 mm (2.1653 – 2.1655 in.) U/S 0.25 54.745 – 54.755 mm (2.1553 – 2.1557 in.) Crank pin diameter: EM3553 STD 51.985 – 52.000 mm (2.0466 – 2.0472 in.) U/S 0.25 51.745 – 51.755 mm (2.0372 – 2.0376 in.) If the diameter is not as specified, check the oil clearance. (See page EM–86) If necessary, grind or replace the crankshaft. (2) Check each main journal and crank pin for taper and out–of–round as shown. Maximum taper and out–of–round: 0.02 mm (0.0008 in.) If the taper and out–of–round is greater than maximum, replace the crankshaft. 6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter. (See procedure in step 5) Install new main journal and/or crankshaft pin undersized bearings. Author: Date: 1275 EM–104 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK EM08K–03 REPLACEMENT SST 1. (a) REPLACE CONNECTING ROD BUSHINGS Using SST and a press, press out the bushing. SST 09222–30010 (b) Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222–30010 EM1321 (c) Oil Hole EM7329 (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM–97) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. REPLACE OVERSIZED (O/S) PISTONS FOR CYLINDER BORING P01038 2. HINT:
EM1322
(a) Bore all the 4 cylinders for the O/S piston outside diameter. Replace all the piston rings with ones to match the O/S pistons. Keep 4 new O/S pistons. O/S 0.50 piston diameter: 87.350 – 87.380 mm (3.4390 – 3.4402 in.) Author: Date: 1276 EM–105 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK (b) 20.5 mm A07352 SST S01546 Cut Position Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 20.5 mm (0.807 in.) from the piston head. (c) Calculate the amount of each cylinder is to be rebored as follows: Size to be rebored = P + C – H P = Piston diameter C = Piston oil clearance 0.175 – 0.195 mm (0.0068 – 0.0076 in.) H = Allowance for honing 0.02 mm (0.0008 in.) or less (d) Bore and hone the cylinders to calculated dimensions. Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished roundness. 3. REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal. (a) If the oil pump is removed from the cylinder block: (1) Using a screwdriver and hammer, tap out the oil seal. (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09226–10010 (3) Apply MP grease to the oil seal lip. (b) If the oil pump is installed to the cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Pry S05573 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09226–10010 SST S05572 Author: Date: 1277 EM–106 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK 4. REPLACE CRANKSHAFT REAR OIL SEAL HINT: there are 2 methods ((a) and (b)) to replace the oil seal. (a) If the rear oil seal retainer is removed from the cylinder block: (1) Using a screwdriver and hammer, tap out the oil seal. EM7362 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09950–70010 (09951–07100) (3) Apply MP grease to the oil seal lip. SST P19502 (b) If rear oil seal retainer is installed to cylinder block: (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut position S06005 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09950–70010 (09951–07100) SST S06004 Author: Date: 1278 EM–107 ENGINE MECHANICAL (5S–FE) – CYLINDER BLOCK EM08L–03 REASSEMBLY HINT:


Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O–rings and oil seals with new parts. 1. (a) ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring on one side of the piston pin hole. (b) Gradually heat the piston to 80 – 90°C (176 – 194°F). (c) (d) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Using a small screwdriver, install a new snap ring on the other side of the piston pin hole. A06586 A01776 Front Mark (Cavity) Front Mark (Protrusion) A07349 A06587 Author: Date: 1279 EM–108 ENGINE MECHANICAL (5S–FE) 2. (a) (b) Code Mark No.1 No.2 – CYLINDER BLOCK INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the No.2 and No.1 piston rings with the code mark facing upward. Code mark: No.1 1N or T No.2 2N or 2T Code Mark A06588 Upper Side Rail Expander No.2 Compression Ring No.1 Compression Ring (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. Front Mark (Cavity) Lower Side Rail P A07351 3. (a) (b) INSTALL BEARINGS Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap. P00797 Others No.3 22.9 mm 19.2 mm P05533 4. INSTALL MAIN BEARINGS HINT:
Main bearings come in widths of 19.2 mm (0.756 in.) and 22.9 mm (0.902 in.). Install the 22.9 mm (0.902 in.) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 in.) bearings in the other positions.
Upper bearings have an oil groove and oil holes; lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. P05353 Author: Date: 1280 EM–109 ENGINE MECHANICAL (5S–FE) (b) – CYLINDER BLOCK Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. Mark 1, 2, 3, 4, or 5 P03177 5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward. 6. PLACE CRANKSHAFT ON CYLINDER BLOCK P05354 7. (a) INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward. P03173 (b) Install the 5 main bearing caps in their proper locations. HINT: Each bearing cap has a number and front mark. S06012 (c) 7 1 3 9 5 (d) 10 2 6 (e) 8. 4 8 Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. Install and uniformly tighten the 10 bolts of the main bearing cap in several passes, in the sequence shown. Torque: 59 N·m (600 kgf·cm, 43 ft·lbf) Check that the crankshaft turns smoothly. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM–86) P00104 Author: Date: 1281 EM–110 ENGINE MECHANICAL (5S–FE) 9. (a) – CYLINDER BLOCK INSTALL PISTON AND CONNECTING ROD ASSEMBLES Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. EM2082 Front Mark (Cavity) (b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. 10. PLACE CONNECTING ROD CAP ON CONNECTING ROD Match the numbered connecting rod cap with the connecting rod. Install the connecting rod cap with the front mark facing forward. INSTALL CONNECTING ROD CAP NUTS Push Front A06614 Front Mark (Protrusion) (a) (b) 11. HINT: N01001

The cap nuts are tightened in 2 progressive steps (steps (b) and (d)). If any one of the connecting rod bolts is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the nuts of the connecting rod cap. (b) Install and alternately tighten the 2 cap nuts in several passes. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) If any one of the cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set. Z19381 Author: Date: 1282 EM–111 ENGINE MECHANICAL (5S–FE) (c) (d) (e) Painted Mark 90° Front 90° (f) 12. – CYLINDER BLOCK Mark the front of the cap nut with the paint. Retighten the cap nuts 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM–86) S02826 13. (a) INSTALL ENGINE BALANCER Turn the crankshaft, and set the No.1 cylinder TDC as shown in the illustration. (b) Set the balance shafts so that the punch marks of the balance shafts are aligned with the grooves of the No.2 housing. Pulley Set Key Cylinder Block Top Surface S05945 P01478 (c) Wipe clean the installation surface of the spacer. (d) Place the spacers on the cylinder block. HINT: When replacing the crankshaft and/or balance shaft, use the thickest spacers. P00716 (e) (f) Place the engine balancer on the cylinder block. Check that punch marks shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing. P00733 Author: Date: 1283 EM–112 ENGINE MECHANICAL (5S–FE) (g) 3 1 5 – CYLINDER BLOCK While pulling the center part of the engine balancer in the direction of the arrow, uniformly tighten the 6 bolts in several passes, in the sequence shown. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 6 2 4 Pull S04614 (h) Recheck that the punch marks of the balance shafts are aligned with the grooves of the No.2 housing. 14. CHECK AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR (See page EM–86) 15. INSTALL REAR OIL SEAL RETAINER Install a new gasket and the retainer with the 6 bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) P01477 16. 3 1 2 Z19357 INSTALL WATER PUMP, WATER BYPASS PIPE AND OIL COOLER (w/ OIL COOLER) ASSEMBLY (a) Install a new O–ring to the water pump cover. (b) Install the water pump, water bypass pipe and oil cooler (w/ oil cooler) assembly with the 3 bolts. Tighten the bolts in the sequence shown. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) (c) Install the generator drive belt adjusting bar with the bolt. Torque: 22 N·m (224 kgf·cm, 16 ft·lbf) (d) w/ Oil Cooler: Install the oil cooler. (See page LU–18) 17. INSTALL OIL FILTER (See page LU–2) 18. INSTALL KNOCK SENSOR 1 (See page SF–57) 19. INSTALL PS PUMP BRACKET Install the PS pump bracket with the 3 bolts. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) 20. INSTALL OIL PUMP AND OIL PAN (a) Install the oil pump and oil pan. (See page LU–13) (b) Install the crankshaft position sensor connector to the generator drive belt adjusting bar. 21. INSTALL OIL DIPSTICK 22. INSTALL CYLINDER HEAD ASSEMBLY (a) Install the cylinder head assembly. (See page EM–33) (b) Install the 2 bolts holding the water bypass pipe to the cylinder head. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (c) Install the VSV for EGR to the cylinder head with the bolt. (d) Connect the knock sensor 1 connector. (e) Connect the crankshaft position sensor connector. Author: Date: 1284 EM–113 ENGINE MECHANICAL (5S–FE) (f) (g) (h) (i) (j) (k) 23. 24. – CYLINDER BLOCK Install the wire clamp to the generator drive belt adjusting bar. Connect the IAC valve water bypass hose to the water bypass pipe. Connect the water bypass hose (from the water bypass pipe) to the water outlet. Install the camshafts. (See page EM–53) Install the cylinder head cover. (1) Install the cylinder head cover. (See page EM–53) (2) Connect the PCV hose to the intake manifold. Install the No.3 timing belt cover with the 3 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL TIMING BELT AND PULLEYS (See page EM–23) DISCONNECT ENGINE FROM ENGINE STAND Author: Date: 1285 EM–114 ENGINE MECHANICAL (5S–FE) – EXHAUST SYSTEM EXHAUST SYSTEM EM08M–03 COMPONENTS Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing oxygen sensor, twist sensor wire counterclockwise 3 and 1/2 turns.
After installing oxygen sensor, check that sensor wire is not twisted. If it is twisted, remove oxygen sensor and reinstall it. Heat Insulator Ring Bracket Tailpipe 33 (330, 24) Ring  Gasket Heat Insulator 56 (570, 41) Heat Insulator Center Exhaust Pipe 56 (570, 41) Heated Oxygen Sensor (Bank 1 Sensor 2) 44 (450, 32) Bracket Heat Insulator 19 (195, 14)  Gasket  Gasket Bracket TWC (Except California) Rear TWC (California)    62 (630, 46) Front Exhaust Pipe Bracket Stay 33 (330, 24) 33 (330, 24) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A07369 Author: Date: 1286 EM–1 ENGINE MECHANICAL (1MZ–FE) – CO/HC CO/HC EM04I–04 INSPECTION CO/HC Meter HINT: This check is used only to determine whether or not the idle CO/ HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. S04994 Author: Date: 1287 EM–2 ENGINE MECHANICAL (1MZ–FE) – CO/HC If the CO/HC concentration dose not comply with regulations, troubleshoot in the order given below. See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO HC Problems Causes Normal High Rough idle 1. Faulty ignitions:
Incorrect timing
Fouled, shorted or improperly gapped plugs
O Open en or crossed high–tension cords 2. Incorrect valve clearance 3 Leaky EGR valve 4.Leaky intake and exhaust valves 5.Leaky cylinder Low High Rough idle (Filtrating HC reading) 1. Vacuum leaks:
PCV hose
EGR valve
Intake manifold
Air intake chamber
Throttle body
IAC valve
Brake booster line 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system
Faulty pressure regulator
Defective ECT sensor
Faulty ECM
Faulty injectors
Faulty throttle position sensor
Faulty MAF meter Author: Date: 1288 EM–3 ENGINE MECHANICAL (1MZ–FE) – COMPRESSION COMPRESSION EM04J–03 INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE IGNITION COILS AND HIGH–TENSION CORDS (See page IG–7) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs. 4. (a) (b) (c) Compression Gauge P19471 CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum pressure: 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm2, 15 psi) or less (e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression.
If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged.
If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. REINSTALL SPARK PLUGS 6. INSTALL IGNITION COILS AND HIGH–TENSION CORDS (See page IG–8) Author: Date: 1289 EM–4 ENGINE MECHANICAL (1MZ–FE) – VALVE CLEARANCE VALVE CLEARANCE EM04K–04 INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE RH FENDER APRON SEAL 2. DRAIN ENGINE COOLANT 3. REMOVE V–BANK COVER (a) Using a 5 mm hexagon wrench, remove the 2 nuts. (b) Disconnect the 2 clips, and remove the cover. 4. REMOVE HIGH–TENSION CODE SET (See page IG–7) 5. REMOVE AIR INTAKE CHAMBER ASSEMBLY (See page EM–32) 6. REMOVE IGNITION COILS 7. DISCONNECT RADIATOR HOSE FROM WATER OUTLET 8. REMOVE CYLINDER HEAD COVERS (See page EM–32) 9. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 (IN and EX) are loose. If not, turn the crankshaft 1 revolution (360°) and align the mark as above. P18805 10. (a) 3 3 RH EX RH IN 1 1 Front INSPECT VALVE CLEARANCE Check only those valves indicated in the illustration. (1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft. (2) Record out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 – 0.25 mm (0.006 – 0.010 in.) Exhaust 0.25 – 0.35 mm (0.010 – 0.014 in.) 6 6 LH IN LH EX 2 2 P13074 Author: Date: 1290 EM–5 ENGINE MECHANICAL (1MZ–FE) 5 5 – VALVE CLEARANCE (b) Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) (c) Turn the crankshaft a further 2/3 of a revolution (240°), and check only the valves indicated in the illustration. Measure the valve clearance. (See step (a)) 11. (a) ADJUST VALVE CLEARANCE Remove the adjusting shim. (1) Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. (2) Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft. RH EX RH IN 2 2 3 3 Front LH IN LH EX 4 4 P13072 1 1 RH EX RH IN 5 5 Front 4 4 LH IN LH EX 6 6 P13073 Upward Notch P12919 Author: Date: 1291 EM–6 ENGINE MECHANICAL (1MZ–FE) – VALVE CLEARANCE (3) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248–55040 (09248–05410, 09248–05420) Front of No.1 and No.2 Cylinder SST (A) HINT:
SST (B)
Others Apply SST (B) at a slight angle on the side marked with ”9” or ”7”, at the position shown in the illustration. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. SST (A) SST (B) Z09456 SST (B)
Using a small screwdriver and magnetic finger, remove the adjusting shim. (b) Determine the replacement adjusting shim size according to these Formula or Charts: (1) Using a micrometer, measure the thickness of the removed shim. (2) Calculate the thickness of a new shim so the valve clearance comes within the specified value. T .......... Thickness of used shim A .......... Measured valve clearance N .......... Thickness of new shim Intake N = T + (A – 0.20 mm (0.008 in.)) Exhaust N = T + (A – 0.30 mm (0.012 in.)) (3) Select a new shim with a thickness as close as possible to the calculated values. Magnetic Finger P12920 EM0494 HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299 in.). Author: Date: 1292 EM–7 ENGINE MECHANICAL (1MZ–FE) SST (A) (c) SST (B) (d) – VALVE CLEARANCE Install a new adjusting shim. (1) Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. (2) Press down the valve lifter with SST (A), and remove SST (B). SST 09248–55040 (09248–05410, 09248–05420) Recheck the valve clearance. P12979 12. 13. 14. 15. 16. 17. 18. 19. 20. REINSTALL CYLINDER HEAD COVERS (See page EM–57) CONNECT RADIATOR HOSE TO WATER OUTLET REINSTALL IGNITION COILS REINSTALL AIR INTAKE CHAMBER ASSEMBLY (See page EM–57) INSTALL HIGH–TENSION CORD SET (See page IG–8) INSTALL V–BANK COVER REFILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS REINSTALL RH FENDER APRON SEAL Author: Date: 1293 EM–8 Adjusting Shim Selection Chart (Intake) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (1MZ–FE) – Author: Shim No. Thickness Shim No. mm (in.) Thickness Date: V00719 1294 Intake valve clearance (Cold): 0.15 – 0.25 mm (0.006 – 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.12 shim. HINT: New shims have the thickness in millimeters imprinted on the face. VALVE CLEARANCE New shim thickness Adjusting Shim Selection Chart (Exhaust) Installed shim thickness mm (in.) Measured clearance mm (in.) ENGINE MECHANICAL (1MZ–FE) – Author: Shim No. Thickness Shim No. mm (in.) Thickness VALVE CLEARANCE New shim thickness Date: HINT: New shims have the thickness in millimeters imprinted on the face. EM–9 V00720 1295 Exhaust valve clearance (Cold): 0.25 – 0.35 mm (0.010 – 0.014 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No.12 shim. EM–10 ENGINE MECHANICAL (1MZ–FE) – IGNITION TIMING IGNITION TIMING EM04L–03 INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. TOYOTA Hand–Held Tester S05358 E1 DLC1 SST 2. CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL (a) Connect a TOYOTA hand–held tester or OBDII scan tool to the DLC3. (b) Please refer to the TOYOTA hand–held tester or OBDII scan tool operator’s manual for further details. 3. CONNECT TIMING LIGHT TO ENGINE Connect the tester probe of a timing light to the No.1 high–tension cord for No.4 cylinder. 4. CHECK IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 ± 50 rpm 5. (a) INSPECT IGNITION TIMING Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 (b) Using a timing light, check the ignition timing. Ignition timing: 8 – 12° BTDC @ idle (Transmission in neutral position) Remove the SST from the DLC1. SST 09843–18020 TE1 DLC1 S04529 (c) A06644 Author: Date: 1296 EM–11 ENGINE MECHANICAL (1MZ–FE) 6. – IGNITION TIMING FURTHER CHECK IGNITION TIMING Ignition timing: 7 – 24° BTDC @ idle (Transmission in neutral position) HINT: The timing mark moves in a range between 7° and 24°. 7. DISCONNECT TIMING LIGHT FROM ENGINE 8. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Author: Date: 1297 EM–12 ENGINE MECHANICAL (1MZ–FE) – IDLE SPEED IDLE SPEED EM0YN–01 INSPECTION 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing check correctly (h) Transmission in neutral position 2. CONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL (See page EM–10) 3. INSPECT IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TOYOTA HAND–HELD TESTER OR OBDII SCAN TOOL Author: Date: 1298 EM–13 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT TIMING BELT EM04N–03 COMPONENTS RH Fender Apron Seal 64 (650, 47) 32 (320, 23) Generator Drive Belt Engine Moving Control Rod RH Engine Mounting Stay 64 (650, 47) No.2 RH Engine Mounting Bracket PS Pump Drive Belt No.2 RH Engine Mounting Stay (M/T) Ground Strap Engine Coolant Reservoir Hose N·m (kgf·cm, ft·lbf) : Specified torque A06654 Author: Date: 1299 EM–14 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT Timing Belt Gasket No.2 Timing Belt Cover RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley Engine Wire Protector RH Camshaft Timing Pulley No.2 Idler Pulley 215 (2,200, 159) 125 (1,300, 94) *88 (900, 65) LH Camshaft Timing Pulley 43 (440, 32) 125 (1,300, 94) No.1 Idler Pulley Plate Washer Dust Boot
34 (350, 25) Timing Belt Plate Crankshaft Timing Pulley 27 (280, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part
Precoated part Timing Belt Tensioner * For use with SST B06384 Author: Date: 1300 EM–15 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT EM04O–04 REMOVAL 1. 2. 3. P18754 REMOVE RH FRONT WHEEL REMOVE RH FENDER APRON SEAL REMOVE GENERATOR DRIVE BELT (See page CH–6) 4. REMOVE PS PUMP DRIVE BELT Loosen the 2 bolts, and remove the drive belt. 5. DISCONNECT ENGINE COOLANT RESERVOIR HOSE FROM WATER OUTLET 6. DISCONNECT GROUND STRAP CONNECTORS 7. REMOVE RH ENGINE MOUNTING STAY, NO.2 RH ENGINE MOUNTING STAY (M/T), ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET (See page EM–71) 8. (a) (b) REMOVE NO.2 GENERATOR BRACKET Loosen the generator pivot bolt. Remove the nut and bracket. 9. (a) REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213–54015 (91651–60855), 09330–00021 (b) Using SST, remove the pulley. SST 09950–50012 (09951–05010, 09952–05010, 09953–05010, 09953–05020, 09954–05020) P18816 SST P18817 SST P18819 Author: Date: 1301 EM–16 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT 10. REMOVE NO.1 TIMING BELT COVER Remove the 4 bolts and timing belt cover. 11. REMOVE TIMING BELT GUIDE P18820 12. (a) Clamp Clamp (b) REMOVE NO.2 TIMING BELT COVER Disconnect the engine wire protector clamps from the No.3 timing belt cover. Remove the 5 bolts and timing belt cover. A01800 13. REMOVE RH ENGINE MOUNTING BRACKET Remove the 2 bolts, nut and mounting bracket. P18814 14. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt to the crankshaft. (b) Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. P18808 (c) Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°). (d) Remove the crankshaft pulley bolt. A05052 Author: Date: 1302 EM–17 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT 15. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place 3 new installation marks on the timing belt to match the timing marks of the timing pulleys, and place a new front mark on the timing belt. A01804 16. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. 17. REMOVE TIMING BELT A05053 18. (a) REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and RH timing pulley. SST 09249–63010, 09960–10010 (09962–01000, 09963–01000) LH (b) Using SST, remove the LH timing pulley. SST 09960–10010 (09962–01000, 09963–01000) SST HINT: Arrange the camshaft timing pulleys (RH and LH sides). RH SST P12764 P12762 19. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. A05055 Author: Date: 1303 EM–18 ENGINE MECHANICAL (1MZ–FE) Plate Washer 10 mm Hexagon Wrench – TIMING BELT 20. REMOVE NO.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer. A01802 21. (a) (b) REMOVE CRANKSHAFT TIMING PULLEY Remove the bolt and timing belt plate. Using SST, remove the crankshaft timing pulley. SST 09950–50012 (09951–05010, 09952–05010, 09953–05010, 09953–05020, 09954–05010) NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. SST P20026 Author: Date: 1304 EM–19 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT EM04P–03 INSPECTION NO! EM3336 1. INSPECT TIMING BELT NOTICE:
Do not bend, twist or turn the timing belt inside out.
Do not allow the timing belt to come into contact with oil, water or steam.
Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check these points: (a) Premature parting
Check for proper installation.
Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. (a) INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. P20042 A02309 (b) Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. P12604 Author: Date: 1305 EM–20 ENGINE MECHANICAL (1MZ–FE) 3. (a) – TIMING BELT INSPECT TIMING BELT TENSIONER Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. A05058 (b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn’t move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing downward. P18764 (c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 – 10.8 mm (0.394 – 0.425 in.) If the protrusion is not as specified, replace the tensioner. Protrusion P18770 Author: Date: 1306 EM–21 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT EM0YO–01 INSTALLATION Inward Sensor A05060 Plate Washer 10 mm Hexagon Wrench 1. (a) INSTALL CRANKSHAFT TIMING PULLEY Align the pulley set key with the key groove of the timing pulley, and slide on the timing pulley. (b) Install the timing pulley, facing the sensor side inward. NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. (c) Install the timing belt plate with the bolt. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 2. (a) (b) INSTALL NO.1 IDLER PULLEY Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 10 mm hexagon wrench, install the plate washer and idler pulley with the pivot bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Check that the pulley bracket moves smoothly. A01802 3. (a) (b) INSTALL NO.2 IDLER PULLEY Install the idler pulley with the bolt. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) Check that the idler pulley moves smoothly. A05055 4. (a) (b) INSTALL RH CAMSHAFT TIMING PULLEY Face the flange side of the timing pulley outward. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. Author: Date: 1307 EM–22 ENGINE MECHANICAL (1MZ–FE) (c) RH SST Fulcrum Length – TIMING BELT Using SST, install the pulley bolt. SST 09249–63010, 09960–10010 (09962–01000, 09963–01000) Torque: 88 N·m (900 kgf·cm, 65 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.). SST P20069 LH 5. (a) (b) INSTALL LH CAMSHAFT TIMING PULLEY Face the flange side of the timing pulley inward. Align the knock pin on the camshaft with the knock pin groove of the timing pulley, and slide on the timing pulley. (c) Using SST, install the pulley bolt. SST 09960–10010 (09962–01000, 09963–01000) Torque: 125 N·m (1,300 kgf·cm, 94 ft·lbf) 6. (a) SET NO.1 CYLINDER TO TDC/COMPRESSION Crankshaft Timing Pulley Position: Temporarily install the crankshaft pulley bolt to the crankshaft. Crankshaft Timing Pulley Position: Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body. SST P12762 (b) P18811 (c) SST Camshaft Timing Pulley Positions: Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No.3 timing belt cover. SST 09960–10010 (09962–01000, 09963–01000) A05063 Author: Date: 1308 EM–23 ENGINE MECHANICAL (1MZ–FE) 5th 2nd 6th 3rd 4th 1st A02338 TIMING BELT 7. INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Remove any oil or water on the pulleys, and keep them clean. NOTICE: Only wipe the pulleys; do not use any cleansing agent. (b) Face the front mark on the timing belt forward. (c) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. (d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. (e) Install the timing belt in this order: 1st: Crankshaft timing pulley 2nd: Water pump pulley 3rd: LH camshaft timing pulley 4th: No.2 idler pulley 5th: RH camshaft timing pulley 6th: No.1 idler pulley 8. (a) (c) SET TIMING BELT TENSIONER Using a press, slowly press in the push rod using 981 – 9,807 N (100 – 1,000 kgf, 200 – 2,205 lbf) of pressure. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. Release the press. (d) Install the dust boot to the tensioner. 9. (a) (b) INSTALL TIMING BELT TENSIONER Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) Remove the 1.27 mm hexagon wrench from the tensioner. (b) 1.27 mm Hexagon Wrench – A05064 A05065 (c) 1.27 mm Hexagon Wrench A05066 Author: Date: 1309 EM–24 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT 10. (a) CHECK VALVE TIMING Slowly turn the crankshaft 2 revolutions, and align the timing marks of the crankshaft timing pulley and oil pump body. NOTICE: Always turn the crankshaft clockwise. P18808 (b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (c) Remove the crankshaft pulley bolt. 11. INSTALL RH ENGINE MOUNTING BRACKET Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) A05052 12. (a) INSTALL NO.2 TIMING BELT COVER Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps:
Using a screwdriver and gasket scraper, remove all the old gasket material.
Thoroughly clean all components to remove all the loose material.
Length = 1,410 mm (55.51 in.) (b) (c) P12983 Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. Install the timing belt cover with the 5 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) Install the engine wire protector clamps to the No.3 timing belt cover. 13. INSTALL TIMING BELT GUIDE Install the timing belt guide, facing the cup side outward. P18815 Author: Date: 1310 EM–25 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT 14. (a) INSTALL NO.1 TIMING BELT COVER Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket has cracks or peeling, etc., replace it using these steps:
Using a screwdriver and gasket scraper, remove all the old gasket material.
Thoroughly clean all components to remove all the loose material. Length = 240 mm (9.45 in.)
Join Line Join Line Length = 460 mm (18.11 in.) P12982 Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. NOTICE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. (b) Install the timing belt cover with the 4 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) 15. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install the pulley bolt. SST 09213–54015 (91651–60855), 09330–00021 Torque: 215 N·m (2,200 kgf·cm, 159 ft·lbf) SST A04693 16. INSTALL NO.2 GENERATOR BRACKET Install the generator bracket with the pivot bolt and nut. Do not tighten the bolt yet. Torque: (Nut): 28 N·m (290 kgf·cm, 21 ft·lbf) P18816 17. 18. 19. 20. 21. INSTALL NO.2 RH ENGINE MOUNTING BRACKET, ENGINE MOVING CONTROL ROD, NO.2 RH ENGINE MOUNTING STAY (M/T) AND RH ENGINE MOUNTING STAY (See page EM–76) CONNECT GROUND STRAP CONNECTORS CONNECT ENGINE COOLANT RESERVOIR HOSE TO WATER OUTLET INSTALL PS PUMP DRIVE BELT INSTALL GENERATOR DRIVE BELT (See page CH–16) Author: Date: 1311 EM–26 ENGINE MECHANICAL (1MZ–FE) – TIMING BELT 22. INSTALL RH FENDER APRON SEAL 23. INSTALL RH FRONT WHEEL 24. VEHICLE ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smoothly operation. Author: Date: 1312 EM–27 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD CYLINDER HEAD EM04R–05 COMPONENTS RH Fender Apron Seal 64 (650, 47) 32 (320, 23) Generator Drive Belt RH Engine Mounting Stay 64 (650, 47) No.2 RH Engine Mounting Bracket PS Pump Drive Belt MAF Meter Connector EVAP Hose No.2 RH Engine Mounting Stay (M/T) 43 (440, 32) Air Cleaner Cap Assembly PS Pump EGR Vacuum Hose Air Filter
Gasket
Gasket
Gasket
56 (570, 41) Front Exhaust Pipe Bracket 62 (630, 46) Stay 33 (330, 24) 33 (330, 24)
62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A06651 Author: Date: 1313 EM–28 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD Air Intake Chamber Stay PS Pressure Tube 12 (120,9) 19.5 (200, 14) 39 (400,29) No.1 Engine Hanger 43 (440,32)
Gasket V–Bank Cover No.2 EGR Pipe Throttle Position Sensor Connector
Gasket Brake Booster Vacuum Hose VSV Connector for EGR Engine Wire EGR Valve Position Sensor Connector IAC Valve Accelerator Cable Connector VSV Connector for EVAP Ground Cable Ground Cable Throttle Cable Ground Strap DLC1 PCV Hose Air Intake Chamber Assembly Purge Hose Vacuum Hose Air Assist Hose Water Bypass Hose
Gasket VSV Connector for ACIS Engine Coolant 15 (150,11) Reservoir Hose Water Bypass ECT Sender Hose Gauge Connector Upper Radiator Hose ECT Sensor Connector Grand Strap Connector 15 (150,11) Water Outlet
Gasket EGR Gas Temperature Sensor Connector Water Bypass Hose
Retainer Fuel Inlet Hose Heater Hose Intake Manifold Assembly Ignition Coil Connector
Gasket Injector Connector Ignition Coil Spark Plug High–Tension Cord Set N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A06657 Author: Date: 1314 EM–29 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD Timing Belt No.2 Timing Belt Cover Gasket RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley 215 (2,200, 159) Engine Wire Protector No.2 Idler Pulley RH Camshaft Timing Pulley 125 (1,300, 94) *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley 125 (1,300, 94) Dust Boot Timing Belt Tensioner 27 (280, 20) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part * For use with SST A05070 Author: Date: 1315 EM–30 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD M/T and California A/T RH Exhaust Manifold 34 (350,25) Engine Wire RH Exhaust Manifold Stay Engine Wire Protector
Gasket Heated Oxygen Sensor (Bank 1 Sensor 1) Connector Engine Wire Protector 20 (200, 14) RH Exhaust Manifold (Except M/T and California A/T) 49 (500, 36) RH Exhaust Manifold Stay (Except M/T and Calif. A/T) x6 12 (120, 9) Cylinder Head Rear Plate No.1 EGR Pipe
Gasket PS Pump Bracket Ground Strap
O–Ring 43 (440, 32) Heated Oxygen Sensor (Bank 2 Sensor 1) Connector Gasket No.3 Timing Belt Cover Water Inlet Pipe Collar Bushing Camshaft Position Sensor Connector Gasket Camshaft Position Sensor x6 20 (200, 14) Engine Wire
Gasket x6 49 (500, 36) California A/T Oil Dipstick Guide 34 (350,25) LH Exhaust Manifold Stay (Except M/T and California A/T ) LH Exhaust Manifold (Except California A/T)
O–Ring x6 LH Exhaust Manifold Stay 49 (500, 36) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part LH Exhaust Manifold A06635 Author: Date: 1316 EM–31 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD LH Cylinder Head Cover Adjusting Shim Valve Lifter Keeper Spring Retainer Valve Spring Wave Washer Spring Seat Gasket
Oil Seal Camshaft Gear Spring
Spark Plug Tube Gasket LH Intake Camshaft
Valve Guide Bushing Snap Ring Valve Camshaft Sub–Gear LH Exhaust Camshaft RH Cylinder Head Cover Gasket Wave Washer See Page EM–57 1st 54 (550, 40) 2nd Turn 90° 18 (185, 13) x8 Snap Ring Camshaft Gear Spring Camshaft Sub–Gear Semi–Circular Plug Semi–Circular Plug LH Cylinder Head RH Exhaust Camshaft RH Intake Camshaft 16 (160, 12) Camshaft Bearing cap RH Cylinder Head
Camshaft Oil Seal
RH Cylinder Head Gasket
LH Cylinder Head Gasket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A02013 Author: Date: 1317 EM–32 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM04S–05 REMOVAL 1. 2. 3. 4. 5. 6. (a) (b) 7. Hexagon Clip S04528 8. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (l) (n) DRAIN ENGINE COOLANT REMOVE AIR CLEANER CAP ASSEMBLY AND AIR FILTER REMOVE ENGINE RH FENDER APRON SEAL REMOVE FRONT EXHAUST PIPE (See page EM–71) REMOVE RH ENGINE MOUNTING STAY REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 nuts. Disconnect the 2 clips, and remove the cover. REMOVE HIGH–TENSION CORD SET (See page IG–7) REMOVE AIR INTAKE CHAMBER ASSEMBLY Disconnect the accelerator cable. Disconnect the A/T throttle cable. Disconnect the throttle position sensor connector. Disconnect the IAC valve connector. Disconnect the EGR gas temperature sensor connector. Disconnect the EGR valve position sensor connector. Disconnect the VSV connector for the ACIS. Disconnect the VSV connector for the EVAP. Disconnect the VSV connector for the EGR. Disconnect the DLC1 from the bracket on the intake air control valve. Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger. Disconnect the PCV hose from the PCV valve on the RH cylinder head. Disconnect the ground strap and cable from the intake air control valve for the ACIS. Disconnect the ground cable from the air intake chamber. (n) (m) (t) (r) A06658 (o) (o) (p) (q) (r) (p) (s) (s) (q) S05049 Disconnect the brake booster vacuum hose from the air intake chamber. Disconnect the 2 water bypass hoses from the throttle body. Disconnect the air assist hose from the throttle body. Disconnect the purge hose from the pipe on emission control valve set. Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS. Author: Date: 1318 EM–33 ENGINE MECHANICAL (1MZ–FE) Chamber Stay – CYLINDER HEAD (t) Disconnect the engine wire clamp from the emission control valve set. (u) (v) (w) Remove the 2 bolts and No.1 engine hanger. Remove the 2 bolts and air intake chamber stay. Remove the 4 nuts, No.2 EGR pipe and 2 gaskets. (x) Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, the air intake chamber assembly and gasket. Engine Hanger EGR Pipe S04790 8 mm Hexagon Wrench S04791 9. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Disconnect the 6 injector connectors. (b) Disconnect the fuel inlet hose from the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–1) (c) Disconnect the heater hose from the intake manifold. (b) (c) A01807 (d) Remove the 9 bolts, 2 nuts, 2 plate washers, the intake manifold, delivery pipes and injectors assembly. NOTICE:
Be careful not to drop the injectors when removing the delivery pipes.
Pay attention to put any hung load on the injector to and from the side direction. A01808 Author: Date: 1319 EM–34 ENGINE MECHANICAL (1MZ–FE) P20049 REMOVE WATER OUTLET Disconnect the ECT sender gauge connector. Disconnect the ECT sensor connector. Disconnect the ground strap (connector). Disconnect the radiator hose. Disconnect the engine coolant reservoir hose. (f) (g) Remove the 2 bolts, 2 nuts and 2 plate washers. Disconnect the water bypass hose, and remove the water outlet. Remove the 2 gaskets. REMOVE GENERATOR DRIVE BELT (See page CH–6) REMOVE PS PUMP (See page SR–21) REMOVE IGNITION COILS REMOVE SPARK PLUGS REMOVE TIMING BELT (See page EM–15) REMOVE CAMSHAFT TIMING PULLEYS (See page EM–15) REMOVE NO.2 IDLER PULLEY (See page EM–15) 12. 13. 14. 15. 16. 17. 18. (a) Clamp CYLINDER HEAD 10. (a) (b) (c) (d) (e) (h) 11. Gasket – Clamp (b) REMOVE NO.3 TIMING BELT COVER Disconnect the 3 engine wire clamps from the timing belt cover. Remove the 6 bolts and timing belt cover. Clamp A05077 19. DISCONNECT ENGINE WIRE PROTECTOR FROM REAR SIDE Remove the 2 nuts, and disconnect the engine wire protector from the RH cylinder head and water inlet. S04786 Author: Date: 1320 EM–35 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 20. DISCONNECT ENGINE WIRE AND PROTECTOR FROM RH SIDE Remove the 5 nuts, and disconnect the engine wire and protector from the RH cylinder head cover. S04787 21. DISCONNECT ENGINE WIRE PROTECTOR FROM LH SIDE Remove the 2 bolts, and disconnect the engine wire protector from the LH cylinder head cover. A01812 22. Rear Plate (a) (b) 23. Ground Strap (a) Inlet Pipe S04789 (b) DISCONNECT CYLINDER HEAD REAR PLATE FROM LH CYLINDER HEAD Remove the nut, and disconnect the ground strap. Remove the bolt, and disconnect the rear plate. DISCONNECT WATER INLET PIPE FROM LH CYLINDER HEAD AND WATER INLET Remove the bolt, and disconnect the inlet pipe from the water inlet. Remove the O–ring from the inlet pipe. 24. REMOVE NO.1 EGR PIPE Remove the 4 nuts, EGR pipe and 2 gaskets. P18773 Author: Date: 1321 EM–36 ENGINE MECHANICAL (1MZ–FE) 25. (a) M/T and California A/T (b) (c) (d) – CYLINDER HEAD REMOVE RH EXHAUST MANIFOLD California A/T: Disconnect the A/F sensor connector. Except California A/T: Disconnect the heated oxygen sensor (bank 1 sensor 1) connector. Remove the bolt, nut and exhaust manifold stay. Remove the 6 nuts, exhaust manifold and gasket. Manifold Stay Except M/T and California A/T Manifold Stay A06649 26. REMOVE PS PUMP BRACKET Remove the 3 bolts and pump bracket. P18769 27. (a) California A/T (b) Manifold Stay (c) (d) 28. REMOVE LH EXHAUST MANIFOLD California A/T: Disconnect the A/F sensor connector. Except California A/T: Disconnect the heated oxygen sensor (bank 2 sensor 1) connector. Except M/T: Remove the bolt, nut and exhaust manifold stay. Remove the 6 nuts, exhaust manifold and gasket. REMOVE CAMSHAFT POSITION SENSOR Except California A/T Manifold Stay (Except M/T) A01522 Author: Date: 1322 EM–37 ENGINE MECHANICAL (1MZ–FE) 29. (a) (b) (c) – CYLINDER HEAD REMOVE OIL DIPSTICK AND GUIDE Remove the bolt holding the dipstick guide to the LH cylinder head. Pull out the dipstick guide together with the dipstick from the No.1 oil pan. Remove the O–ring from the dipstick guide. O–Ring P12710 30. REMOVE CYLINDER HEAD COVERS Remove the 8 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers. A01816 31. REMOVE CAMSHAFTS OF RH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Intake Align Intake Remove the intake camshaft. (1) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. P12811 (2) Secure the exhaust camshaft sub–gear to the main gear with a service bolt. Recommended service bolt: Main Gear Sub–Gear Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 – 20 mm (0.63 – 0.79 in.) Service Bolt P12871 Author: Date: 1323 EM–38 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD HINT: When removing the camshaft, mark certain that the torsional spring force of the sub–gear has been eliminated by the above operation. (3) Intake 2 6 10 (4) 1 5 Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. Remove the 5 bearing caps and intake camshaft. 9 8 7 4 3 P12780 Exhaust 1 5 9 7 3 (b) 2 6 10 Remove the exhaust camshaft. (1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (2) Remove the 5 bearing caps, oil seal and exhaust camshaft. 8 4 P12888 32. REMOVE CAMSHAFTS OF LH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Intake Remove the intake camshaft. (1) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. Align P12917 Author: Date: 1324 EM–39 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD (2) Secure the exhaust camshaft sub–gear to the main gear with a service bolt. Recommended service bolt: Intake Service Bolt Main Gear Sub–Gear P12873 5 1 9 7 3 6 (c) 2 6 mm Thread pitch 1.0 mm Bolt length 16 – 20 mm (0.63 – 0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub–gear has been eliminated by the above operation. (b) Intake Thread diameter Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. Remove the 5 bearing caps and intake camshaft. 10 8 4 P12958 Exhaust (d) 2 1 6 10 5 9 7 HINT: 8 4 3 Remove the exhaust camshaft. (1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (2) Remove the 5 bearing caps, oil seal and exhaust camshaft.

Arrange the camshafts in the correct order. Arrange the bearing caps in the correct order. P12886 33. (a) DISASSEMBLE EXHAUST CAMSHAFTS Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P12596 Author: Date: 1325 EM–40 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD (b) Using SST, turn the sub–gear counterclockwise, and remove the service bolt. SST 09960–10010 (09962–01000, 09963–00500) (c) (d) Using snap ring pliers, remove the snap ring. Remove the wave washer, camshaft sub–gear, and camshaft gear spring. SST P12797 HINT: Arrange the camshaft sub–gears and gear springs (RH and LH side). P12590 34. (a) Recessed Head Bolt REMOVE CYLINDER HEADS Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side, as shown. 8 mm Hexagon Wrench Front P12816 Author: Date: 1326 EM–41 ENGINE MECHANICAL (1MZ–FE) 7 5 3 4 6 8 1 4 6 8 1 2 7 5 3 Front CYLINDER HEAD (b) Uniformly loosen and remove the 8 cylinder head (12 pointed head) bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washers. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. 12 Pointed Head Bolt 2 – P12735 (c) P12424 Lift the cylinder head from the dowels on the cylinder block and place the 2 cylinder heads on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. Author: Date: 1327 EM–42 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM04T–03 DISASSEMBLY 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in the correct order. P12683 2. (a) SST (b) REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202–70020 (09202–00010) Remove the spring retainer, valve spring and valve. (c) Using needle–nose pliers, remove the oil seal. (d) Using compressed air and a magnetic finger, remove the spring seat by blowing air. P12476 P12686 Magnetic Finger HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. P12720 Author: Date: 1328 EM–43 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM0YP–01 INSPECTION 1. (a) CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. P12689 (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. P12492 2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. P12700 3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. P12701 4. CLEAN CYLINDER HEADS Using a soft brush and solvent, thoroughly clean the cylinder head. P12703 Author: Date: 1329 EM–44 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 5. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings. P12755 6. INSPECT FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylinder head. P12733 7. INSPECT FOR CRACKS Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. P12702 8. (a) (b) CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve. EM0580 Author: Date: 1330 EM–45 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 9. (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 – 5.530 mm (0.2169 – 0.2177 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: P12754 (c) Z00052 Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.) Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.) Subtract the valve stem diameter measurement from the guide bushing guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. 10. (a) (b) INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° 44.5° Z00054 (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. Margin Thickness EM0181 Author: Date: 1331 EM–46 ENGINE MECHANICAL (1MZ–FE) (d) Overall Length EM2534 – CYLINDER HEAD Check the valve overall length. Standard overall length: Intake 95.45 mm (3.5779 in.) Exhaust 95.40 mm (3.7559 in.) Minimum overall length: Intake 94.95 mm (3.7382 in.) Exhaust 94.90 mm (3.7362 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. EM0255 11. (a) (b) INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. P12704 (c) Width P12729 45° 30° Check the valve face and seat for the following:
If blue appears 360° around the face, the valve is concentric. If not, replace the valve.
If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat.
Check that the seat contact is in the middle of the valve face with the following width: 1.0 – 1.4 mm (0.039 – 0.055 in.) If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. 1.0 – 1.4 mm Z03988 Author: Date: 1332 EM–47 ENGINE MECHANICAL (1MZ–FE) – (2) 75° 45° CYLINDER HEAD If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. 1.0 – 1.4 mm Z03989 (d) (e) Hand–lap the valve and valve seat with an abrasive compound. After hand–lapping, clean the valve and valve seat. P12705 12. (a) INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. Deviation EM0988 (b) Using vernier calipers, measure the free length of the valve spring. Free length: 45.50 mm (1.7913 in.) If the free length is not as specified, replace the valve spring. EM0801 (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring. EM0281 Author: Date: 1333 EM–48 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 13. (a) (b) INSPECT CAMSHAFT FOR RUNOUT Place the camshaft on V–blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft. EM1628 14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.11 – 42.21 mm (1.6579 – 1.6618 in.) Exhaust 41.96 – 42.06 mm (1.6520 – 1.6559 in.) Minimum cam lobe height: EM2011 Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) If the cam lobe height is less than minimum, replace the camshaft. 15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: Intake 26.949 – 26.965 mm (1.0610 – 1.0616 in.) Exhaust 26.959 – 26.975 mm (1.0613 – 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. EM2538 16. INSPECT CAMSHAFT BEARINGS Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. A05236 Author: Date: 1334 EM–49 ENGINE MECHANICAL (1MZ–FE) 17. (a) (b) (c) Plastigage – CYLINDER HEAD INSPECT CAMSHAFT JOURNAL OIL CLEARANCE Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of Plastigage across each of the camshaft journal. P13009 (d) Install the bearing caps. (See page EM–57) Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. P12892 (f) Measure the Plastigage at its widest point. Standard oil clearance: Intake 0.035 – 0.072 mm (0.0014 – 0.0028 in.) Exhaust 0.025 – 0.062 mm (0.0010 – 0.0024 in.) Maximum oil clearance: P13004 Intake 0.10 mm (0.0039 in.) Exhaust 0.09 mm (0.0035 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. (h) Remove the camshafts. 18. (a) (b) P12891 INSPECT CAMSHAFT THRUST CLEARANCE Install the camshafts. (See page EM–57) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 – 0.090 mm (0.0016 – 0.0035 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Author: Date: 1335 EM–50 ENGINE MECHANICAL (1MZ–FE) (c) – CYLINDER HEAD Remove the camshafts. 19. (a) P12960 Free Distance INSPECT CAMSHAFT GEAR BACKLASH Install the camshafts without installing the exhaust cam sub–gear. (See page EM–57) (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater then maximum, replace the camshafts. (c) Remove the camshafts. 20. INSPECT CAMSHAFT GEAR SPRING Using vernier calipers, measure the free distance between the spring ends. Free distance: 18.2 – 18.8 mm (0.712 – 0.740 in.) If the free distance is not as specified, replace the gear spring. EM3322 21. (a) INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 – 31.018 mm (1.2205 – 1.2212 in.) P12685 (b) EM6368 Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.2191 – 1.2195 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 – 0.050 mm (0.0009 – 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. Author: Date: 1336 EM–51 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 22. INSPECT AIR INTAKE CHAMBER Using a precision straight edge and feeler gauge, measure the surface contacting the intake manifold for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the chamber. P12400 23. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake chamber for warpage. Maximum warpage: Cylinder Head Side Air intake chamber side 0.15 mm (0.0059 in.) Cylinder head side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the manifold. Air Intake Chamber Side Z09167 24. INSPECT EXHAUST MANIFOLDS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.50 mm (0.0196 in.) If warpage is greater than maximum, replace the manifold. RH Side LH Side Z09168 Author: Date: 1337 EM–52 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD 25. INSPECT 12 POINTED HEAD CYLINDER HEAD BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard outside diameter: 8.95 – 9.05 mm (0.3524 – 0.3563 in.) Minimum outside diameter: 8.75 mm (0.3445 in.) If the diameter is less than minimum, replace the bolt. P12496 Author: Date: 1338 EM–53 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM0YQ–01 REPLACEMENT 80 – 100°C 1. (a) REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). (b) Using SST and a hammer, tap out the guide bushing. SST 09201–01055, 09950–70010 (09951–07100) (c) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. P12688 SST P12803 P12956 Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 10.295 – 10.313 (0.4053 – 0.4060) Use STD 10.345 – 10.363 (0.4073 – 0.4080) Use O/S 0.05 Intake 34.5 mm (1.358 in.) (d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bushing bore to the following dimension: 10.345 – 10.363 mm (0.4073 – 0.4080 in.) If the bushing bore diameter of the cylinder head is greater than 10.363 mm (0.4080 in.), replace the cylinder head. HINT: Different bushings are used for the intake and exhaust. (e) Gradually heat the cylinder head to 80 – 100°C (176 – 212°F). Exhaust 40.5 mm (1.594 in.) P11510 Author: Date: 1339 EM–54 ENGINE MECHANICAL (1MZ–FE) (f) SST – CYLINDER HEAD Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201–01055, 09950–70010 (09951–07100) Protrusion height: Intake 11.1 – 11.3 mm (0.437 – 0.453 in.) Exhaust 8.9 – 9.3 mm – (0.350 – 0.366 in.) P12802 (g) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EM–43) between the guide bushing and valve stem. 2. (a) (b) REPLACE SPARK PLUG TUBE GASKETS Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out. Using a screwdriver and hammer, tap out the gasket. (c) Using needle–nose pliers, pry out the gasket. (d) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09608–03071 Apply a light coat of MP grease to the gasket lip. Return the ventilation plate tab to its original position. Z09124 P13235 P13236 SST (e) (f) P13224 Author: Date: 1340 EM–55 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM04V–04 REASSEMBLY HINT:


Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones. 1. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, spark plug tubes must be installed. (a) Apply adhesive to the end of the spark plug tube. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent Adhesive 10 – 15 mm (0.39 – 0.59 in.) P11511 (b) Protrusion Using a press, press in a new spark plug tube until there is 42.4 – 43.4 mm (1.669 – 1.709 in.) protruding from the camshaft bearing cap installation surface of the cylinder head. NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of the protrusion while pressing. P12572 2. INSTALL PCV PIPES HINT: When using a new cylinder head, PCV pipe must be installed. Using a wooden block and hammer, tap in a new PCV pipe until its top side is flush with the cylinder head edge. NOTICE: Be careful not to damage the cylinder head edge. Flush P12869 3. (a) SST INSTALL VALVES Using SST, push in a new oil seal. SST 09201–41020 P12719 Author: Date: 1341 EM–56 ENGINE MECHANICAL (1MZ–FE) Intake CYLINDER HEAD HINT: The intake valve oil seal is light brown and the exhaust valve oil seal is gray. NOTICE: Pay much attention when assembling the oil seal for intake and exhaust. Assembling the wrong one may cause a failure. Exhaust Mark TMC made ”NOK” TMMK made ”FN , IN” Light Brown Surface – Gray Surface Z19062 (b) Install the valve (1), spring seat (2), valve spring (3) and spring retainer (4). (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202–70020 (09202–00010) (4) (3) (2) (1) P12668 SST P12476 (d) Using a plastic–faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to assure proper fit. NOTICE: Be careful not do damage the valve stem tip. 4. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. A05246 Author: Date: 1342 EM–57 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD EM0YR–01 INSTALLATION 1. (a) PLACE CYLINDER HEAD ON CYLINDER BLOCK Place 2 new cylinder head gaskets in position on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the 2 cylinder heads in position on the cylinder head gaskets. P12393 2. INSTALL 12 POINTED HEAD CYLINDER HEAD BOLTS HINT:
The cylinder head bolts are tightened in 2 progressive steps (steps (c) and (e)).
If any bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install the plate washer to the cylinder head bolt. (c) Install and uniformly tighten the cylinder head bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown. Torque: 54 N·m (550 kgf·cm, 40 ft·lbf) If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. 12 Pointed Head Bolt Front 7 2 4 6 5 3 1 8 5 3 1 8 7 2 4 6 P12736 (d) (e) Painted Mark 90° Front 90° (f) Mark the front of the cylinder head bolt head with paint. Retighten the cylinder head bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. P25742 Author: Date: 1343 EM–58 ENGINE MECHANICAL (1MZ–FE) 3. (a) Recessed Head Bolt (b) – CYLINDER HEAD INSTALL RECESSED HEAD CYLINDER HEAD BOLTS Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. Using an 8 mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side, as shown. Torque: 18.5 N·m (185 kgf·cm, 13 ft·lbf) 8 mm Hexagon Wrench Front P12814 4. (a) ASSEMBLE EXHAUST CAMSHAFTS Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. P12595 (b) (3) (2) Install the camshaft gear spring (1) and camshaft sub– gear (2). HINT: Attach the pins on the gears to the gear spring ends. (c) Install the wave washer (3). (1) Z09320 (d) Using snap ring pliers, install the snap ring. P12590 Author: Date: 1344 EM–59 ENGINE MECHANICAL (1MZ–FE) (e) SST (f) Main Gear – CYLINDER HEAD Using SST, align the holes of the camshaft main gear and sub–gear by turning camshaft sub–gear counterclockwise, and temporarily install a service bolt. SST 09960–10010 (09962–01000, 09963–00500) Align the gear teeth of the main gear and sub–gear, and tighten the service bolt. Sub–Gear P12974 5. INSTALL CAMSHAFTS OF RH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Exhaust 90° (a) Install the exhaust camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Place the exhaust camshaft at 90° angle of timing mark (2 dot marks) on the cylinder head. (3) Apply MP grease to a new oil seal lip. P12963 (4) Exhaust Install the oil seal to the camshaft. Front P12804 (5) (6) Remove any old packing (FIPG) material. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent Exhaust Seal Packing A02008 Author: Date: 1345 EM–60 ENGINE MECHANICAL (1MZ–FE) Exhaust – CYLINDER HEAD (b) Install the 5 bearing caps in their proper locations. (c) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) P12890 Exhaust 10 6 2 4 8 9 (d) 5 1 3 7 P12887 Intake (e) Install the Intake camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Align the timing marks (2 dot marks) of the camshaft drive and driven gears. (3) Place the intake camshaft on the cylinder head. Align P12875 (4) Intake Install the 5 bearing caps in their proper locations. P12798 (5) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (6) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Intake 5 1 2 9 6 10 3 7 4 8 P25422 Author: Date: 1346 EM–61 ENGINE MECHANICAL (1MZ–FE) – (7) Intake CYLINDER HEAD Remove the service bolt. Service Bolt P12870 6. INSTALL CAMSHAFTS OF LH CYLINDER HEAD NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. (a) Exhaust 90° Install the exhaust camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Place the exhaust camshaft at 90° angle of timing mark (1 dot mark) on the cylinder head. (3) Apply MP grease to a new oil seal lip. P12884 (4) Exhaust Install the oil seal to the camshaft. Front P12805 (5) (6) Remove any old packing (FIPG) material. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent Exhaust Seal Packing A02008 Author: Date: 1347 EM–62 ENGINE MECHANICAL (1MZ–FE) (7) Exhaust – CYLINDER HEAD Install the 5 bearing caps in their proper locations. P12962 (8) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (9) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Exhaust 9 5 10 6 1 2 3 4 7 8 P25421 (b) Intake Align Install the intake camshaft. (1) Apply new engine oil to the thrust portion and journal of the camshaft. (2) Align the timing marks (1 dot mark) of the camshaft drive and driven gears. (3) Place the intake camshaft on the cylinder head. P12874 (4) Intake Install the 5 bearing caps in their proper locations. P12961 (5) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts. (6) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) Intake 2 4 8 6 10 9 5 1 3 7 P12959 Author: Date: 1348 EM–63 ENGINE MECHANICAL (1MZ–FE) Intake Service Bolt – CYLINDER HEAD (7) Remove the service bolt. 7. CHECK AND ADJUST VALVE CLEARANCE (See page EM–4) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. P12872 8. (a) (b) INSTALL SEMI–CIRCULAR PLUGS Remove any old packing (FIPG) material. Apply seal packing to the semi–circular plug grooves. Seal packing: Part No. 08826–00080 or equivalent (c) Install the 4 semi–circular plugs to the cylinder heads. Seal Packing P13274 Semi–Circular Plug Front P12813 Author: Date: 1349 EM–64 ENGINE MECHANICAL (1MZ–FE) : Seal Packing 9. (a) RH Side (b) (c) Front – CYLINDER HEAD INSTALL CYLINDER HEAD COVERS Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Install the gasket to the cylinder head cover. Install the cylinder head cover with the 8 bolts. Uniformly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) LH Side P12812 10. (a) M/T and California A/T (b) Manifold Stay Except M/T and California A/T (c) (d) INSTALL RH EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut. Torque: M/T and California A/T 34 N·m (350 kgf·cm, 25 ft·lbf) Except M/T and California A/T: 20 N·m (200 kgf·cm, 15 ft·lbf) California: Connect the A/F sensor connector. Except California: Connect the heated oxygen sensor (bank 1 sensor 1) connector. Manifold Stay A06649 11. INSTALL NO.1 EGR PIPE Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) 12. INSTALL PS PUMP BRACKET Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) P18773 Author: Date: 1350 EM–65 ENGINE MECHANICAL (1MZ–FE) 13. (a) (b) (c) (d) New O–Ring P12710 (e) 14. 15. (a) California A/T (b) Manifold Stay Except California A/T (c) (d) – CYLINDER HEAD INSTALL OIL DIPSTICK AND GUIDE Install a new O–ring to the dipstick guide. Apply soapy water to the O–ring. Push in the dipstick guide end into the guide hole of the No.1 oil pan. Install the dipstick guide with the bolt. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Install the dipstick. INSTALL CAMSHAFT POSITION SENSOR INSTALL LH EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Except M/T: Install the exhaust manifold stay with the bolt and nut. Alternately tighten the bolt and nut. Torque: California A/T: 34 N·m (350 kgf·cm, 25 ft·lbf) Except California A/T: 20 N·m (200 kgf·cm, 15 ft·lbf) California: Connect the A/F sensor connector. Except California: Connect the heated oxygen sensor (bank 2 sensor 1) connector. Manifold Stay (Except M/T) A01522 Rear Plate Ground Strap Inlet Pipe S04789 16. (a) (b) (c) (d) INSTALL WATER INLET PIPE Install a new O–ring to the water inlet pipe. Apply soapy water to the O–ring. Connect the water inlet pipe to the water inlet. Install the bolt holding the water inlet pipe to the cylinder head. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) 17. INSTALL CYLINDER HEAD REAR PLATE Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 18. INSTALL ENGINE WIRE PROTECTOR 19. INSTALL NO.3 TIMING BELT COVER (a) Check that the timing belt cover gaskets have no cracks or peeling, etc. If the gaskets have cracks or peeling etc., replace them using these steps:
Using a screwdriver and gasket scraper, remove all the old gasket material.
Thoroughly clean all components to remove all the loose material. Author: Date: 1351 EM–66 ENGINE MECHANICAL (1MZ–FE)
L = 72 mm (2.83 in.) L = 180 mm (7.09 in.) L = 133 mm (5.24 in.) L = 180 mm (7.09 in.) Join Line Join Line L = 335 mm (13.19 in.) L = Length New Gasket A05194 Z14262 6 4 10 7 1 9 CYLINDER HEAD Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in the illustration. NOTICE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket.
After installing the gasket, press down on it so that the adhesive firmly sticks to the timing belt cover. (b) Install the timing belt cover with the 6 bolts. Torque: 8.5 N·m (85 kgf·cm, 74 in.·lbf) (c) Install the 3 engine wire clamps to the timing belt cover. 20. INSTALL NO.2 IDLER PULLEY (See page EM–21) 21. INSTALL CAMSHAFT TIMING PULLEYS (See page EM–21) 22. INSTALL TIMING BELT (See page EM–21) 23. INSTALL SPARK PLUGS 24. INSTALL IGNITION COILS 25. INSTALL PS PUMP DRIVE BELT 26. INSTALL GENERATOR DRIVE BELT (See page SR–28) 27. INSTALL WATER OUTLET (a) Install 2 new gaskets. (b) Connect the water outlet to the bypass hose. (c) Install the water outlet with the 2 bolts, 2 nuts and 2 plate washers. Alternately tighten the bolts and nuts. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt. (d) Connect the ECT sender gauge connector. (e) Connect the ECT sensor connector. (f) Connect the ground strap (connector). (g) Connect the radiator hose. (h) Connect the engine coolant reservoir hose. 28. (a) 2 8 – INSTALL INTAKE MANIFOLD ASSEMBLY Install the intake manifold, delivery pipe and injectors assembly with the 9 bolts, 2 plate washers and 2 nuts. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 11 5 3 A01808 Author: Date: 1352 EM–67 ENGINE MECHANICAL (1MZ–FE) 8 mm Hexagon Wrench – CYLINDER HEAD (b) Connect the fuel inlet hose to the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precaution. (See page SF–1) (c) Connect the heater hose to the intake manifold. 29. RETIGHTEN WATER OUTLET MOUNTING BOLTS AND NUTS Tighten the 2 bolts and 2 nuts. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 30. INSTALL AIR INTAKE CHAMBER ASSEMBLY (a) Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber assembly with the 2 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) S04791 Chamber Stay (b) (c) (d) (e) EGR Pipe Engine Hanger S04790 (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v) Install 2 new gaskets and No.2 EGR pipe with the 4 nuts. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Install the No.1 engine hanger with the 2 bolts. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Install the air intake chamber stay with the 2 bolts. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) Connect the PCV hose to the PCV valve on the RH cylinder head. Connect the ground strap and cable to the intake air control valve for the ACIS. Connect the ground cable and strap with the nut. Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf) Connect the ground cable to the air intake chamber. Connect the brake booster vacuum hose to the air intake chamber. Connect the 2 water bypass hoses to the throttle body. Connect the air assist hose to the throttle body. Connect the purge hose to the emission control valve set. Connect the 2 vacuum hoses to the vacuum tank for the ACIS. Connect the engine wire clamp to the emission control valve set. Install the PS pressure tube with the 2 nuts. Connect the throttle position sensor connector. Connect the IAC valve connector. Connect the EGR gas temperature sensor connector. Connect the EGR valve position sensor connector. Connect the VSV connector for the ACIS. Connect the VSV connecter for the EVAP. Connect the VSV connector for the EGR. Author: Date: 1353 EM–68 ENGINE MECHANICAL (1MZ–FE) – CYLINDER HEAD (w) Connect the DLC1 to the bracket on the intake air control valve. (x) Connect the accelerator cable. (y) Connect the A/T throttle cable. 31. INSTALL HIGH–TENSION CORD SET 32. INSTALL V–BANK COVER 33. INSTALL RH ENGINE MOUNTING STAY (See page EM–76) 34. INSTALL AIR FILTER AND AIR CLEANER CAP ASSEMBLY 35. INSTALL RH FENDER APRON SEAL 36. INSTALL FRONT EXHAUST PIPE (See page EM–76) 37. FILL WITH ENGINE COOLANT 38. START ENGINE AND CHECK FOR LEAKS 39. VEHICLE ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smoothly operation. 40. RECHECK ENGINE COOLANT LEVEL Author: Date: 1354 EM–69 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT ENGINE UNIT EM04X–04 COMPONENTS No.2 Cooling Fan Connector Upper Radiator Support Radiator Upper Hose Radiator Assembly RH Fender Apron Seal Upper Radiator Support No.1 Cooling Fan Connector Washer Hose for Windshield No.1 ECT Switch Wire Connector Lower Radiator Support
O–Ring Drain Lower Radiator Plug Support EGR Vacuum Hose Generator Drive Belt Hood EVAP Hose MAF Meter Connector PS Pump Drive Belt Hold–Down Clamp Air Filter Air Cleaner Case Air Cleaner Cap Assembly 43 (440, 32) PS Pump Battery Insulator A/C Compressor Connector A/C Compressor Battery Generator Drive Belt Adjusting Bar Bracket Battery Tray Radiator Lower Hose 25 (250, 18) LH Fender Apron Seal A/T Oil Cooler Hose
Gasket Actuator Cover 56 (570, 41) Accelerator Cable
Gasket
Cruise Control Actuator
Gasket Front Exhaust Pipe 62 (630, 46) Cruise Control Actuator Connector Bracket Stay 33 (330, 24) 33 (330, 24)
62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A06650 Author: Date: 1355 EM–70 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT RH Drive Shaft Tie Rod End LH Drive Shaft 64 (650, 47) 49 (500, 36) 294 (3,000, 217) 32 (320, 23) Engine Moving Control Rod RH Engine Mounting Stay
64 (650, 47) Lower Suspension Arm No.2 RH Engine Mounting Stay (M/T) 64 (650, 47) 127 (1,300, 94) Rear Engine Mounting Insulator No.2 RH Engine Mounting Bracket Engine and Transaxle Assembly Front Engine Mounting Insulator 66 (670, 48) 64 (650, 47) Transaxle Control Cable 48 (490, 35) TMC Made 80 (820,59) TMMK Made Green Clolr Bolt 66 (670, 48) Silver Clolr Bolt 44 (450,32) 64 (650, 47) Engine Mounting Absorber N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part A06646 Author: Date: 1356 EM–71 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT EM04Y–03 REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. (a) (b) (c) (d) S05048 (e) 11. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) REMOVE BATTERY AND TRAY REMOVE HOOD REMOVE ENGINE FENDER APRON SEALS DRAIN ENGINE COOLANT DRAIN ENGINE OIL DISCONNECT ACCELERATOR CABLE REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE REMOVE CRUISE CONTROL ACTUATOR REMOVE RADIATOR (See page CO–18) REMOVE FRONT EXHAUST PIPE Remove the 2 bolts holding the support stay to the support bracket. Remove the 2 bolts holding the support bracket to the front frame. Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds. Remove the front exhaust pipe and 3 gaskets. DISCONNECT CONNECTORS, CABLE, CLAMPS AND HOSES Disconnect the igniter connector on the LH fender apron. Disconnect the noise filter connector on the LH fender apron. Disconnect the generator wire and connector. Disconnect the starter wire and connector. Disconnect the 2 ground strap connectors from the LH fender apron. Disconnect the 2 ground strap connectors from the RH fender apron. Disconnect the ground cable from the battery body bracket. Disconnect the engine wire protector clamp from the battery body bracket. Disconnect the engine wire clamp from the bracket on the RH fender apron. Disconnect the engine wire clamp from the bracket on the fuel filter. Author: Date: 1357 EM–72 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT (k) Disconnect the brake booster vacuum hose from the air intake chamber. (l) Disconnect the engine coolant reservoir hose from the water outlet. (m) Disconnect the heater hose from the intake manifold. (n) Disconnect the heater hose from the water inlet housing. (o) Disconnect the fuel inlet hose from the fuel filter. CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing the precautions. (See page SF–6) (p) Disconnect the purge hose from the pipe on the emission control valve set. (q) Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS. 12. (a) (b) (c) (d) S04497 13. 14. 15. 16. (a) (b) (c) (d) 17. Bracket Connector DISCONNECT ENGINE WIRE FROM CABIN Remove the No.2 instrument lower panel. Disconnect the 3 ECM connectors. Disconnect the 3 cowl wire connectors from the connectors on the bracket. Disconnect the grommet from the cowl panel, and pull out the engine wire. REMOVE DRIVE SHAFTS (See page SA–26) M/T only: REMOVE STARTER (See page ST–5) M/T only: DISCONNECT CLUTCH RELEASE CYLINDER AND ACCUMULATOR WITHOUT DISCONNECTING TUBE DISCONNECT A/C COMPRESSOR FROM ENGINE Disconnect the A/C compressor connector. Remove the drive belt. Remove the 4 bolts, nut and drive belt adjusting bar bracket. Disconnect the A/C compressor from the engine. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE B00881 Author: Date: 1358 EM–73 ENGINE MECHANICAL (1MZ–FE) 18. (a) (b) (c) – ENGINE UNIT DISCONNECT PS PUMP FROM ENGINE Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger. Loosen the 2 bolts, and remove the drive belt. Remove the 2 bolts, and disconnect the PS pump from the engine. P18775 19. M/T (a) DISCONNECT TRANSAXLE FROM LH ENGINE MOUNTING INSULATOR M/T: Remove the 3 bolts holding the transaxle to the mounting insulator. S05393 A/T (b) A/T: Remove the 4 bolts holding the transaxle to the mounting insulator. 20. DISCONNECT REAR ENGINE MOUNTING BRACKET FROM FRONT FRAME Remove the 2 hole plugs. Remove the 4 nuts holding the front frame to the mounting bracket. Z18907 (a) (b) P18752 21. REMOVE ENGINE MOUNTING ABSORBER Remove the 4 bolts and mounting absorber. A05426 Author: Date: 1359 EM–74 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT 22. DISCONNECT FRONT ENGINE MOUNTING INSULATOR FROM FRONT FRAME Remove the 3 bolts holding the mounting insulator to the front frame. P18755 23. (a) Engine Hanger P19478 ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS Install the No.2 engine hanger in the correct direction. Part No.: No.2 engine hanger 12282–20020 Bolt 91621–60822 Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) (b) Attach the sling device to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 24. REMOVE RH ENGINE MOUNTING STAY Remove the 3 bolts and RH engine mounting stay. S04501 25. M/T only: REMOVE NO.2 RH ENGINE MOUNTING STAY Remove the 2 bolts and No.2 RH engine mounting stay. S05451 Author: Date: 1360 EM–75 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT 26. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET Remove the 3 bolts, control rod and mounting bracket. S04754 27. Lift S04993 REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE:
Be careful not to hit the PNP switch.
Make sure the engine is clear of all wiring, hoses and cables. (b) Place the engine and transaxle assembly onto the stand. 28. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE Remove the 4 bolts and mounting insulator. 29. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE Remove the 4 bolts, the mounting insulator and bracket assembly. 30. SEPARATE ENGINE AND TRANSAXLE E153 M/T (See page MX–4) A541E A/T (See page AX–23) Author: Date: 1361 EM–76 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT EM04Z–04 INSTALLATION 1. Lower S04992 ASSEMBLE ENGINE AND TRANSAXLE E153 M/T (See page MX–4) A541E A/T (See page AX–23) 2. INSTALL REAR ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 3. INSTALL FRONT ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) 4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Attach the engine sling device to the engine hangers. (b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting. NOTICE: Be careful not to hit the park/neutral position switch. (c) Keep the engine level, and align RH and LH mountings with the body bracket. 5. INSTALL NO.2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD Install the mounting moving control rod and No.2 RH engine mounting bracket with the 3 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) S04754 6. M/T only: INSTALL NO.2 RH ENGINE MOUNTING STAY Install the No.2 RH engine mounting stay with the 2 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) S05451 7. INSTALL RH ENGINE MOUNTING STAY Install the RH mounting stay with the 3 bolts. Torque: 32 N·m (320 kgf·cm, 23 ft·lbf) S04501 Author: Date: 1362 EM–77 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT 8. CONNECT FRONT ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 3 bolts. Torque: TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK made: 44 N·m (450 kgf·cm, 32 ft·lbf) for silver color bolt 66 N·m (670 kgf·cm, 48 ft·lbf) for green color bolt P18755 9. INSTALL ENGINE MOUNTING ABSORBER Install the engine mounting absorber with the 4 bolts. Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) A05426 10. (a) (b) CONNECT REAR ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 4 nuts. Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) Install the 2 hole plugs. P18752 M/T 11. (a) CONNECT LH ENGINE MOUNTING INSULATOR M/T: Connect the mounting insulator with the 3 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) (b) A/T: Connect the mounting insulator with the 4 bolts. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) REMOVE ENGINE SLING DEVICE CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE S05393 A/T 12. 13. Z18907 Author: Date: 1363 EM–78 ENGINE MECHANICAL (1MZ–FE) 14. (a) (b) (c) – ENGINE UNIT INSTALL PS PUMP Install the PS pump with the 2 bolts. Torque: 43 N·m (440 kgf·cm, 31 ft·lbf) Install the drive belt. Connect the PS pressure tube with the 2 nuts. P18775 15. (a) C B A A Connector Bracket A B00881 (b) (c) 16. 17. 18. 19. (a) (b) (c) (d) INSTALL A/C COMPRESSOR Install the A/C compressor and drive belt adjusting bar bracket with the 4 bolts and nut. Torque: Bolt A: 25 N·m (250 kgf·cm, 18 ft·lbf) Bolt B: 18 N·m (185 kgf·cm, 13 ft·lbf) Nut C: 25 N·m (250 kgf·cm, 18 ft·lbf) Install the drive belt. Connect the A/C compressor connector. M/T only: INSTALL CLUTCH RELEASE CYLINDER AND ACCUMULATOR M/T only: INSTALL STARTER (See page ST–19) INSTALL DRIVE SHAFTS (See page SA–32) CONNECT ENGINE WIRE TO CABIN Push in the engine wire through the cowl panel. Install the grommet. Connect the 3 engine ECM connectors. Connect the 3 cowl wire connectors to the connectors on the bracket. Install the No.2 instrument lower panel. S04497 20. (a) (b) (c) (d) (e) CONNECT CONNECTORS, CABLE, CLAMPS AND HOSES Connect the igniter connector on the LH fender apron. Connect the noise filter connector on the LH fender apron. Connect the generator connector and wire. Connect the starter connector and wire. Connect the 2 ground strap connectors to the RH fender apron. Author: Date: 1364 EM–79 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT (f) Connect the 2 ground strap connectors to the LH fender apron. (g) Connect the DLC1 to the RH fender apron. (h) Connect the ground cable to the battery body bracket. (i) Connect the engine wire protector clamp to the battery body bracket. (j) Connect the engine wire clamp to the bracket on the RH fender apron. (k) Connect the engine wire clamp to the bracket on the fuel filter. (l) Connect the brake booster vacuum hose to the air intake chamber. (m) Connect the engine coolant reservoir hose to the water outlet. (n) Connect the heater hose to the intake manifold. (o) Connect the heater hose to the water inlet housing. (p) Connect the fuel inlet hose to the fuel filter. CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions. (See page SF–6) (q) Connect the purge hose to the pipe on the emission control valve set. (r) Connect the 2 vacuum hoses to the vacuum tank for the ACIS. 21. (a) (b) (c) S05048 (d) (e) 22. 23. 24. 25. 26. 27. INSTALL FRONT EXHAUST PIPE Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) Tighten the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) Install the bracket with the 2 bolts. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Install the support stay with the 2 bolts. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) INSTALL RADIATOR (See page CO–24) INSTALL CRUISE CONTROL ACTUATOR INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE CONNECT ACCELERATOR CABLE INSTALL ENGINE FENDER APRON SEALS INSTALL BATTERY TRAY AND BATTERY Author: Date: 1365 EM–80 ENGINE MECHANICAL (1MZ–FE) – ENGINE UNIT 28. INSTALL HOOD 29. FILL ENGINE WITH OIL 30. FILL WITH ENGINE COOLANT 31. START ENGINE AND CHECK FOR LEAKS 32. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 33. RECHECK ENGINE COOLANT AND OIL LEVELS Author: Date: 1366 EM–81 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK CYLINDER BLOCK EM050–03 COMPONENTS Knock Sensor Connector Knock Sensor 39 (400, 29) No.2 ECT Switch Connector Engine Wire Band Engine Wire Water Inlet Housing (With Water Inlet) x8 8 (80, 69 in.·lbf)  Gasket 28 (290, 21) No.2 Idler Pulley Bracket EGR Cooler Water Seal Plate 9 (90, 78 in.·lbf)  Gasket 14.5 (145, 10) Water Pump
Engine Coolant Drain Union Oil Filter Union 8 (80, 69 in.·lbf)  O–Ring
Oil Pressure Switch Oil Pump  Crankshaft Front Oil Seal Oil Filter x9 10mm Head 7.8 (80, 69 in.·lbf) 12mm Head 19.5 (200,14) 25 (250, 18) Oil Pressure Switch Connector Crankshaft Position Sensor Connector A/C Compressor Housing Bracket No.1 Oil Pan x 15 or 17 or 0 or 0  Gasket 10mm Head 8 (80, 69 in.·lbf) 12mm Head 19.5 (200,14) Engine Wire 8 (80, 69 in.·lbf) Oil Strainer  Gasket No.2 Oil Pan Generator x 10 Drain Plug N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part
Precoated part 45 (460, 33) 8 (80, 69 in.·lbf) A06640 Author: Date: 1367 EM–82 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK No.1 Piston Ring No.2 Piston Ring Oil Ring (Side Rail) Oil Ring (Expander)  Snap Ring Piston Pin Piston  Snap Ring  Connecting Rod Bushing Connecting Rod Connecting Rod Bearing Connecting Rod Cap See Page EM–101 1st 24.5 (250, 18) 2nd Turn 90°  Crankshaft Rear Oil Seal x6  Seal Washer 8 (80, 69 in.·lbf) Rear Oil Seal Retainer Cylinder Block Upper Crankshaft Thrust Washer Upper Main Bearing Crankshaft Lower Crankshaft Thrust Washer Lower Main Bearing Main Bearing Cap 27 (275, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part See Page EM–101 1st 22 (225, 16) 2nd Turn 90°  Seal Washer Z18551 Author: Date: 1368 EM–83 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK EM051–04 DISASSEMBLY 1. 2. 3. 4. 5. 6. (a) (b) 7. M/T: REMOVE FLYWHEEL A/T: REMOVE DRIVE PLATE INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY REMOVE TIMING BELT AND PULLEYS (See page EM–15) REMOVE CYLINDER HEAD (See page EM–32) REMOVE GENERATOR, ADJUSTING BAR AND BRACKET ASSEMBLY Disconnect the 2 wire clamps from the wire brackets. Remove the 3 nuts, the generator, adjusting bar and bracket assembly. REMOVE OIL PRESSURE SWITCH (See page LU–1) S04921 8. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 3 bolts and compressor housing bracket. P12946 9. REMOVE NO.2 IDLER PULLEY BRACKET Remove the 2 bolts and idler pulley bracket. P18761 10. (a) (b) SST REMOVE KNOCK SENSORS Disconnect the 2 knock sensor connectors. Using SST, remove the 2 knock sensors. SST 09816–30010 P12389 Author: Date: 1369 EM–84 ENGINE MECHANICAL (1MZ–FE) P18762 Water Seal Plate Oil Filter Union 12 mm Hexagon Wrench – CYLINDER BLOCK 11. REMOVE WATER INLET HOUSING (a) Remove the engine wire band. (b) Disconnect the engine wire clamp from the bracket. (c) Remove the 8 bolts, 2 nuts and water inlet housing. 12. REMOVE WATER PUMP (See page CO–6) 13. REMOVE NO.2 OIL PAN (See page LU–9) 14. REMOVE OIL STRAINER (See page LU–9) 15. REMOVE NO.1 OIL PAN (See page LU–9) 16. REMOVE OIL PUMP (See page LU–9) 17. REMOVE OIL FILTER (See page LU–9) 18. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union. 19. REMOVE WATER SEAL PLATE Remove the 2 nuts and seal plate. 20. REMOVE ENGINE COOLANT DRAIN UNION Coolant Drain Union P18763 21. REMOVE EGR COOLER Remove the 3 bolts, 2 nuts, EGR cooler and gasket. P12410 22. (a) (b) REMOVE REAR OIL SEAL RETAINER Remove the 6 bolts. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap. P12508 P12695 23. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Author: Date: 1370 EM–85 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK Connecting rod thickness: 20.80 – 20.85 mm (0.8189 – 0.8209 in.) 24. (a) (b) REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. P13329 (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the connecting rod cap. P12707 (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. P12696 (f) Plastigage Lay a strip of Plastigage across the crank pin. P12728 Author: Date: 1371 EM–86 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (g) P12697 Install the connecting rod cap with the 2 bolts. (See page EM–101) Torque: 1st: 24.5 N·m (250 kgf·cm, 18 ft·lbf) 2nd: Turn extra 90° NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bearing. (See steps (b) and (c)) (i) Measure the Plastigage at its widest point. Standard oil clearance: 0.038 – 0.064 mm (0.0015 – 0.0025 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. P12698 HINT: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked ”1”, ”2”, ”3” and ”4” accordingly. Reference: Standard bearing center wall thickness: Mark Number Mark mm (in.) ”1” 1.484 – 1.487 (0.0584 – 0.0585) ”2” 1.487 – 1.490 (0.0585 – 0.0587) ”3” 1.490 – 1.493 (0.0587 – 0.0588) ”4” 1.493 – 1.496 (0.0588 – 0.0589) (j) Completely remove the Plastigage. 25. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. Number Mark P14127 (a) (b) HINT: P12500

Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order. Author: Date: 1372 EM–87 ENGINE MECHANICAL (1MZ–FE) P12799 – CYLINDER BLOCK 26. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 – 0.24 mm (0.0016 – 0.0095 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 1.930 – 1.980 mm (0.0760 – 0.0780 in.) 27. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers, in the several passes, in the sequence shown. P12585 8 6 2 14 13 10 9 1 4 12 16 11 15 7 5 (b) Uniformly loosen and remove the 16 main bearing cap bolts, in several passes, in the sequence shown. (c) Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps, lower bearings and (No.2 main bearing cap only) 2 lower thrust washers. 3 P12752 P12603 NOTICE: Pull up the main bearing cap little by little to the right and the left by turns and pay attention not to damage the joint surface of the cylinder block and the main bearing cap. HINT:
Keep the lower bearing and main bearing cap together.
Arrange the main bearing caps and lower thrust washers in correct order. Joint Surface S06200 Author: Date: 1373 EM–88 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (d) Lift out the crankshaft. HINT: Keep the upper bearings together with the cylinder block. (e) Clean each main journal and bearing. (f) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. P12495 (g) (h) Plastigage Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. P12980 (i) P12954 Install the 4 main bearing caps. (See page EM–101) Torque: 12 pointed head bolts: 1st: 22 N·m (225 kgf·cm, 16 ft·lbf) 2nd: Turn extra 90° Hexagon head bolts: 27 N·m (275 kgf·cm, 20 ft·lbf) NOTICE: Do not turn the crankshaft. (j) Remove the main bearing caps. (See steps (a) to (c) ) (k) Measure the Plastigage at its widest point. Standard oil clearance: No.1 and No.4 journals 0.014 – 0.036 mm (0.0006 – 0.0014 in.) No.2 and No.3 journals 0.026 – 0.048 mm (0.0010 – 0.0019 in.) Maximum clearance: P12993 No.1 and No.4 journals 0.05 mm (0.0020 in.) No.2 and No.3 journals 0.06 mm (0.0024 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. Author: Date: 1374 EM–89 ENGINE MECHANICAL (1MZ–FE) No.2 No.1 – CYLINDER BLOCK HINT: If using a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. The No.1 and No.4 journal bearings have 5 standard bearing sizes, marked ”3”, ”4”, ”5”, ”6” and ”7” accordingly. The No.2 and No.3 journal bearings have 5 standard bearing sizes, marked ”1”, ”2”, ”3”, ”4” and ”5” accordingly. No.3 No.4 Number Mark No.2 No.3 No.4 No.1 No.1 and No.4 journal bearings Total number 0–5 6 – 11 Use bearing ”3” ”4” EXAMPLE: Number Mark Number Mark Cylinder block (A) + Crankshaft (B) ” ”: Number mark 12 – 17 18 – 23 24 – 28 ”5” ”6” ”7” Cylinder block ”06” (A) + Crankshaft ”08” (B) = Total number 14 (Use bearing ”5”) P12734 No.1 and No.4 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 01 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 02 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 03 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 04 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 05 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 06 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 07 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 08 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 09 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 10 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 11 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 12 5 5 5 5 5 5 6 6 6 6 6 6 7 7 7 7 7 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”5” Author: Date: 1375 EM–90 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK No.2 and No.3 journal bearings Total number Cylinder block (A) + Crankshaft (B) 0–5 6 – 11 Use bearing ”1” ”2” EXAMPLE: ” ”: Number mark 12 – 17 18 – 23 24 – 28 ”3” ”4” ”5” Cylinder block ”06” (A) + Crankshaft ”08” (B) = Total number 14 (Use bearing ”3”) No.2 and No.3 journal standard bearings selection chart Cylinder block number mark Crankshaft number mark 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 00 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 01 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 02 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 03 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 04 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 05 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 06 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 07 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 08 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 09 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 10 2 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 11 2 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 12 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”3” Author: Date: 1376 EM–91 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK Reference Item Mark mm (in.) Cylinder block main journal bore diameter (A) ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” ”12” ”13” ”14” ”15” ”16” 66.000 (2.5984) 66.001 (2.5985) 66.002 (2.5985) 66.003 (2.5985) 66.004 (2.5986) 66.005 (2.5986) 66.006 (2.5987) 66.007 (2.5987) 66.008 (2.5987) 66.009 (2.5988) 66.010 (2.5988) 66.011 (2.5989) 66.012 (2.5989) 66.013 (2.5989) 66.014 (2.5990) 66.015 (2.5990) 66.016 (2.5990) Crankshaft main journal diameter (B) ”00” ”01” ”02” ”03” ”04” ”05” ”06” ”07” ”08” ”09” ”10” ”11” ”12” 61.000 (2.4016) 60.999 (2.4015) 60.998 (2.4015) 60.997 (2.4015) 60.996 (2.4014) 60.995 (2.4014) 60.994 (2.4013) 60.993 (2.4012) 60.992 (2.4012) 60.991 (2.4012) 60.990 (2.4012) 60.989 (2.4011) 60.988 (2.4011) Standard bearing center wall thickness (TMC made) ”1” ”2” ”3” ”4” ”5” ”6” ”7” 2.486 – 2.489 (0.0979 – 0.0980) 2.489 – 2.492 (0.0980 – 0.0981) 2.492 – 2.495 (0.0981 – 0.0982) 2.495 – 2.498 (0.0982 – 0.0983) 2.498 – 2.501 (0.0983 – 0.0985) 2.501 – 2.504 (0.0985 – 0.0986) 2.504 – 2.507 (0.0986 – 0.0987) Standard bearing center wall thickness (TMMK made) ”1” ”2” ”3” ”4” ”5” ”6” ”7” 2.485 – 2.488 (0.0978 – 0.0980) 2.488 – 2.491 (0.0980 – 0.0981) 2.491 – 2.494 (0.0981 – 0.0982) 2.494 – 2.497 (0.0982 – 0.0983) 2.497 – 2.500 (0.0983 – 0.0984) 2.500 – 2.503 (0.0984 – 0.0985) 2.503 – 2.506 (0.0985 – 0.0987) (l) 28. (a) (b) Completely remove the Plastigage. REMOVE CRANKSHAFT Lift out the crankshaft. Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. Author: Date: 1377 EM–92 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK 29. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. P12404 30. (a) REMOVE PISTON RINGS Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. (b) HINT: Arrange the piston rings in the correct order only. P12405 31. (a) DISCONNECT CONNECTING ROD FROM PISTON Using a small screwdriver, pry out the 2 snap rings. (b) Gradually heat the piston to approx. 60°C (140°F). (c) Using a plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. P12403 60°C P12416 HINT:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. P12415 Author: Date: 1378 EM–93 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK EM0YS–01 INSPECTION P12499 1. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. 2. CLEAN CYLINDER BLOCK Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45°C (113°F) or less. 3. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.07 mm (0.0028 in.) If warpage is greater than maximum, replace the cylinder block. Z09222 4. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. P12498 Author: Date: 1379 EM–94 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK 5. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 87.500 – 87.512 mm (3.4449 – 3.4453 in.) Maximum diameter: 87.52 mm (3.4457 in.) If the diameter is greater than maximum, replace the cylinder block. 1 Thrust Direction Front 2 1 A 2 Axial Direction 10 mm (0.39 in.) B C 10 mm (0.39 in.) Z09220 6. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. P12500 7. INSPECT 12 POINTED HEAD MAIN BEARING CAP BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.500 – 7.600 mm (0.2953 – 0.2992 in.) Minimum diameter: 7.20 mm (0.2835 in.) If the diameter is less than minimum, replace the bolt. P12497 8. (a) CLEAN PISTON Using a gasket scraper, remove the carbon from the piston top. P12507 Author: Date: 1380 EM–95 ENGINE MECHANICAL (1MZ–FE) (b) – CYLINDER BLOCK Using a groove cleaning tool or broken ring, clean the piston ring grooves. P12491 (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. P12505 AISIN Made RH Piston 23.2 mm LH Piston S06041 9. (a) INSPECT PISTON OIL CLEARANCE AISIN made: (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23.2 mm (0.913 in.) from the piston head. Piston diameter: 87.406 – 87.416 mm (3.4412 – 3.4416 in.) (2) Measure the cylinder bore diameter in the thrust directions. (See page EM–93) (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.084 – 0.106 mm (0.0033 – 0.0042 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. Author: Date: 1381 EM–96 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (b) MAHLE Made RH Piston 41.2 mm LH Piston MAHLE made: (1) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 41.2 mm (1.622 in.) from the piston head. Piston diameter: 87.453 – 87.467 mm (3.4430 – 3.4436 in.) (2) Measure the cylinder bore diameter in the thrust directions. (See inspection in cylinder block) (3) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.033 – 0.059 mm (0.0013 – 0.0023 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace all the 6 pistons. If necessary, replace the cylinder block. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. S06042 10. INSPECT PISTON RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between new piston right and the wall of the ring groove. Ring groove clearance: No.1 0.020 – 0.070 mm (0.0008 – 0.0028 in.) No.2 0.020 – 0.060 mm (0.0008 – 0.0024 in.) If the clearance is not as specified, replace the piston. P12504 11. (a) (b) INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the end gap. Standard end gap: 105 mm P12583 No.1 0.25 – 0.35 mm (0.0098 – 0.0138 in.) No.2 0.35 – 0.45 mm (0.0138 – 0.0177 in.) Oil (Side rail) 0.15 – 0.40 mm (0.0059 – 0.0157 in.) Maximum end gap: EM7639 No.1 0.95 mm (0.0374 in.) No.2 1.05 mm (0.0413 in.) Oil (Side rail) 1.00 mm (0.0394 in.) Author: Date: 1382 EM–97 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. 12. INSPECT PISTON PIN FIT At 60°C (140°F), you should be able to push the piston pin into the piston pin hole with your thumb. P12506 13. INSPECT CONNECTING ROD ALIGNMENT Using a rod aligner and feeler gauge, check the connecting rod alignment.
Check for out–of–alignment. Maximum out–of–alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the connecting rod assembly. Z04012
Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connecting rod assembly. Z04011 14. (a) INSPECT PISTON PIN OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 – 22.014 mm (0.8663 – 0.8667 in.) EM6525 Author: Date: 1383 EM–98 ENGINE MECHANICAL (1MZ–FE) (b) (c) – CYLINDER BLOCK Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 – 22.006 mm (0.8660 – 0.8664 in.) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 – 0.011 mm (0.0002 – 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) EM0227 15. INSPECT CONNECTING ROD BOLTS Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.2 – 7.3 mm (0.284 – 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) If the diameter is less than minimum, replace the bolt. EM6347 16. (a) (b) INSPECT CRANKSHAFT FOR CIRCLE RUNOUT Place the crankshaft on V–blocks. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. P12406 17. (a) P12493 INSPECT MAIN JOURNALS AND CRANK PINS Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 60.988 – 61.000 mm (2.4011 – 2.4016 in.) Crank pin diameter: 52.992 – 53.000 mm (2.0862 – 2.0866 in.) If the diameter is not as specified, check the oil clearance. (See page EM–83) If necessary, replace the crankshaft. (b) Check each main journal and crank pin for taper and out– of–round as shown. Maximum taper and out–of–round: 0.02 mm (0.0008 in.) If the taper and out–of–round is greater than maximum, replace the crankshaft. Author: Date: 1384 EM–99 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK EM0YT–01 REPLACEMENT SST 1. (a) REPLACE CONNECTING ROD BUSHING Using SST and a press, press out the bushing. SST 09222–30010 (b) Align the oil holes of a new bushing and the connecting rod. Using SST and a press, press in the bushing. SST 09222–30010 EM6363 (c) Oil Hole EM6364 (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM–93) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. REPLACE CRANKSHAFT FRONT OIL SEAL (See page LU–13) EM6535 2. P00326 3. REPLACE CRANKSHAFT REAR OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal which are as follows: (a) If the rear oil seal retainer is removed from the cylinder block. (1) Using a screwdriver and hammer, tap out the oil seal. P12589 Author: Date: 1385 EM–100 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09950–70010 (09951–07100) (3) Apply MP grease to the oil seal lip. SST P12570 (b) If the rear oil seal retainer is installed to the cylinder block. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position P12808 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09950–70010 (09951–07100) SST P12810 Author: Date: 1386 EM–101 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK EM053–04 REASSEMBLY HINT:


1. (a) Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. Replace all gaskets, O–rings and oil seals with new parts. ASSEMBLE PISTON AND CONNECTING ROD Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. A05260 (b) Gradually heat the piston to about 60°C (140°F). (c) (d) Coat the piston pin with engine oil. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. 60°C P12417 AISIN Made RH Piston Front Mark (2 Cavities) (e) HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. Front Mark (Mold Mark) LH Piston Front Mark (1 Cavity) Front Mark (Mold Mark) S06044 Author: Date: 1387 EM–102 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK MAHLE Made RH Piston Front Mark (1 Cavity) Front Mark (Mold Mark) LH Piston Front Mark (1 Cavity) Front Mark (Mold Mark) S06043 2. (a) (b) Code Mark No.1 Code Mark No.2 INSTALL PISTON RINGS Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark: No.1 1R, T or G1 No.2 2R, 2T or G2 Z09179 (c) RH Piston No.2 Lower Side Rail Compression Front Mark Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. Expander No.1 Compression or Upper Side Rail LH Piston Lower Side Rail Front Mark No.2 Front Mark Compression Expander No.1 Compression Upper Side Rail S06058 Author: Date: 1388 EM–103 ENGINE MECHANICAL (1MZ–FE) 3. (a) (b) – CYLINDER BLOCK INSTALL CONNECTING ROD BEARINGS Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap. P12402 No.1 and No.4 No.2 and No.3 Upper Lower 22.4 mm 19.0 mm Z09177 4. INSTALL MAIN BEARINGS HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No.1 and No.4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.2 and No.3 positions.
Upper bearings have an oil groove and oil holes; lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Install the bearing with the oil hole in the cylinder block. P12599 (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. Mark 1, 2, 3 or 4 A05263 5. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward. P12600 Author: Date: 1389 EM–104 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK 6. PLACE CRANKSHAFT ON CYLINDER BLOCK 7. PLACE MAIN BEARING CAPS AND LOWER THRUST WASHERS ON CYLINDER BLOCK Install the 2 thrust washers on the No.2 bearing cap with the grooves facing outward. P12495 (a) A05264 (b) Temporarily place the 4 main bearing caps level and let them in their proper locations. (c) Apply a light coat of engine oil on the threads and under the main bearing cap bolts for the 12 pointed head. Temporarily install the 8 main bearing cap bolts to the inside positions. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block will become less than 6 mm (0.23 in.) by making the 2 internal main bearing cap bolts as a guide. A05265 (d) (e) Less than 6 mm A05266 (f) 8. Using a plastic–faced hammer, lightly tap the bearing cap to ensure a proper fit. INSTALL 12 POINTED HEAD MAIN BEARING CAP BOLTS HINT:

A05267 The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the main bearing cap bolts is broken or deformed, replace it. Author: Date: 1390 EM–105 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (a) 9 11 3 15 7 13 1 5 6 2 4 Apply a light coat of engine oil on the threads and under the main bearing cap bolts. (b) Install and uniformly tighten the 16 main bearing cap bolts, in several passes, in the sequence shown. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. 14 10 12 8 16 P12753 (c) (d) Painted Mark 90° Front 90° (e) Mark the front of the main bearing cap bolts with paint. Retighten the main bearing cap bolts by 90° in the numerical order shown. Check that the painted mark is now at a 90° angle to the front. P25741 9. 4 1 2 3 (a) (b) 7 6 5 (c) 10. 8 P12586 INSTALL HEXAGON HEAD MAIN BEARING CAP BOLTS Install a new seal washer to the main bearing cap bolt. Install and uniformly tighten the 8 main bearing cap bolts, in several passes, in the sequence shown. Torque: 27 N·m (275 kgf·cm, 20 ft·lbf) Check that the crankshaft turns smoothly. CHECK CRANKSHAFT THRUST CLEARANCE (See page EM–83) Author: Date: 1391 EM–106 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK 11. AISIN Made INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. Front Front Mark (2 Cavities) RH Piston Front Front Mark (1 cavity) MAHLE Made LH Piston Front Front Mark (1 cavity) RH Piston Front Front Mark (1 cavity) LH Piston S06045 12. (a) (b) PLACE CONNECTING ROD CAP ON CONNECTING ROD Match the numbered connecting rod cap with the connecting rod. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod. P12699 (c) Front 13. HINT:
Protrusion
Check that the protrusion of the connecting rod cap is facing in the correct direction. INSTALL CONNECTING ROD CAP BOLTS The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the connecting rod cap bolts is broken or deformed, replace it. P12801 Author: Date: 1392 EM–107 ENGINE MECHANICAL (1MZ–FE) – CYLINDER BLOCK (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 N·m (250 kgf·cm, 18 ft·lbf) If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. P12697 (c) (d) (e) Painted Mark 90° 90° Front (f) 14. P25743 15. (a) Mark the front of the connecting cap bolts with paint. Retighten the cap bolts by 90° as shown. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. CHECK CONNECTING ROD THRUST CLEARANCE (See page EM–83) INSTALL REAR OIL SEAL RETAINER Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. (b) A A B Seal Width 2 – 3 mm B P12911 Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 2 – 3 mm (0.08 – 0.12 in.) opening.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install the oil seal retainer with the 6 bolts Uniformly tighten the bolt in several passes, in the sequence shown. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 16. INSTALL EGR COOLER Install a new gasket and the EGR cooler with the 3 bolts and 2 nuts. Torque: 9 N·m (90 kgf·cm, 78 in.·lbf) Author: Date: 1393 EM–108 ENGINE MECHANICAL (1MZ–FE) 17. (a) Seal Packing (b) P12477 A A B Seal Width 3 – 5 mm CYLINDER BLOCK INSTALL ENGINE COOLANT DRAIN UNION Apply seal packing to 2 or 3 threads. Seal packing: Part No. 08826–00100 or equivalent Install the drain union. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward. 18. INSTALL WATER SEAL PLATE (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. (b) B – Z09223 (c) 19. 20. 21. 22. 23. 24. 25. 26. (a) Apply seal packing to the seal plate as shown in the illustration. Seal packing: Part No. 08826–00100 or equivalent
Install a nozzle that has been cut to a 3 – 5 mm (0.12 – 0.20 in.) opening.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. Install the seal plate with the 2 nuts. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) INSTALL OIL FILTER UNION Torque: 30 N·m (310 kgf·cm, 22 ft·lbf) INSTALL OIL FILTER (See page LU–15) INSTALL OIL PUMP (See page LU–15) INSTALL NO.1 OIL PAN (See page LU–15) INSTALL OIL STRAINER (See page LU–15) INSTALL NO.2 OIL PAN (See page LU–15) INSTALL WATER PUMP (See page CO–8) INSTALL WATER INLET HOUSING Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material. Author: Date: 1394 EM–109 ENGINE MECHANICAL (1MZ–FE)
(b) Seal Width 3 – 5 mm P12909 3 1 6 (d) (e) 7 8 CYLINDER BLOCK Using a non–residue solvent, clean both sealing surfaces. Apply seal packing to the water inlet housing as shown in the illustration. Seal packing: Part No. 08826–00100 or equivalent
Install a nozzle that has been cut to a 3 – 5 mm (0.12 – 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) 9 – Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Install the engine wire band. Install the engine wire clamp. 5 2 10 4 Z14261 27. (a) SST (b) 28. 29. P12389 INSTALL KNOCK SENSORS Using SST, install the 2 knock sensors. SST 09816–30010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Connect the 2 knock sensor connectors. INSTALL NO.2 IDLER PULLEY BRACKET Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) INSTALL A/C COMPRESSOR HOUSING BRACKET Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Author: Date: 1395 EM–110 ENGINE MECHANICAL (1MZ–FE) 30. 31. 32. 33. 34. 35. (a) Adhesive (b) – CYLINDER BLOCK INSTALL OIL PRESSURE SWITCH (See page LU–1) INSTALL GENERATOR, BRACKET AND ADJUSTING BAR ASSEMBLY Torque: 43 N·m (440 kgf·cm, 32 ft·lbf) INSTALL CYLINDER HEAD (See page EM–57) INSTALL TIMING PULLEYS AND BELT (See page EM–21) REMOVE ENGINE STAND A/T: INSTALL DRIVE PLATE Apply adhesive to 2 or 3 threads of the bolt end. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent Install the front spacer, drive plate and rear plate on the crankshaft. P00601 (c) 1 5 7 36. 4 3 Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) M/T: INSTALL FLYWHEEL (See step 35) Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) 6 8 2 A05416 Author: Date: 1396 EM–111 ENGINE MECHANICAL (1MZ–FE) – EXHAUST SYSTEM EXHAUST SYSTEM EM0YU–01 COMPONENTS California A/T Ring Heat Insulator Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 33 (330, 24) 1/2 turns.
After installing the sensor wire is not twisted. If it is twisted, remove the oxygen sensor Ring Heat Insulator and reinstall it. Tailpipe Heat Insulator  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) 56 (570, 41) 44 (450, 33) 56 (570, 41) Center Exhaust Pipe Heat Insulator 19 (195, 14) Bracket  Gasket Stay Bracket 21 (210, 15) Front Exhaust Pipe (Type A)  Gasket  Gasket Type B Front Exhaust Pipe Bracket  62 (630, 46) 33 (330, 24)   Stay 33 (330, 24) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A06653 Author: Date: 1397 EM–112 ENGINE MECHANICAL (1MZ–FE) – EXHAUST SYSTEM Heat Insulator Except California A/T Heated Oxygen Sensor (Bank 1 Sensor 2) HINT:
Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
After installing the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it. Ring 33 (330, 24) Ring Tailpipe Heat Insulator Heat Insulator  Gasket Heated Oxygen Sensor (Bank 1 Sensor 2) 56 (570, 41) 44 (450, 33) Center Exhaust Pipe 56 (570, 41) Heat Insulator 19 (195, 14) Bracket Stay 21 (210, 15) Bracket  Gasket  Gasket  Gasket M/T Front Exhaust Pipe Bracket Stay    62 (630, 46) 33 (330, 24) 33 (330, 24) Front Exhaust Pipe (A/T) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part A06652 Author: Date: 1398 LU–1 LUBRICATION (5S–FE) LU03H–03 INSPECTION 10W – 30 5W – 30 PREFERRED –20 –29 0 –18 20 –7 40 4 60 16 80 27 OIL AND FILTER OIL AND FILTER Recommended Viscosity (SAE) : °F °C – 100 38 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE B00319 Curved Tip Insert 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SJ, Energy–Conserving or ILSAC multigrade engine oil. SAE 5W–30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL After warming up the engine and then 5 minutes after the engine stop, oil level should be between ”L” and ”F” of the dipstick. If low, check for leakage and add oil up to ”F” mark. NOTICE:
Do not fill with engine oil above the ”F” mark.
When inserting the oil dipstick, insert the curved tip of the dipstick facing the same direction as the curve of the guide.
If the dipstick gets caught while inserting it, do not force it in. Reconfirm the direction of the dipstick. S05317 3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL PRESSURE GAUGE 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: Oil Pressure Gauge At idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 3,000 rpm 245 – 490 kPa (2.5 – 5.0 kgf/cm2, 36 – 71 psi) S05298 6. Adhesive (a) (b) P13638 (c) 7. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Reinstall the oil pressure switch. START ENGINE AND CHECK FOR OIL LEAKS Author: Date: 1647 LU–2 LUBRICATION (5S–FE) – OIL AND FILTER LU03I–03 REPLACEMENT CAUTION:
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Care should be taken, therefore, when changing engine oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water–less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. (a) SST (b) (c) REPLACE OIL FILTER Using SST, remove the oil filter. SST 09228–06501 Clean the oil filter contact surface on the oil filter mounting. Lubricate the filter rubber gasket with clean engine oil. S05318 (d) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. S05319 Author: Date: 1648 LU–3 LUBRICATION (5S–FE) (e) 3. (a) SST 3/4 Turn (b) – Using SST, give it an additional 3/4 turn to seat the filter. SST 09228–06501 FILL WITH ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Fill with new engine oil. Capacity: Drain and refill S05320 Dry fill (c) 4. 5. OIL AND FILTER w/ Oil filter change w/o Oil filter change 3.6 liters (3.8 US qts, 3.2 lmp. qts) 3.4 liters (3.6 US qts, 3.0 lmp. qts) w/ Oil cooler w/o Oil cooler 4.3 liters (4.5 US qts, 3.8 lmp. qts) 4.2 liters (4.4 US qts, 3.7 lmp. qts) Reinstall the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL Author: Date: 1649 LU–4 LUBRICATION (5S–FE) – OIL PUMP OIL PUMP LU03J–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt RH Front Fender Apron Seal PS Pump Drive Belt Exhaust Pipe Bracket Oil Pan Insulator No.2 Rear End Plate LH Stiffener Plate No.2 Exhaust Manifold Stay
Gasket (TMMK Made) (TMC Made)
56 (570, 41)
Gasket Bracket

Front Exhaust Pipe 62 (630, 46) Stay Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part S05595 Author: Date: 1650 LU–5 LUBRICATION (5S–FE) – OIL PUMP Generator Wire Generator Connector Generator * Gasket Wire Clamp Wire Clamp Timing Belt No.2 Timing Belt Cover No.1 Timing Belt Cover Timing Belt Guide Crankshaft Pulley * Gasket High–Tension Cord Spark Plug 18 (180, 13) 108 (1,100, 80) Clamp Clamp Wire Clamp No.1 Idler Pulley 42 (425, 31)
Gasket No.2 Idler Pulley Tension Spring 42 (425, 31) Oil Pump Pulley 24 (245, 18) Oil Pump
Gasket x 10 Crankshaft Timing Pulley 8.8 (90, 78 in.·lbf) 5.4 (55, 48 in.·lbf) Oil Strainer Crankshaft Position Sensor Oil Pan x 17
Gasket N·m (kgf·cm, ft·lbf) : Specified torque * Replace only if damaged Drain Plug
Non–reusable part 5.4 (55, 48 in.·lbf) B06345 Author: Date: 1651 LU–6 LUBRICATION (5S–FE) – OIL PUMP Oil Pump Body Driven Rotor Drive Rotor 8.8 (90, 7.8 in.·lbf)
O–Ring Relief Valve
Crankshaft Front Oil Seal Spring Oil Pump Body Cover Retainer Snap Ring
Oil Pump Oil Seal N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19079 Author: Date: 1652 LU–7 LUBRICATION (5S–FE) – OIL PUMP LU03K–03 REMOVAL HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. DRAIN ENGINE OIL 2. REMOVE FRONT EXHAUST PIPE (See page EM–69) 3. REMOVE NO.2 EXHAUST MANIFOLD STAY AND LH STIFFENER PLATE (See page EM–69) 4. REMOVE EXHAUST PIPE BRACKET, OIL PAN INSULATOR AND NO.2 REAR END PLATE (See page EM–69) 5. (a) (b) REMOVE OIL PAN Remove the oil dipstick. Remove the 17 bolts and 2 nuts. S05311 (c) Insert the blade of SST between the cylinder block and oil pan, and cut off applied sealer and remove the oil pan. SST 09032–00100 NOTICE:
Do not use SST for the oil pump body side and rear oil seal retainer.
Be careful not to damage the oil pan flange. SST SST S05952 6. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 7. REMOVE TIMING BELT (See page EM–17) 8. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 9. REMOVE CRANKSHAFT TIMING PULLEY (See page EM–17) 10. REMOVE OIL PUMP PULLEY (See page EM–17) S05928 Author: Date: 1653 LU–8 LUBRICATION (5S–FE) – OIL PUMP 11. REMOVE OIL PUMP Remove the 12 bolts, oil pump and gasket. S05607 Author: Date: 1654 LU–9 LUBRICATION (5S–FE) – OIL PUMP LU03L–03 DISASSEMBLY 1. (a) (b) REMOVE RELIEF VALVE Using snap ring pliers, remove the snap ring. Remove the retainer, spring and relief valve. S01168 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 2 bolts, pump body cover, O–ring, the drive and driven rotors. S01169 Author: Date: 1655 LU–10 LUBRICATION (5S–FE) – OIL PUMP LU03M–03 INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn’t, replace the relief valve. If necessary, replace the oil pump assembly. S01170 2. (a) S01483 INSPECT DRIVE AND DRIVEN ROTORS Inspect the rotors for body clearance. Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.10 – 0.16 mm (0.0039 – 0.0063 in.) Maximum body clearance: 0.20 mm (0.0079 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. (b) Inspect the rotors for tip clearance. Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.04 – 0.16 mm (0.0016 – 0.0063 in.) Maximum tip clearance: 0.20 mm (0.0079 in.) If the tip clearance is greater than maximum, replace the rotors as a set. S01484 Author: Date: 1656 LU–11 LUBRICATION (5S–FE) – OIL PUMP LU03N–03 REPLACEMENT 1. (a) REPLACE OIL PUMP OIL SEAL Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump cover edge. SST 09950–60010 (09951–00350), 09950–70010 (09951–07100) Apply MP grease to the oil seal lip. REPLACE CRANKSHAFT FRONT OIL SEAL (See page EM–104) S01162 (c) 2. SST S01485 Author: Date: 1657 LU–12 LUBRICATION (5S–FE) – OIL PUMP LU0FP–01 REASSEMBLY 1. (a) Mark (b) INSTALL DRIVE AND DRIVEN ROTORS Place the drive and driven rotors into pump body with the mark on the driven rotor facing the pump body side. Install a new O–ring to the oil pump body. Downward S01487 (c) Install the oil pump body cover with the 2 bolts. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) 2. (a) INSTALL RELIEF VALVE Insert the relief valve, spring and retainer into the oil pump body hole. Using snap ring pliers, install the snap ring. S01169 (b) S01168 Author: Date: 1658 LU–13 LUBRICATION (5S–FE) – OIL PUMP LU03P–03 A A INSTALLATION A A A A A A A A B B Z19249 1. INSTALL OIL PUMP Install a new gasket and the oil pump with the 12 bolts. Uniformity tighten the bolts in several passes. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) HINT: Each bolt length is indicated in the illustration. Bolt length: 25 mm (0.98 in.) for A 35 mm (1.38 in.) for B 2. INSTALL OIL PUMP PULLEY (See page EM–23) 3. INSTALL CRANKSHAFT TIMING PULLEY (See page EM–23) 4. INSTALL NO.2 IDLER PULLEY (See page EM–23) 5. INSTALL TIMING BELT (See page EM–23) 6. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) S05928 7. (a) Seal Width 3 – 5 mm B A C A B C 5 mm (0.20 in.) LU0420 INSTALL OIL PAN Remove any old seal packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surface. NOTICE: Do not use a solvent which will affect the painted surfaces. (b) Apply seal packing to the oil pan shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 3 – 5 mm (0.12 – 0.20 in.) opening.
Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Author: Date: 1659 LU–14 LUBRICATION (5S–FE) – OIL PUMP
(c) (d) 8. 9. 10. 11. 12. 13. Immediately remove nozzle from the tube and reinstall the cap. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Install the dipstick. INSTALL NO.2 REAR END PLATE, OIL PAN INSULATOR AND EXHAUST PIPE BRACKET (See page EM–75) INSTALL LH STIFFENER PLATE AND NO.2 EXHAUST MANIFOLD STAY (See page EM–23) INSTALL FRONT EXHAUST PIPE (See page EM–75) FILL WITH ENGINE OIL START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL Author: Date: 1660 LU–15 LUBRICATION (5S–FE) – OIL COOLER OIL COOLER LU03Q–03 COMPONENTS Water Bypass Hose Oil Filter Union Bolt 78.5 (800, 58) Oil Cooler
O–Ring N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part S05996 Author: Date: 1661 LU–16 LUBRICATION (5S–FE) – OIL COOLER LU03R–03 REMOVAL 1. 2. DRAIN ENGINE COOLANT REMOVE OIL FILTER (See page LU–2) 3. (a) (b) (c) (d) REMOVE OIL COOLER Disconnect the 2 water bypass hoses from the oil cooler. Remove the union bolt and plate washer. Remove the nut and oil cooler. Remove the O–ring from the oil cooler. S05613 Author: Date: 1662 LU–17 LUBRICATION (5S–FE) – OIL COOLER LU03S–03 INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. S05929 Author: Date: 1663 LU–18 LUBRICATION (5S–FE) – OIL COOLER LU03T–03 INSTALLATION New O–Ring 1. (a) (b) INSTALL OIL COOLER Clean the oil cooler contact surface on the oil cooler mounting. Install a new O–ring to the oil cooler. S05930 (c) (d) (e) (f) S05613 (g) 2. 3. 4. 5. Temporarily install the oil cooler with the nut. Apply a light coat of engine oil on the threads and under the head of the union bolt. Install the plate washer and union bolt. Torque: 78.5 N·m (800 kgf·cm, 58 ft·lbf) Tighten the nut. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) Connect the 2 water bypass hoses to the oil cooler. INSTALL OIL FILTER (See page LU–2) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS CHECK ENGINE OIL LEVEL Author: Date: 1664 LU–1 LUBRICATION (1MZ–FE) – OIL AND FILTER OIL AND FILTER Recommended Viscosity (SAE): LU0FR–01 INSPECTION 10W–30 5W–30 PREFERRED °F –20 °C –29 0 –18 20 –7 40 4 60 16 80 27 100 38 TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE B00319 SST 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SJ, Energy–Conserving or ILSAC multigrade engine oil. SAE 5W – 30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. 2. CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop, oil level should be between the low level and full level marks on the dipstick. If low, check for leakage and add oil up to the full level mark. NOTICE: Do not fill with engine oil above the full level mark. 3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE (a) Using SST, remove the oil pressure switch. SST 09816–30010 P25173 (b) Oil Pressure Gauge Install the oil pressure gauge. P25171 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 3,000 rpm 294 – 539 kPa (3.0 – 5.5 kgf/cm2, 43 – 78 psi) Author: Date: 1665 LU–2 LUBRICATION (1MZ–FE) 6. Adhesive (a) (b) (c) P12478 7. – OIL AND FILTER REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Using SST, install the oil pressure switch. SST 09816–30010 Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) START ENGINE AND CHECK FOR LEAKS Author: Date: 1666 LU–3 LUBRICATION (1MZ–FE) – OIL AND FILTER LU026–03 REPLACEMENT CAUTION:
Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.
Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water–less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.
In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. 1. (a) (b) DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug, and drain the oil into a container. 2. (a) REPLACE OIL FILTER Using SST, remove the oil filter. SST 09228–07501 Check and clean the oil filter installation surface. Apply clean engine oil to the gasket of a new oil filter. P12486 SST (b) (c) P12580 (d) SST (e) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn. SST 09228–07501 Additional 3/4 Turn P12582 Author: Date: 1667 LU–4 LUBRICATION (1MZ–FE) 3. (a) (b) – OIL AND FILTER REFILL WITH ENGINE OIL Clean and install the oil drain plug with a new gasket. Torque: 45 N·m (460 kgf·cm, 33 ft·lbf) Fill with fresh engine oil. Capacity: Drain and refill w/ Oilfilter change w/o Oilfilter change Dry fill (c) 4. 5. 4.7 liters (5.0 US qts, 4.1 lmp. qts) 4.5 liters (4.8 US qts, 4.0 lmp. qts) 5.2 liters (5.5 US qts, 4.6 lmp. qts) Install the oil filler cap. START ENGINE AND CHECK FOR OIL LEAKS RECHECK ENGINE OIL LEVEL Author: Date: 1668 LU–5 LUBRICATION (1MZ–FE) – OIL PUMP OIL PUMP LU027–04 COMPONENTS RH Fender Apron Seal Engine Moving Control Rod 64 (650, 47) Generator Drive Belt 32 (320, 23) 64 (650, 47) RH Engine Mounting Stay Ground Strap No.2 RH Engine Mounting Bracket PS Pump Drive Belt PS Pump Drive Belt Adjusting Strut No.2 RH Engine Mounting Stay (M/T) Radiator Reservoir Hose A/C Compressor Connector A/C Compressor Generator Drive Belt Adjusting Bar Bracket Bracket 21 (210, 15) 56 (570, 41)  Gasket  Gasket  Front Exhaust Pipe 62 (630, 46) Bracket Stay 33 (330, 24) N·m (kgf·cm, ft·lbf) : Specified torque   Non–reusable part 33 (330, 24) 62 (630, 46) B06398 Author: Date: 1669 LU–6 LUBRICATION (1MZ–FE) – OIL PUMP Timing Belt Gasket No.2 Timing Belt Cover RH Engine Mounting Bracket Timing Belt Guide 28 (290, 21) No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley Engine Wire Protector RH Camshaft Timing Pulley No.2 Idler Pulley 215 (2,200, 159) 125 (1,300, 94) *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley 125 (1,300, 94) No.1 Idler Pulley Plate Washer Dust Boot
34 (350, 25) Timing Belt Plate Crankshaft Timing Pulley 27 (280, 20) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part
Precoated part Timing Belt Tensioner * For use with SST B06384 Author: Date: 1670 LU–7 LUBRICATION (1MZ–FE) – OIL PUMP No.3 Timing Belt Cover Gasket Collar Bushing 8.5 (85, 74 in.·lbf) x6  O–Ring Engine Wire 8 (80, 69 in.·lbf) x6 A/C Compressor Housing Bracket Crankshaft Position Sensor Oil Pump Oil Pan Baffle Plate Crankshaft Position Sensor Connector 8 (80, 69 in.·lbf) x9 (A/T only) x 17 or 19 No.1 Oil Pan (A/T only) 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) or 0 or 0 Flywheel Housing Under Cover Exhaust Pipe Support Stay 10 mm Head 8 (80, 69 in.·lbf) 12 mm Head 19.5 (200, 14) 14 mm Head 37.2 (380, 27) 8 (80, 69 in.·lbf) Oil Strainer  Gasket No.2 Oil Pan Drain Plug 45 (460, 33) x 10 N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part 8 (80, 69 in.·lbf) B04401 Author: Date: 1671 LU–8 LUBRICATION (1MZ–FE) – OIL PUMP Oil Pump Body Cover Drive Rotor Oil Pump Body Driven Rotor x9  Crankshaft Front Oil Seal Relief Valve Spring  Gasket Plug 36.8 (375, 27) N·m (kgf·cm, ft·lbf) : Specified torque  Non–reusable part B01016 Author: Date: 1672 LU–9 LUBRICATION (1MZ–FE) – OIL PUMP LU028–03 REMOVAL HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. REMOVE RH FRONT WHEEL 2. REMOVE RH FENDER APRON SEAL 3. DRAIN ENGINE OIL 4. REMOVE FRONT EXHAUST PIPE (See page EM–32) 5. REMOVE FRONT EXHAUST PIPE BRACKET FROM NO.1 OIL PAN 6. REMOVE GENERATOR DRIVE BELT (See page CH–6) 7. DISCONNECT A/C COMPRESSOR FROM ENGINE (See page AC–41) 8. Pivot Bolt Adjusting Strut Adjusting Bolt (a) (b) 9. 10. 11. P18778 REMOVE PS PUMP DRIVE BELT AND ADJUSTING STRUT Loosen the pivot and adjusting bolts, and remove the drive belt. Remove the bolt, nut and adjusting strut. REMOVE TIMING BELT (See page EM–15) REMOVE TIMING PULLEYS (See page EM–15) REMOVE NO.3 TIMING BELT COVER (See page EM–32) 12. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 3 bolts and housing bracket. B01015 13. (a) REMOVE NO.2 OIL PAN Remove the 10 bolts and 2 nuts. P18801 Author: Date: 1673 LU–10 LUBRICATION (1MZ–FE) – OIL PUMP (b) SST SST Insert the blade of SST between the No.1 and No.2 oil pans, and cut off applied sealer and remove the No.1 oil pan. SST 09032–00100 NOTICE:
Be careful not to the damage the No.2 oil pan contact surface of the No.1 oil pan.
Be careful not to damage the No.2 oil pan flange. P12716 14. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. P18802 15. (a) (b) REMOVE NO.1 OIL PAN Remove the 2 bolts, exhaust pipe support stay and flywheel housing under cover. Remove the 19 bolts (or 17 bolts and 2 nuts). B04136 (c) Using a screwdriver, remove the oil pan by prying the portions between the cylinder block and oil pan. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. 16. REMOVE BAFFLE PLATE FROM NO.1 OIL PAN 17. REMOVE CRANKSHAFT POSITION SENSOR B04137 18. (a) (b) (c) Pry REMOVE OIL PUMP Remove the 9 bolts. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap. Remove the O–ring. P20050 Author: Date: 1674 LU–11 LUBRICATION (1MZ–FE) – OIL PUMP LU029–03 DISASSEMBLY 1. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. P12680 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 9 screws, pump body cover, drive and driven rotors. P12681 Author: Date: 1675 LU–12 LUBRICATION (1MZ–FE) – OIL PUMP LU02A–03 INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. P12419 2. PLACE DRIVE AND DRIVEN ROTORS INTO OIL PUMP BODY Place the drive and driven rotors into the oil pump body with the mark facing upward. Mark P12807 3. INSPECT ROTOR SIDE CLEARANCE Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 – 0.090 mm (0.0012 – 0.0035 in.) Maximum side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. P12597 4. INSPECT ROTOR TIP CLEARANCE Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.110 – 0.240 mm (0.0043 – 0.0094 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the rotors as a set. P12593 5. INSPECT ROTOR BODY CLEARANCE Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.100 – 0.175 mm (0.0039 – 0.0069 in.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. P12592 Author: Date: 1676 LU–13 LUBRICATION (1MZ–FE) – OIL PUMP LU02B–03 REPLACEMENT REPLACE CRANKSHAFT FRONT OIL SEAL HINT: There are 2 methods ((a) and (b)) to replace the oil seal which are as follows: (a) If the oil pump is removed from the cylinder block. (1) Using a screwdriver, pry out the oil seal. P12413 (2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223–00010 (3) Apply MP grease to the oil seal lip. SST P12392 (b) If the oil pump is installed to the cylinder block. (1) Using a knife, cut off the oil seal lip. (2) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Cut Position P12475 (3) (4) Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09223–00010 SST P12473 Author: Date: 1677 LU–14 LUBRICATION (1MZ–FE) – OIL PUMP LU02C–03 REASSEMBLY 1. (a) Mark P12807 INSTALL DRIVE AND DRIVEN ROTORS Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install the pump body cover with the 9 screws. 2. INSTALL RELIEF VALVE Insert the relief valve and spring into the pump body hole, and install the plug with a new gasket. Torque: 36.8 N·m (375 kgf·cm, 37 ft·lbf) Author: Date: 1678 LU–15 LUBRICATION (1MZ–FE) – OIL PUMP LU02D–03 INSTALLATION 1. (a) INSTALL OIL PUMP Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 2 – 3 mm (0.08 – 0.12 in.) opening. B A HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. C A B Seal Width 2 – 3 mm C P12969 (c) Place a new O–ring on the cylinder block. New O–Ring P18779 Author: Date: 1679 LU–16 LUBRICATION (1MZ–FE) (d) (e) P12694 2. 3. 4. (a) – OIL PUMP Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes. Torque: 10 mm head: 8 N·m (80 kgf·cm, 69 in.·lbf) 12 mm head: 19.5 N·m (200 kgf·cm, 14 ft·lbf) INSTALL CRANKSHAFT POSITION SENSOR INSTALL BAFFLE PLATE TO NO.1 OIL PAN Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL NO.1 OIL PAN Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. Author: Date: 1680 LU–17 LUBRICATION (1MZ–FE) (b) Type A Region ”Y” Region ”X” B Type B A Region ”X” C Region ”Y” C A A Seal Width Type A: 4 – 5 mm Type B: 3 – 4 mm B C B04402 – OIL PUMP Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Region ”X” is at the outer side of the bolt hole. Region ”Y” is at the inner side of the bolt hole.
Install a nozzle that has been cut to a 4 – 5 mm (0.16 – 0.20 in.) (Type A) or 3 – 4 mm (0.12 – 0.16 in.) (Type B) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install the oil pan with the 19 bolts (or 17 bolts and 2 nuts). Uniformly tighten the bolts and nuts in several passes. Torque: 10 mm head: 8 N·m (80 kgf·cm, 69 in.·lbf) 12 mm head: 19.5 N·m (200 kgf·cm, 14 ft·lbf) 14 mm head: 37.2 N·m (380 kgf·cm, 27 ft·lbf) (d) Install the flywheel housing under cover and exhaust pipe support stay with the 2 bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 5. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 6. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the No.1 and No.2 oil pans.
Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
Thoroughly clean all components to remove all the loose material.
Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. Author: Date: 1681 LU–18 LUBRICATION (1MZ–FE) (b) A B A Seal Width 4 – 5 mm B P12568 – OIL PUMP Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent
Install a nozzle that has been cut to a 4 – 5 mm (0.16 – 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface.
Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 7. INSTALL A/C COMPRESSOR HOUSING BRACKET Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) 8. INSTALL NO.3 TIMING BELT COVER (See page EM–21) 9. INSTALL TIMING PULLEYS (See page EM–21) 10. INSTALL TIMING BELT (See page EM–21) 11. INSTALL ADJUSTING STRUT AND PS PUMP DRIVE BELT (a) Temporarily install the adjusting strut with the bolt and the nut. (b) Install the drive belt with the pivot and adjusting bolts. Torque: 43.1 N·m (440 kgf·cm, 32 ft·lbf) (c) Tighten the nut. Torque: 43.1 N·m (440 kgf·cm, 32 ft·lbf) 12. INSTALL A/C COMPRESSOR (See page AC–47) 13. INSTALL GENERATOR DRIVE BELT (See page CH–16) 14. INSTALL FRONT EXHAUST PIPE BRACKET TO NO.1 OIL PAN Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) 15. INSTALL FRONT EXHAUST PIPE (See page EM–76) 16. REMOVE RH FENDER APRON SEAL 17. REMOVE RH FRONT WHEEL 18. FILL ENGINE WITH OIL 19. START ENGINE AND CHECK FOR LEAKS 20. RECHECK ENGINE OIL LEVEL Author: Date: 1682 RS–1 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG SRS AIRBAG RS01Y–22 PRECAUTION NOTICE:
The CAMRY is equipped with SRS, which comprises a driver airbag, front passenger airbag, and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedures described in the repair manual.
Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs before disconnecting the battery.
Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger airbag assembly, side airbag assembly (TMC made and TMMK made), airbag sensor assembly, front airbag sensor and side airbag sensor assembly should be inspected. (See page RS–16, RS–29, RS–41, RS–54, RS–60, RS–65 and RS–70)
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly in order to reuse it.
If the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.
Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting the system’s electrical circuits.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.
After work on the SRS is completed, perform the SRS warning light check (See page DI–626).
If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. CAUTION:
Work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 seconds from disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.)
When the negative (–) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as they were before and adjust the clock. To avoid erasing the memory in each memory system, never use a back– up power supply from outside the vehicle.
Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.
Do not expose the steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor assembly, front airbag sensor or side airbag sensor assembly directly to hot air or flames. Author: Date: 2146 RS–2 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG RS0ET–01 OPERATION 1. STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the SRS are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. W03512 2. SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. Spiral Cable R09725 3. FRONT PASSENGER AIRBAG ASSEMBLY The inflater and bag of the SRS are stored in the front passenger airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge and gas generant, etc., and inflates the bag when instructed by the airbag sensor assembly. W03511 4. SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge and gas generant, etc., and inflates the bag when instructed by the side airbag sensor assembly. H01347 5. SEAT BELT PRETENSIONER The seat belt pretensioner system is a component of the front seat outer belt. The pretensioner contains a squib, gas generant, wire, piston, etc., and operates in the event of a frontal collision. H02610 Author: Date: 2147 RS–3 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG 6. SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the airbag sensor assembly self–diagnosis. In normal operation conditions when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off. H02309 7. AIRBAG SENSOR ASSEMBLY The airbag sensor assembly is mounted on the floor inside the lower center finish panel. The airbag sensor assembly consists of an airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc. It receives signals from the airbag sensor and judges whether the SRS must be activated or not. H02266 8. FRONT AIRBAG SENSOR A front airbag sensor is mounted inside each of the side members. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit, contact is made in the sensor, sending a signal to the airbag sensor assembly. The sensor cannot be disassembled. H08235 9. SIDE AIRBAG SENSOR ASSEMBLY The side airbag sensor assembly is mounted in the LH and RH center pillars. The side airbag sensor assembly consists of a lateral deceleration sensor, safing sensor and diagnosis circuit, etc. It receives signals to the airbag sensor assembly to judge from the side airbag sensors whether the SRS side airbag must be activated or not. H03284 Author: Date: 2148 RS–4 SUPPLEMENTAL RESTRAINT SYSTEM 10. – SRS AIRBAG TMC made: SRS CONNECTORS 8 Side Airbag Assembly (RH) (Squib) 9 Seat Belt Pretensioner (RH) 10 Side Airbag Sensor (RH) 11 12 Front Airbag Sensor (RH) 4 2 Airbag Sensor Assembly Front Passenger Airbag Assembly (Squib) Spiral Cable 7 5 1 3 Steering Wheel Pad (Squib) 6 No.1 J/B 13 Front Airbag Sensor (LH) 14 Side Airbag Sensor (LH) 15 Seat Belt Pretensioner (LH) 16 Side Airbag Assembly (LH) (Squib) H08316 No. Item Application (1) Terminal Twin–Lock Mechanism Connectors 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16 (2) Airbag Activation Prevention Mechanism Connectors 1, 2, 3, 4, 5, 7, 8, 9, 15, 16 (3) Electrical Connection Check Mechanism Connectors 1, 2, 3 (4) Connector Twin–Lock Mechanism Connectors 5, 6, 7 Author: Date: 2149 RS–5 SUPPLEMENTAL RESTRAINT SYSTEM 11. – SRS AIRBAG TMMK made: SRS CONNECTORS 18 8 Side Airbag Assembly (RH) (Squib) 9 Seat Belt Pretensioner (RH) 10 Side Airbag Sensor (RH) 11 12 Front Airbag Sensor (RH) 4 Front Passenger Airbag Assembly (Squib) Spiral Cable 7 2 Airbag Sensor Assembly 5 1 3 Steering Wheel Pad (Squib) 6 No.1 J / B 13 Front Airbag Sensor (LH) 14 Side Airbag Sensor (LH) 15 17 Seat Belt Pretensioner (LH) 16 Side Airbag Assembly (LH) (Squib) H08247 No. Item Application (1) Terminal Twin–Lock Mechanism Connectors 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18 (2) Airbag Activation Prevention Mechanism Connectors 1, 2, 3, 4, 5, 7, 8, 9, 15, 16, 17, 18 (3) Electrical Connection Check Mechanism Connectors 1, 2, 3 (4) Connector Twin–Lock Mechanism Connectors 5, 6, 7 Author: Date: 2150 RS–6 SUPPLEMENTAL RESTRAINT SYSTEM (a) Housing (2) Female Male Z05953 SRS AIRBAG All connectors in the SRS are colored in yellow to distinguish them from other connectors. Connectors having special functions and specifically designed for the SRS are used in the locations shown on the previous page to ensure high reliability. These connectors use durable gold–plated terminals. (1) Spacer – Terminal twin–lock mechanism Each connector has a two–piece component consisting of a housing and a spacer. This design enables the terminal to be locked securely by two locking devices (the retainer and the lance) to prevent terminals from coming out. Airbag activation prevention mechanism Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects positive (+) terminal and negative (–) terminal of the squib. When Connector is Connected When Connector is Disconnected Short Spring Plate Short Spring Plate Contacting Male Terminal Housing Housing Short Spring Plate ON Terminal Squib Connectors Squib Short Spring Plate Closed Circuit Author: Date: R10587 2151 RS–7 SUPPLEMENTAL RESTRAINT SYSTEM – SRS AIRBAG HINT: The type of connector is shown in the diagram on the previous page. (3) SRS Warning Light Disconnection Detection Pin Airbag Sensor Assembly Electrical connection check mechanism This mechanism electrically checks that connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector housing lock is locked. R12076
Half Connection
Complete Connection Terminal for Diagnosis Terminal for Diagnosis Disconnection Detection Pin H01315 HINT: The connectors shown in this illustration are connectors, ”1”, ”2” and ”3” in step 10 and 11. Author: Date: 2152 RS–8 SUPPLEMENTAL RESTRAINT SYSTEM (4) – SRS AIRBAG Connector twin–lock mechanism With this mechanism connectors (male and female connectors) are locked by 2 locking devices to increase the connection reliability. If the primary lock is incomplete, ribs interfere and prevent the secondary lock. Secondary Lock Primary Lock Complete (Secondary Lock Permitted) Primary Lock Incomplete (Secondary Lock Prevented) (b) Fig.1 Power Source Safing Sensor Fig.2 Lock Lock Primary Lock Squibs Twin–Lock Completed AB0089 When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the predetermined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller deceleration rate than the airbag sensor. As illustrated in Fig. 2, ignition is caused when current flows to the squib, which happens when a safing sensor and the deceleration sensor go on simultaneously. When a deceleration force acts on the sensors, 2 squibs in the driver airbag and front passenger airbag ignite and generate gas. The gas discharging into the driver airbag and front passenger airbag rapidly increases the pressure inside the bags, breaking open the steering wheel pad and instrument panel door. Bag inflation then ends, and the bags deflate as the gas is discharged through discharge holes at the bag’s rear or side. Deceleration Sensor Z14034 Author: Date: 2153 RS–9 SUPPLEMENTAL RESTRAINT SYSTEM 12. Outer (a) (b) H01581 – SRS AIRBAG DISCONNECTION OF FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR CONNECTOR While holding both flank sides of the outer, slide the outer to the direction shown by an arrow. Lock of the connectors is released, then disconnect the connectors. HINT: Make sure to hold both flank sides of the outer. If holding the top and bottom sides, it will obstruct disconnection. Lock of connector is released Disconnection is completed H01582 13. CONNECTION OF FRONT AIRBAG SENSOR AND SIDE AIRBAG SENSOR CONNECTOR (a) Align the male connector (of the side of sensor) and female connector in the same direction as shown in the illustration and fit in them without rubbing. (b) As they are fitted in, the outer slides rearward. Press it until the outer returns to its original position again. If fitting stops half way, connectors will separate. (c) Make sure to insert until they are locked. After fitting in, pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:  Do not fit in while holding the outer.  When fitting in, the outer slides. Do not touch it. Outer Outer H01583 Author: Date: 2154 RS–10 SUPPLEMENTAL RESTRAINT SYSTEM 14. (a) (b) (c) Slider – SRS AIRBAG DISCONNECTION OF SIDE AIRBAG CONNECTOR Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Disconnection is completed H01584 Author: Date: 2155 RS–11 SUPPLEMENTAL RESTRAINT SYSTEM 15. (a) (b) – SRS AIRBAG CONNECTION OF SIDE AIRBAG CONNECTOR Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Make sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Slider Slider H01585 Author: Date: 2156 RS–12 SUPPLEMENTAL RESTRAINT SYSTEM 16. (a) (b) (c) Slider – SRS AIRBAG DISCONNECTION OF CONNECTORS FOR FRONT PASSENGER AIRBAG ASSEMBLY Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Disconnection is completed H01586 Author: Date: 2157 RS–13 SUPPLEMENTAL RESTRAINT SYSTEM 17. (a) (b) – SRS AIRBAG CONNECTION OF CONNECTORS FOR FRONT PASSENGER AIRBAG ASSEMBLY Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustration, fit in them without rubbing. Make sure to insert until they are locked. After fitting in pull them slightly to check that they are locked. (When locked, make sure that the outer returns to its original position and sound at the time of fitting in can be heard.) HINT:   As the slider slides, do not touch it. Be careful not to deform the release board. If the release board is deformed, replace it with a new one. Slider Slider H01587 Author: Date: 2158 RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE STEERING WHEEL PAD AND SPIRAL CABLE RS00Y–20 COMPONENTS Column Upper Cover Steering Wheel Lower No.2 Cover Steering Wheel Spiral Cable 35 (360, 26) Steering Wheel Lower No.2 Cover Steering Wheel Pad Torx Screw 7.1 (72, 63 in.·lbf) Column Lower Cover N·m (kgf·cm, ft·lbf) : Specified torque H03294 Author: Date: 2159 RS–15 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS00Z–14 REMOVAL HINT: For step 1 to 4, refer to page SR–11. 1. REMOVE STEERING WHEEL PAD 2. REMOVE STEERING WHEEL 3. REMOVE UPPER AND LOWER COLUMN COVERS 4. REMOVE SPIRAL CABLE Author: Date: 2160 RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS010–19 INSPECTION 1. (a) (b) W03512 2. (a) (b) W03513 Horn Button Contact Plate VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the steering wheel pad (with airbag) installed in the vehicle. Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion.
Check cuts and cracks in wire harnesses, and chipping in connectors.
Check the deformation of the horn button contact plate on the steering wheel. HINT:
If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. W03521 Author: Date: 2161 RS–17 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE
There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see page SR–11 and SR–16, and be sure to follow the correct procedure. W03651 3. (a) (b) VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the steering wheel pad (with airbag) removed from the vehicle.
Check the deformation on the horn button contact plate of the steering wheel.
Check the damage on the spiral cable connector and wire harness. HINT:

If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel assembly with a new one. There should be no interference between the steering wheel pad and steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel. Author: Date: 2162 RS–18 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS011–19 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same procedure given in step 1–(d) in ”DISPOSAL”. CAUTION:
Never dispose of a steering wheel pad which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out–of– doors and where it will not create a nuisance to nearby residents.
SST

AB0152


When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the steering wheel pad. The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a steering wheel pad with the deployed airbag. Author: Date: 2163 RS–19 SUPPLEMENTAL RESTRAINT SYSTEM 1. Battery – STEERING WHEEL PAD AND SPIRAL CABLE AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. SST AB0158 (a) Check functioning of the SST. CAUTION: When deploying the airbag, always use the specified SST: SRS Airbag Deployment Tool. SST 09082–00700 SST AB0152 (1) Battery Connect the SST to the battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which will be connected with the supplemental restraint system. SST AB0158 (2) SST Check functioning of the SST. Press the SST activation switch, and check that the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. H01580 (b) Install the SST. CAUTION: Check that there is no looseness in the steering wheel and steering wheel pad. (1) Remove the steering column lower cover. Remove the 3 screws and steering column lower cover as shown in the illustration. (2) Disconnect the airbag connector of the spiral cable. W03515 Author: Date: 2164 RS–20 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE (3) Connect the SST connector to the airbag connector of the spiral cable. SST 09082–00700 SST W03508 (4) Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (5) NOTICE: Take care not to damage the SST wire harness. (6) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (–) terminal. 10 m (33 ft) or more R13455 (c) R06753 Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. (d) Dispose of steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with the deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with the deployed airbag. (1) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. (2) When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. Author: Date: 2165 RS–21 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 2. DEPLOYMENT WHEN DISPOSING OF STEERING WHEEL PAD ONLY NOTICE:
When disposing of the steering wheel pad (with airbag) only, never use the customers vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the steering wheel pad. (See page SR–11) CAUTION: When storing the steering wheel pad, keep the upper surface of the pad facing upward. (b) Remove the steering wheel pad connector. Remove the connector on the rear surface of the steering wheel pad from the bracket. Inflacter Cover Connector W03520 (c) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service–purpose wire harness, tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2. or more). CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 (1) L M H06693 Install the 2 bolts with washers in the 2 bolt holes in the steering wheel pad. Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until the bolts become difficult to turn.
Do not tighten the bolts too much. Author: Date: 2166 RS–22 SUPPLEMENTAL RESTRAINT SYSTEM (2) – STEERING WHEEL PAD AND SPIRAL CABLE Using 3 wire harnesses, wind the wire harness at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION:
Tightly wind the wire harness around the bolts so that there is no slack.
If there is slack in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed. This is highly dangerous. 2 Times or more H06694 (3) H06695 Battery Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION:
Make sure that the wire harness is tight. It is very dangerous when looseness in the wire harness results in the steering wheel pad coming free through the shock from the airbag deploying.
Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock from the airbag deploying and the steering wheel pad will be thrown into the air. NOTICE: The disc wheel will be marked by airbag deployment, so when disposing of the airbag use a redundant disc wheel. (d) Check functioning of the SST. (See step 1–(a)) SST 09082–00700 SST AB0158 Author: Date: 2167 RS–23 SUPPLEMENTAL RESTRAINT SYSTEM SST H06696 – STEERING WHEEL PAD AND SPIRAL CABLE (e) Install the SST. CAUTION: Place the disc wheel on the level ground. (1) Connect the connector of SST to the steering wheel pad connector. SST 09082–00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also, secure some slack for the SST wire harness inside the disc wheel. (2) Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. (f) y y x Weight H00401 Cover the steering wheel pad with a cardboard box or tires.
Covering method using a cardboard box: Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N (20 kg, 44 lb). Size of cardboard box: Must exceed the following dimensions: x= 460 mm (18.11 in.) When dimension of the cardboard box exceeds the diameter of the disc wheel with tire to which the steering wheel pad is tied x= 460 mm (18.11 in.) + width of tire y= 650 mm (25.59 in.) NOTICE: If a cardboard box smaller than the specified size is used, the cardboard box will be broken by the shock from the airbag deployment.
Covering method using tires: Place at least 3 tires without disc wheel on top of the disc wheel with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions– Width: 185 mm (7.87 in.) Inner diameter: 360 mm (14.17 in.) Inner Diam. Width Tires (3 or More) R04211 Author: Date: 2168 RS–24 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE CAUTION: Do not use tires with disc wheels. NOTICE: The tires may be marked by the airbag deployment, so use the redundant tires. (g) 10 m (33 ft) or more R13763 Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the disc wheel which the steering wheel pad is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. AB0166 (h) Dispose of the steering wheel pad (with airbag). CAUTION:
The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a steering wheel pad with deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a steering wheel pad with deployed airbag. (1) Remove the steering wheel pad from the disc wheel. (2) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Author: Date: 2169 RS–25 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS012–19 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable. Case Replacing part If the airbag has been deployed. Steering wheel pad If the steering wheel pad has been found to be faulty in troubleshooting. Steering wheel pad If the spiral cable has been found to be faulty in troubleshooting. Spiral cable If the steering wheel pad has been found to be faulty during checking items. (See page RS–16) Steering wheel pad If the steering wheel has been found to be faulty during checking items. (See page RS–16) Steering wheel If the spiral cable has been found to be faulty during checking items. (See page RS–16) Spiral cable If the steering wheel pad has been dropped. Steering wheel pad CAUTION: For removal and installation of the steering wheel pad, see page SR–11 and SR–16. Be sure to follow the correct procedure. Author: Date: 2170 RS–26 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE RS013–15 INSTALLATION HINT: For step 1 to 4, refer to page SR–16. 1. INSTALL SPIRAL CABLE 2. INSTALL UPPER AND LOWER COLUMN COVERS 3. INSTALL STEERING WHEEL 4. INSTALL STEERING WHEEL PAD Author: Date: 2171 RS–27 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY RS014–21 COMPONENTS Front Passenger Airbag Assembly 20 (205, 15) Glove Compartment Box Glove Compartment Door Finish Plate Cowl Side Trim RH Front Door Scuff Plate RH N·m (kgf·cm, ft·lbf) : Specified torque H08321 Author: Date: 2172 RS–28 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS02P–03 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is in ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. HINT: For step 2 to 4, refer to page BO–75. 1. (a) H03287 DISCONNECT AIRBAG CONNECTOR Remove the glove compartment door finish plate inside the glove compartment box. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Pull up the connector. (c) Disconnect the front passenger airbag connector. 2. REMOVE FRONT DOOR SCUFF PLATE 3. REMOVE COWL SIDE TRIM 4. REMOVE GLOVE COMPARTMENT BOX 5. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the 2 bolts, 4 nuts and front passenger airbag assembly. CAUTION:
Do not store the front passenger airbag assembly with the airbag deployment side facing downward.
Never disassemble the front passenger airbag assembly. W03509 Author: Date: 2173 RS–29 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS02Q–03 INSPECTION 1. (a) (b) W03511 2. (a) (b) W03517 VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the front passenger airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly and instrument panel. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check cuts, minute cracks or marked discoloration on the front passenger airbag assembly.
Check cuts and cracks in wire harnesses, and for chipping in connectors.
Check the deformation or cracks on the instrument panel and instrument panel reinforcement. HINT:
If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. W03510
There should be no interference between the instrument panel and the front passenger airbag assembly. CAUTION: For removal and installation of the front passenger airbag assembly, see page RS–28 and RS–38, and be sure to follow the correct procedure. W03511 Author: Date: 2174 RS–30 SUPPLEMENTAL RESTRAINT SYSTEM 3. (a) (b) – FRONT PASSENGER AIRBAG ASSEMBLY VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle.
Check the deformation or cracks on the instrument panel and instrument panel reinforcement.
Check the damage on the connector and wire harness. HINT: If the instrument panel or instrument panel reinforcement is deformed or cracked, never repair it. Always replace it with a new one. Author: Date: 2175 RS–31 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS05F–02 DISPOSAL HINT: When scrapping vehicle equipped with an SRS or disposing of a front passenger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a front passenger airbag assembly with an airbag deployed in a collision, follow the same procedure given in step 1–(e) in ”DISPOSAL”. CAUTION:
Never dispose of a front passenger airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out–of– doors and where it will not create a nuisance to nearby residents.
SST

AB0152


When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool). Perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the front passenger airbag assembly. The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. Author: Date: 2176 RS–32 SUPPLEMENTAL RESTRAINT SYSTEM 1. – FRONT PASSENGER AIRBAG ASSEMBLY AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST. (See page RS–18) SST 09082–00700 Battery SST AB0158 (b) Disconnect the airbag connector. (1) Remove the lower instrument cover inside the No.2 under cover. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (2) Pull up the connector. (3) Disconnect the airbag connector. H03287 (c) Install the SST. (1) Connect the connector of 2 SST to the front passenger airbag assembly connector. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H08317 (2) Move the SST to at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the negative (–) terminal. 10 m (33 ft) or more R13455 (d) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. H03286 Author: Date: 2177 RS–33 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (e) Dispose of the front passenger airbag assembly. CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. (1) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front passenger airbag assembly still installed. (2) When moving a vehicle for scrapping which has a front passenger airbag assembly with deployed airbag, use gloves and safety glasses. 2. DEPLOYMENT WHEN DISPOSING OF FRONT PASSENGER AIRBAG ASSEMBLY ONLY NOTICE:
When disposing of the front passenger airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) W03619 Wire Harness Diameter Remove the front passenger airbag assembly. (See page RS–28) CAUTION:
When removing the front passenger airbag assembly, work must be started 90 seconds after the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Store the front passenger airbag assembly with the airbag deployment side facing upward. (b) Using a service–purpose wire harness for the vehicle, tie down the front passenger airbag assembly to the tire. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in.2 or more) Stripped Wire Harness Section AB0163 Author: Date: 2178 RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY CAUTION: If the front passenger airbag assembly is tied down with too thin wire harness, it may snap. This is highly dangerous. Always use a wire harness which is at least 1.25 mm2 (0.0019 in.2). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 X (Diameter)2 divided by 4 (1) L M W03519 Install the 2 bolts with washers in the 2 bolt holes in the front passenger airbag assembly, Bolt: L: 35.0 mm (1.387 in.) M: 6.0 mm (0.236 in.) Pitch: 1.0 mm (0.039 in.) NOTICE:
Tighten the bolts by hand until the bolts become difficult to turn.
Do not tighten the bolts too much. (2) Using 3 wire harness, wind the wire harness at least 2 times each around the bolts installed on the front passenger airbag assembly. 2 times or more W03652 (3) Width Inner Diam. R08582 Position the front passenger airbag assembly inside the tire with the airbag deployment side facing inside. Tire size: Must exceed the following dimensions– Width: 185 mm (7.28 in.) Inner diameter: 360 mm (14.17 in.) CAUTION:
Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the front passenger airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the front passenger airbag assembly with the airbag deployment side facing inside. NOTICE: The tire will be marked by the airbag deployment, so use a redundant tire. Author: Date: 2179 RS–35 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (c) Check functioning of the SST. SST 09082–00700 (d) Place tires. (1) Place at least 2 tires under the tire to which the front passenger airbag assembly is tied. (2) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire should have the wheel installed. Battery SST AB0158 Tires (5 or more) H04528 (3) Tie the tires together with 2 wire harness. CAUTION: Make sure that the wire harness is tight. It is very dangerous if loose wire harness result in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Provide at least 1 m (3 ft) of slack for the wire harness. R05403 (e) Battery SST Front Passenger Airbag Assembly 10 m (33 ft) or more R09690 Install the SST. Connect the connector of 2 SST to the front passenger airbag assembly connector. SST 09082–00700, 09082–00760 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. (f) Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the front passenger airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. Author: Date: 2180 RS–36 SUPPLEMENTAL RESTRAINT SYSTEM R09687 – FRONT PASSENGER AIRBAG ASSEMBLY (g) Dispose of the front passenger airbag assembly. CAUTION:
The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front passenger airbag assembly with deployed airbag. (1) Remove the front passenger airbag assembly from the tire. (2) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts. Author: Date: 2181 RS–37 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS018–17 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front passenger airbag assembly, instrument panel or instrument panel reinforcement. Case Replacing part If the airbag has been deployed. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty in troubleshooting. Front passenger airbag assembly If the front passenger airbag assembly has been found to be faulty during checking items. (See page RS–29) Front passenger airbag assembly If the instrument panel has been found to be faulty during checking items. (See page RS–29) Instrument panel If the instrument panel reinforcement has been found to be faulty during checking items. (See page RS–29) Instrument panel reinforcement If the front passenger airbag assembly has been dropped. Front passenger airbag assembly CAUTION: For replacement of the front passenger airbag assembly, see page RS–28 and RS–38. Be sure to follow the correct procedure. Author: Date: 2182 RS–38 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY RS019–05 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. HINT: For step 2 to 4, refer to page BO–81. 1. (a) W03509 INSTALL FRONT PASSENGER AIRBAG ASSEMBLY Install the front passenger airbag assembly with the 2 bolts. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Install the 4 nuts. CAUTION:
Make sure that no foreign objects are trapped between the airbag bag and the module.
Do not damage the strap when installing the module. NOTICE: If the front passenger airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger airbag assembly with a new one. 2. INSTALL GLOVE COMPARTMENT BOX 3. INSTALL COWL SIDE TRIM 4. INSTALL FRONT DOOR SCUFF PLATE 5. (a) (b) (c) CONNECT AIRBAG CONNECTOR Connect the airbag connector. Put the connector on the glove compartment door finish plate. Install the glove compartment door finish plate to the glove compartment box. H03288 Author: Date: 2183 RS–39 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) SIDE AIRBAG ASSEMBLY (TMC Made) RS05G–02 COMPONENTS Headrest Headrest Support Front Seatback Assembly Front Seat Cushion Inner Shield Side Airbag Assembly Front Seat Cushion Assembly Front Seatback Cover Hinge Cover 15 (150, 11) 18 (185, 13) Seat Track Cover 37 (375, 27) Front Seat Cushion Shield Release Handle Vartical Adjuster Knob Power adjuster type: Front Seat Cushion Shield Front Seat Cushion Lower Shield Front Seat Cushion Lower Shield N·m (kgf·cm, ft·lbf) : Specified torque H08245 Author: Date: 2184 RS–40 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) RS0EU–01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is in ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. (a) (b) H02270 REMOVE FRONT SEAT Remove the 2 seat track covers and 4 bolts. Power adjuster type: Disconnect the power seat and side airbag connectors. (c) Manual adjuster type: Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (d) Remove the front seat. NOTICE: Be careful not to damage the body. 2. REMOVE FRONT SEAT CUSHION LOWER SHIELD 3. Manual adjuster type: REMOVE RELEASE HANDLE 4. Manual adjuster type: REMOVE VERTICAL ADJUSTER KNOB 5. Power adjuster type: DISCONNECT CONNECTOR Disconnect the connector from the power seat switch. 6. REMOVE FRONT SEAT CUSHION SHIELD 7. REMOVE FRONT SEAT CUSHION INNER SHIELD 8. REMOVE HEADREST 9. REMOVE HEADREST SUPPORT 10. (a) (b) (c) REMOVE SEATBACK ASSEMBLY Remove the 4 bolts. Remove the hog rings. Remove the seatback assembly. H02259 Author: Date: 2185 RS–41 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) RS05I–02 INSPECTION 1. (a) (b) VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the seatback assembly installed in the vehicle. Check that there are no cuts or frayed seams and outside of seatback cover. Cross Section H01608 2. H08274 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED (a) Do a diagnostic system check. (See page DI–626) (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check cuts and cracks of the side airbag assembly.
Check cuts and cracks in wire harnesses, and chipping in connectors. CAUTION: For removal and installation of the seatback assembly, see page RS–40 and RS–49. Be sure to follow the correct procedure. 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED (a) Do a diagnostic system check. (See page DI–626) (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check the seatback installation part of the seat adjuster.
Check the damage to the connector and wire harness. HINT: If the seat adjuster is deformed, never repair it. Always replace it with a new one. Author: Date: 2186 RS–42 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) RS05J–02 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the side airbag assembly always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC. When disposing of a side airbag assembly with an airbag deployed in a collision, follow the same procedure given in step 1–(e) in ”DISPOSAL”. CAUTION:
Never dispose of a side airbag assembly which has an undeployed airbag.
The airbag produces a sizeable exploding sound when it deploys, so perform the operation out of doors and where it will not create a nuisance to nearby residents.
SST

AB0152


When deploying the airbag, always use the specified SST (SRS Airbag Deployment Tool), perform the operation in a place away from electrical noise. SST 09082–00700 When deploying an airbag, perform the operation at least 10 m (33 ft) away from the airbag assembly. The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling side airbag assembly with the deployed airbag. Always wash your hands with water after completing the operation. Do not apply water, etc. to a side airbag assembly with the deployed airbag. Author: Date: 2187 RS–43 SUPPLEMENTAL RESTRAINT SYSTEM 1. Battery SST – SIDE AIRBAG ASSEMBLY (TMC Made) AIRBAG DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. (a) Check functioning of the SST. (See page RS–18) SST 09082–00700 AB0158 (b) Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. H01353 (c) Battery Install the SST. (1) Connect the connector of 2 SST to the airbag connector. SST 09082–00700, 09082–00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H01354 (2) Move the SST at least 10 m (33 ft) away from the front of the vehicle. Close all the doors and windows of the vehicle. (3) NOTICE: Take care not to damage the SST wire harness. (4) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. 10 m (33 ft) or more R13455 (d) Deploy the airbag. (1) Check that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. (2) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of SST activation switch lights up. H01326 Author: Date: 2188 RS–44 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) (e) Dispose of side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water, etc. to a side airbag assembly with the deployed airbag.
Always wash your hands with water after completing the operation. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the side airbag assembly still installed. 2. DEPLOYMENT WHEN DISPOSING OF SIDE AIRBAG ASSEMBLY NOTICE:
When disposing of the side airbag assembly only, never use the customer’s vehicle to deploy the airbag.
Be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. (a) Remove the seatback assembly. (b) Remove the side airbag assembly from the seatback assembly. CAUTION: Store the side airbag assembly with the airbag deployment side facing upward. (c) Wire Harness Diameter Stripped Wire Harness Section AB0163 Using a service–purpose wire harness tie down the side airbag assembly. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.0019 in2 or more) CAUTION: If a wire harness which is too thin or some other thing is used to tie down the side airbag assembly, it may be snapped by the shock when the airbag is deployed. This is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.0019 in2). HINT: To calculate the square of the stripped wire harness section: Square = 3.14 x (Diameter)2 divided by 4 Author: Date: 2189 RS–45 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) (1) Install the 2 nuts to the side airbag assembly. (2) Wind the wire harness around the stud bolts of the side airbag assembly as shown in the illustration. H01333 H01334 (3) Width Inner Diam. H08326 Position the side airbag assembly inside the tire with the airbag deployment direction facing inside. Tire size : Must exceed the following dimensions:– Width 185 mm (7.28 in.) Inner diameter 360 mm (14.17 in.) CAUTION:
Make sure the wire harness is tight. It is very dangerous when a loose wire harness results in the side airbag assembly coming free due to the shock from the airbag deploying.
Always tie down the side airbag assembly with the airbag door facing inside. NOTICE: The tire will be marked by the airbag deployment, so when disposing of the airbag use a redundant tire. (d) Check functioning of the SST. (See page RS–18) SST 09082–00700 Battery SST AB0158 Author: Date: 2190 RS–46 SUPPLEMENTAL RESTRAINT SYSTEM (e) Tires (5 or More) – SIDE AIRBAG ASSEMBLY (TMC Made) Place the tires. (1) Place at least 2 tires under the tire to which the side airbag assembly is tied. (2) Place at least 2 tires over the tire to which the side airbag assembly is tied. The top tire should have the wheel installed. H01336 (3) Tie the tires together with the 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. It is very dangerous when loose wire harnesses result in the tires coming free due to the shock from the airbag deploying. HINT: Place the SST connector and wire harness inside tires. Secure at least 1 m (3 ft) of slack for the wire harness. R05403 (f) Battery (g) SST Side Airbag Assembly 10 m (33 ft) or more H01337 Install the SST. Connect the connector of 2 SST to the side airbag assembly connector. SST 09082–00700, 09082–00750 Deploy the airbag. (1) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around the tire which the side airbag assembly is tied to. (3) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. H00544 (h) Dispose of the side airbag assembly. CAUTION:
The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Do not apply water etc. to a side airbag assembly with the deployed airbag. Author: Date: 2191 RS–47 SUPPLEMENTAL RESTRAINT SYSTEM
– SIDE AIRBAG ASSEMBLY (TMC Made) Always wash your hands with water after completing the operation. (1) Remove the side airbag assembly from the tire. (2) Place the side airbag assembly in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts disposal. Author: Date: 2192 RS–48 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) RS05K–02 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the seatback assembly or seatback cover. Case Replacing part If the side airbag has been deployed. Seatback assembly If the side airbag assembly has been found to be faulty in troubleshooting. Seatback assembly If the side airbag assembly has cuts during checking items. (See page RS–41) Seatback assembly If the seatback cover has cuts and frayed seams during checking items. (See page RS–41) Seatback cover If the side airbag assembly has been found to be faulty during checking items. (See page RS–41) Seatback assembly If the seatback cover has been found to be faulty during checking items. (See page RS–41) Seatback cover If the seatback assembly has been dropped. Seatback assembly CAUTION: For removal and installation of the seatback assembly, see page RS–40 and RS–49. Be sure to follow the correct procedure. Author: Date: 2193 RS–49 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMC Made) RS0EV–01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. A B H02259 1. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly. (b) Install new hog rings. HINT: Install the hog rings to prevent wrinkles as little as possible. (c) Install the 4 bolts. Torque: Bolt A: 18 N·m (185 kgf·cm, 13 ft·lbf) Bolt B: 15 N·m (150 kgf·cm, 11 ft·lbf) 2. INSTALL FRONT SEAT CUSHION INNER SHIELD 3. INSTALL FRONT SEAT CUSHION SHIELD 4. Manual adjuster type: INSTALL VERTICAL ADJUSTER KNOB 5. Manual adjuster type: INSTALL RELEASE HANDLE 6. Power adjuster type: CONNECT CONNECTOR Connect the connector to the power seat switch. 7. INSTALL FRONT SEAT CUSHION LOWER SHIELD 8. INSTALL HEADREST SUPPORT 9. INSTALL HEADREST 10. INSTALL FRONT SEAT (a) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (b) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front position will slip off. (c) Power adjuster type: Connect the side airbag connector and power seat connector. (d) Manual adjuster type: Connect the side airbag connector. (e) Tighten the bolts on the rear side temporarily, starting from the bolt on the inner side tighten them completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Author: Date: 2194 RS–50 SUPPLEMENTAL RESTRAINT SYSTEM (f) – SIDE AIRBAG ASSEMBLY (TMC Made) Slide the seat to the rearmost position to install the bolts on the front side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Author: Date: 2195 RS–51 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) SIDE AIRBAG ASSEMBLY (TMMK Made) RS05M–03 COMPONENTS Headrest Headrest Support Seatback Assembly Front Seat Cushion Assembly Side Airbag Assembly Seat Truck Cover 37 (375, 27) Front Seat Cushion Shield Release Handle Vartical Adjuster Knob Power adjuster type: Front Seat Cushion Lower Shield Front Seat Cushion Shield Front Seat Cushion Lower Shield Sub Wire Harness N·m (kgf·cm, ft·lbf) : Specified torque H08246 Author: Date: 2196 RS–52 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) RS0EW–01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected and the ignition switch is at ON or ACC position, DTCs will be recorded.
Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. (a) (b) H02270 REMOVE FRONT SEAT Remove the 2 seat track covers and 4 bolts. Power adjuster type: Disconnect the power seat and side airbag connectors. (c) Manual adjuster type: Disconnect the side airbag connector. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (d) Remove the front seat. NOTICE: Be careful not to damage the body. 2. REMOVE FRONT SEAT CUSHION LOWER SHIELD 3. Manual adjuster type: REMOVE RELEASE HANDLE 4. Manual adjuster type: REMOVE VERTICAL ADJUSTER KNOB 5. Power adjuster type: DISCONNECT CONNECTOR Disconnect the connector from the power seat switch. 6. REMOVE FRONT SEAT CUSHION SHIELD 7. (a) (b) (c) REMOVE SEATBACK ASSEMBLY Remove the 4 bolts. Remove the hog rings. Disconnect the side airbag connector of the side airbag assembly side. H02259 Author: Date: 2197 RS–53 SUPPLEMENTAL RESTRAINT SYSTEM (d) (e) – SIDE AIRBAG ASSEMBLY (TMMK Made) Remove the side airbag sub wire harness after removing clips. Remove the seatback assembly. H01871 Author: Date: 2198 RS–54 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) RS05O–03 INSPECTION 1. (a) (b) VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) Do a visual check which includes the following items with the seatback assembly installed in the vehicle. Check that there are no cuts or frayed in seams and outside of seatback cover. Cross Section H01608 2. H08275 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED (a) Do a diagnostic system check. (See page DI–626) (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check cuts and cracks of the side airbag assembly.
Check cuts and cracks in wire harnesses, and chipping in connectors. CAUTION: For removal and installation of the seatback assembly, see page RS–52 and RS–57. Be sure to follow the correct procedure. 3. VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS DEPLOYED (a) Do a diagnostic system check. (See page DI–626) (b) Do a visual check which includes the following items with the seatback assembly removed from the vehicle.
Check the seatback installation part of the seat adjuster.
Check the damage to the connector and wire harness. HINT: If the seat adjuster is deformed, never repair it. Always replace it with a new one. Author: Date: 2199 RS–55 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) RS05P–02 DISPOSAL (See page RS–42) Author: Date: 2200 RS–56 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) RS05Q–03 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the seatback assembly or seat cover. Case Replacing part If the side airbag has been deployed. Seatback assembly If the side airbag assembly has been found to be faulty in troubleshooting. Seatback assembly If the side airbag assembly has cuts during checking items. (See page RS–54) Seatback assembly If the seatback cover has cuts and frayed seams during checking items. (See page RS–54) Seatback cover If the side airbag assembly has been found to be faulty during checking items. (See page RS–54) Seatback assembly If the seatback cover has been found to be faulty during checking items. (See page RS–54) Seatback cover If the seatback assembly has been dropped. Seatback assembly CAUTION: For removal and installation of the seatback assembly, see page RS–52 and RS–57. Be sure to follow the correct procedure. Author: Date: 2201 RS–57 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG ASSEMBLY (TMMK Made) RS0EX–01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 1. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly. (b) (c) H01871 Securely fix the side airbag sub wire harness to the seat cushion with clips. Connect the side airbag connector of the side airbag assembly side. Install new hog rings. (d) HINT: Install the hog rings to prevent wrinkles as little as possible. (e) Install the 4 bolts. 2. INSTALL FRONT SEAT CUSHION SHIELD 3. Manual adjuster type: INSTALL VERTICAL ADJUSTER KNOB 4. Manual adjuster type: INSTALL RELEASE HANDLE 5. Power adjuster type: CONNECT CONNECTOR Connect the connector to the power seat switch. 6. INSTALL FRONT SEAT CUSHION LOWER SHIELD 7. INSTALL HEADREST SUPPORT 8. INSTALL HEADREST 9. INSTALL FRONT SEAT (a) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (b) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front position will slip off. (c) Tighten the bolts on the rear side temporarily, starting from the bolt on the inner side tighten them completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (d) Slide the seat to the rearmost position to install the bolts on the front side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (e) Power adjuster type: Connect the side airbag connector and power seat connector. (f) Manual adjuster type: Connect the side airbag connector. Author: Date: 2202 RS–58 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SENSOR ASSEMBLY AIRBAG SENSOR ASSEMBLY RS01G–11 COMPONENTS 20 (205, 15) Airbag Sensor Assembly 20 (205, 15) N·m (kgf·cm, ft·lbf) : Specified torque H02269 Author: Date: 2203 RS–59 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SENSOR ASSEMBLY RS0EY–01 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) REMOVE AIRBAG SENSOR ASSEMBLY (a) Disconnect the airbag sensor connectors. NOTICE: Disconnect the connectors with the sensor assembly installed. (b) Using a torx wrench, remove the 4 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042–00020 or locally manufactured tool) LH side: RH side: H02267 H02268 H08322 Author: Date: 2204 RS–60 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SENSOR ASSEMBLY RS05T–01 INSPECTION 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check. (See page DI–626) 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly. (See page RS–59) Author: Date: 2205 RS–61 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SENSOR ASSEMBLY RS01J–13 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly.
If the SRS has been deployed in a collision.
If the airbag sensor assembly has been found to be faulty in troubleshooting.
If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly, see page RS–59 and RS–62. Be sure to follow the correct procedure. Author: Date: 2206 RS–62 SUPPLEMENTAL RESTRAINT SYSTEM – AIRBAG SENSOR ASSEMBLY RS0EZ–01 INSTALLATION NOTICE:
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed.
Never repair a sensor in order to reuse it. LH side: RH side: H02267 H02268 H08322 INSTALL AIRBAG SENSOR ASSEMBLY (a) Using a torx wrench, install the airbag sensor assembly with 4 screws. Torx wrench: T40 (Part No.09042–00020 or locally manufactured tool) Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Connect the airbag sensor connectors. NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor assembly is installed with the specified torque.
If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.
When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts.
After installing , shake the sensor assembly to check that there is no looseness. Author: Date: 2207 RS–63 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR FRONT AIRBAG SENSOR RS01L–14 COMPONENTS 20 (205, 15) 20 (205, 15) Front Airbag Sensor (LH) Front Airbag Sensor (RH) 20 (205, 15) Turn Signal Light RH Turn Signal Light LH Head Light RH Head Light LH N·m (kgf·cm, ft·lbf) : Specified torque H08233 Author: Date: 2208 RS–64 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS0F0–01 REMOVAL NOTICE:
If the wiring connector of the SRS is disconnected with the ignition switch at ON or ACC position, DTCs will be recorded.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.
Never reuse the sensor involved in a collision when the SRS has deployed.
Never repair a sensor in order to reuse it. 1. REMOVE HEAD LIGHT LH AND RH (a) Remove the 2 clips and turn signal lights. (b) Remove the 4 bolts and head lights. 2. LH: REMOVE FRONT AIRBAG SENSOR (a) Disconnect the connector. NOTICE: Disconnect the connector with sensor assembly installed. (b) Remove the 2 bolts and front airbag sensor LH. H08318 3. RH: REMOVE FRONT AIRBAG SENSOR (a) Disconnect the connector. NOTICE: Disconnect the connector with sensor assembly installed. (b) Remove the 2 bolts and front airbag sensor RH. H08319 Author: Date: 2209 RS–65 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS01N–16 INSPECTION H08235 LH: 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) 2. VEHICLE INVOLVED IN COLLISION (a) Do a diagnostic system check. (See page DI–626) (b) If the front fender of the car or its periphery is damaged, do a visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed:
Bracket deformation
Paint peeling off the bracket
Cracks, dents or chips in the case
Cracks, dents, chipping and scratches in the connector
Peeling off of the label or damage to the serial number RH: H06728 Author: Date: 2210 RS–66 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS01O–10 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor.
If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.)
If the front airbag sensor has been found to be faulty in troubleshooting.
If the front airbag sensor has been found to be faulty during checking items. (See page RS–65)
If the front airbag sensor has been dropped. CAUTION: For removal and installation of the front airbag sensor, see page RS–64 and RS–67. Be sure to follow the correct procedure. Author: Date: 2211 RS–67 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR RS01P–14 INSTALLATION 1. (a) LH: RH: H06728 INSTALL FRONT AIRBAG SENSOR LH AND RH Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) NOTICE:
Connection of the connector is done after the sensor assembly has been installed.
Make sure the sensor is installed with the specified torque.
If the sensor has been dropped, or there are cracks, dents or other defects in the case, brackets or connector, replace the removed sensor with a new one.
The front sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnostic system. (b) Connect the front airbag sensor connector. 2. INSTALL HEAD LIGHT LH AND RH (See page BE–28) 3. INSTALL TURN SIGNAL LIGHT LH AND RH Author: Date: 2212 RS–68 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR ASSEMBLY SIDE AIRBAG SENSOR ASSEMBLY RS01Q–06 COMPONENTS Side Airbag Sensor Assembly 7.5 (76, 66 in.·lbf) 20 (205, 15) Front Seat Outer Belt Retractor 42 (430, 31) Center Pillar Lower Garnish Front Door Scuff Plate N·m (kgf·cm, ft·lbf) : Specified torque H03285 Author: Date: 2213 RS–69 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR ASSEMBLY RS01R–05 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) 1. REMOVE FRONT DOOR SCUFF PLATE 2. REMOVE CENTER PILLAR LOWER GARNISH 3. (a) (b) REMOVE FRONT SEAT OUTER BELT RETRACTOR (See page BO–126) Disconnect the pretensioner connector. Remove the 2 bolts and retractor. H01346 H01339 4. REMOVE SIDE AIRBAG SENSOR ASSEMBLY (a) Disconnect the side airbag sensor assembly connector. NOTICE: Disconnect the connector with the sensor assembly installed. (b) Using a torx wrench, remove the 3 screws and side airbag sensor assembly. Torx wrench: T40 (Part No.09042–00020 or locally manufactured tool) Author: Date: 2214 RS–70 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR ASSEMBLY RS05V–03 INSPECTION 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check. (See page DI–626) 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly. (See page RS–69) Author: Date: 2215 RS–71 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR ASSEMBLY RS01T–06 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side airbag sensor assembly.
If the side airbag sensor assembly has been deployed in a collision.
If the side airbag sensor assembly has been found to be faulty in troubleshooting.
If the side airbag sensor assembly has been dropped. CAUTION: For removal and installation of the side airbag sensor assembly, see page RS–69 and RS–72. Be sure to follow the correct procedure. Author: Date: 2216 RS–72 SUPPLEMENTAL RESTRAINT SYSTEM – SIDE AIRBAG SENSOR ASSEMBLY RS05W–02 INSTALLATION NOTICE:
Never use SRS parts from another vehicle. When replacing parts, replace them with new ones.
Never reuse the side airbag sensor assembly involved in a collision when the airbag has deployed.
Never repair a sensor in order to reuse it. 1. (a) H01339 INSTALL SIDE AIRBAG SENSOR ASSEMBLY Using a torx wrench, install the side airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042–00020 or locally manufactured tool) Torque: 20 N·m (205 kgf·cm, 15 ft·lbf) (b) Connect the side airbag sensor assembly connector. NOTICE:
Connection of the connector is done after the sensor assembly has been installed. Make sure the sensor assembly is installed with the specified torque.
If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.
When installing the sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts.
After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL FRONT SEAT OUTER BELT RETRACTOR (See page BO–134) (a) Install the retractor with the 2 bolts. Torque: Upper bolt: 7.5 N·m (76 kgf·cm, 66 in.·lbf) Lower bolt: 42 N·m (430 kgf·cm, 31 ft·lbf) (b) 3. 4. Connect the pretensioner connector. INSTALL CENTER PILLAR LOWER GARNISH INSTALL FRONT DOOR SCUFF PLATE H01352 Author: Date: 2217 RS–73 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR WIRE HARNESS AND CONNECTOR RS01V–11 LOCATION Airbag Sensor Assembly Front Airbag Sensor (RH) Combination Meter (Warning Light) Front Passenger Airbag Assembly Spiral Cable Side Airbag Assembly (RH) Front Airbag Sensor (LH) Side Airbag Sensor Assembly (RH) Steering Wheel Pad (with Airbag) Side Airbag Sensor Assembly (LH) Seat Belt Pretensioner (LH) Seat Belt Pretensioner (RH) Side Airbag Assembly (LH) H08282 Author: Date: 2218 RS–74 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR RS01W–09 INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check. (See page DI–626) 2. VEHICLE INVOLVED IN COLLISION (a) Do a diagnostic system check. (See page DI–626) (b) Check breaks in all wires of the SRS wire harness, and exposed conductors. (c) Check to see if the SRS wire harness connectors are cracked or chipped. Author: Date: 2219 RS–75 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR RS01X–09 REPLACEMENT In the following cases, replace the wire harness or connector.
If any part of the SRS wire harness or any connector has been found to be faulty in troubleshooting.
If any part of the SRS wire harness or any connector has been found to be faulty during checking items. (See page RS–74) CAUTION: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. Author: Date: 2220 IG–1 IGNITION (5S–FE) – IGNITION SYSTEM IGNITION SYSTEM IG0DB–01 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1. INSPECT SPARK TEST Check that the spark occurs. (1) Disconnect the high–tension cord from the spark plug. (2) Remove the spark plug. (3) Install the spark plug to the high–tension cord. (4) Ground the spark plug. (5) See if spark occurs while engine is being cranked. NOTICE: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 5 – 10 seconds at time. If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTION OF IGNITION COIL WITH IGNITER CONNECTORS Connect securely. BAD OK CHECK RESISTANCE OF HIGH–TENSION CORDS (See step 2) Maximum resistance: 25 kΩ per cord Replace cord(s). BAD OK CHECK POWER SUPPLY TO IGNITION COILS WITH IGNITERS 1. Turn ignition switch to ON. 2. Check that there is battery positive voltage at ignition coil positive (+) terminal. Check wiring between ignition switch to ignition coils with igniters. BAD OK CHECK RESISTANCE OF IGNITION COILS (See step 4) Resistance: Cold Hot Secondary 9.7 – 16.7 kΩ 12.4 – 19.6 kΩ Replace ignition coil(s) with igniter(s). BAD OK Replace sensor(s). CHECK RESISTANCE OF SENSORS (See steps 5 and 6) Resistance: Cold Hot Camshaft position sensor 835 – 1,400 Ω 1,060 – 1,645 Ω Crankshaft position sensor 985 – 1,600 Ω 1,265 – 1,890 Ω BAD OK CHECK IGT SIGNAL FROM ECM (See page DI–22) Check wiring between ECM and igniters, and BAD then try another ECM. TRY ANOTHER IGNITER Author: Date: 1683 IG–2 IGNITION (5S–FE) – IGNITION SYSTEM 2. (a) INSPECT HIGH–TENSION CORDS Remove the high–tension cords. Disconnect the high–tension cords at the rubber boot. Do not pull on the high–tension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. CORRECT WRONG S05295 (b) Ohmmeter S05542 (b) Megger Ground Using an ohmmeter, measure the high–tension cord resistance. Maximum resistance: 25 kΩ per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high–tension cord. (c) Reinstall the high–tension cords. 3. INSPECT SPARK PLUGS NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used spark plug.
Spark plugs should be replaced every 100,000 km (60,000 miles). (a) Disconnect the high–tension cords from the spark plugs. IG0147 Inspect the electrode. Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 MΩ or more If the resistance is less than specified, proceed to step (d). HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. Simple Method:
Quickly race the engine to 4,000 rpm 5 times.
Remove the spark plug. (See step (c))
Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step (d)
Reinstall the spark plug. (See step (g)) S03776 Author: Date: 1684 IG–3 IGNITION (5S–FE) – IGNITION SYSTEM (c) (d) Using a 16 mm plug wrench, remove the 4 spark plugs. Visually check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: 16 mm Plug Wrench DENSO made PK20TR11 NGK made BKR6EKPB11 S05308 (e) P20584 IG0152 Inspect the electrode gaps. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. (f) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. (g) Using a 16 mm plug wrench, install the 4 spark plugs. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (h) Reconnect the high–tension cords from the spark plugs. 4. (a) (b) Ohmmeter INSPECT IGNITION COILS WITH IGNITERS Disconnect the high–tension cords from the ignition coils. Inspect the secondary coil resistance. Using an ohmmeter, measure the resistance between the high–tension terminals. Secondary coil resistance: Cold 9.7 – 16.7 kΩ Hot 12.4 – 19.6 kΩ B06373 Author: Date: 1685 IG–4 IGNITION (5S–FE) – IGNITION SYSTEM If the resistance is not as specified, replace the ignition coil. (See page IG–6) (c) Reconnect the high–tension cords to the ignition coils. (d) Inspect the igniters. (See procedure spark test) 5. (a) (b) Ohmmeter S05528 Ohmmeter S05310 INSPECT CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Using an ohmmeter, measure the resistance between terminals. Resistance: Cold 835 – 1,400 Ω Hot 1,060 – 1,645 Ω If the resistance is not as specified, replace the sensor. (See page IG–9) (c) Reconnect the camshaft position sensor connector. 6. (a) (b) INSPECT CRANKSHAFT POSITION SENSOR Disconnect the crankshaft position sensor connector. Using an ohmmeter, measure the resistance between terminals. Resistance: Cold 985 – 1,600 Ω Hot 1,265 – 1,890 Ω If the resistance is not as specified, replace the sensor. (See page IG–12) (c) Reconnect the crankshaft position sensor connector. Author: Date: 1686 IG–5 IGNITION (5S–FE) – IGNITION COIL IGNITION COIL IG041–03 COMPONENTS Vacuum Hose Accelerator Cable
Gasket Throttle Cable (A/T) 19 (195, 14) Throttle Body High–Tension Cord Ignition Coil and No.2 Intake Manifold Stay Assembly EVAP Hose Air Cleaner Hose EVAP Hose PCV Hose EVAP Hose Ignition Coil Connector IAT Sensor Connector (TMMK Made) (TMC Made) Ignition Coil and No.2 Intake Manifold Stay Assembly No.2 Intake Manifold Stay Air Cleaner Cap VSV Connector for EVAP No.1 Ignition Coil No.2 Ignition Coil N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B01286 Author: Date: 1687 IG–6 IGNITION (5S–FE) – IGNITION COIL IG0DC–01 REPLACEMENT 1. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLD (See page SF–32) 2. Wire Clamp S05549 REMOVE IGNITION COILS AND NO.2 INTAKE MANIFOLD STAY ASSEMBLY (a) Disconnect the 2 ignition coil connectors. (b) Disconnect the wire clamp from the manifold stay. (c) TMC Made: Remove the 2 nuts, 2 bolts, 2 ignition coils and manifold stay assembly. (d) TMMK Made: Remove the nut, 3 bolts, 2 ignition coils and manifold stay assembly. 3. REMOVE IGNITION COILS FROM NO.2 INTAKE MANIFOLD STAY Remove the 2 bolts and ignition coil. Remove the 2 ignition coils. 4. No.1 No.2 S05604 REINSTALL IGNITION COILS TO NO.2 INTAKE MANIFOLD STAY Install the ignition coil with the 2 bolts. Install the 2 ignition coils. Torque: 9.8 N·m (100 kgf·cm, 87 in.·lbf) NOTICE: The installation positions of the ignition coils are different for No.1 and No.2. 5. REINSTALL IGNITION COILS AND NO.2 INTAKE MANIFOLD STAY ASSEMBLY (a) TMC Made: Install the 2 ignition coils and manifold stay assembly with the 2 nuts and 2 bolts. (b) TMMK Made: Install the 2 ignition coils and manifold stay assembly with the nut and 3 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) for 12 mm head 42 N·m (428 kgf·cm, 31 ft·lbf) for 14 mm head (c) Install the wire clamp to the manifold stay. (d) Connect the 2 ignition coil connectors. Author: Date: 1688 IG–7 IGNITION (5S–FE) 6. – IGNITION COIL REINSTALL THROTTLE BODY (See page SF–34) Author: Date: 1689 IG–8 IGNITION (5S–FE) – CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR IG044–03 COMPONENTS Camshaft Position Sensor Connector Camshaft Position Sensor S03783 Author: Date: 1690 IG–9 IGNITION (5S–FE) – CAMSHAFT POSITION SENSOR IG0DD–01 REPLACEMENT 1. (a) (b) 2. (a) (b) REMOVE CAMSHAFT POSITION SENSOR Disconnect the sensor connector. Remove the bolt and sensor. REINSTALL CAMSHAFT POSITION SENSOR Install the sensor with the bolt. Torque: 9.5 N·m (97 kgf·cm, 84 in.·lbf) Connect the sensor connector. Author: Date: 1691 IG–10 IGNITION (5S–FE) – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG047–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt PS Pump Drive Belt RH Front Fender Apron Seal N·m (kgf·cm, ft·lbf) : Specified torque S05284 Author: Date: 1692 IG–11 IGNITION (5S–FE) – CRANKSHAFT POSITION SENSOR Generator Wire Generator Connector Generator * Gasket Wire Clamp No.2 Timing Belt Cover * Gasket No.1 Timing Belt Cover Timing Belt Guide Crankshaft Pulley 108 (1,100, 80) Wire Clamp Crankshaft Position Sensor Connector Wire Clamp Wire Clamp Crankshaft Position Sensor N·m (kgf·cm, ft·lbf) :Specified torque * Replace only if damaged S05938 Author: Date: 1693 IG–10 IGNITION (5S–FE) – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG047–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt PS Pump Drive Belt RH Front Fender Apron Seal N·m (kgf·cm, ft·lbf) : Specified torque S05284 Author: Date: 1692 IG–11 IGNITION (5S–FE) – CRANKSHAFT POSITION SENSOR Generator Wire Generator Connector Generator * Gasket Wire Clamp No.2 Timing Belt Cover * Gasket No.1 Timing Belt Cover Timing Belt Guide Crankshaft Pulley 108 (1,100, 80) Wire Clamp Crankshaft Position Sensor Connector Wire Clamp Wire Clamp Crankshaft Position Sensor N·m (kgf·cm, ft·lbf) :Specified torque * Replace only if damaged S05938 Author: Date: 1693 IG–1 IGNITION (1MZ–FE) – IGNITION SYSTEM IGNITION SYSTEM IG0DF–01 ON–VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1. INSPECT IGNITER AND SPARK TEST Check that the spark occurs. (1) Remove the ignition coil. (2) Remove the spark plug. (3) Install the spark plug to the ignition coil, and connect the ignition coil connector. (4) Ground the spark plug. (5) Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 – 10 seconds at a time. If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTION OF IGNITION COIL AND IGNITER CONNECTORS Connect securely. BAD OK Replace the cord(s). CHECK RESISTANCE OF HIGH–TENSION CORD Maximum resistance: 25 kΩ per cord BAD OK CHECK POWER SUPPLY OF HIGH–TENSION COIL AND IGNITER 1. Turn ignition switch to ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. BAD Check wiring between ignition switch to ignition coil and igniter. OK CHECK RESISTANCE OF IGNITION COIL Resistance: Cold AISAN made: Primary 0.70 – 0.94 Ω Secondary 10.8 – 14.9 kΩ Diamond made: Primary 0.70 – 0.94 Ω Secondary 6.8 – 11.7 kΩ Replace the ignition coil (s). Hot 0.85 – 1.10 Ω 13.1 – 17.5 kΩ BAD 0.85 – 1.10 Ω 8.6 – 13.7 kΩ OK Continue to the next page Author: Date: 1695 IG–2 IGNITION (1MZ–FE) – IGNITION SYSTEM Continued from the previous page OK CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR Resistance: Cold Hot DENSO made: 1,060 – 1,645 Ω 835 – 1,400 Ω 2,145 – 3,010 Ω 1,690 – 2,560 Ω Wabash made: Replace the camshaft position sensor. BAD OK CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR Resistance: Cold Hot 1,630 – 2,740 Ω 2,065 – 3,225 Ω Replace the crankshaft position sensor. BAD OK CHECK IGT SIGNAL FROM ECM BAD Check wiring between ECM and igniter, and then try another ECM. OK TRY ANOTHER IGNITER 2. (a) (b) INSPECT HIGH–TENSION CORDS Remove the V–bank cover. Disconnect the high–tension cords from the spark plugs. (1) Using needle–nose pliers, disconnect the cord clamp from the engine wire protector. B00848 (2) WRONG Disconnect the high–tension cords from the spark plugs. NOTICE: Pulling on or bending the cords may damage the conductor inside. (3) Disconnect the high–tension cords from the clamp. CORRECT P24453 (c) P24457 Disconnect the high–tension cords from the ignition coils. (1) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (2) Disconnect the high–tension cord at the grommet. NOTICE:
Pulling on or bending the cords may damage the conductor inside.
Do not wipe any of the oil from the grommet after the high–tension cord is disconnected. Author: Date: 1696 IG–3 IGNITION (1MZ–FE) (d) (1) (2) – IGNITION SYSTEM Remove the high–tension cords set. (1) Disconnect the clamp from the emission control valve set. (2) Remove the high–tension cords set in indicated direction. P25722 (e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 kΩ per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high–tension cord. Ohmmeter P25768 (f) Install the high–tension cords set. S06107 Author: Date: 1697 IG–4 IGNITION (1MZ–FE) (g) Holder Grommet CORRECT – IGNITION SYSTEM Connect the high–tension cords to the ignition coils. (1) Assemble the holder and grommet. (2) Align the spline of the ignition coil with the spline of the holder, and push in the cord. P24458 WRONG Clearance S00813 (c) Megger Ground NOTICE: Check that the holder is correctly installed to the grommet and ignition coil as shown in the illustration. (3) Check that the lock claw of the holder is engaged by lightly pulling the holder. (h) Connect the high–tension cords to the spark plugs. (i) Install the V–bank cover. 3. INSPECT SPARK PLUGS NOTICE:
Never use a wire brush for cleaning.
Never attempt to adjust the electrode gap on a used spark plug.
Spark plugs should be replaced every 100,000 km (60,000 miles). (a) Remove the high–tension cords set. (See step 2) (b) Remove the ignition coils. IG0147 Inspect the electrode. Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 MΩ or more If the resistance is less than specified, proceed to step (e). HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. (d) Simple Method: (1) Quickly race the engine to 4,000 rpm 5 times. (2) Remove the spark plug. (See step (e)) (3) Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step (f) (4) Install the spark plug. (See step (i)) S03776 Author: Date: 1698 IG–5 IGNITION (1MZ–FE) (e) 16 mm Plug Wrench – IGNITION SYSTEM Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. P13225 (f) Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: DENSO PK20TR11 DENSO made PK20TR11 NGK made BKR6EKPB11 NGK BKR6EKPB11 P25746 (g) P20584 IG0152 Inspect the electrode gaps. Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. (h) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. (i) Using a 16 mm plug wrench, install the 6 spark plugs to the RH and LH cylinder heads. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (j) Install the ignition coils. (k) Install the high–tension cords set. (See step 2) 4. INSPECT IGNITION COILS (a) Disconnect the high–tension cords from the ignition coils. (b) Disconnect the ignition coil connectors. Author: Date: 1699 IG–6 IGNITION (1MZ–FE) (c) Ohmmeter – IGNITION SYSTEM Using an ohmmeter, measure the primary coil resistance between the positive (+) and negative (–) terminals. Primary coil resistance: Cold 0.70 – 0.94 Ω Hot 0.85 – 1.10 Ω If the resistance is not as specified, replace the ignition coil. S05622 Ohmmeter (d) Using an ohmmeter, measure the secondary coil resistance between the positive (+) and high–tension terminal. Secondary coil resistance: AISAN made B00849 Ohmmeter S04599 Cold 10.8 – 14.9 kΩ AISAN made Hot 13.1 – 17.5 kΩ Diamond made Cold 6.8 – 11.7 kΩ Diamond made Hot 8.6 – 13.7 kΩ If the resistance is not as specified, replace the ignition coil. (e) Connect the ignition coil connectors. (f) Connect the high–tension cords to the ignition coils. 5. (a) (b) INSPECT CAMSHAFT POSITION SENSOR Disconnect the camshaft position sensor connector. Using an ohmmeter, measure the resistance between terminals. Resistance: DENSO made Cold 835 – 1,400 Ω DENSO made Hot 1,060 – 1,645 Ω Wabash made Cold 1,690 – 2,560 Ω Wabash made Hot 2,145 – 3,010 Ω If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Author: Date: 1700 IG–7 IGNITION (1MZ–FE) – IGNITION COIL IGNITION COIL IG02I–03 REMOVAL 1. DISCONNECT HIGH–TENSION CORDS FROM IGNITION COILS (See page IG–1) 2. (a) (b) REMOVE IGNITION COILS Disconnect the 3 connectors from the ignition coil. Remove the 3 bolts and 3 ignition coils from the LH cylinder head. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) HINT: Arrange the ignition coils in correct order. S04720 Author: Date: 1701 IG–8 IGNITION (1MZ–FE) – IGNITION COIL IG02J–01 INSTALLATION Installation is in the reverse order of removal. (See page IG–7) Author: Date: 1702 IG–9 IGNITION (1MZ–FE) – CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR IG02K–03 REMOVAL REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the 2 bolts and camshaft position sensor. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) S04589 Author: Date: 1703 IG–10 IGNITION (1MZ–FE) – CAMSHAFT POSITION SENSOR IG02L–01 INSTALLATION Installation is in the reverse order of removal. (See page IG–9) Author: Date: 1704 IG–11 IGNITION (1MZ–FE) – CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG02M–03 REMOVAL 1. REMOVE RH FENDER APRON SEAL 2. (a) REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and disconnect the crankshaft position sensor. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) Disconnect the crankshaft position sensor connecter. (b) P20105 Author: Date: 1705 IG–12 IGNITION (1MZ–FE) – CRANKSHAFT POSITION SENSOR IG02N–03 INSPECTION Ohmmeter P14244 NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the sensor itself. ”Cold” is from –10°C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance: Cold 1,630 – 2,740 Ω Hot 2,065 – 3,225 Ω If the resistance is not as specified, replace the crankshaft position sensor. Author: Date: 1706 IG–13 IGNITION (1MZ–FE) – CRANKSHAFT POSITION SENSOR IG02O–01 INSTALLATION Installation is in the reverse order of removal. (See page IG–11) Author: Date: 1707 Technical Service BULLETIN July 21, 2000 Introduction A/C COMPRESSOR MAINTENANCE FOR STORED VEHICLES Models: All Models When a vehicle is stored for a long period (more than one month), the volume of oil in the A/C compressor may decrease due to oil flow into the condenser, pipes, etc. If the A/C system is turned on at high engine RPM after a long storage period, A/C compressor damage may result. To minimize the possibility of damage to the A/C compressor while storing a vehicle, perform the following recommended maintenance procedure at least once a month to lubricate the compressor. Maintenance Procedure Recommended Maintenance Procedure For A/C Compressor Lubrication: 1. Turn off A/C and blower switches prior to starting engine. 2. Start and warm–up engine until engine speed drops below 1,000 RPM. 3. Turn on the A/C system (including the rear A/C) using the following settings: S A/C switch: On S Blower Speed: High S Engine Speed: Below 1,000 RPM 4. Keep A/C on with engine idling for at least 30 seconds. 5. Turn off A/C system and stop engine. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 HEATING & AIR CONDITIONING AC002–00 Title: May 16, 1997 Introduction All Models The cassette tape head and capstan should be cleaned regularly to prevent poor sound quality and/or cassettes from jamming. Head Pinch Roller Capstan Fig. 1 Conditions The following conditions can easily be avoided by regularly cleaning the head with a tape cleaner and only using good quality cassettes. Poor Sound Quality due to Dirty Head Since the tape head contacts the cassette tape, the tape head accumulates metal oxides and dirt particles from the tape. In time, a layer of dirt forms on the tape head resulting in poor transfer of information between the tape and the tape head. This typically causes a reduction of the higher frequencies or a reduction of the brightness in sound quality. Tape Speed Tape speed is controlled by the tape capstan and pinch rollers. If the capstan and pinch rollers accumulate dirt, the tape may slip causing the music to play too fast or too slow. Jamming Dirt can make the capstans sticky, causing the tape to become entangled in the cassette mechanism. This can cause the cassette to become jammed in the player. Cassette Tape Head Cleaners To reduce the occurrence of these conditions, the following approved cassette cleaners are available through the non–parts system (Material Distribution Center). TOOLS & MATERIALS MATERIAL NUMBER DESCRIPTION Allsop 3 Cassette Recorder Cleaner 00113–AS710–00 Cleaning Cassette and Cleaning Solution with Instruction Sheet NOTE: Allow 15 minutes for the cleaning fluid to evaporate before playing a tape. Page 1 of 2 AUDIO Models: AU001–97 TSB CLEANING CASSETTE TAPE HEADS AND CAPSTANS REVISED Title: CLEANING CASSETTE TAPE HEADSAND CAPSTANS – AU001–97 (Revised) Cassette Tape Care Procedure May 16, 1997 The following precautions should be taken to keep cassettes in good condition: 1. Remove the cassette from the player when the cassette is not in use. 2. Store the cassette in its case. 3. Store the cassette in a cool, dry area away from direct sunlight and magnetic components such as speakers. 4. Avoid touching the tape itself. This could result in poor sound quality or sound drop out. 5. Keep the tape tightly wound as shown in figure 2. Tape speed can be affected by loosely wound tape. Use a pencil to tighten up loose tapes. Fig. 2 Peeling Label 6. Avoid inserting a cassette into the player if the cassette label is loose or peeling as shown in figure 3. This can cause a cassette to become stuck in the player. Fig. 3 7. Use cassettes that are 90 minutes or less in length. Cassettes over 90 minutes use extremely thin tape that is subject to stretch, resulting in poor sound quality. Page 2 of 2 Tape length in minutes Fig. 4 AUDIO AU002–96 OCTOBER 25, 1996 ALL MODELS AM STATIC NOISE ON VEHICLES WITH POWER ANTENNAS Page 1 of 2 Vehicles with power antennas may exhibit audible electrical noise on weak AM stations when various electrical accessories (turn signals, rear defogger, cruise control, brakes, etc.) are operated. Poor antenna grounding can cause this condition. To eliminate or reduce the intensity of the noise, use the following repair procedure: REPAIR PROCEDURE: 1. Tune the radio to a strong, static–free AM station and slowly move the tip of the antenna mast forward and back approximately 2 inches (Fig. 1). If static noise is not heard, go to Step 2. If static noise is heard during antenna movement, replace the antenna mast and go to Step 3. Fig. 1 NOTE: Do not touch the antenna mast with your bare hands. Use a glove or nonmetallic object to move the antenna. (If you touch the antenna with your hands, you will change the antenna sensitivity). Inspection Area Fig. 2 2. Remove the antenna mast and inspect the base of the mast for corrosion and damage (Fig. 2). Clean with 1500 grit sandpaper. 3. Remove the antenna assembly and inspect the inner fender around the antenna hole for corrosion (Fig. 3). Clean with 1500 grit sandpaper. Fig. 3 AM STATIC NOISE ON VEHICLES WITH POWER ANTENNAS Page 2 of 2 REPAIR PROCEDURE (Cont’d): 4. Remove the antenna spacer grommet at the top of the antenna assembly and inspect for corrosion (Fig. 4). Clean with 1500 grit sandpaper. Inspection Area Fig. 4 5. Reinstall the antenna assembly. Be sure to install the external antenna nut (escutcheon) first. Then install the nut which holds the assembly to the inner bracket (Fig. 5). 2 1 3 Push 6. Check to make sure that the teeth on the antenna spacer grommet make good contact with the inner fender well (Fig. 6). Fig. 5 Antenna Teeth Fender Fig. 6 7. Inspect the antenna cable connection and clean as necessary (Fig. 7). Reconnect the antenna cable, the wire harness and the drain hose. Inspection Area Fig. 7 WARRANTY INFORMATION: OPCODE DESCRIPTION TIME OPN T1 T2 AU6001 Listed repair procedure (All items) 1.0 86300–XXXXX 76 73 Technical Service BULLETIN TOYOTA DINGHY" TOWING GUIDE Models: All Models March 17, 2000 Introduction The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome. CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer / Service Outlet for recommended towing equipment. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 ACCESSORIES AX001–00 Title: TOYOTA “DINGHY” TOWING GUIDE – AX001–00 Affected Vehicles March 17, 2000 S All Models DINGHY TOWABLE SPEED/DISTANCE LIMITS YEAR MODEL 1995 – 2000 Avalon 1992 – 2000 Camry Yes No None 1999 – 2000 Solara Yes No None 1994 – 1999 Celica Yes No None 2000 Celica GT Yes No None 2000 Celica GT–S Yes – None – Yes 55 MPH / 200 Miles 1993 – 2000 Corolla Yes No None 2000 ECHO Yes No None 1992 – 2000 Land Cruiser 2000 MR2 Spyder Yes N/A None 1996 – 1998 Paseo Yes No None 1992 – 1997 Previa 2WD Not Towable – 1992 – 1997 Previa 4WD Not Towable – 1998 – 2000 Sienna Not Towable – 1994 – 1999 Supra Not Towable – 1996 – 2000 RAV4 2WD Yes No None 1996 – 2000 RAV4 4WD Yes No None 1995 – 1998 Tercel Yes No None 1996 – 2000 4Runner 2WD Not Towable – 1996 – 2000 4Runner 4WD Not Towable – 1995 – 2000 Tacoma 2WD Not Towable – 1995 – 2000 Tacoma 4WD Not Towable – 1993 – 1999 T100 2WD Not Towable – 1993 – 1999 T100 4WD Not Towable – 2000 Tundra 2WD Not Towable – 2000 Tundra 4WD Not Towable – M/T A/T Not Towable Not Towable – – NOTE: After “Dinghy” Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or resuming towing. NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are observed. The transmission must be placed in the “neutral” position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Page 2 of 2 RETRO-FIT INTERNAL TRUNK RELEASE KITS Models: All Applicable ’90 – ’00 Models March 9, 2001 Introduction In order to respond to requests of our valued customers, we are offering Retro–Fit Internal Trunk Release Kits. These kits allow the trunk to be opened from the inside in case of entrapment. Applicable Vehicles MODEL MODEL CODE MODEL YEAR # CLAMPS MCX10 1995 – 1999 4 MCX20 2000 4 SXV10, MCV10, VCV10 1992 – 1996 4 SXV20, MCV20 1997 – 2000 4 AT200, ST204 1994 – 1999 4 AE10# 1993 – 1997 4 ZZE110 1998 – 2000 5 ECHO NCP12 2000 4 MR2 SW20, 21 1990 – 1995 2 EL44 1992 – 1995 4 EL54 1996 – 1999 4 SXV20, MCV20 1999 – 2000 4 EL42 1991 – 1994 4 EL53 1995 – 1999 4 Avalon Camry Celica (Coupe) Corolla (Sedan) Paseo Solara Tercel Parts Information Installation Procedure Warranty Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME – 64640–33030 Trunk Release – 64610–17040 Trunk Release (MR2 Only) – 90464–00551 Clamp – MDC 00107–00316–TR Installation Instructions Order the appropriate trunk release, at least as many clamps as listed above, and a set of installation instructions. Follow the installation procedure detailed in the installation instructions. Installation time is 0.7 hours. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ACCESSORIES Technical Service BULLETIN AX001-01 Title: Technical Service BULLETIN March 31, 2000 Introduction PORT INSTALLED RS3000 TVIP TRUNK COURTESY CONNECTION Models: ’99 Camry The trunk courtesy connection for 1999 model year Camry vehicles equipped with a Port Installed Option RS3000 (V3) has been relocated from the luggage compartment light switch to below the dash (lower finish panel) on the driver’s side in the Instrument Panel J/B. (Refer to Illustrations A & B on page 2.) S The location was changed to improve the installation process. S A splicing connector is used for the new trunk courtesy wire installation (blue) to the vehicle’s wire harness at Instrument Panel J/B (red/yellow). S The previous location is the same as the dealer installed RS3000 trunk courtesy connection to the luggage compartment light switch connection. For service related purposes, this bulletin describes the procedures to locate the new trunk courtesy connection at Instrument Panel J/B in vehicles equipped with PIO RS3000. LED Microphone Remote Control S Applicable Vehicles Warranty Information The remote transmitter has two buttons, Top and Bottom. Status Monitor S The status monitor has a Toyota label, LED, and microphone. S 1999 model year Camry vehicles equipped with PIO (V3) TVIP. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 ACCESSORIES AX003–00 Title: PORT INSTALLED RS3000 TVIP TRUNK COURTESY CONNECTION – AX003–00 Locating Procedure March 31, 2000 New Location: These steps below are to be followed to locate the new trunk courtesy connection when servicing Camry vehicles equipped with the PIO RS3000 TVIP. 1. Remove the negative battery cable. 2. Remove the driver’s step cover. 3. Remove the driver’s cowl cover (1 nut). 4. Locate the Connector Junction Block in the driver’s cowl area. You will notice a RED/YELLOW wire routed to the Blue 10P connector which terminates at an adjacent splicing connector. This is the TVIP Trunk Courtesy Wire. Connector Junction Block 10P Connector (Blue) Illustration A 5. Disconnect the Blue 10P connector from the Connector Junction Block. With the tab of the Blue 10P connector facing up, look at the back (wire side) and locate the wire in the bottom row, second space from the right, which has the splicing connector attached to it. This is the Vehicle’s Trunk Courtesy Signal Wire. 6. After completing the parts inspection and repairs if applicable, reconnect the Blue 10P connector and install all previously removed parts. Wire Side View TVIP Trunk Courtesy Wire (Yellow/Red) Splicing Connector 10P Connector (Blue) Previous Location: The White 1P connector for the Vehicle’s Trunk Courtesy Signal is located at the trunk courtesy lamp switch near the trunk latch in the vehicle’s trunk. Page 2 of 2 Illustration B Technical Service BULLETIN TOYOTA DINGHY" TOWING GUIDE Models: All Models March 19, 1999 Introduction The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome. CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer / Service Outlet for recommended towing equipment. Affected Vehicles S All Models DINGHY TOWABLE YEAR MODEL M/T 1995–1999 1992–1999 1993–1999 1995–1998 1996–1998 1994–1999 1994–1998 1996–1999 1996–1999 1995–1999 1995–1999 1996–1999 1996–1999 1993–1998 1993–1998 1992–1999 1992–1999 1992–1999 1998–1999 Avalon Camry Corolla Tercel Paseo Celica Supra RAV4 2WD RAV4 4WD Tacoma 2WD Tacoma 4WD 4Runner 2WD 4Runner 4WD T100 2WD T100 4WD Land Cruiser Previa 2WD Previa 4WD Sienna A/T SPEED/DISTANCE LIMITS Not Towable Yes No Yes No Yes No Yes No Yes No Not Towable Yes No Yes No Not Towable Not Towable Not Towable Not Towable Not Towable Not Towable Not Towable Not Towable Not Towable Not Towable – None None None None None – None None – – – – – – – – – – NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The transmission must be placed in the “neutral” position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.) Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ACCESSORIES AX004–99 Title: Models: ‘97 Camry April 25, 1997 Introduction Affected Vehicles Procedure ACCESSORY TSB 1997 CAMRY REAR SPOILER INSTALLATION AX005-97 Title: Upon installation of the rear spoiler, as outlined in the Dealer Installation Instruction sheet enclosed with the spoiler, please follow the outlined procedure for verification of the trunk lid operation: 1997 Model Year Camry. 1. Reinstall the carpet trim panel on the inside of the trunk lid with the appropriate fasteners. Upper Slot 2. The trunk lid must remain open and hold its position, up to approximately 45 degrees from horizontal as shown. 3. If the trunk lid does not hold its open position and the trunk lid closes: a. Move the end of one of the torsion rods to the next upper open slot. b. Verify that the trunk lid functions as outlined above. c. If the condition is not corrected, adjust the other torsion bar to the next upper open slot position. 4. If the trunk lid does not hold its open position and the trunk lid opens fully forcibly: Lower Slot a. Move the end of one of the torsion rods to the next lower open slot position. b. Verify that the trunk lid functions as outlined above. c. If the condition is not corrected, please adjust the other torsion bar to the next lower open slot position. NOTE: Upon completion of the procedure described in this bulletin, please refer to the Dealer Installation Instructions for final checks. Page 1 of 1 Technical Service BULLETIN TOYOTA VIP RS3000 PROGRAMMING Models: All Models April 9, 1999 Introduction This bulletin describes the procedures that are used to program the two–button remote control for vehicles that are equipped with the dealer or port installed option (PIO), not the factory security system. For factory security system remote control programming, refer to the appropriate vehicle repair manual. Verification of the dealer or PIO Toyota VIP can easily be performed by identifying the status monitor or remote transmitter. LED Microphone Remote Control S The remote transmitter has two buttons, Top and Bottom. Status Monitor S The status monitor has a Toyota label, LED, and microphone. Starting with 1998 MY, the remote controls for the RS3000 System were revised with new coding logics. The color of the remote control cases was changed from Black to Gray to help identify the new remote controls. The new (Gray) remote controls will not work with the RS3000 ECU’s produced prior to 1998 MY. The old (Black) remote controls are still available for Service Parts. NOTE: The TVIP is programmed to operate with the two remote controls that come with the vehicle. The ECU (computer) can be programmed to operate with up to four different remote controls. For customer satisfaction, request that any existing remote be furnished when programming a new or replacement unit. Affected Vehicles Warranty Information S All models with dealer or PIO equipped Toyota VIP (RS3000) CODE DESCRIPTION TIME OPN T1 T2 N/A Not applicable to warranty – – – – Toyota Supports ASE Certification Page 1 of 4 ACCESSORIES AX005–99 Title: TOYOTA VIP RS3000 PROGRAMMING – ALL MODELS – AX005–99 Programming Procedure April 9, 1999 For location of the RS3000 ECU, refer to ECU Mounting Locations, Page 4. I. To program (add) a REMOTE CONTROL to the system: 1. Insert the key into ignition switch, and turn it to “ON”. 2. Press and hold the ECU’s PROGRAMMING SWITCH for 3 seconds. Press and Hold for 3 Seconds The STATUS MONITOR LED turns on for 5 seconds. NOTE: YOU MUST PERFORM THE NEXT STEP WITHIN 5 SECONDS. 3. Press and release a REMOTE CONTROL’s top or bottom button.* Lights Up Press Once The STATUS MONITOR LED turns off. The Piezo “chirper” chirps once. The exterior lights flash once. 4. Turn off the ignition. The ECU will now operate with the REMOTE CONTROL just programmed. * Page 2 of 4 Either button on your REMOTE CONTROL can be programmed to operate the system. The bottom button can be programmed to operate a second vehicle with the Toyota VIP. TOYOTA VIP RS3000 PROGRAMMING – ALL MODELS – AX005–99 Programming Procedure (Continued) April 9, 1999 II. To erase all REMOTE CONTROL codes from the system: 1. Insert key into the ignition switch, and turn it to “ON”. 2. Press and hold the ECU’s PROGRAMMING SWITCH for 3 seconds. Press and Hold for 3 Seconds The STATUS MONITOR LED turns on for 5 seconds. NOTE: YOU MUST PERFORM THE NEXT STEP WITHIN 5 SECONDS. Lights Up 3. Press and hold the ECU’s PROGRAMMING SWITCH for over 2 seconds again. The STATUS MONITOR LED turns off, then flashes 3 times. The Piezo “chirper” chirps three times and the exterior lights flash 3 times. Press and Hold Again, for 2 Seconds 4. Turn off the ignition. The ECU has cleared all REMOTE CONTROL codes; until another REMOTE CONTROL is programmed, the system will not work with any REMOTE CONTROL. Page 3 of 4 TOYOTA VIP RS3000 PROGRAMMING – ALL MODELS – AX005–99 ECU MOUNTING LOCATIONS 1. ’98 Model and prior has ECU located beneath the driver’s seat. 2. ’97 Model and prior has ECU located beneath the driver’s seat. Page 4 of 4 April 9, 1999 Technical Service BULLETIN April 14, 2000 Introduction RS3000 TVIP AUTOMATIC DOOR LOCK FEATURE PROGRAMMING Models: All Models As a convenience feature, the RS3000 TVIP system is programmed to automatically lock all of the vehicle’s doors (for vehicles equipped with power door locks) when the ignition key is turned to “ON” or “START”, and unlock them when the key is turned back to “ACC” or “LOCK”. The initial factory setting of this programmable feature is “ON”. For some customers however, this feature is not desirable due to instances of passenger lockout when the driver enters the vehicle first and starts the ignition. For vehicles equipped with RS3000 TVIP, this bulletin advises the dealers to communicate the following information to the customers at vehicle delivery: 1. Inform the customers of the RS3000 system’s automatic (ignition controlled) door lock/unlock feature. 2. Inquire about the customers’ preference for it to be set “ON” or “OFF”. 3. Reprogram the feature’s setting according to the customer’s preference. To change the feature’s operation mode, follow the programming procedures on page 2. Verification of the Dealer–Installed Option (DIO) or Port–Installed Option (PIO) RS3000 TVIP System can easily be performed by identifying the status monitor and remote transmitter. LED Microphone Remote Control S Applicable Vehicles Warranty Information The remote transmitter has two buttons, Top and Bottom. Status Monitor S The status monitor has a Toyota label, LED, and microphone. S All models equipped with DIO or PIO RS3000 TVIP. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 ACCESSORIES AX005–00 Title: RS30000 TVIP AUTOMATIC DOOR LOCK FEATURE PROGRAMMING – AX005–00 Programming Procedure April 14, 2000 AUTOMATIC (IGNITION–CONTROLLED) DOOR LOCKING/UNLOCKING FUNCTION The factory setting for the Automatic Door Locking/Unlocking Function is “ON”. To change this feature’s operation, follow the steps below: 1. Sit in the driver’s seat with driver’s door open. 2. Insert the key into the ignition switch, and turn it to “ON” position (not “ACC”) 5 times (ON > LOCK > ON > LOCK > ON > LOCK > ON > LOCK > ON) within a 10 second period. System Response: The STATUS MONITOR’s LED turns on, and the PIEZO BUZZER sounds once. NOTE: You must perform the next steps within 30 seconds. 3. Select the customer’s preferred operating mode. Mode Programming Step Programming Completion Turn the ignition switch to the “LOCK” position. AUTOMATIC DOOR LOCKING/UNLOCKING “ON” AUTOMATIC DOOR LOCKING/UNLOCKING “OFF” Page 2 of 2 Close the driver’s door. Close the driver’s door, then open and close it one more time. System Response: The PIEZO BUZZER sounds once, and the exterior lights flash once. Turn the ignition switch to the “LOCK” position. System Response: The PIEZO BUZZER sounds twice, and the exterior lights flash twice. Technical Service BULLETIN April 23, 1999 Introduction RS3000 TVIP PROGRAMMING CHANGES FOR GBS Models: All Models Starting with 1999 MY, the programming in the RS3000 ECU for the Glass Breakage Sensor (GBS) to trigger the alarm has been changed to improve the Toyota Vehicle Intrusion Protection (TVIP) system’s theft warning feature when glass breakage or impact to the glass is detected. Previous operation of GBS (for 1998 MY and prior): S Upon (first) detection of breakage of the vehicle’s glass, the GBS will sound the security system for 5 seconds (3 horn honks). S If there is a second detection of glass breakage, within 5 seconds of the first detection, the security system will sound for the full duration of 59 seconds. Improved operation of GBS (from 1999 MY): S Upon (first) detection of breakage of the vehicle’s glass, the GBS will sound the security system for 20 seconds. S If there is a second detection of glass breakage, the security system will sound for the full duration of 59 seconds, regardless of time between the first and second detections. S After the first detection, any subsequent detection will trigger the alarm for the full duration of 59 seconds as long as the security system is armed. The GBS trigger cycle will reset once the security system is disarmed and then rearmed. This improvement is intended to enhance the previous trigger cycle of the security system and ward off an intruder. The color of the previous (1998 MY and prior) RS3000 ECU was black. The new RS3000 ECU color is gray. Affected Vehicles Parts Information Warranty Information S All Models PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME 08585–00921 SAME RS3000 Base Kit OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not applicable to warranty – – – – Toyota Supports ASE Certification Page 1 of 2 ACCESSORIES AX006–99 Title: RS3000 TVIP PROGRAMMING CHANGES FOR GBS – AX006–99 Repair Procedure April 23, 1999 When performing the RS3000 System Test, check the Glass Breakage Sensor sensitivity as follows: 1. Press and release the Remote Control’s top button to arm the system. 2. Wait two seconds. 3. With the tip of the ignition key (or striker tool), softly tap the center of the driver’s door window glass. S If the system is triggered (horn sounds for 20 seconds), the sensitivity must be adjusted. Turn the Glass Breakage Sensor ECU’s adjustment screw clockwise one notch, and repeat this step again. 4. If the system is not triggered, repeat the glass tapping with moderate force. S The system should trigger when the glass is tapped with moderate force. If it is not triggered, turn the Glass Breakage Sensor ECU’s adjustment screw clockwise one notch, and repeat this step again. CAUTION: Use caution when performing the step above. Do not tap the window glass with too much force, or the glass may crack or break. Use extra caution when the temperature is extremely cold. NOTE: The Owner’s Guide included in the RS3000 Base Kit is changed to reflect the (GBS logic) improvement. There is no change to the GBS ECU itself. Page 2 of 2 INTERCHANGEABILITY OF ACCESSORY ALLOY WHEELS Technical Service BULLETIN Models: ’99 – ’01 Avalon, Camry, Solara & Sienna September 22, 2000 Introduction This bulletin introduces a new accessory alloy wheel for 1999 through 2001 model year Avalon, Camry, Solara and Sienna vehicles. This new wheel is similar in appearance to an existing alloy wheel. This bulletin points out that the two wheels are not interchangeable. Applicable Vehicles S 1999 – 2001 model year Avalon, Camry, Solara & Sienna. Parts Information WHEEL WHEEL PART NUMBER REMARK Style 1, Split 5 Spoke PT351–00990 Conical (Tapered) Seat Lug Nut Style 2, Split 5 Spoke PT351–00991 Flat Seat Lug Nut Flat Seat Lug Nut Conical (Tapered) Seat Lug Nut Every applicable vehicle must be installed with all four wheels of the same part number. In cases where replacement of one wheel is necessitated, it must be replaced by a wheel of the same part number. Replacement of one part number with the other is permitted only as a set of four wheels. The service part numbers for the lug nuts are not interchangeable. WHEEL PART NUMBER LUG NUT PART NUMBER LUG NUT DESCRIPTION PT351–00990 PT351–00990–LN Conical (Tapered) Seat PT351–00991 PT351–12009–01 Flat Seat The service part numbers for the center caps are not interchangeable. Warranty Information WHEEL PART NUMBER CENTER CAP PART NUMBER PT351–00990 PT351–00991–WC PT351–00991 PT351–00991–CC OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ACCESSORIES AX007–00 Title: Technical Service BULLETIN SEAT BELT EXTENDER Models: ’98 – ’00 Model Year January 21, 2000 Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. Seat Belt S The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. S The extender is available only in black. Extender S Owners are informed of the seat belt extender availability through the Toyota Owner’s Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the seat belt extender worksheet. The worksheet will allow the proper fitting and selection of a seat belt extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Label and review the “owner instruction sheet” with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer’s file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the seat belt extender issue. From past sales history, it is recommended that dealerships do not stock Seat belt extenders due to low demand and the need for customer fitting. This bulletin contains the following information: Procedure and Sample Label.................Page 2 Application Charts .................................Page 3–4 Part Number Information........................Page 5 Owner Instructions..................................Page 6 Seat Belt Extender Worksheet............... Page 7 Applicable Vehicles Warranty Information S All Toyota models, 1998 through 2000 model years. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 7 BODY BO002–00 Title: SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 Procedure January 21, 2000 1. Owner requests a seat belt extender from dealer. 2. Dealer verifies the need for a seat belt extender and obtains a current copy of this TSB and copies the worksheet. 3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network. 4. Dealer receives seat belt extender and calls the customer in to check fit of the part. 5. If the seat belt extender fit is good, dealership personnel completes the customer information label on the part, explains usage of the part, and gives the customer a copy of the completed worksheet. 6. Dealer places a copy of the completed worksheet in the customer’s records. PARTS SUPPLY DEALER MEASURE CUSTOMER & COMPLETE WORKSHEET PLACE CRITICAL ORDER THROUGH TDN SHIP SEAT BELT EXTENDER TO DEALER DEALER TEST FIT CUSTOMER WITH PART COMPLETE LABEL AND ADVISE OWNER FILE WORKSHEET IN CUSTOMER RECORDS Sample Seat Belt Extender Customer Information Label Page 2 of 7 CAUTION OWNER RECEIVE COPY OF WORKSHEET & USE EXTENDER SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 Front Seat Belt Extender Applications January 21, 2000 FRONT SEAT – EXTENDER APPLICATION MODEL TYPE ’00 ’99 ’98 RAV4 — R–5 R–5 R–5 RAV4 EV — R–5 R–5 R–5 — R–5 R–5 — R–5 R–5 CONVERTIBLE — N–6 N–6 — K–5 — — Q–4 Q–4 Q–4 — N–6 — — LIFTBACK & COUPE N–6 CONVERTIBLE — N–6 N–6 Q–4 Q–4 Q–4 TERCEL RH LH COUPE (RH) COUPE (LH) PASEO ECHO COROLLA MR2 CELICA TMMC PRODUCTION NUMMI PRODUCTION TMC PRODUCTION CAMRY TMMK PRODUCTION CAMRY SOLARA COUPE Q–4 Q–4 — COVERTIBLE Q–4 — — SUPRA — — — R–3 — T–1 Q–2 Q–2 — Q–4 Q–4 Q–4 — S–1 S–1 S–1 4RUNNER — K–5 K–5 K–5 LAND CRUISER — K–5 K–5 K–5 T100 *1 — — — R–5 TUNDRA *1 — Q–4 — — AVALON *1 SIENNA TACOMA *1 *1 The extender must not be used for the center seat belt of Avalon, Tacoma, T100 and Tundra which have bench seats. Page 3 of 7 SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 Rear Seat Belt Extender Applications January 21, 2000 REAR SEAT – EXTENDER APPLICATION MODEL RAV4 RAV4 EV TERCEL PASEO ECHO COROLLA CELICA CAMRY TYPE W/TOKAI RIKA ’01 R–5*1 ’00 R–5*1 ’99 R–5*1 W/QSS Q–4*2 Q–4*2 Q–4*2 — Q–4 Q–4 Q–4 W/TOKAI RIKA — R–5*1 R–5*1 W/QSS — Q–4*2 Q–4*2 COUPE — R–5 R–5 CONVERTIBLE (RH) — N–3 N–1*3, N–3*4 CONVERTIBLE (LH) — N–6 N–5*3, N–6*4 — R–5 — — TMMC PRODUCTION Q–4 Q–4 Q–4 NUMMI PRODUCTION T–1 T–1 T–1 LIFTBACK & COUPE N–6 N–6 N–6 CONVERTIBLE (RH) — N–1 N–1 CONVERTIBLE (LH) — N–5 N–5 Q–4 Q–4 Q–4 TMC PRODUCTION TMMK PRODUCTION CAMRY SOLARA COUPE Q–4 Q–4 — CONVERTIBLE Q–4 — — SUPRA — — — R–3 AVALON — T–1 Q–2 Q–2 SIENNA — Q–4 Q–4 Q–4 TACOMA XTRACAB A–2 A–2 A–2 4RUNNER — R–5 R–5 R–5 LAND CRUISER — K–5 K–5 K–5 T100 XTRACAB — — K–4 TUNDRA ACCESS CAB Q–4 — — *1 This seat belt was supplied by TOKAI RIKA. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. *2 This seat belt was supplied by QSS. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. *3 N–1 and N–5 are applied to PASEO convertible from September 1997 to November 1997 production. *4 N–3 and N–6 are applied to PASEO convertible from December 1997 production. Page 4 of 7 SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 Parts Information January 21, 2000 PART NUMBER PREFIX: 73399– SERIES LENGTH 6 INCH 9 INCH 12 INCH 15 INCH 18 INCH R–1 –12010 –12020 –12030 –12040 –12050 R–2 –12160 –12170 –12180 –12190 –12200 R–3 –50010 –50020 –50030 –50040 –50050 R–4 –16010 –16020 –16030 –16040 –16050 R–5 –16060 –16070 –16080 –16090 –16100 N–1 –12060 –12070 –12080 –12090 –12100 N–3 –20011 –20021 –20031 –20041 –20051 N–4 –20060 –20070 –20080 –20090 –20100 N–5 –20110 –20120 –20130 –20140 –20150 N–6 –20160 –20170 –20180 –20190 –20200 K–1 –12110 –12120 –12130 –12140 –12150 K–2 –22010 –22020 –22030 –22040 –22050 K–3 –22060 –22070 –22080 –22090 –22100 K–4 –33010 –33020 –33030 –33040 –33050 K–5 –35010 –35020 –35030 –35040 –35050 A–1 –02010 –02020 –02030 –02040 –020050 A–2 –01060*1 –01070 –01080 –01090 –01100 Q–1 –02060 –02070 –02080 –02090 –02100 Q–2 –06010 –06020 –06030 –06040 –06050 Q–3 –06060 –06070 –06080 –06090 –06100 Q–4 –0W010 –0W020 –0W030 –0W040 –0W050 S–1 –04010 –04020 –04030 –04040 –04050 T–1 –01110 –01120 –01130 –01140 –01150 *1 Length: 7 1/4” Page 5 of 7 SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 Owner Instructions January 21, 2000 Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: A. By anyone other than for whom it was provided (name recorded on seat belt extender). B. In any vehicle and/or seat position other than the one for which it was provided. C. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. S The Seat Belt Extender must never be used with any child safety seats. S Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the “PRESS” signs on the buckle–release buttons of the extender and the seat belt are both facing outward as shown. Seat Belt Release You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle–release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. Seat Belt Extender When not in use, remove the extender and store in the vehicle for future use. Page 6 of 7 SEAT BELT EXTENDER: ’98 – ’00 – BO002–00 January 21, 2000 SEAT BELT EXTENDER WORKSHEET PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED CAUTIONS: S To minimize the chance and/or severity of injury in an accident, the seat belt extender must only be used: 1 By the person for whom it was provided 2 In the seat position for which it was provided S The seat belt extender must never be used with any child safety seats. S When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use. DEALER DEALER CODE SEAT BELT EXTENDER APPLICATION DEALER NAME APPLICANT APPLICANT NAME ADDRESS ADDRESS CITY & STATE EMPLOYEE NAME MODEL YEAR ZIP CITY & STATE BODY TYPE SEATING POSITION ZIP PHONE VEHICLE IDENTIFICATION NUMBER DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH 1. 2. S S S 3. 4. 5. 6. Place the seat in the position the applicant normally uses With applicant in the seat, wearing thickest coat expected to be worn, pull belt all the way out and try to buckle belt If the belt latches into buckle and feels comfortable against upper chest area, an extender is not needed. If belt does not buckle continue with step 3 If buckle latches but belt has no slack remaining, continue with step 3 Measure distance between applicant’s navel and seat belt buckle (dimension A) and enter on worksheet With belt all the way out, measure distance between latch tip and buckle tip (dimension B) and enter on worksheet NOTE: If belt latches but there is no slack enter zero as dimension B Subtract dimension B from dimension A and record number in check number box on worksheet Seat belt extender length is dimension B rounded up to next extender length (without exceeding check number) NOTE: If extender length exceeds check number, an extender can not be provided to the customer Dimension A: NAVEL TO BUCKLE Dimension B: LATCH TO BUCKLE Latch Navel Buckle Buckle A B SEAT BELT EXTENDER CALCULATION DIMENSION A: DIMENSION B: CHECK NUMBER: SEAT BELT EXTENDER AUTHORIZATION S The same seat belt extender can be used for right and left seating applications. Each seat belt extender will have a label identifying the owner, VIN and seating position. Seat belt extenders are available only in black. S Applicant’s Signature: _________________________________________ Date: ______________________ (Actual user of seat belt extender) Page 7 of 7 Technical Service BULLETIN SEAT BELT EXTENDER Models: ’99 – ’01 Model Year January 26, 2001 TSB UPDATE NOTICE: The information contained in this TSB updates BO020–00 dated August 11, 2000. Revised text is red and underlined. Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. Seat Belt S The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. S The extender is available only in black. Extender S Owners are informed of the Seat Belt Extender availability through the Toyota Owner’s Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the Seat Belt Extender worksheet. The worksheet will allow the proper fitting and selection of a Seat Belt Extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Customer Information Label and review the “Owner Instruction Sheet” with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer’s file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the Seat Belt Extender issue. It is recommended that dealerships do not stock Seat Belt Extenders due to the need for proper fitting to individual customers. This bulletin contains the following information: Procedure and Sample Label . . . . . . . . . . Page 2 Application Charts . . . . . . . . . . . . . . . . . . . . Pages 3–4 Part Number Information . . . . . . . . . . . . . . Page 5 Owner Instructions . . . . . . . . . . . . . . . . . . . Page 6 Seat Belt Extender Worksheet . . . . . . . . . Page 7 Applicable Vehicles Warranty Information S 1999 through 2001 model year Toyota vehicles. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 7 BODY BO002-01 Title: SEAT BELT EXTENDER: ’99–’01 MODEL YEAR – BO002-01 Procedure January 26, 2001 1. Owner requests a Seat Belt Extender from dealer. 2. Dealer verifies the need for a Seat Belt Extender and obtains a current copy of this TSB and copies the Worksheet. 3. Dealer measures the customer and completes the Worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network. 4. Dealer receives Seat Belt Extender and calls the customer in to check fit of the part. 5. If the Seat Belt Extender fit is good, dealership personnel completes the Customer Information Label on the part, explains usage of the part, and gives the customer a copy of the completed Worksheet. 6. Dealer places copy of the completed Worksheet in the customer’s records. DEALER MEASURE CUSTOMER & COMPLETE WORKSHEET PLACE CRITICAL ORDER THROUGH TDN PARTS SUPPLY SHIP SEAT BELT EXTENDER TO DEALER DEALER TEST FIT CUSTOMER WITH PART COMPLETE LABEL AND ADVISE OWNER DEALER RECEIVE COPY OF WORKSHEET & USE EXTENDER FILE WORKSHEET IN CUSTOMER RECORDS Sample Seat Belt Extender Customer Information Label CAUTION THIS SEAT BELT EXTENDER IS TO BE USED ONLY BY: ON VEHICLE: VIN: SEATING POSITION: USE BY OTHERS, OR IN ANOTHER SEATING POSITION, OR IN ANOTHER VEHICLE COULD REDUCE SEAT BELT RESTRAINT IN AN ACCIDENT AND RESULT IN PERSONAL INJURY. Page 2 of 7 Front Seat Belt Extender Applications FRONT SEAT – EXTENDER APPLICATION MODEL TYPE ’01 ’00 ’99 RAV4 – R–5 R–5 R–5 ECHO – K–5 K–5 – Q–4 Q–4 Q–4 COROLLA TMMC PRODUCTION NUMMI PRODUCTION PRIUS – N–7 – – MR2 SPYDER – N–6 N–6 – LIFTBACK & COUPE N–6 N–6 CONVERTIBLE – – Q–4 Q–4 Q–4 Q–4 CELICA CAMRY CAMRY SOLARA TMC PRODUCTION TMMK PRODUCTION COUPE CONVERTIBLE N–6 Q–4 Q–4 – AVALON* – T–1 T–1 Q–2 SIENNA – Q–4 Q–4 Q–4 TACOMA* – S–2 S–1 S–1 4RUNNER – K–5 K–5 K–5 LAND CRUISER – K–5 K–5 K–5 SEQUOIA – Q–4 – – TUNDRA* – Q–4 Q–4 – HIGHLANDER – R–5 – – * The extender must not be used for the center seat of Avalon, Tacoma, and Tundra which have bench seats. Page 3 of 7 SEAT BELT EXTENDER: ’99–’01 MODEL YEAR – BO002-01 Rear Seat Belt Extender Applications REAR SEAT – EXTENDER APPLICATION MODEL RAV4 TYPE ’01 ’00 ’99 W/TOKAI RIKA R–5 R–5*1 R–5*1 W/QSS – Q–4*2 Q–4*2 – R–5 R–5 – TMMC PRODUCTION Q–4 Q–4 Q–4 NUMMI PRODUCTION T–1 T–1 T–1 – N–7 – – LIFTBACK & COUPE N–6 N–6 N–6 – – Q–4 Q–4 Q–4 Q–4 ECHO COROLLA PRIUS CELICA CONVERTIBLE (RH) CONVERTIBLE (LH) CAMRY CAMRY SOLARA TMC PRODUCTION TMMK PRODUCTION COUPE CONVERTIBLE N–1 N–5 Q–4 Q–4 – AVALON – T–1 T–1 Q–2 SIENNA – Q–4 Q–4 Q–4 TACOMA XTRACAB A–2 A–2 A–2 4RUNNER – R–5 R–5 R–5 LAND CRUISER – K–5 K–5 K–5 REAR SEAT #1 T–1 REAR SEAT #2 Q–4 – – TUNDRA ACCESS CAB Q–4 Q–4 – HIGHLANDER – R–5 – – SEQUOIA *1 This seat belt was supplied by TOKAI RIKA. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. *2 This seat belt was supplied by QSS. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. NOTE: The seat belt extender must not be used for the center rear seat belt. Page 4 of 7 January 26, 2001 Part Number Information PART NUMBER PREFIX: 73399– SERIES LENGTH 6 INCH 9 INCH 12 INCH 15 INCH 18 INCH R–5 –16060 –16070 –16080 –16090 –16100 N–1 –12060 –12070 –12080 –12090 –12100 N–5 –20110 –20120 –20130 –20140 –20150 N–6 –20160 –20170 –20180 –20190 –20200 N–7 –47010 –47020 –47030 –47040 –47050 K–5 –35010 –35020 –35030 –35040 –25050 A–2 –01060* –01070 –01080 –01090 –01100 Q–2 –06010 –06020 –06030 –06040 –06050 Q–4 –0W010 –0W020 –0W030 –0W040 –0W050 S–1 –04010 –04020 –04030 –04040 –04050 S–2 –04060 –04070 –04080 –04090 –04100 T–1 –01110 –01120 –01130 –01140 –01150 * Length: 7-1/4” Page 5 of 7 SEAT BELT EXTENDER: ’99–’01 MODEL YEAR – BO002-01 Owner Instructions January 26, 2001 Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized Seat Belt Extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the Seat Belt Extender, observe the following. Failure to follow these instructions could result in reduced effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S Never use the Seat Belt Extender if you can COMFORTABLY fasten the seat belt without it. S The Seat Belt Extender must never be used with any child safety seats. S Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the “PRESS” signs on the buckle-release buttons of the extender and the seat belt are both facing outward as shown. Seat Belt Release You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Page 6 of 7 Seat Belt Extender PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED CAUTIONS: S To minimize the chance and/or severity of injury in an accident, the Seat Belt Extender must only be used: 1 By the person for whom it was provided. 2 In the seat position for which it was provided. S The Seat Belt Extender must never be used with any child safety seats. S When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use. DEALER DEALER CODE SEAT BELT EXTENDER APPLICATION DEALER NAME ADDRESS ADDRESS CITY & STATE EMPLOYEE NAME 1. 2. 3. 4. 5. 6. APPLICANT APPLICANT NAME MODEL YEAR ZIP CITY & STATE ZIP BODY TYPE SEATING POSITION PHONE VEHICLE IDENTIFICATION NUMBER DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH Place the seat in the position the applicant normally uses. With the applicant in the seat, wearing the thickest coat expected to be worn, pull belt all the way out and try to buckle belt. S If belt latches into buckle and feels comfortable against upper chest area, an extender is not needed. S If belt does not buckle, continue with Step 3. S If buckle latches but belt has no slack remaining, continue with Step 3. Measure distance between applicant’s navel and seat belt buckle (Dimension A) and enter on Worksheet. With belt all the way out, measure distance between latch tip and buckle tip (Dimension B) and enter on Worksheet. NOTE: If belt latches but there is no slack enter zero as Dimension B. Subtract Dimension B from Dimension A and record number in Check Number box on Worksheet. Seat Belt Extender length is Dimension B rounded up to next extender length (without exceeding Check Number). NOTE: If extender length exceeds Check Number, an extender cannot be provided to the customer. Dimension A: NAVEL TO BUCKLE Dimension B: LATCH TO BUCKLE Latch Navel Buckle A B Buckle SEAT BELT EXTENDER CALCULATION DIMENSION A: DIMENSION B: CHECK NUMBER: SEAT BELT EXTENDER AUTHORIZATION S The same Seat Belt Extender can be used for right and left seating applications. Each Seat Belt Extender will have a label identifying the owner, VIN and seating position. Seat Belt Extenders are available only in black. S Applicant’s Signature: (Actual user of seat belt extender) Date: Page 7 of 7 Models: All Models February 21, 1997 Introduction Affected Vehicles Parts Information A kit containing special foam sponge material has been developed. This kit, when used in conjunction with procedures outlined in the Wind Noise Service Information book (P/N 00401–42978), specific Service Tips and Technical Service Bulletins, should enable effective wind noise repairs. D All Models PART NUMBER PART NAME SIZE (MM) QTY 08231–00810 Kit, Wind Noise ––– 1 08231–00811 * Caulking Sponge Sealant No. 1 297 x 150 (T = 3.0) 2 08231–00812 * Caulking Sponge Sealant No .2 297 x 150 (T = 5.0) 2 08231–00813 * Caulking Sponge Sealant No. 3 297 x 150 (T = 10.0) 2 08231–00814 * Caulking Sponge Sealant No. 4 297 x 150 (T = 3.0) 2 08231–00815 * Caulking Sponge Sealant No. 5 297 x 150 (T = 5.0) 2 08231–00816 * Caulking Sponge Sealant No. 6 297 x 150 (T = 5.0) 2 * All of these parts are included in the kit. Kit Components 1. Caulking Sponge Sealant No. 1, No. 2 and No. 3 (Ept–sealer). With adhesive tape 2. Caulking Sponge Sealant No. 4 and No. 5 (Ept–sealer). This sheet is divided into 27 strips, 5 mm wide. With adhesive tape 3. Caulking Sponge Sealant No. 6 (Ept–sealer). With adhesive tape Page 1 of 1 BODY TSB WIND NOISE REPAIR KIT BO003-97 Title: CAMRY CENTER CONSOLE LATCH IMPROVEMENTS Technical Service BULLETIN Models: ’97–’99 Camry March 26, 1999 Introduction Affected Vehicles The center console compartment door has been changed to improve the durability of the console box latch. S 1997 – 1999 Camrys produced before VIN: 4T1BG ** K * XU414881 (L4) 4T1BF ** K * XU076659 (V6) 4T1BG ** K * XU867323 (L4) 4T1BF ** K * XU930092 (V6) Parts Information Repair Procedure PREVIOUS PART # CURRENT PART # PART NAME 58910–AA010–XX 58910–AA011–XX Console Box Assembly 58905–AA010–XX 58905–AA011–XX Console Compartment Door S On vehicles produced before the production change, replace the Rear Console Box with P/N 58910–AA011–XX. Refer to Repair Manual, page BO–72 for detailed repair procedures. NOTE: On vehicles produced after the production change, replace the console compartment door only. These vehicles can be identified by a metal hinge on the console compartment door. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 743641 R & R Rear Console Box Assembly 0.3 58910–AA010–XX 54 12 743931 R & R Rear Console Compartment Door 0.2 58905–AA010–XX 54 12 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BODY BO005–99 Title: Technical Service BULLETIN April 16, 1999 Introduction Affected Vehicles TMMK CAMRY/SIENNA HEADLIGHT ALIGNMENT Models: ’97–’99 Camry, ’98–’99 Sienna To enhance headlamp performance on dark roads, the headlamp alignment process has been modified. S 1997–1999 TMMK Camrys produced before the following VINs: Camry (4–Cyl) 4T1BG2 * K * XU453367 Camry (V–6) 4T1BF2 * K * XU079094 Camry (4–Cyl) 4T1BG2 * K * XU877828 Camry (V–6) 4T1BF2 * K * XU930732 S 1998–1999 Siennas produced before the following VIN: Sienna 4T3ZF13C * XU119213 Required Tools and Material Headlight Aiming Device. Repair Procedure Refer to the ’98 Camry Repair Manual page BE–27. Adjust the headlight nominal line 1’’ higher. State and Federal standards apply. New Nominal cutline 1’’ up NOTE: Vehicle lighting will remain within the tolerances of all applicable federal and state regulations. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not applicable to warranty – – – – * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BODY BO007–99 Title: BODY BO008–96 AUGUST 9, 1996 ALL MODELS STAINS ON RAPGARD APPLIED AREAS Page 1 of 1 On some Toyota models, when Rapgard is removed from the vehicle, a stain is left on the paint surface. This stain can be seen under the clear coat and is not a defect of the clear coat. The stain corresponds to a wrinkled area of Rapgard which retained liquids, such as window washer fluid, that left a discoloration. Stain REPAIR PROCEDURE: To remove a stain from a vehicle, heat the stain surface to a temperature of 70_C – 80_C. When the stain is removed it will not reappear. Equipment – 1. Infrared lamp or dryer to heat the surface. 2. Aluminum foil or a damp cloth to protect plastic parts from deformation. Procedure – 1. Apply aluminum foil to adjoining plastic parts or cool with damp cloth periodically. 2. Use an infrared lamp or dryer on the stain developed area and heat for 5 to 10 minutes at 70_C – 80_C. 3. After heating for 5 minutes, check whether the stain has disappeared. If the stain still remains, reheat the area and check again. NOTE: Take care that the body’s paint surface temperature does not become too high. WARRANTY INFORMATION: OPCODE BD6004 DESCRIPTION Remove stains from paint surface caused by Rapguard TIME OPN T1 T2 0.6 53301–XXXXX 61 99 Technical Service BULLETIN April 28, 2000 LOOSE CENTER HVAC VENT ADJUSTMENT Models: ’98 – ’99 CBU Camry TSB Revision Notice: The information updated in this TSB is red and underlined. Introduction Applicable Vehicles Production Change Information Parts Information Repair Procedure A repair procedure has been made available to remedy customer complaints regarding loose vertical adjustment of the center vents on 1998 – 1999 CBU Camry. S 1998 through 1999 model year Japan built Camry. MODEL/PLANT STARTING VIN JT2BG2*K*X0339018 2000 MY Japan Built Camry JT2BF2*K*X0200364 PART NUMBER PART NUMBER QUANTITY 90202–05129 Washer 2 1. Remove the left vent barrel by gently prying using a wide flat tool with smooth edges. Be careful not to damage the vent assembly. 2. Install a washer (P/N 90202–05129) on the shaft inside the vent duct. 3. Reinstall the vent barrel by carefully pushing it into position until it locks onto the shafts on the sides of the duct. Be sure the spacer and/or washer do not fall down into the vent duct. Vent Duct Center Vent Assembly Install Washer (P/N 90202–05129) on Shaft Inside Vent Duct Vent Barrel Install Spacer Here NOTE: The spacer (P/N 55682–12140) can be ordered, if lost. 4. Confirm that the vent vertical adjustment is tighter and moves smoothly. 5. Repeat steps 1 through 4 for the right center vent. Warranty Information Spacer (P/N 55682–12140) Side View of Vent Barrel OP CODE DESCRIPTION TIME OPN BD0025 Remove & Reinstall Vent Barrels 0.2 55660–33080–XX T1 T2 40 14 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BODY BO009–00 Title: BODY BO010–96 NOVEMBER 22, 1986 CAM 1997 CAMRY DOOR MIRROR INSTALLATION Page 1 of 2 The following procedures explain in detail how to install the 1997 Camry Door Mirrors. CAUTION: Should the door mirror be installed incorrectly, a wind noise (air leakage noise) might be generated. INSTALLATION PROCEDURES: 1. Remove the retaining clip and tweeter (if applicable) from the door. Discard the removed clip. Clip Tweeter 2. In order to secure the door mirror to the correct position, insert the 2 pins of the door mirror base into the holes of the door. Pins 3. Push the door mirror against the door and check that the door mirror base edge is in contact with the door frame molding lip. NOTE: This area is critical to wind noise reduction. Molding Lip Mirror Base 1997 CAMRY DOOR MIRROR INSTALLATION Page 2 of 2 INSTALLATION PROCEDURES (Cont’d): 4. Tighten the three mirror mounting nuts A , B and C for vehicles without a tweeter. B C Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) A Connect the mirror wire. 5. Tighten the two mirror mounting nuts A and B for vehicles with a tweeter. B Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) A Connect the mirror wire. While lightly pulling the mirror wire backward, install the tweeter and tighten nut C. C Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) NOTE: Check that the mirror wire is free from the tweeter bracket. 6. Check the following items: D D There is no clearance between the door mirror base and the door molding lip. The door frame molding lip is not tucked under the mirror base. Molding Lip Mirror Base 7. Install the front door lower frame bracket garnish. 8. Install the black cap onto the nut. Garnish Cap Technical Service BULLETIN May 24, 2002 Introduction CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION Models: ’83 – ’00 All Models Child restraint seat top strap bracket installation procedures are provided to supplement the Owner’s Manual. Beginning with 2001 models, the top strap brackets are factory installed. NOTE: S The child restraint seat top strap assembly is not available as a service part. Contact the child restraint seat manufacturer for recommended top strap information, top strap to child restraint seat installation instructions, and top strap retailers. S The top strap brackets can only be installed on vehicles that have nuts welded in place by the factory. The locations of these nuts can be found in the Owner’s Manual (for most 1983 and newer models.) Toyota does not recommend modifying vehicles that do not have nuts welded in place by the factory. Some Land Cruiser and RAV4 vehicles, prior to 2001 model year, may not have these nuts welded in by the factory. Top Strap Top Strap Bracket Applicable Vehicles Parts Information Warranty Information S 1983 – 2000 model year vehicles, all models. PART NUMBER PART NAME 73709–12010 Bracket Sub–Assembly (Bracket, Bolt, 10 mm Spacer, and Washers) 04731–22012 CRS Kit (two Bolts [15 mm, 30 mm], three Spacers [5 mm, 10 mm, 15 mm], and Locking Clip) OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 9 BODY BO010-02 Title: CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Procedure May 24, 2002 Child Restraint Seat Top Strap Bracket Installation Obtain the exact year and vehicle model Toyota Owner’s Manual before beginning installation. 1. Confirm with the customer which seat location(s) they will be installing the child restraint seat. The Owner’s Manual seat section provides an illustration showing available top strap bracket location(s). The illustration page in the Owner’s Manual is provided in pages 4–9 of this bulletin. NOTE: Determine which kit parts are needed for each specific child seat location, by referring to pages 4–9 of this bulletin. Bolt Anchor Bracket 345 mm (13.6 in.) Spacer 100 mm (4.0 in.) 185 mm (7.3 in.) Example of 1999 Camry Showing Three (3) Available Bracket Locations 2. Remove a 20 mm diameter area of the carpet or trim material above the bracket mounting location. In some vehicles, a 20 mm circle is already pre–cut into the interior trim material. Once the interior trim material is removed, the nuts welded in by the factory should be visible. Example of Pre–Cut Circle in Package Tray Finisher 3. If a 5 mm or 15 mm spacer is specified, remove the red lock washer from the Bracket Sub–Assembly (P/N 73709–12010) and remove the 10 mm spacer. Assure the red lock washer is re–installed onto the bolt. If a 5 mm spacer is needed, use the 15 mm bolt from the CRS Kit (P/N 04731–22012). Bolt Wave Washer Bracket Nylon Washer Spacer (5/10/15 mm) Red Lock Washer Page 2 of 9 CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Procedure (Continued) 4. Install the bracket assembly, according to the directions in the Owner’s Manual. Tighten the bolt to 16.5 – 24.7 N–m, (1.68 – 2.52 kgf–m, 12.2 – 18.2 ft–lbf). May 24, 2002 Top Strap Installed S Assure the top strap is attached to the child seat, according to the child seat manufacturer’s instructions. Bracket Assembly Installed Body Nut Welded in Place S Assure the child seat is installed in the vehicle according to the Toyota Owner’s Manual (seat section). Installation Reference Information Owner’s Manual Installation Reference Information The following pages of this bulletin contain a reference information chart. This chart contains: S Owner’s Manual page(s) that provide the illustration showing available top strap bracket location(s). The information goes back to 1983 model year. 2001 models and newer already had the bracket installed by the factory. S Installation notes, such as bracket spacer sizes for each specific child seat location. EXAMPLE: This cell contains information on the 2000 4Runner OWNER’S MANUAL 4Runner 2000 pg 73 a Refer to this page in the Owner’s Manual to find the illustration showing available top strap bracket locations. Installation Note. In this case, all bracket positions on the 2000 4Runner will require a 15 mm spacer. INSTALLATION NOTE COMMENT a Spacer – 15 mm for all anchors b Spacer – 10 mm for outer, 15 mm for center c Spacer – 15 mm for outer, 10 mm for center d Spacer – 5 mm for all anchors e Spacer – 15 mm for outer, none for center f Spacer – 15 mm for center, none for outer g No Spacer h Spacer – 10 mm for all anchors i Bolt for All–Trac/4WD only (Part No. 91511–60814) (Celica & Previa) NP Spacer pictured but no specifications N/A Top strap anchor bracket mounting not available Standard No installation necessary, anchor already installed by factory Page 3 of 9 CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) OWNER’S MANUAL 4Runner Avalon Camry Sedan 2000 pg 73 a Standard Standard Standard 1999 pg 71 a pg 72 a pg 71–73 a pg 68 a 1998 pg 53 a pg 70 a pg 68–69 a pg 48 a 1997 pg 52 a pg 52 a pg 56–57 a pg 45 a 1996 pg 45 NP pg 40 a pg 47 a pg 48 a pg 37 a 1995 pg 31 g pg 39 a pg 44–45 a pg 45 a pg 36 a 1994 pg 29 g pg 41–42 a pg 42 a pg 31 a 1993 pg 26 g pg 33 a pg 33–34 a Camry Solara Camry Wagon Celica All Trac 4WD Celica Coupe 1992 pg 26 g pg 27 a 1991 pg 27 g pg 29 c 1990 pg 27 g 1989 pg 49 a pg 30 i, g pg 29 a pg 30 i, g pg 29 a pg 29 g pg 29–30 i, g pg 29 a pg 29 c pg 29 g pg 29–30 i, g pg 29 a pg 31–33 g pg 32 c pg 33 g pg 29–30 i, g pg 31 a 1988 pg 19–20 g pg 32 b pg 32 g pg 16 i, g pg 16 a 1987 pg 18 g pg 15 b pg 16 g 1986 pg 17 g pg 13 e pg 14 f pg 12 a 1985 pg 16 g pg 13 e pg 13 f pg 12 a 1984 pg 15–16 g pg 13 e pg 13 f pg 12 a pg 12–13 e pg 13 f pg 11–12 a 1983 Page 4 of 9 Camry Liftback May 24, 2002 pg 13 a CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) Corolla FWD Liftback Corolla 4WD Wagon May 24, 2002 Corolla RWD 2–Door Coupe OWNER’S MANUAL Celica Liftback Corolla FWD Sedan 2000 Standard Standard 1999 pg 49 a pg 67 a 1998 pg 49–50 a pg 65 a 1997 pg 46–47 a pg 61 h 1996 pg 37–38 a pg 49 h 1995 pg 37–38 a pg 43 h 1994 pg 32 a pg 39 h 1993 pg 30 g pg 32–33 h 1992 pg 30 g pg 34 h pg 34 g 1991 pg 29–30 g pg 44 h pg 45 g pg 45 a 1990 pg 29–30 g pg 44–45 h pg 46 g pg 45 a 1989 pg 31 g pg 40 h pg 41–42 g pg 41 a 1988 pg 16 g pg 21–22 h 1987 pg 13 g pg 13–14 a pg 14 f pg 12 h 1986 pg 13 g pg 12 a pg 12 f pg 12 h 1985 pg 13 g pg 13 a pg 14 f pg 12 h 1984 pg 12 g pg 12–13 a pg 13 f pg 12 h 1983 pg 12 g pg 10 a pg 11 g Corolla Coupe pg 22 a pg 11 g Corolla FX/FX16 Corolla Hardtop pg 26 f pg 10 h Page 5 of 9 CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) OWNER’S MANUAL Corolla RWD 3–Door Coupe Corolla Wagon Cressida Cressida Wagon 2000 Echo Land Cruiser Standard N/A MR2 Paseo Coupe & Convert. 1999 N/A pg 63 a 1998 N/A pg 61 a 1997 N/A pg 55 a pg 40 h 1996 pg 49–50 h N/A 1995 pg 44 h N/A pg 38 a pg 37 h 1994 pg 40 h N/A pg 33 a pg 33 h 1993 pg 33 h N/A pg 31 a pg 31 h 1992 pg 35 h pg 29 c N/A pg 31 a pg 27 h 1991 pg 46 h pg 29 c N/A pg 31 a 1990 pg 46–47 g pg 30 c N/A 1989 pg 42 a pg 34 c N/A pg 28 a 1988 pg 23 h pg 30 h N/A pg 12 a 1987 pg 13 g pg 21 h pg 21 g N/A pg 11 a 1986 pg 12 g pg 16 h pg 16 g N/A pg 11 a 1985 pg 11 g pg 15–16 h pg 16 g N/A pg 11 a 1984 pg 11 g pg 15 g pg 15 g N/A pg 15 g pg 15 g N/A 1983 Page 6 of 9 May 24, 2002 pg 11 g CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) OWNER’S MANUAL Previa RAV4 RAV EV Sienna 2000 N/A Standard pg 99 a 1999 N/A N/A pg 96 a 1998 N/A Starlet pg 74 a May 24, 2002 Supra T100 Ext. Cab 2WD T100 Ext. Cab 4WD pg 49 d N/A N/A 1997 pg 60 a N/A pg 49 d N/A N/A 1996 pg 47–48 a N/A pg 36 d N/A N/A 1995 pg 46–47 a pg 36–37 d N/A N/A 1994 pg 41–42 a pg 32–33 d 1993 pg 41–42 a pg 32–33 d 1992 pg 37–38 i pg 32 h 1991 pg 33–34 i pg 33 h 1990 pg 31 h 1989 pg 31 h 1988 pg 32 h 1987 pg 15 h 1986 pg 13–14 g 1985 pg 13 g 1984 pg 9 g pg 12 g 1983 pg 9 g pg 11 g Page 7 of 9 CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) OWNER’S MANUAL T100 Reg Cab 4WD T100 Reg Cab 2WD Tacoma 2000 N/A 1999 N/A 1998 N/A N/A N/A 1997 N/A N/A N/A 1996 N/A N/A N/A 1995 N/A N/A N/A 1994 N/A N/A 1993 N/A N/A Tercel 2 Door Tercel 4WD Wagon May 24, 2002 Tercel 3/5 Tercel 4WD Tercel All Models 1992 1991 Page 8 of 9 1990 pg 31 a pg 31 h 1989 pg 30–31 a pg 30 h 1988 pg 18 a, d pg 17 h 1987 pg 12 g pg 12 g 1986 pg 12 g pg 12 g 1985 pg 11–13 g 1984 pg 11 g 1983 pg 11 g CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION – BO010-02 Installation Reference Information (Continued) OWNER’S MANUAL Tercel Sedan/ Coupe Tercel Wagon Truck 2x4 Truck 4x4 2000 May 24, 2002 Tundra Van Standard 1999 pg 60 h 1998 pg 59 h 1997 pg 54 h 1996 pg 41 h 1995 pg 38 h 1994 pg 39 h pg 32 g pg 32 g 1993 pg 35 h pg 27 g pg 27 g 1992 pg 29 h pg 27 g pg 27 g 1991 pg 28 h pg 26 g pg 26 g 1990 pg 26 g pg 26 g 1989 pg 29 g pg 29 g pg 37 a 1988 pg 13 g pg 19 g pg 23 a 1987 pg 12 g pg 11 g pg 14 g pg 18 g pg 21 a 1986 pg 12 g pg 12 g pg 13 g pg 17 g pg 20 a 1985 pg 12 g pg 15 g pg 17 a 1984 pg 12 g pg 12 g pg 17 a 1983 N/A N/A Page 9 of 9 Technical Service BULLETIN March 23, 2001 Introduction All Applicable Models MODEL YEAR Avalon 1995 – 2001 Camry 1983 – 2001 Corolla 1980 – 2001 Camry Solara 1999 – 2001 Sienna (Front Seat Belt Only) 1998 – 2001 RAV4 1997 – 2001 4Runner 1992 – 2001 Land Cruiser 1991 – 2001 Tundra 2000 – 2001 Tacoma 1997 – 2000 ECHO 2000 – 2001 Celica 1980 – 2001 Prius 2001 Tercel 1981 – 1999 PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME N/A 73219–02010 Stopper, Tongue Plate (Black)* N/A 73219–02020 Stopper, Tongue Plate (Gray)* N/A 73219–02030 Stopper, Tongue Plate (Beige)* * Warranty Information Models: A new service part for the seat belt tongue plate stopper has been introduced. Installation procedures are provided to supplement the Repair Manual. Applicable Vehicles Parts Information NEW SEAT BELT TONGUE PLATE STOPPER SERVICE PARTS Use a stopper color that is closest to the seat belt webbing color. OP CODE DESCRIPTION TIME OPN BD0047 Install Seat Belt Tongue Plate Stopper 0.1 73219–020#0 T1 T2 62 12 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 3 BODY BO011–01 Title: NEW SEAT BELT TONGUE PLATE STOPPER SERVICE PARTS – BO011–01 Installation Procedure 1. Preparation A. Shift the Tongue Plate to the upper portion of the Tongue Plate Stopper, and temporarily hold it with a clip or tape. B. Remove any pieces of the original Tongue Plate Stopper in the webbing, with a pair of pliers. CAUTION: Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly must be replaced if: S The webbing is cut, frayed, worn, or damaged. S It has been used in a severe impact. Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful not to damage the webbing during repair. Tongue Plate March 23, 2001 Tape Example of Broken Tongue Plate Stopper 2. Install the New Tongue Plate Stopper A. Install a new Tongue Plate Stopper in the hole of the webbing. NOTE: Be aware of the installation direction of the Tongue Plate Stopper as shown in the illustration. Tongue Plate Stopper B. Pinch the Tongue Plate Stopper into the webbing using an adjustable wrench, and turn and push the adjustment screw by hand. HINT: Press the adjustment screw in order to position the male and female parts of the Tongue Plate Stopper parallel to each other, as shown in illustration. CAUTION: DO NOT use pliers. They may damage the webbing. Page 2 of 3 Webbing NEW SEAT BELT TONGUE PLATE STOPPER SERVICE PARTS – BO011–01 Installation Procedure (Continued) March 23, 2001 C. When the adjustment screw for the adjustable wrench can’t be turned by hand, tighten the adjustment screw using a pair of adjustable joint pliers until the space between jaws of the adjustable wrench is 4.5 – 5.0 mm. (See illustrations.) 4.5 – 5.0 mm D. Check to be sure that the male pin of the Tongue Plate Stopper has become deformed evenly in the hole of the female part and is firmly held to the belt webbing. (See illustrations.) CORRECT INCORRECT Page 3 of 3 Technical Service BULLETIN DOOR GLASS DISPLACEMENT FIELD FIX Models: ’98 – ’99 TMMK Camry September 3, 1999 Introduction Applicable Vehicles On some 1998 and 1999 Camry Vehicles, the door glass may be displaced from the front door glass run if the door is closed forcefully with the windows partially down. A field fix has been developed in order to remedy this condition. S 1998 – 1999 TMMK Camrys built before 4T1BG * * K * XU553205 4T1BF * * K * XU084313 4T1BG * * K * XU903993 4T1BF * * K * XU932180 Parts Information Warranty Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME N/A 67212–AA010 Self–Adhesive Stopper OP CODE 670301 COMBO DESCRIPTION TIME OPN A R&R Door Trim/Install Rubber Stopper – Both Sides 0.5 67402–AA011 T1 T2 53 57 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 BODY BO012–99 Title: DOOR GLASS DISPLACEMENT FIELD FIX – BO012–99 Repair Procedure September 3, 1999 Refer to 1998 Camry Repair Manual (Vol. 2) Pages BO–11–14. 1. Remove the front door trim to gain access to the window components. 2. Inspect the front and rear lower frames and the door glass run for damage as a result of the glass being displaced. S In cases of slight deformation of window frames, reform as necessary. If significantly deformed or damaged, replace the frame. S Replace the window run if cut, torn, mutilated, etc. 3. Replace any damaged parts. 4. Remove front lower frame from the door and attach the self–adhesive rubber stopper (P/N 67212–AA010) 120 mm from the top of the frame as shown below. NOTE: To insure proper adhesion of the self–adhesive rubber stopper, the surface of the frame must be cleaned to remove any foreign material. 5. Reinstall the front lower frame, door glass run, and door trim. Stopper 67212–AA010 (50 x 12 x 4.76 mm) (double sided tape) 120 mm Page 2 of 2 Technical Service BULLETIN DOOR MIRROR INSTALLATION Models: ’97 – ’00 Japan Built Camry March 24, 2000 Introduction The procedures in this bulletin explain in detail how to install the door mirrors. CAUTION: If the door mirror is installed incorrectly, a wind noise (air leakage noise) might be generated. Applicable Vehicles Warranty Information Installation Procedure S 1997 – 2000 model year Japan built Camry OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – 1. Remove the retaining clip and speaker (if applicable) from the door. Discard the removed clip. Clip Speaker 2. In order to secure the door mirror in the correct position, insert the 2 pins of the door mirror base into the holes of the door. Pins 3. Push the door mirror against the door and check that the door mirror base edge is in contact with the door frame molding lip. Molding Lip Mirror Base NOTE: This area is critical to wind noise reduction. Toyota Supports ASE Certification Page 1 of 2 BODY BO015–00 Title: DOOR MIRROR INSTALLATION – BO015-00 Installation Procedure (Continued) March 24, 2000 4. For vehicles without a speaker, tighten the three mirror mounting nuts. Mounting Nuts Torque: 5.5 NSm (56 kgfScm, 49 inSlbf) Connect the mirror wire. 5. For vehicles with a speaker, tighten the two mirror mounting nuts. Mounting Nuts Torque: 5.5 NSm (56 kgfScm, 49 inSlbf) Connect the mirror wire. Speaker While lightly pulling the mirror wire backward, reinstall the door speaker (one nut at the lower bracket) onto the door as shown in the illustration. INCORRECT CORRECT Torque: 5.5 NSm (56 kgfScm, 49 inSlbf) NOTE: S Do NOT mount the upper speaker bracket behind the nut. 6. Check the following items: S There is no clearance between the door mirror base and the door molding lip. S The mirror wire is free from the speaker bracket. S The door frame molding lip is not tucked under the mirror base. S The speaker wire does not contact the mirror mounting screw. S Make sure the power mirror adjustment and the door speaker functions properly. Mounting Lip Mirror Base Speaker Cover Garnish 7. Install the front door lower frame bracket garnish/speaker cover. 8. Install the black cap onto the nut. Cap Page 2 of 2 POWER SEAT MOTOR CABLE REPAIR TIP Technical Service BULLETIN Models: ’99 – ’00 Camry & Solara, ’99 – ’01 Sienna May 25, 2001 TSB REVISION NOTICE: June 25, 2003: The Parts Information table has been updated. The previous TSB should be discarded. Introduction Applicable Vehicles Parts Information A field fix has been developed to repair loose power seat motor cables (instead of seat adjuster replacement). Loose cables can cause seat movement feel or no movement of seat adjustment. S 1999 – 2000 model year Camry and Solara vehicles. S 1999 – 2001 model year Sienna vehicles. 3M PART NUMBER PART NAME QUANTITY 3M 36596 3M EPS–300 Thin–Wall 1 Per Seat Motor Required Tools & Material Warranty Information OP CODE BD1017 TOOLS & MATERIALS QUANTITY Heat Gun 1 DESCRIPTION R & R Seat Assembly; Install Shrink Sleeves TIME OPN 0.5 72020–06020 (Solara) 72020–AA011 (Camry 72020–08010 (Sienna) T1 T2 95 15 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 BODY BO017-01 Title: POWER SEAT MOTOR CABLE REPAIR TIP – BO017-01 Revised Repair Procedure May 25, 2001 1. Remove the seat assembly from the vehicle. Turn the seat over and detach motors from the mounting brackets. NOTE: The lower seat cushion must be removed from the seat frame to access the motor mounting screws on some models. 2. Remove the drive cable from the motor gear boxes. Slide a shrink wrap tube (3/4” diameter x 1.75”, 3M P/N 36596) on each end of the flex shaft, as shown in the illustration. S The Camry and Sienna will require six (6) shrink tubes. S The Solara will require only one (1) shrink tube. Front Camry/Sienna Solara 3. Attach the drive cables to the motors and reinstall motors to the motor mounts. 4. Position each shrink wrap tube so that it overlaps the drive cable housing and motor housing or gear box housing, as necessary. 5. Using a heat gun, apply heat to the shrink tubes in a direction from the center of the drive cable toward the gear box or motor housing. Be sure to apply just enough heat to shrink the tubing. 6. Reinstall the seat cushion to the seat frame. Tighten the mounting screws to torque specifications listed in the BO section of the Repair Manual. 7. Reinstall the seat assembly to the floor of the vehicle. Assure all connectors are secure and the power seat adjustments properly function. Torque: 37 NSm, 380 kgfScm, 27 ftSlbs Page 2 of 2 Heat Gun Shrink Tube Technical Service BULLETIN TRIM GARNISH LOOSE Models: All Models September 9, 2003 TSB REVISION NOTICE: March 3, 2004: The TSB has been changed to include new inspection and replacement instructions. Previous versions of this TSB should be discarded. Introduction Customers may experience an interior trim panel either loose or fitting poorly due to a deformed or missing panel attachment clips. When a trim garnish (A, B, C or D pillar garnish, door trim panel, etc.) is removed and reinstalled using the old clips, there is a possibility that the garnish may exhibit a loose condition. To prevent this condition from occurring, please use the following procedures. Inspection/ Replacement Procedure All Models – All trim panel attachment clips must be inspected prior to reassembly and replaced if any damage or wear is detected. If no damage is visible, the clip may be reused. Always check to make sure that the garnish is properly attached after reinstallation of all interior trim panels. 2002 – 2004 model year Camry and 2004 model year Solara – When removing the A–pillar garnish panels, replace the white plastic attachment clips (P/N 90467–A0025). Applicable Vehicles Warranty Information S All models. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 BODY BO017-03 Title: Technical Service BULLETIN DOOR GLASS DISPLACEMENT Models: ’98 – ’99 TMMK Camry November 26, 1999 Introduction Applicable Vehicles On some 1998 and 1999 Camry vehicles, the door glass may be displaced from the front door glass run if the door is closed forcefully with the window partially down. A field fix has been developed to remedy this condition. S 1998 – 1999 TMMK Camrys vehicles produced prior to VINs listed below. Production Change Information MODEL STARTING VIN 1999 TMMK produced Camry 4T1BG**K*XU602813 4T1BF**K*XU088877 4T1BG**K*XU917744 4T1BF**K*XU933406 NOTE: Refer to 1998 Camry Repair Manual (Vol. 2) BO–Section for Door Panel Removal and Window Regulator Servicing information. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 BD9008 R&R Door Trim / Modify Hole (both sides) 0.5 67402–AA011 53 57 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 BODY BO017–99 Title: DOOR GLASS DISPLACEMENT – BO017–99 Repair Procedure November 26, 1999 1. Lower the door glass, disconnect the power window switch, remove the front door trim panel, speaker, and loosen the door mirror mounts to gain access to the door glass and lower frames. Remove the front lower frame (2 screws). 2. Locate the lower window frame mounting hole on the door (see illlustration). Place a towel or shop rag in the speaker hole to catch metal chips. Using a round file or die grinder, enlarge the hole 2 mm toward the speaker (rear of the vehicle). Remove the towel or shop rag and any metal chips in the door. Apply touch–up paint or rust preventative to the hole. 2 mm → ← 3. Install a rubber stopper to the lower window frame according to directions in TSB BO012–99. 4. Install the lower window frame. Assure the frame is tight against the glass and the run is fully inserted in the lower window frame channel. 5. Temporarily connect the power window switch and operate the window. Check to assure the door glass fully opens and closes easily. 6. Reinstall the door panel and components, check lock/unlock function and door opening handle function. Page 2 of 2 Technical Service BULLETIN DOOR MIRROR WIND NOISE Models: ’97 – ’99 Camry December 3, 1999 Introduction Applicable Vehicles Wind/road noise heard around the door mirrors of some Japan produced Camry vehicles may be caused by an improperly positioned mirror wire harness grommet and/or harness connector. S 1997 through 1999 Camry vehicles. (Japan produced only) Production Change Information Warranty Information PLANT STARTING VIN TMC JT2BG22K * X0367325 JT2BG28K * X0367352 JT2BF22K * X0227381 JT2BF28K * X0227306 OP CODE DESCRIPTION TIME OPN T1 T2 BD9006 Adjust the Wire Harness Grommet and/or Connector (both sides) 0.4 87910–33150 59 57 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Repair Procedure 1. Carefully pry off the door speaker cover and remove the nut using a 10 mm socket that secures the speaker to the door. 2. Look through the door mirror harness access hole and check the position of the wire harness grommet and wire harness connector – the harness connector should be inside the grommet and the grommet should be fully seated in the mirror housing. Connector and Grommet Mirror Housing Connector Grommet CORRECT POSITION Toyota Supports ASE Certification Page 1 of 2 BODY BO019–99 Title: DOOR MIRROR WIND NOISE – BO019–99 INCORRECT POSITION A December 3, 1999 INCORRECT POSITION B Mirror Housing Mirror Housing Grommet Connector Repair Procedure INCORRECT POSITION C Mirror Housing Grommet Grommet Connector Connector 3. To reposition the grommet and/or harness connector onto the mirror housing: S Remove the mirror housing (3 nuts) from the door and carefully unclip the mirror from the housing. This will allow easier access and reinstallation of the grommet and/or harness connector. S Reposition the grommet so it is fully seated to the mirror housing. Assure the harness connector is inside the grommet. Rear View Mirror Outside Door Mirror Mirror Housing Connector Grommet CORRECT POSITION NOTE: Refer to the 1998 Camry Repair Manual pages BO–23 through BO–26. 4. Reinstall the door mirror and speaker assembly: S Secure the mirror to the housing. Outside Rear View Mirror Cover S Properly align and reinstall the mirror assembly to the door. tighten the three nuts. Torque: 5.5 NSm (56 KgfScm, 49 inSlb) S Reinstall the door speaker (one nut) and speaker cover onto the door. S Assure the power mirror adjustment and the door speaker functions properly. Page 2 of 2 Door Trim 5.5 (55, 49, ftSlbf) NSm (kgfScm, ftSlbf) : Specified Torque Technical Service BULLETIN 1999 TOYOTA SEAT BELT EXTENDERS Models: All ’95 through ’99 model years July 3, 1998 Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. Seat Belt S The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. S The extender is available only in black. Extender S Owners are informed of the seat belt extender availability through the Toyota Owner’s Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the seat belt extender worksheet. The worksheet will allow the proper fitting and selection of a seat belt extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Label and review the “owner instruction sheet” with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer’s file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the seat belt extender issue. From past sales history, it is recommended that dealerships do not stock Seat belt extenders due to low demand and the need for customer fitting. This bulletin contains the following information: Procedure and Flow Chart...................... Page Application Chart and Notes.................. Page Part Number Information........................ Page Owner Instructions.................................. Page Seat Belt Extender Worksheet............... Page Affected Vehicles Warranty Information 2 3 5 6 7 S All Toyota models, 1995 through 1999 model years. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 7 BODY BO020–98 Title: SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 Procedure July 3, 1998 1. Owner requests a seat belt extender from dealer. 2. Dealer verifies the need for a seat belt extender and obtains a current copy of this TSB and copies the worksheet. 3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network. 4. Dealer receives seat belt extender and calls the customer in to check fit of the part. 5. If the seat belt extender fit is good, dealership personnel completes the customer information label on the part, explains usage of the part, and gives the customer a copy of the completed worksheet. 6. Dealer places a copy of the completed worksheet in the customer’s records. PARTS SUPPLY DEALER MEASURE CUSTOMER & COMPLETE WORKSHEET PLACE CRITICAL ORDER THROUGH TDN SHIP SEAT BELT EXTENDER TO DEALER RECEIVE COPY OF WORKSHEET & USE EXTENDER COMPLETE LABEL AND ADVISE OWNER TEST FIT CUSTOMER WITH PART FILE WORKSHEET IN CUSTOMER RECORDS EXTENDER FLOW CHART Sample Seat Belt Extender Label CAUTION Driver Page 2 of 7 OWNER DEALER Passenger Front Rear SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 Front Seat Belt Extender Applications July 3, 1998 FRONT SEAT – EXTENDER APPLICATION MODEL TYPE ’99 ’98 R 5 R–5 R 5 R–5 R–5 R–5 R–5 R–5 N–6 N–6 N–6 N/A N/A N/A N/A N/A R–5 R–3 Q–4 Q–4 Q–4 Q–4 Q–2 N/A N/A N/A N/A R–3 N–6 N–6 N–6 N–6 R–3 RAV4 RH EXCEPT CONVERTIBLE LH EXCEPT CONVERTIBLE PASEO CONVERTIBLE RH & LH SDN & WGN..JPP W/TR COROLLA SDN & WGN..JPP W/QSS *3 MR2 CELICA JPP CAMRY TOKAI RIKA QSS PREVIA SIENNA *4 JPP..TOKAI RIKA T100 4RUNNER JPP..QSS NAP XTRACAB R–3*1 R–3 *3 *4 *4 R–5 R–3 SUPRA REGULAR CAB ’95 N/A R 5 R–5 *2 NAP COMPACT TRUCK (PICKUP) *4 R–5 *2 NAP (NUMMI, TMMC) TACOMA ’96 K–5 TERCEL AVALON ’97 Q–4 Q–4 Q–2 Q–2 Q–2 N/A R–3 R–3 R–3 R–3 Q–2 Q–2 Q–2 Q–2 Q–2 N/A N/A R–5 R–3 R–3 Q–4 Q–4 N/A N/A N/A S–1 S–1 Q–4 Q–4 Q–4 *2 R–1 *3 N/A N/A N/A N/A (ALL) Q–1 R–1 (ALL) R–5 R–5 R–5 R–5 R–5 4 DOOR K–5 K–5 K–5 K–1 K–1 K–5 R–3 R–3 R–3 R–3 LAND CRUISER *1 If dimension “L” (length when in use) is under 24 inches the extender must not be used due to its design and construction (illustration). L Extender Lap Belt Page 3 of 7 SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 Rear Seat Belt Extender Applications July 3, 1998 REAR SEAT – EXTENDER APPLICATION MODEL TYPE ’99 ’98 ’97 ’96 R–5 R–5 R–5 R–5 Q–4 Q–4 Q–4 Q–4 R–5 R–5 R–5 R–5 R–5 Q–4 Q–4 Q–4 Q–4 Q–4 N–3 N–3*5 N–1 N–6 N–6*5 N–5 N/A N/A R–5 R–5 R–5 R–5 R–3 N/A N/A N/A R–5 R–3 NAP (TMMC) Q–4 Q–4 Q–4 Q–4 Q–2 NAP (NUMMI) T–1 T–1 A–2 A–2 A–2 LIFTBACK & COUPE N–6 N–6 N–6 N–6 N–3 RH ..CONVERTIBLE N–1 N–1 N–1 N–1 N–1 N–5 N–5 N–5 N–5 N–5 N/A N/A N/A R–3 R–3 Q–4 Q–4 Q–4 Q–2 Q–2 N/A N/A N/A N/A Q–2 Q–2 Q–2 Q–2 Q–2 SUPRA N/A R–3 R–3 PREVIA N/A N/A R–5 R–3 R–3 SIENNA Q–4 Q–4 N/A N/A N/A XTRACAB A–2 A–2 K–3 K–3 K–3 XTRACAB N/A N/A N/A N/A R–1 XTRACAB N/A K–4 K–4 K–4 K–4 4RUNNER R–5 R–5 R–5 R–5 R–1 LAND CRUISER K–5 K–5 K–4 K–4 K–4 TOKAI RIKA RAV4 QSS *3 TOKAI RIKA TERCEL QSS *2 *2 *3 RH.. CONVERTIBLE LH.. CONVERTIBLE PASEO RH & LH ..COUPE SDN & WGN..JPP W/TR SDN ..JPP COROLLA CELICA *2 W/QSS *3 LH ..CONVERTIBLE JPP QSS NAP COUPE & WAGON N/A SOLARA Q–4 *4 AVALON *4 TACOMA *4 T100 *4 *2 This seat belt was supplied by TOKAI RIKA. Make sure that the identification mark on the back side of the seat belt buckle is the same as shown. *3 This seat belt was supplied by QSS. Make sure that the identification mark on the back side of the seat belt buckle is the same as shown. Page 4 of 7 N/A *3 SDN CAMRY PICKUP TOKAI RIKA *2 ’95 SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 Rear Seat Belt Extender Applications (Continued) July 3, 1998 *4 Extenders must not be used for center front seat belt positions for Avalon, Tacoma, Compact Pickup and T100 models with bench seats or for the center rear seat belt positions, except for the 1997 – 1999 Camry. *5 For 1998 model year through November 1997 production of Paseo convertibles, use N–1 for RH and N–5 for LH. For 1998 Paseo convertible models from December 1997 production, use N–3 and N–6. Parts Information PART NUMBER PREFIX: 73399– SERIES LENGTH 6 INCH 9 INCH 12 INCH 15 INCH 18 INCH R–1 –12010 –12020 –12030 –12040 –12050 R–2 –12160 –12170 –12180 –12190 –12200 R–3 –50010 –50020 –50030 –50040 –50050 R–4 –16010 –16020 –16030 –16040 –16050 R–5 –16060 –16070 –16080 –16090 –16100 N–1 –12060 –12070 –12080 –12090 –12100 N–3 –20011 –20021 –20031 –20041 –20051 N–4 –20060 –20070 –20080 –20090 –20100 N–5 –20110 –20120 –20130 –20140 –20150 N–6 –20160 –20170 –20180 –20190 –20200 K–1 –12110 –12120 –12130 –12140 –12150 K–2 –22010 –22020 –22030 –22040 –22050 K–3 –22060 –22070 –22080 –22090 –22100 K–4 –33010 –33020 –33030 –33040 –33050 K–5 –35010 –35020 –35030 –35040 –35050 A–1 –02010 –02020 –02030 –02040 –02050 A–2 –01060*6 –01070 –01080 –01090 –01100 Q–1 –02060 –02070 –02080 –02090 –02100 Q–2 –06010 –06020 –06030 –06040 –06050 Q–3 –0W010 –0W020 –0W030 –0W040 –0W050 Q–4 –0W010 –0W020 –0W030 –0W040 –0W050 S–1 –04010 –04020 –04030 –04040 –04050 T–1 –01110 –01120 –01130 –01140 –01150 *6 Length: 7 1/4” Page 5 of 7 SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 Owner Instructions July 3, 1998 Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The seat belt extender must not be used: A. By anyone other than for whom it was provided (name recorded on seat belt extender). B. In any vehicle and/or seat position other than the one for which it was provided. C. When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S Never use the seat belt extender if you can COMFORTABLY fasten the seat belt without it. S Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the “PRESS” signs on the buckle–release buttons of the extender and the seat belt are both facing outward as shown. Seat Belt Release You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle–release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. Seat Belt Extender When not in use, remove the extender and store in the vehicle for future use. Page 6 of 7 SEAT BELT EXTENDERS: ’95 – ’99 – BO020–98 July 3, 1998 SEAT BELT EXTENDER WORKSHEET PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED CAUTION: When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S To minimize the chance and/or severity of injury in an accident, the seat belt extender must only be used: 1 By the person for whom it was provided 2 In the seat position for which it was provided S The seat belt extender must never be used with any child safety seats. S When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use. DEALER DEALER CODE SEAT BELT EXTENDER APPLICATION DEALER NAME APPLICANT APPLICANT NAME ADDRESS ADDRESS CITY & STATE EMPLOYEE NAME MODEL YEAR ZIP CITY & STATE BODY TYPE SEATING POSITION ZIP PHONE VEHICLE IDENTIFICATION NUMBER DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH 1. 2. S S S 3. 4. 5. 6. Place the seat in the position the applicant normally uses With applicant in the seat, wearing thickest coat expected to be worn, pull belt all the way out and try to buckle belt If the belt latches into buckle and feels comfortable against upper chest area, an extender is not needed. If belt does not buckle continue with step 3 If buckle latches but belt has no slack remaining, continue with step 3 Measure distance between applicant’s navel and seat belt buckle (dimension A) and enter on worksheet With belt all the way out, measure distance between latch tip and buckle tip (dimension B) and enter on worksheet NOTE: If belt latches but there is no slack enter zero as dimension B Subtract dimension B from dimension A and record number in check number box on worksheet Seat belt extender length is dimension B rounded up to next extender length (without exceeding check number) NOTE: If extender length exceeds check number, an extender can not be provided to the customer Dimension A: NAVEL TO BUCKLE Dimension B: LATCH TO BUCKLE A Navel Buckle B Latch Buckle SEAT BELT EXTENDER CALCULATION DIMENSION A: DIMENSION B: CHECK NUMBER: SEAT BELT EXTENDER AUTHORIZATION S The same seat belt extender can be used for right and left seating applications. Each seat belt extender will have a label identifying the owner, VIN and seating position. Seat belt extenders are available only in black. S Applicant’s Signature: _________________________________________ Date: ______________________ (Actual user of seat belt extender) Page 7 of 7 Technical Service BULLETIN SEAT BELT EXTENDER Models: ’99 – ’01 Model Year August 11, 2000 Introduction Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no cost through their local Toyota dealer. Seat Belt S The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths. S The extender is available only in black. Extender S Owners are informed of the seat belt extender availability through the Toyota Owner’s Manual included in each vehicle. The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements made and to complete the seat belt extender worksheet. The worksheet will allow the proper fitting and selection of a seat belt extender for the customer. The dealership personnel should then determine the applicable part number and place a Critical Order through the TDN Parts Network. The dealership service department should complete the affixed Seat Belt Extender Label and review the “owner instruction sheet” with the customer. The dealership should give a copy of the completed worksheet to the customer and keep the original in the customer’s file. To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activities related to the seat belt extender issue. From past sales history, it is recommended that dealerships do not stock Seat belt extenders due to low demand and the need for customer fitting. This bulletin contains the following information: Procedure and Sample Label.................Page 2 Application Charts .................................Page 3–4 Part Number Information........................Page 5 Owner Instructions..................................Page 6 Seat Belt Extender Worksheet............... Page 7 Applicable Vehicles Warranty Information S 1999 through 2001 model year Toyota vehicles. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 7 BODY BO020–00 Title: SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 Procedure August 11, 2000 1. Owner requests a seat belt extender from dealer. 2. Dealer verifies the need for a seat belt extender and obtains a current copy of this TSB and copies the worksheet. 3. Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and places a Critical Order for the part through the TDN Parts Network. 4. Dealer receives seat belt extender and calls the customer in to check fit of the part. 5. If the seat belt extender fit is good, dealership personnel completes the customer information label on the part, explains usage of the part, and gives the customer a copy of the completed worksheet. 6. Dealer places a copy of the completed worksheet in the customer’s records. PARTS SUPPLY DEALER MEASURE CUSTOMER & COMPLETE WORKSHEET PLACE CRITICAL ORDER THROUGH TDN SHIP SEAT BELT EXTENDER TO DEALER DEALER TEST FIT CUSTOMER WITH PART COMPLETE LABEL AND ADVISE OWNER FILE WORKSHEET IN CUSTOMER RECORDS Sample Seat Belt Extender Customer Information Label Page 2 of 7 CAUTION OWNER RECEIVE COPY OF WORKSHEET & USE EXTENDER SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 Front Seat Belt Extender Applications August 11, 2000 FRONT SEAT – EXTENDER APPLICATION MODEL TYPE ’01 ’00 ’99 RAV4 — R–5 R–5 R–5 ECHO — K–5 5–5 — Q–4 Q–4 Q–4 COROLLA TMMC PRODUCTION NUMMI PRODUCTION PRIUS — N–7 — — MR2 SPYDER — N–6 N–6 — LIFTBACK & COUPE N–6 N–6 CONVERTIBLE — — Q–4 Q–4 Q–4 Q–4 — T–1 T–1 Q–2 — Q–4 Q–4 Q–4 — S–2 S–1 S–1 4RUNNER — K–5 K–5 K–5 LAND CRUISER — K–5 K–5 K–5 SEQUIOA — Q–4 — — — Q–4 Q–4 — CELICA TMC PRODUCTION CAMRY TMMK PRODUCTION CAMRY SOLARA AVALON *1 SIENNA TACOMA TUNDRA *1 *1 COUPE COVERTIBLE N–6 Q–4 Q–4 — *1 The extender must not be used for the center seat belt of Avalon, Tacoma and Tundra which have bench seats. Page 3 of 7 SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 Rear Seat Belt Extender Applications REAR SEAT – EXTENDER APPLICATION MODEL RAV4 ECHO COROLLA PRIUS CELICA TYPE ’01 R–5 ’00 R–5*1 ’99 R–5*1 W/TOKAI RIKA W/QSS — Q–4*2 Q–4*2 — R–5 R–5 — TMMC PRODUCTION Q–4 Q–4 Q–4 NUMMI PRODUCTION T–1 T–1 T–1 — N–7 — — LIFTBACK & COUPE N–6 N–6 N–6 — — Q–4 Q–4 Q–4 Q–4 CONVERTIBLE (RH) CONVERTIBLE (LH) CAMRY TMC PRODUCTION TMMK PRODUCTION COUPE N–1 N–5 Q–4 Q–4 CAMRY SOLARA CONVERTIBLE AVALON — T–1 T–1 Q–2 SIENNA — Q–4 Q–4 Q–4 TACOMA XTRACAB A–2 A–2 A–2 4RUNNER — R–5 R–5 R–5 LAND CRUISER — K–5 K–5 K–5 SEQUOIA REAR SEAT #1 T–1 SEQUOIA REAR SEAT #2 Q–4 — — TUNDRA ACCESS CAB Q–4 Q–4 — *1 This seat belt was supplied by TOKAI RIKA. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. *2 This seat belt was supplied by QSS. Make sure that the I/D mark on the back side of the seat belt buckle is the same as shown. NOTE: The seat belt extender must not be used for the center rear seat belt. Page 4 of 7 August 11, 2000 — SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 Parts Information August 11, 2000 PART NUMBER PREFIX: 73399– SERIES LENGTH 6 INCH 9 INCH 12 INCH 15 INCH 18 INCH R–5 –16060 –16070 –16080 –16090 –16100 N–1 –12060 –12070 –12080 –12090 –12100 N–5 –20110 –20120 –20130 –20140 –20150 N–6 –20160 –20170 –20180 –20190 –20200 N–7 –47010 –47020 –47030 –47040 –47050 K–5 –35010 –35020 –35030 –35040 –35050 A–2 –01060*1 –01070 –01080 –01090 –01100 Q–2 –06010 –06020 –06030 –06040 –06050 Q–4 –0W010 –0W020 –0W030 –0W040 –0W050 S–1 –04010 –04020 –04030 –04040 –04050 T–1 –01110 –01120 –01130 –01140 –01150 *1 Length: 7 1/4” Page 5 of 7 SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 Owner Instructions August 11, 2000 Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system in case of vehicle collision, causing personal injury. The Seat Belt Extender must not be used: a. By anyone other than for whom it was provided (name recorded on seat belt extender). b. In any vehicle and/or seat position other than the one for which it was provided. c. When the Seat Belt Extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when in use. If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your Toyota dealer free of charge. Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. CAUTION: When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury. S Never use the Seat Belt Extender if you can comfortably fasten the seat belt without it. S The Seat Belt Extender must never be used with any child safety seats. S Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the “PRESS” signs on the buckle–release buttons of the extender and the seat belt are both facing outward as shown. Seat Belt Release You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle–release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. Page 6 of 7 Seat Belt Extender SEAT BELT EXTENDER: ’99 – ’01 MODEL YEAR – BO020–00 August 11, 2000 SEAT BELT EXTENDER WORKSHEET PLEASE COPY THIS ORIGINAL WORKSHEET FOR EACH EXTENDER NEEDED CAUTION: S S S To minimize the chance and/or severity of injury in an accident, the seat belt extender must only be used: 1 By the person for whom it was provided 2 In the seat position for which it was provided The seat belt extender must never be used with any child safety seats. When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure the retractor is locked when extender belt is in use. DEALER DEALER CODE SEAT BELT EXTENDER APPLICATION DEALER NAME APPLICANT APPLICANT NAME ADDRESS ADDRESS CITY & STATE EMPLOYEE NAME MODEL YEAR ZIP CITY & STATE BODY TYPE SEATING POSITION ZIP PHONE VEHICLE IDENTIFICATION NUMBER DIRECTIONS FOR DETERMINING PROPER EXTENDER LENGTH 1. 2. S S S 3. 4. 5. 6. Place the seat in the position the applicant normally uses With applicant in the seat, wearing thickest coat expected to be worn, pull belt all the way out and try to buckle belt If the belt latches into buckle and feels comfortable against upper chest area, an extender is not needed. If belt does not buckle continue with step 3 If buckle latches but belt has no slack remaining, continue with step 3 Measure distance between applicant’s navel and seat belt buckle (dimension A) and enter on worksheet With belt all the way out, measure distance between latch tip and buckle tip (dimension B) and enter on worksheet NOTE: If belt latches but there is no slack enter zero as dimension B Subtract dimension B from dimension A and record number in check number box on worksheet Seat belt extender length is dimension B rounded up to next extender length (without exceeding check number) NOTE: If extender length exceeds check number, an extender can not be provided to the customer Dimension A: NAVEL TO BUCKLE Dimension B: LATCH TO BUCKLE Latch Navel Buckle Buckle A B SEAT BELT EXTENDER CALCULATION DIMENSION A: DIMENSION B: CHECK NUMBER: SEAT BELT EXTENDER AUTHORIZATION S The same seat belt extender can be used for right and left seating applications. Each seat belt extender will have a label identifying the owner, VIN and seating position. Seat belt extenders are available only in black. S Applicant’s Signature: _________________________________________ Date: ______________________ (Actual user of seat belt extender) Page 7 of 7 Technical Service BULLETIN SLIDING ROOF DIAGNOSTIC TIPS Models: ’97 – ’01 TMMK Camry August 17, 2001 Introduction Applicable Vehicles The 1997 – 2001 model year TMMK Camry sliding roof assembly components are now available as service parts. Additional diagnostic and repair information has been developed to supplement the Repair Manual and to provide service tips for the sliding roof components.
1997 – 2001 model year Camry vehicles built in the US (TMMK). MODEL/PLANT STARTING VIN Camry (TMMK) All VINs Begin with “4” Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Parts Information REF PART NUMBER PART NAME QTY 1 63201–AA010–83 Glass Sub–Assy, Sliding Roof 1 2 63202–AA010 Rail Sub–Assy, Slide Roof 1 3 63209–AA010 Panel Sub–Assy, Roof Wind Deflector 1 4 63214–AA010 Channel, Roof Drip, RR 1 5 63217–AA010 Garnish, Sliding Roof Side, RH 1 6 63218–AA010 Garnish, Sliding Roof Side, LH 1 7 63221–AA010 Guide, Roof Channel, RH 1 8 63222–AA010 Guide, Roof Channel, LH 1 9 63223–AA010 Cable, Sliding Roof Drive, RH 1 10 63224–AA010 Cable, Sliding Roof Drive, LH 1 11 63225–AA010 Spring, Roof Wind Deflector, RH 1 12 63226–AA010 Spring, Roof Wind Deflector, LH 1 13 63227–AA010 Arm, Sliding Roof Lift, RH 1 14 63228–AA010 Arm, Sliding Roof Lift, LH 1 15 63241–AA010 Bracket, Sliding Roof Housing Fr. Mtg., RH 2 16 63245–AA010 Bracket, Sliding Roof Housing Fr. Mtg., LH 2 17 63251–AA010 Weatherstrip, Sliding Roof 1 18 63260–AA010 Gear Assy, Sliding Roof Drive (Not Illustrated) 1 Toyota Supports ASE Certification Page 1 of 7 BODY BO020-01 Title: SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 Parts Information (Continued) August 17, 2001 REF PART NUMBER PART NAME QTY 19 63287–AA010 Cap, Sliding Roof Housing Drain End, RH 1 20 63288–AA010 Cap, Sliding Roof Housing Drain End, LH 1 21 63306–AA010–A1/B1/G1 Trim Sub–Assy, Sliding Shade 1 22 90080–11209 Bolt, With Washer 8 23 90084–14004 Screw, Hex Lobular 2 24 90084–15005 Screw, With Washer 4 25 90084–16013 Screw, Hex Lobular Tapping (Long) 2 26 90084–16014 Screw, Hex Lobular Tapping (Short) (Not Illustrated) 2 27 90084–26003 Rivet 6 28 90084–53003 Fastener, Hook 3 29 90159–60545 Screw, With Washer Tapping (Ground Wire) 1 30 90179–06069 Nut 6 1 24 5 17 25 6 3 11 4 13 12 7 8 14 10 21 9 23 Page 2 of 7 SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 August 17, 2001 Parts Information (Continued) 27 19 2 28 15 20 16 22 30 Repair Procedure CONDITION Glass Won’t Tilt Glass Won’t Close POSSIBLE CAUSE 29 COMMON REPAIR Guide pin mis–adjusted Re–adjust guide pin Mechanism unlatched Re–adjust guide pin Damaged drive gear assembly Replace drive gear assembly Damaged cable assembly Replace cable assembly Other damaged part Replace damaged part Rubber bumper comes off Replace lift arm assembly Foreign material Remove foreign material and re–adjust guide pin Guide pin mis–adjusted Re–adjust guide pin Mechanism unlatched Re–adjust guide pin Damaged drive gear assembly Replace drive gear assembly Damaged cable assembly Replace cable assembly Other damaged part Replace damaged part Rubber bumper comes off Replace lift arm assembly Foreign material Remove foreign material and re–adjust guide pin Page 3 of 7 SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 Repair Procedure (Continued) CONDITION Glass Won’t Open p Glass J Gl Jammed/ d/ Binding/Seized Abnormal Noise Sunshade Difficult to Move Page 4 of 7 POSSIBLE CAUSE August 17, 2001 COMMON REPAIR Guide pin mis–adjusted Re–adjust guide pin Mechanism unlatched Re–adjust guide pin Damaged drive gear assembly Replace drive gear assembly Damaged cable assembly Replace cable assembly Other damaged part Replace damaged part Rubber bumper comes off Replace lift arm assembly Foreign material Remove foreign material and re–adjust guide pin Guide pin mis–adjusted Re–adjust guide pin Mechanism unlatched Re–adjust guide pin Damaged drive gear assembly Replace drive gear assembly Damaged cable assembly Replace cable assembly Other damaged part Replace damaged part Rubber bumper comes off Replace lift arm assembly Foreign material Remove foreign material and re–adjust guide pin Guide pin mis–adjusted Re–adjust guide pin Damaged drive gear assembly Replace drive gear assembly Damaged garnish Replace garnish Damaged roof drip channel guide Replace roof drip channel guide Other damaged part Replace damaged part Opening trim molding installed incorrectly Adjust trim position. See Service Tip on page 7 of this bulletin. Bent sunshade Replace sunshade Damaged or bent center reinforcement Straighten or replace center reinforcement Damaged or bent rear reinforcement Straighten or replace rear reinforcement Damaged or bent roof drip channel Straighten or replace drip channel SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 Service Tips August 17, 2001 H The recommended sliding roof removal and disassembly procedure is provided in the 2001 Camry Repair Manual, pages BO–62 through BO–65. Take time to read the procedure before disassembling the sliding roof assembly. H When the system is diagnosed and the failed part is identified, the failed part can be removed by following the disassembly procedure in the 2001 Camry Repair Manual pages BO–66 through BO–67. Adjustment information is available on pages BO–68 and BO–69. H Electrical diagnosis information can be found:
2001 Camry Repair Manual, pages BE–89 through BE–92.
2001 Camry Electrical Wiring Diagram, pages 168 through 170. The following service tips are not provided in the Repair Manuals: Drain Tube Function
To clear clogs in the drain tubes, insert a long speedometer cable.
A long speedometer cable can be inserted into each drain, to determine if the drain tubes are exiting to the ground instead of inside the vehicle.
Do NOT blast air down the tube because this can cause the drain tube to become disconnected from the sliding roof. Guide Pin Adjustment
Adjustments are noted in the 2001 Camry Repair Manual, page BO–69.
In addition, when the guide pin roller moves up and down, the Lift Arm should be able to move forward–backward a distance of 0.6 mm +/– 0.2 mm. Move Forward 0.6 mm +/– 0.2 mm Down Page 5 of 7 SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 Service Tips (Continued) Rear Drain Cap Installation
The Repair Manual recommends applying Seal Packing P/N 08826–00090 for installation of the drain cap. Since this product is not available through the parts department, the recommended product is: 3M Windo–Weld Sealer – Black (3M Part Number 08606) Moon Roof Opening Trim Removal
The opening trim has three integrated snaps.
First remove the front section in a perpendicular motion, then remove the other sections. Glass Panel Removal
If the screws (4 screws, Torx Screw Driver) cannot be reached, move the sliding roof forward by turning the motor drive shaft with a hex wrench.
Assure the glass panel is adjusted according to the specifications in the 2001 Camry Repair Manual page BO–62. Page 6 of 7 August 17, 2001 SLIDING ROOF DIAGNOSTIC TIPS – BO020-01 Service Tips (Continued) August 17, 2001 Glass Panel Adjustment 1. Glass Panel Closed, Skewed in the Opening Lift Arm Assembly
Tilt the glass panel
From the outside of the vehicle, loosen the guide pin. Guide Pin
Move the guide pin rearward in small increments, until glass closes evenly and exhibits no popping sound. Tighten the pin. Slide Rail
Cycle the sliding roof to verify proper adjustment. 2. Glass Panel Tilts Down but Does Not Retract
Tilt the glass panel
From the outside of the vehicle, loosen the guide pin.
Move the pin forward in small increments, until the glass retracts quietly. Tighten the pin.
Cycle the sliding roof to verify proper adjustment. Sunshade Difficult to Move
Confirm the opening trim molding is attached to the headliner so it does not contact the sunshade.
If the trim is pushed up, it will rub against the sunshade and cause the sunshade to drag. Opening Trim Molding Sunshade WRONG CORRECT Headliner Page 7 of 7 Technical Service BULLETIN SEAT COVER LOOSENESS Models: ’99 Camry & Sienna December 17, 1999 Introduction Applicable Vehicles On some 1999 Camry front seats and Sienna captain seats, the seat bottom cover may become loose at the front lower J–clip. To correct this condition a change has been made to the way the seat cover is fastened to the seat bottom. S 1999 Camry & Sienna vehicles produced within the following VIN ranges. MODEL/PLANT BETWEEN VIN Camry (Plant 1) BG * XU575466 – BF * XU578340 / BF * XU085983 – BF * XU086274 Camry (Plant 2) BG * XU908651 – BG * XU910853 / BF * XU932462 – BF * XU932748 Sienna XU167107 – XU168859 NOTE: When working with sheet metal wear Kevlar Gloves to protect your hands. Camry Warranty Information OP CODE COMBO DESCRIPTION TIME A&B Re–attach Re attach Lower Portion of Front Seat Cover (RH & LH) 11 1.1 OP CODE COMBO DESCRIPTION TIME 711041 A&B Re attach Lower Portion of Re–attach Captain Seat Cover (RH & LH) 06 0.6 711041 OPN T1 T2 62 14 T1 T2 62 14 71071–xxxxx–xx 71072–xxxxx–xx Sienna OPN 71071–xxxxx–xx 71074–xxxxx–xx Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 3 BODY BO020–99 Title: SEAT COVER LOOSENESS – BO020–99 Repair Procedure December 17, 1999 1. For easier repair remove the complete seat assembly. 2. If necessary, remove the manual seat adjuster handle. J–Clip/Rail Seat Cover Locking Tabs Seat Bottom 3. Bend the locking tabs down. 4. Completely disengage the J–clip from the seat adjuster frame (front area only). 5. Using a screwdriver, bend the frame J–clip retention clips to the front. (Approximately 1.5 mm) Up Seat Adjuster Frame Front NOTE: Original Condition: Retention clips are bent to the rear. J–clip NOTE: With a screwdriver, bend all 5 retention clips 1.5 mm forward. 1.5 mm Page 2 of 3 SEAT COVER LOOSENESS – BO020–99 Repair Procedure (Continued) December 17, 1999 6. Reassemble the seat cushion. 7. Bend the locking tabs over the cushion. Locking Tabs 8. After reinstallation of the seat and manual seat adjuster handle (if removed), check the seat cushion retention and seat operation (sit on seat and push cushion down). 9. Tighten the seat mounting screws to the torque specifications in the Repair Manual. Page 3 of 3 Technical Service BULLETIN SUNROOF OPERATION Models: ’97 – ’99 TMMK Camry December 17, 1999 Introduction Applicable Vehicles Production Change Information Parts Information Some 1997 – 1999 TMMK Camry vehicles may experience an interruption in sunroof operation (not opening or closing). Changes have been made to the roof drip channel guides to improve operation. The guides were modified to increase the clearance between the sun shade and opening flange by 2 mm. A radius was added to eliminate the sharp corners of the guides. S 1997 – 1999 TMMK Camry vehicles built before the production change. MODEL Camry (TMMK) PREVIOUS PART NUMBER STARTING VIN Plant 1 4T1BG*XU543595/BF*XU083791 Plant 2 4T1BG*XU901534/BF*XU932010 CURRENT PART NUMBER 63222–AA010 63221–AA010 Warranty Information PLANT PART NAME Roof Drip Channel Guide – LH Same Roof Drip Channel Guide – RH OPCODE DESCRIPTION TIME OPN 614141 R & R Drip Channel Guide, Both RH and LH 2.0 63222–AA010 T1 T2 53 83 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 BODY BO021–99 Title: SUNROOF OPERATION – BO021–99 Repair Procedure December 17, 1999 Remove the Roof Drip Channel Guides (left & right) and replace with the current parts. RH Lift Arm and Cable Assembly Roof Drip Channell RH Roof Drip Channel Guide LH Roof Drip Channel Guide LH Lift Arm and Cable Assembly Drive Rail Assembly Page 2 of 2 Technical Service BULLETIN October 12, 2001 Introduction SUNVISOR VANITY MIRROR IMPROVEMENT Models: ’97 – ’01 NAP Camry Production changes have been implemented on the 1997 – 2001 model year NAP Camry vanity mirror assembly to improve strength and durability of the mirror cover hinge. Mirror Cover Hinge Applicable Vehicles S 1997 – 2001 model year NAP Camry vehicles. Production Change Information Parts Information Repair Procedure Warranty Information MODEL STARTING VIN 2001 Camry 4T1B#2#K#1U045764 (Line 1) 4T1B#2#K#1U798163 (Line 2) PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME 74310–AA095–A0/B0/G0 74310–AA096–A0/B0/G0 Right Sunvisor Assembly 74320–AA055–A0/B0/G0 74320–AA056–A0/B0/G0 Left Sunvisor Assembly Replace damaged sunvisor with a service part. OP CODE DESCRIPTION TIME OPN T1 752101 R & R RH and/or LH Sunvisor Assembly 0.2 74310–AA095–## or 74320–AA055–## T2 62 16 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BODY BO025-01 Title: Technical Service BULLETIN October 19, 2001 Introduction Applicable Vehicles SHOULDER BELT ANCHOR TAPE SET Models: All Applicable Avalon, Camry, Corolla, Previa & Sienna To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor, the following procedure has been developed. S 1996 – 1999 model year Avalon vehicles. S 1996 – 2001 model year Camry vehicles. S 1993 – 2001 model year Corolla vehicles. S 1996 – 1997 model year Previa vehicles. S 1998 – 2001 model year Sienna *1 vehicles. *1 Parts Information Except rear seat belt. CURRENT PART NUMBER PART NAME 73205–48011 Tape Set, Shoulder Belt Anchor NOTE: The above tape set contains the fluorocarbon resin tape (2 pieces) and Velcro tape (1 piece). Warranty Information OP CODE DESCRIPTION TIME OPN T1 BD1011 Clean the Shoulder Belt Anchor 0.3 73210–#####–##*1 73220–#####–##*1 T2 61 99 *1 OPN should be part number of whichever belt assembly that the procedure is performed on. Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 4 BODY BO026-01 Title: SHOULDER BELT ANCHOR TAPE SET – BO026-01 Installation Procedure 1. CLEAN SHOULDER BELT ANCHOR NOTE: S Do not install the tape when the vehicle temperature is below the freezing point. S Do not re–use removed fluorocarbon resin tape. A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration. HINT: Preventing the seat belt from retraction with a clip will make the following work easier. B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush–shaped side to the anchor. C. Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by moving the Velcro tape several times as shown in the illustration. NOTE: Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly. Page 2 of 4 October 19, 2001 SHOULDER BELT ANCHOR TAPE SET – BO026-01 Installation Procedure (Continued) October 19, 2001 2. INSTALL FLUOROCARBON RESIN TAPE A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration. NOTE: Before installation of the fluorocarbon resin tape, it is necessary to pre–release the colored film about 5 mm for each side. (Not fully released.) B. By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Match the shoulder belt anchor to the center of the tape. C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outside of the shoulder belt anchor. NOTE: S Be sure to affix the fluorocarbon tape securely along all edges. S Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape. E. Remove the clip. Page 3 of 4 SHOULDER BELT ANCHOR TAPE SET – BO026-01 Installation Procedure (Continued) F. By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocarbon resin tape and confirm the smoothness of the belt movement. NOTE: Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure. NOTE: If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the seat belt after it is completely dried, to confirm proper operation. Page 4 of 4 October 19, 2001 Technical Service BULLETIN November 3, 2000 Introduction Applicable Vehicles LEAKS INTO TRUNK Models: ’97 - ’01 Camry (U.S.), ’98 - ’01 Sienna, ’99 - ’01 Solara & ’01 Avalon A field fix is available for incidents of moisture and odors permeating into the vehicle. The Quarter Panel Air Duct flaps may have become loose or missing. Replacing the Quarter Panel Air Duct will remedy the condition. S S S S 1997 1998 1999 2001 – 2001 model year Camry (U.S. produced) – 2001 model year Sienna – 2001 model year Solara model year Avalon Production Change Information MODEL STARTING VIN 2001 MY Sienna 4T1BG22K81U019710 4T1BG22KB1U768622 4T1BF28K11U116208 4T1BF22K51U958204 4T3ZF13C#1U335575 2001 MY Solara 2T1CF22P#1C435983 2001 MY Solara Convertible 2T1FF28P#1C435448 2001 MY Avalon 4T1BF28B11U123532 2001 MY Camry, 4 cylinder 2001 MY Camry, 6 cylinder Parts Information Repair Procedure Warranty Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME 62940-AA010 62940-AA011 Quarter Panel Air Duct Replace the Quarter Panel Air Duct. OP CODE DESCRIPTION TIME OPN BD0036 R & R Quarter Panel Air Duct 1.0 62940-AA010 T1 T2 62 57 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BODY BO028-00 Title: Technical Service BULLETIN December 7, 2001 Introduction Applicable Vehicles Warranty Information Maintenance, Cleaning and Use WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING Models: All Models The following procedures are recommended to maintain windshield wiper blade performance. S All models. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Recommendations for Windshield Wiper Maintenance, Cleaning and Use: 1. Scheduled Maintenance S Check wiper rubber blades every 4 – 6 months or 7,500 miles for wear, cracking and contamination. S Clean glass and rubber wiper blades if blades are not clearing glass adequately. If this does not correct the problem, then replace the rubber elements. 2. Cleaning Procedure S Wiper Rubber: Bugs, dirt, sap and road grime on blades will cause streaking. Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with windshield washer fluid or mild detergent. S DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades. S Windshield: Bugs, road grime, sap and car wash wax treatments decrease wiper performance. S Rinse windshield with water and apply non–abrasive cleaner, such as Bon–Ami (www.faultless.com), with a sponge. NOTE: Make sure to use plenty of water with all powder based cleaners so the glass is not scratched. Toyota Supports ASE Certification Page 1 of 2 BODY BO030-01 Title: WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING – BO030-01 Maintenance, Cleaning and Use (Continued) December 7, 2001 3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement) S Dusty areas cause the rubber edge to wear quickly. S Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas with significant snowfall require more frequent wiper replacement. S Heat and time cause the rubber to become excessively “permanent set,” so the rubber does not turn over, resulting in streaking and/or unwiped areas on the glass. S Rubber is easily cut or torn while using ice scrapers on the glass. S Rubber can be torn when pulling blades off a frozen windshield. S Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car warm up can dull, nick, or tear the rubber. S Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to come out of the blade providing the potential to scratch the glass. S Ice forms in wiper blade pin joints, which causes streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber with your hand to loosen the frozen joints. To prevent this condition, use winter blades with a rubber cover. Page 2 of 2 BRAKES BK91-001 MARCH 15, 1991 ALL MODELS BRAKE DISC ANTI–RUST COVER REMOVAL Page 1 of 2 During the removal of the Anti–Rust Covers, do not use screwdrivers or other sharp objects. The use of such tools may result in the scratching of the outer rotor surface. Step–by–step instructions for removing the Anti–Rust Covers are provided on the following page. TOYOTA MOTOR SALES U.S.A., INC. Printed on Recycled Paper. BRAKE DISC ANTI–RUST COVER REMOVAL (CONT’D) Page 2 of 2 RECOMMENDED REMOVAL PROCEDURE: Turn the right front wheel to full right lock. Unhook the Anti–Rust Cover from the disc brake dust cover, then pull the center of the Anti–Rust Cover toward the wheel. This separates the Anti–Rust Cover from the disc brake dust cover (see illustration below). Pull the center of the Anti–Rust Cover by hand towards you to break the thin portion of cover. Remove the Anti–Rust Cover along the arch of the wheel disc by shaking it up and down. If the cover is torn while removing, check to see that no parts of the cover are left inside. Turn the steering wheel to full left lock and perform the same steps on the left front wheel. If applicable, also remove the Anti–Rust Covers on the rear brakes. Indicate on the new car inspection sheet that the Anti–Rust Covers have been removed. Technical Service BULLETIN FRONT BRAKE NOISE Models: ’97–’99 V–6 Camry and ’98–’99 Avalon April 23, 1999 Introduction New Front Brake Pad Kits are available to reduce front brake groan or grinding noise on 1997–1999 V6 Camry and 1998–1999 Avalon. S 1997–1999 V6 Camrys built before VINs 4T1BF2 * K * XU078781 (NAP – Plant 1) Affected Vehicles 4T1BF2 * K * XU930650 (NAP – Plant 2) JT2BF2 * K * X0179640 (TMC) S 1998–1999 Avalons built before VIN 4T1BF18B * XU310454 Parts Information * Repair Procedure PART NUMBER PART NAME 04465–33121 Front Brake Pads 04945–33040 Shim Kit (If Needed*) Visually inspect Shims for heat discoloration. If discolored, replace shims. 1. Surface the disc rotors with the “On–Car Brake Lathe” to within serviceable limits. 2. If the rotors are unserviceable or below minimum thickness, replace the rotors. 3. Check any new disc rotors for runout. 4. If the disc rotor runout is over 0.03 mm (0.00012 in), perform a phase matching procedure. 5. Replace the front brake pads. 6. Road test. Warranty Information OP CODE COMBO DESCRIPTION TIME Grind Front Discs and Replace Pads, Shims (if needed) for Squeak (both sides) 473025 A Grind Front Discs and Replace Pads, Shims (if needed) for Vibration (both sides) Grind Front Discs and Replace Pads, Shims (if needed) for Groan/Grinding (both sides) OPN T1 T2 36 99 2.1 04465–33121 21 99 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BRAKES BR001–99 Title: BRAKES BR94–002 FEBRUARY 7, 1994 ALL MODELS BRAKE VIBRATION AND/OR PULSATION Page 1 of 6 This TSB outlines the causes of brake vibration and pulsation, as well as the best corrective measures to use. CONTENTS 1) 2) 3) 4) Symptoms of brake vibration and pulsation Cause of vibration/pulsation problems Advantages of using an on–car brake lathe Rotor replacement and off–car brake lathe procedure 1) SYMPTOMS OF BRAKE VIBRATION AND PULSATION Brake vibration problems generally involve one or both of two phenomena: body vibration and/ or pedal pulsation. A. BRAKE VIBRATION Applying brakes causes vibration to occur in the instrument panel, steering column, steering wheel, and/or body of the vehicle (See Figure 1 below). Figure 1 TOYOTA MOTOR SALES U.S.A., INC. BRAKE VIBRATION AND/OR PULSATION Page 2 of 6 B. PEDAL PULSATION Applying brakes causes the brake pedal to pulsate. This brake pulsation sometimes causes the steering wheel to oscillate when the brakes are applied (See Figure 2 below). Figure 2 2) CAUSE OF VIBRATION/PULSATION PROBLEMS Brake rotor thickness variation causes brake vibration due to changes in the braking force as thick/thin portions of the rotor pass the pads. Brake rotor thickness variation can be measured with a micrometer as shown in Figure 3 below. 10 mm Divide Into 8 Equal Parts & Measure at each location Thickness Variation = Maximum – Minimum BR002–94 Figure 3 BRAKE VIBRATION AND/OR PULSATION Page 3 of 6 There are two factors which cause excessive rotor thickness variation: A. ROTOR RUNOUT – Rotor runout can be caused by poor mating of flanges between the hub and rotor when assembled as a unit. Manufacturing tolerance stack–up of the rotor and hub may also cause excessive rotor assembly runout (See Figure 4 below). – If there is rotor runout, a portion of the rotor comes into contact with the brake pad on each rotor revolution. If left like this, the portion of the rotor that contacts the brake pad becomes worn, creating thickness variation. Thickness Variation = A – B A Runout B Figure 4 B. EXCESSIVE RUST OR CORROSION ON ROTOR SURFACE – Driving in areas where salt is applied to road surfaces for winter conditions can cause rust and corrosion when the vehicle is parked for an extended period of time. This occurs on the area where the brake pads are not in contact with the rotor. – When a vehicle is driven with rusted rotors, the area with corrosion wears at a different rate than the non–corroded areas, resulting in excessive thickness variation. BR002–94 BRAKE VIBRATION AND/OR PULSATION Page 4 of 6 3) Advantages Of Using An On–Car Brake Lathe Toyota Motor Corporation Engineers strongly recommend that an on–car brake lathe be used for repairing brake vibration and pulsation. This method improves rotor and hub combined runout, and is the preferred method when compared to rotor replacement and off–the–car rotor machining. A. Technical Advantage of Caliper Mounted Brake Lathe – – Installing the brake lathe in the same position as the caliper results in minimal runout relative to the caliper. Eliminating this runout minimizes the pad grinding on the rotor and reduces rotor thickness variation. B. Practical Use Benefits – – Resurfacing rotors on vehicles with rotor/hub assemblies can be performed easily. Vehicles with corrosion between hub and rotor flanges can be machined without removing rotor from hub. 4) Rotor Replacement And Off–Car Brake Lathe Procedures If an on–car brake lathe is not available at your dealership, it may be necessary to use an off–car lathe or replace rotors. In order to ensure proper brake vibration and pulsation repairs, pay close attention to the following precautions: A. Off–Car Brake Lathe Precautions – – – – – Perform routine maintenance of brake lathe components (clearance of arbor shaft to adapters may need to be repaired). Clean all adapters and shaft to maintain accuracy of equipment. When installing rotor to machine, clean mud, rust, and/or foreign material from the adapters and rotors. After installing rotor on machine, check rotor runout using dial indicator. If runout is excessive, determine the cause and correct it. Follow lathe manufacturer repair procedures. Do not cut excessive amounts off rotor during the first cut to save time. Anytime a rotor is machined it must be measured for minimum rotor thickness. The thickness for the rotor is never to be less than minimum thickness as specified in the appropriate repair manual. BR002–94 BRAKE VIBRATION AND/OR PULSATION Page 5 of 6 B. Installation of Rotor – – Check wheel bearing pre–load. If excessive movement is found, adjust bearing pre–load. Using a dial indicator, measure the rotor 10 mm from the outside edge (See Figure 5 below). Figure 5 BR002–94 BRAKE VIBRATION AND/OR PULSATION Page 6 of 6 C. Phase Match Rotor To Hub – If rotor runout is at the maximum value or greater, (refer to appropriate repair manual) index the rotor one lug and measure the runout again. Repeat this process, moving the rotor one lug each time, until the position is found where the runout is at the minimum and within the maximum value listed in the appropriate repair manual (See Figure 6 below). Figure 6 – Tighten lug nuts to the specified torque following a star sequence when installing wheel (See Figure 7 below). Note: DO NOT USE AIR IMPACT WRENCH. Four Holes Five Holes Figure 7 BR002–94 REAR BRAKE DRUM NOISE Technical Service BULLETIN Models: ’99 Camry – NAP July 16, 1999 Introduction Applicable Vehicles Rear Brake Drums are available to reduce rear brake drum howling/groaning noise on NAP built Camrys. S 1999 4 cylinder NAP built Camrys built before: 4T1BG2 * K * XU568428 (NAP – Plant 1) 4T1BG2 * K * XU900266 (NAP – Plant 2) Parts Information Repair Procedure Warranty Information PART NUMBER PART NAME 42431–33020 Rear Brake Drum If the customer encounters a brake groan or howling noise, replace the rear brake drums. OP CODE COMBO DESCRIPTION TIME OPN T1 T2 472151 A R & R Rear Brake Drum (Both Sides) 1.1 42431–33020 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 BRAKES BR004–99 Title: Technical Service BULLETIN BRAKE PAD CLICKING NOISE Models: ’90 – ’00 All Models October 20, 2000 Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction (Drive/Forward to Reverse, Reverse to Drive/Forward). This is a normal noise caused by the required brake pad–to–caliper clearances. When the direction of travel is changed, the brake pads may “shift” towards the new direction of travel. When the brake pad contacts the caliper, a clicking noise may be heard. To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maintenance operations. Under normal usage conditions this grease should be effective for a period of 6 months to 1 year. Applicable Vehicles Parts Information Warranty Information S 1990 – 2000 model year Toyota vehicles, all models. PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME N/A 08887–80609 Disc Brake Caliper Grease (50 g tube) OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 4 BRAKES BR004–00 Title: BRAKE PAD CLICKING NOISE – BR004–00 Application Procedure October 20, 2000 There are two types of brake calipers: floating and fixed. Check the type of brake caliper installed on the vehicle by removing the wheel assembly. 1. Floating Type Brake Caliper A. Lift up or remove the brake caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the brake caliper. B. If equipped with anti–squeal spring: Remove the anti–squeal springs. C. Remove the brake pads with anti–squeal shims. D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque plates and brake pads. E. Apply a small amount of the disc brake caliper grease (1–2 mm thick) to both sides of the pad support plates. Torque Plate Pad Support Plates Pad Support Plates NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to the following flow chart. Apply Disc Brake Caliper Grease Check whether or not the pad support plate and the torque plate are fixed firmly in place with adhesive tape. Fixed firmly in place Without removing the pad support plate, apply a small amount of grease to the portion where the pad touches the surface of the support plate. Page 2 of 4 There is adhesive tape, but it is not fixed firmly in place Adhesive tape is peeled off Remove the pad support plate, peel off the adhesive tape and apply a small amount of grease to both sides of the support plate. Remove the pad support plate and apply a small amount of grease to both sides of the support plate. BRAKE PAD CLICKING NOISE – BR004–00 Application Procedure (Continued) G. Apply a small amount of the disc brake caliper grease (1–2 mm thick) to the caliper as indicated in the illustration. H. Install the brake pads with the anti–squeal shims. I. If equipped with anti–squeal spring: Install the anti–squeal springs. J. Press the piston in firmly and install the brake caliper. October 20, 2000 Apply Disc Brake Caliper Grease NOTE: S Clean excess grease from brake pad and caliper. S Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. K. Install the wheel assembly. 2. Fixed Type Brake Caliper There are two types of brake pads: S Type “A”: Has a projection on the upper and lower side of the brake pad. (See illustration.) Type “A” Brake Pad Type “B” Brake Pad Flat Edge Projection S Type “B”: Has a flat upper and lower edge on the brake pad backing plate. Type “A” Brake Pad A. Remove the anti–squeal spring, clip and pad guide pin. B. Remove the brake pads with the anti–squeal shims. C. Clean any dust from the brake pads. Type “A” Brake Pad Page 3 of 4 BRAKE PAD CLICKING NOISE – BR004–00 Application Procedure (Continued) October 20, 2000 D. Apply a small amount of the disc brake caliper grease (1–2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti–squeal shims. Apply Disc Brake Caliper Grease NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti–squeal spring. G. Install the wheel assembly. Type “B” Brake Pad A. Remove the clip, pins and anti–rattle spring/pad retainer clip. B. Remove the brake pads with the anti–squeal shims. C. Clean any dust from the brake pads. Type “B” Brake Pad D. Apply a small amount of the disc brake caliper grease (1–2 mm thick) to the areas indicated in the illustration. NOTE: Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor. E. Install the brake pads with the anti–squeal shims. NOTE: Clean excess grease from the brake pads and caliper. F. Install the pad guide pin, clip and anti–squeal spring. G. Install the wheel assembly. Page 4 of 4 Apply Disc Brake Caliper Grease Technical Service BULLETIN SINGLE CYLINDER MISFIRES Models: ’99 Avalon, Camry, Sienna & Solara (CA Spec.) January 14, 2000 NOTE: The information contained in this TSB updates EG013–99 dated December 17, 1999. Introduction Applicable Vehicles Parts Information Warranty Information Some 1999 California Emission Specification Avalon, Camry (1MZ–FE), Sienna & Solara (1MZ–FE) vehicles may exhibit a rough idle, and or a M.I.L. “ON“ condition, in which a single cylinder misfire code, or codes are present. Changes have been made in the fuel injector production process to correct this condition. S 1999 CA Emission Spec. TMMK produced Avalon, Camry (1MZ–FE), Sienna & TMMC produced Solara (1MZ–FE) vehicles built between the VIN numbers listed below. MODEL STARTING VIN ENDING VIN Avalon 4T1BF1#B*XU298504 4T1BF1#B*XU319557 Camry 4T1BF2#K*XU076403 4T1BF2#K*XU081214 Camry (cont.) 4T1BF2#K*XU930024 4T1BF2#K*XU931330 Sienna 4T3ZF1#C*XU090887 4T3ZF1#C*XU122589 Solara (U.S.) 2T1CF2#P*XC111083 2T1CF2#P*XC757508 Solara (Canada) 2T1CF2#P*XC744113 2T1CF2#P*XC162681 APPLICABLE PARTS QUANTITY PART NAME 23209–0A010 6 Fuel Injector OP CODE VWC DESCRIPTION TIME 895221 N R & R Fuel Injector Assembly – All 1.8 OPN T1 T2 23209–0A010 02 56 Applicable Warranty*: This repair is covered under the Toyota Federal Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California, Massachusetts, and Vermont due to state emission warranty legislation. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. NOTE: Be sure to enter the DTC No. in the Condition/Cause/Remedy section, if a DTC Code appeared. Toyota Supports ASE Certification Page 1 of 2 ENGINE EG001–00 Title: SINGLE CYLINDER MISFIRE – EG001-00 Repair Procedure 1. Remove all six fuel injectors for verification of production information. Affected injectors will be labeled with a vendor part number of “23250–0A010“ and have a production date code number of “828“ or lower (see illustration for number locations). 2. After determining that one or more of the injectors are affected, replace all six injectors with the above applicable part number. 3. Clear the DTC, if present, and verify that the vehicle now operates as designed. Page 2 of 2 January 14, 2000 Production Date Part Number Technical Service BULLETIN DIAGNOSTIC TROUBLE CODE P1133 Models: ’97 – ’99 Camry: 1MZ–FE CA Spec. February 25, 2000 TSB Revision Notice: The information updated in this TSB is red and underlined. Introduction Applicable Vehicles Under certain driving conditions, some 1MZ–FE equipped 1997 – 1999 Camry California Emission specification vehicles can exhibit a M.I.L. “ON” DTC P1133. An improved Air/Fuel Ratio Sensor has been developed to correct this condition. S 1997 – 1999 Camry (1MZ–FE) with California Emission Specification. Production Change Information Parts Information Repair Procedure MODEL YEAR 1999 Camry ENGINE STARTING VIN 1MZ–FE 4T1BF2#K * XU088001 4T1BF2#K * XU933227 PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME 89467–41020 89467–41021 Sensor, Air/Fuel S Should a M.I.L. “ON” condition with DTC P1133 be encountered, perform diagnostic procedures as described in the Repair Manual. S If the problem source cannot be identified after checking all affected areas according to the Repair Manual, the cause may be an Air/Fuel Ratio Sensor malfunction. In this case, replace the Air/Fuel Ratio Sensor with the current part number listed above. S If the Exhaust Manifold threads are damaged by removal of the sensor, they can be repaired by the proper use of a M18 x 1.5 tap. Warranty Information OP CODE DESCRIPTION TIME OPN 895131 R & R Air/Fuel Ratio Sensor 0.3 89467–41020 T1 T2 99 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. NOTE: Please enter the DTC in the condition/Cause/Remedy section when applying for warranty reimbursement. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 ENGINE EG002–00 Title: ENGINE EG003-96 OCTOBER 11, 1996 ALL MODELS UNDERCOATING ON OXYGEN SENSORS Page 1 of 1 During vehicle processing by Dealers, care must be taken to avoid applying undercoating in the area surrounding the Oxygen Sensors. Application of undercoating on or near the Oxygen Sensors can cause insufficient air to flow around the sensor, and inaccurate information storage by the ECM. If this condition occurs, the Malfunction Indicator Light (MIL) may illuminate. Sub Oxygen Sensor Main Oxygen Sensor Center Pipe to Muffler Avoid undercoating this area Front Pipe to Manifold Technical Service BULLETIN READINESS MONITOR DRIVE PATTERNS Models: All ’96 – ’02 March 29, 2002 TSB REVISION NOTICE: The information updated in this TSB is red and underlined. Introduction The On–Board Diagnostic (OBDII) system is designed to monitor the performance of emission–related components and report any detected abnormalities in the form of Diagnostic Trouble Codes (DTCs). Since the various components need to be monitored during different driving conditions, the OBDII system is designed to run separate monitoring programs called Readiness Monitors. Many state Inspection and Maintenance (I/M) programs require that vehicles complete their Readiness Monitors prior to beginning an emissions test. The current status of the Readiness Monitors can be seen by using the Toyota Diagnostic Tester with version 9.0 software (or newer), or a generic OBDII Scantool. To view the Readiness Monitor status using the Toyota Diagnostic Tester, select “Monitor Status” from the Enhanced OBDII Menu. A status of “complete” indicates that the necessary conditions have been met to run the performance tests for the related Readiness Monitor. The Readiness Monitor will be reset to “incomplete” if:
ECU has lost power (battery or fuse).
DTCs have been cleared.
The conditions for running the Readiness Monitor have not been met. In the event that any Readiness Monitor shows “incomplete,” follow the appropriate Readiness Monitor Drive Pattern to change the readiness status to “complete.” Refer to the Readiness Monitor Drive Pattern Application Table to determine which drive pattern should be followed. Contents SECTION PAGE(S) Readiness Monitor Drive Pattern Application Tables Readiness Monitor Drive Patterns 1 EGR Monitor (All Except 1FZ–FE Engine) 2 EGR Monitor (For 1FZ–FE Engine) 3 Catalyst Monitor (O2S Type) 4 Catalyst Monitor (AF Sensor Type) 5 EVAP Monitor (Internal Pressure Monitor/Non–Intrusive Type) 6 EVAP Monitor (Vacuum Pressure Monitor/Intrusive Type) 7 EVAP Monitor (Without Leak Detection) 8 EVAP Monitor (For Prius) 9 Oxygen Sensor Monitor (Front and Rear O2S System) 10 Oxygen/AF Sensor Monitor (Front AF Sensor and Rear O2S System) 11 Oxygen/AF Sensor Heater Monitor Applicable Vehicles Warranty Information 3–9 10 11 12 13 14–15 16–17 18 19–20 21 22 23
All 1996 – 2002 model year Toyota vehicles. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 23 ENGINE EG003-02 Title: READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Terms & Definitions Required Tools & Material March 29, 2002 J1930 TERM J1930 DEFINITION TOYOTA/LEXUS DIAGNOSTIC TESTER PARAMETER IAT Intake Air Temperature Intake Air ECT Engine Coolant Temperature Coolant Temp TOOLS & MATERIAL PART NUMBER QUANTITY Toyota Diagnostic Tester Kit 01001271 1 12 Megabyte Diagnostic Tester Program Card with version 9.0a Software (or later) 01002593-005 1 NOTE: A generic OBDII Scantool can be used in place of the Toyota Diagnostic Tester. CAUTION: Strict observance of posted speed limits, traffic laws and road conditions are required when performing these drive patterns. NOTE:
These drive patterns represent the fastest method to satisfy all necessary conditions which allow the specific Readiness Monitor to complete.
In the event that the drive pattern must be interrupted (possibly due to traffic conditions or other factors) the drive pattern can be resumed and, in most cases, the Readiness Monitor will still set to “complete.”
To ensure rapid completion of Readiness Monitors, avoid sudden changes in vehicle load and speed (driving up and down hills and/or sudden acceleration). Underhood Emission Control Information Label SAMPLE EMISSION CONTROL INFORMATION LABEL VEHICLE EMISSION CONTROL INFORMATION TOYOTA MOTOR CORPORATION TEST GROUP : 1TYXV02.2JJA SFI, EGR, A/F S, WU–TWC, TWC, HO2S EVAP. FAMILY : 1TYXR0135AK1 2.2 LITER ENGINE TUNE–UP SPECIFICATIONS FOR ALL ALTITUDES VALVE CLEARANCE INTAKE 0.19–0.29 mm [0.007–0.011 in.] (ENGINE AT COLD) EXHAUST 0.28–0.38 mm [0.011–0.015 in.] NO OTHER ADJUSTMENTS NEEDED. 2 2 V A G J J Y 7A650 2AZ–FE USA EGR = Exhaust Gas Recirculation A/F S = Air Fuel Sensor O2S = Oxygen Sensor Page 2 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR EGR 1 2 3 4 SENSOR EVAP 5 6 7 8 9 10 HTR 11 ENGINE Tercel 5E–FE X X X X X Paseo 5E–FE X X X X X Corolla 7A–FE X X X X X 7A–FE X X X X X 5S–FE X X X X X MTM X X X X X ATM X X X X X MTM X X X X X ATM X X X X X 1MZ–FE X X X X X 2JZ–GE X X X X X 2JZ-GTE X X X X RAV4 3S–FE X X X X Previa 2TZ–FZE X X X X X 2RZ–FE X X X X X 3RZ–FE X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 5S FE 5S–FE Camry 1MZ FE 1MZ–FE Avalon Supra CATEGORY CATALYST MODEL Celica 1996 DRIVE TRAIN 2WD Tacoma 5VZ–FE 4WD w/EGR** w/oEGR** 3RZ–FE 4Runner w/EGR** 5VZ FE 5VZ–FE w/oEGR** 3RZ–FE T100 Land Cruiser 5VZ FE 5VZ–FE 2WD or 4WD w/EGR** w/oEGR** N/A N/A X X X X X X X X X X X X X X X N/A 1FZ–FE X X X N/A * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor ** Refer to Underhood Emissions Label on page 2. Page 3 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR DRIVE TRAIN EGR 2 3 4 5 6 7 8 9 10 HTR 11 ENGINE Tercel 5E–FE X X X X X Paseo 5E–FE X X X X X Corolla 7A–FE X X X X X 7A–FE X X X X X 5S–FE X X X X X X X X X X Fed X X X X CA X MTM 5S–FE ATM Camry y X X X X X MTM X X X X X ATM X X X X X 1MZ–FE X X X X X 2JZ–GE X X X X X 2JZ-GTE X X X X RAV4 3S–FE X X X X Previa 2TZ–FZE X X X X X 2RZ–FE X X X X X 3RZ–FE X X X X X X X X X X X X X X X X X X X X X X X X 1MZ FE 1MZ–FE Avalon Supra 1997 1 SENSOR EVAP MODEL Celica CATEGORY CATALYST Tacoma 5VZ–FE 4Runner 2WD or 4WD w/EGR** 4WD w/oEGR** 3RZ–FE X 5VZ–FE N/A 3RZ–FE T100 5VZ–FE Land Cruiser N/A 2WD w/EGR** 2WD or 4WD w/oEGR** X X X X X X X X X X X X X X X N/A 1FZ–FE X X X N/A * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) ** Refer to Underhood Emissions Label on page 2. Page 4 of 23 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR MODEL ENGINE Tercel 5E–FE Paseo 5E–FE Corolla 1ZZ–FE Celica 5S–FE DRIVE TRAIN 1MZ–FE 1998 1MZ–FE 5 6 7 8 9 10 HTR 11 X X X X X X X X X X X X X X X X X X CA X X X X X X X X X X X X Fed X X X X X CA X Fed X CA X X X X X X Fed X X CA X X X X X X X X X X X N/A X X X N/A X X X X X X X X X X X X X X X X X X X 3RZ–FE X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 2WD w/EGR** 4WD w/oEGR** 3RZ–FE 5VZ–FE T100 5VZ–FE N/A X N/A 3RZ–FE Land Cruiser 4 SENSOR EVAP 2RZ–FE 5VZ FE 5VZ–FE 4Runner 3 Fed 2JZ-GTE Sienna 2 X 2JZ–GE 3S FE 3S–FE Tacoma ATM 1MZ FE 1MZ–FE RAV4 1 CATALYST X MTM Camry y Supra CATEGORY N/A 5S FE 5S–FE Avalon EGR 2WD w/EGR** 2WD or 4WD w/oEGR** N/A 2UZ–FE * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor ** Refer to Underhood Emissions Label on page 2. Page 5 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR DRIVE TRAIN CATEGORY 1 CATALYST 2 3 4 SENSOR EVAP 5 6 7 8 9 10 HTR 11 MODEL ENGINE Tercel 5E–FE X X X X X Paseo 5E–FE X X X X X Corolla 1ZZ–FE X X X X Celica 5S–FE X X X X X Fed X X X X X CA X N/A 5S FE 5S–FE MTM Camry y 1MZ–FE ATM 5S FE 5S–FE 1MZ–FE Avalon 1MZ FE 1MZ–FE RAV4 3S FE 3S–FE Sienna 1MZ FE 1MZ–FE ATM X X X X X X Fed X X X X X CA X Fed X CA X X X X X X X X X X X X X X X X X X Fed X X X X X CA X Fed X CA X Fed X CA X Fed CA X X X X X X X X X X X X X X X X X X X X X X X N/A X X X X X X X X X X 3RZ–FE X X X X X X X X X X X X X X X X X X X X X X 5VZ–FE 2WD w/EGR** 2WD or 4WD w/oEGR** 3RZ–FE Land Cruiser X 2RZ–FE Tacoma 4Runner X X MTM Solara 1999 EGR 5VZ FE 5VZ–FE N/A X Fed CA X N/A 2UZ–FE X X X X X X X * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) ** Refer to Underhood Emissions Label on page 2. Page 6 of 23 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR DRIVE TRAIN EGR 1 2 3 4 SENSOR EVAP 5 6 7 8 9 10 HTR 11 MODEL ENGINE ECHO 1NZ–FE X X X X Corolla 1ZZ–FE X X X X X X X X 2ZZ–GE X X X X 1ZZ–FE X X X X X X Celica MR2 CATEGORY CATALYST 1ZZ–FE N/A 5S FE 5S–FE Fed X CA X MTM Camry y 1MZ–FE ATM 5S FE 5S–FE 1MZ–FE Camry CNG 5S–FNE Avalon 1MZ–FE ATM 3S FE 3S–FE Sienna 1MZ FE 1MZ–FE X Fed X X X X X CA X Fed X CA X Land Cruiser 5VZ FE 5VZ–FE 5VZ FE 5VZ–FE X X X X X X X X X X X X X X X X CA X Fed X CA X w/EGR** w/o A/F S, w/oEGR** w/A/F S, w/oEGR** 3RZ–FE Tundra X X X CA 2WD or 4WD X X 3RZ–FE 4Runner X Fed 2RZ–FE 5VZ–FE X X Fed T Tacoma X X X X X X X N/A N/A X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X N/A X X Fed X X X X X X X X X X Fed X X CA CA X N/A N/A 2WD X X X 2000 RAV4 X X MTM Solara X X N/A X X X X X X X X X X 2UZ–FE X X X X 2UZ–FE X X X X * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor ** Refer to Underhood Emissions Label on page 2. Page 7 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR DRIVE TRAIN EGR 2 3 4 5 6 7 8 9 10 HTR 11 ENGINE ECHO 1NZ–FE X X X X Corolla 1ZZ–FE X X X X X X X X 2ZZ–GE X X X X 1ZZ–FE X X X X MR2 1ZZ–FE N/A 5S–FE Camry y 1MZ FE 1MZ–FE X Solara 1MZ FE 1MZ–FE Camry CNG 5S–FNE Avalon 1MZ–FE Prius 1NZ-FXE RAV4 1AZ–FE High Highlander 2AZ–FE Sienna Tacoma Tundra X ATM X X X X X X X X X X X ATM X X X X X X X X X MTM X X X X N/A N/A X X X X X X X X X X X X X X X X X X X X X X 1MZ–FE X X X X 1MZ–FE X X X X N/A 2RZ–FE X X X X X 3RZ–FE X X X X X X X X X X X X X X X X X X 5VZ FE 5VZ–FE 4Runner X MTM 5S–FE 2001 1 SENSOR EVAP MODEL Celica CATEGORY CATALYST 2WD 4WD 5VZ–FE X 5VZ–FE 2UZ–FE X N/A X X X X X X X X X X X Land Cruiser 2UZ–FE X Sequoia 2UZ–FE X X * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. Page 8 of 23 EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Pattern Application Tables (Continued) March 29, 2002 DRIVE PATTERN NUMBER* O2S/AF MODEL YEAR DRIVE TRAIN EGR 1 2 3 4 5 6 7 8 9 10 HTR 11 ENGINE ECHO 1NZ–FE X X X X Corolla 1ZZ–FE X X X X X X X X X X X X X X X X MR2 1ZZ–FE N/A 2ZZ–GE 1ZZ–FE 2AZ–FE Camry y 1MZ FE 1MZ–FE X Solara 1MZ FE 1MZ–FE Camry CNG 5S–FNE Avalon 1MZ–FE Prius 1NZ-FXE RAV4 1AZ–FE High Highlander 2AZ–FE Sienna Tacoma 4Runner Tundra X ATM X X X X X X X X X X X ATM X X X X X X X X X MTM X X MTM 2AZ–FE 2002 SENSOR EVAP MODEL Celica CATEGORY CATALYST X X N/A N/A X X X X X X X X X X X X X X X X X X X X X X 1MZ–FE X X X X 1MZ–FE X X X X N/A 2RZ–FE X X X X X 3RZ–FE X X X X X 5VZ–FE X X X X 5VZ–FE X X X X X 5VZ–FE 2UZ–FE X N/A X X X X X X X X X X X Land Cruiser 2UZ–FE X Sequoia 2UZ–FE X X * Readiness Monitor Drive Patterns: 1. 2. 3. 4. 5. 6. EGR (All Except 1FZ–FE Engine) EGR (For 1FZ–FE Engine) Catalyst (O2S Type) Catalyst (AF Sensor Type) EVAP (Internal Pressure Monitor/Non–Intrusive Type) EVAP (Vacuum Pressure Monitor/Intrusive Type) 7. EVAP (Without Leak Detection) 8. EVAP (For Prius) 9. Oxygen Sensor Monitor (Front & Rear O2S System) 10. Oxygen/AF Sensor Monitor (Front AF Sensor & Rear O2S System) 11. Oxygen/AF Sensor Heater Monitor Page 9 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EGR Monitors March 29, 2002 DRIVE PATTERN NO. 1: EGR Monitor (All Except 1FZ–FE Engine) 43 – 56 mph (70 – 90 km/h) Idling IG SW off Warm up 10 min (a) 3 – 5 min (b) 3 – 5 min (c) 3 – 5 min 3 – 5 min (d) Preconditions The monitor will not run unless:
MIL is OFF.
Altitude is 7800 feet (2400 m) or less.
IAT (Intake Air) is 14tF (–10tC) or greater. Drive Pattern Procedure Connect the OBDII Scantool to the DLC3 connector to check monitor status and preconditions. a. If IAT (Intake Air) is less than 50tF (10tC) when starting the engine, idle the engine for approximately 10 minutes. b. Drive the vehicle at 43 – 56 mph (70 – 90 km/h) for a period of 3 – 5 minutes. NOTE:
Do not allow the Throttle Position (TP) to exceed 30%.
Drive with smooth throttle operation and avoid sudden acceleration. c. Stop the vehicle and let the engine idle for 3 – 5 minutes. d. Repeat steps “b” and “c” once. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “b” through “d.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 10 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EGR Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 2: EGR Monitor (for 1FZ–FE Engine) 43 – 56 mph (70 – 90 km/h) Idling IG SW off 3 – 5 min (a) 3 – 5 min (b) 3 – 5 min 3 – 5 min (c) Preconditions The monitor will not run unless:
MIL is OFF.
Altitude is 7800 feet (2400 m) or less.
IAT (Intake Air) is 14tF (–10tC) or greater.
ECT (Coolant Temp) is less than 104tF (40tC). Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. a. Start the engine and as soon as safely possible begin driving the vehicle at 43 – 56 mph (70 – 90 km/h) for a period of 3 – 5 minutes. NOTE:
Do not allow the Throttle Position (TP) to exceed 30%.
Drive with smooth throttle operation and avoid sudden acceleration. b. Stop the vehicle and let the engine idle for 3 – 5 minutes. c. Repeat steps “a” and “b” once. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” through “c.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 11 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: Catalyst Monitors March 29, 2002 DRIVE PATTERN NO. 3: Catalyst Monitor (O2S Type) 40 – 50 mph (64 – 88 km/h) 35 – 45 mph (56 – 72 km/h) Idling IG SW off Warm up ECT≥176tF IAT < 50tF = 7 min IAT > 50tF = 3 min (a) 7 min (b) Preconditions The monitor will not run unless:
MIL is OFF.
ECT (Coolant Temp) is 176tF (80tC) or greater.
IAT (Intake Air) is 14tF (–10tC) or greater.* * For 2002 MY and later vehicles: The readiness test can be completed in cold ambient conditions (less than 14tF / –10tC), if the drive pattern is repeated a second time after cycling the ignition OFF. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. Note the IAT (Intake Air) value during engine startup. The driving time must be adjusted during step “a” based upon IAT (Intake Air) value at startup. a. Drive the vehicle at 40 – 55 mph (64 – 88 km/h) for the time described below:
If IAT (Intake Air) was less than 50tF (10tC) when the engine was started, drive for 7 minutes.
If IAT (Intake Air) was greater than 50tF (10tC) when the engine was started, drive for 3 minutes. b. Drive the vehicle at 35 – 45 mph (56 – 72 km/h) for approximately 7 minutes. NOTE:
Drive with smooth throttle operation.
Avoid sudden acceleration.
Avoid sudden deceleration as much as possible with the throttle fully closed. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” and “b.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 12 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: Catalyst Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 4: Catalyst Monitor (AF Sensor Type) 40 – 50 mph (64 – 88 km/h) 35 – 45 mph (56 – 72 km/h) Idling IG SW off Warm up ECT≥176tF IAT < 50tF = 7min IAT > 50tF = 3min (a) 16 min (b) Preconditions The monitor will not run unless:
MIL is OFF.
ECT (Coolant Temp) is 176tF (80tC) or greater.
IAT (Intake Air) is 14tF (–10tC) or greater.* * For 2002 MY and later vehicles: The readiness test can be completed in cold ambient conditions (less than 14tF / –10tC), if the drive pattern is repeated a second time after cycling the ignition OFF. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. Note the IAT (Intake Air) value during engine startup. The driving time must be adjusted during step “a” based upon IAT (Intake Air) value at startup. a. Drive the vehicle at 40 – 55 mph (64 – 88 km/h) for the time described below:
If IAT (Intake Air) was less than 50tF (10tC) when the engine was started, drive for 7 minutes.
If IAT (Intake Air) was greater than 50tF (10tC) when the engine was started, drive for 3 minutes. b. Drive the vehicle allowing speed to fluctuate between 35 – 45 mph (56 – 72 km/h) for about 16 minutes. NOTE:
Drive with smooth throttle operation.
Avoid sudden acceleration.
Avoid sudden deceleration as much as possible with the throttle fully closed. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” and “b.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 13 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors March 29, 2002 DRIVE PATTERN NO. 5: EVAP Monitor (Internal Pressure Monitor/Non–Intrusive Type) 45 mph (72 km/h) 25 mph (40 km/h) Idling IG SW off Warm up ECT≥176tF (1a) Soak (1b) Cold Soak 5 min (2a) 15 min (2b) Drive Pattern Cold Soak Preconditions The monitor will not run unless:
MIL is OFF.
Fuel level is between 1/2 to 3/4 full (for faster completion).
Altitude is 7800 feet (2400 m) or less. IMPORTANT: A cold soak must be performed prior to conducting the drive pattern to complete the Internal Pressure Readiness Monitor. Cold Soak Procedure 1a. Start the engine and allow ECT (Coolant Temp) to reach 176tF (80tC) or greater. (This can be done by letting the engine idle or by driving the vehicle.) 1b. Let the vehicle cold soak for 8 hours or until the difference between IAT (Intake Air) and ECT (Coolant Temp) is less than 13tF (7tC). H Example 1
ECT (Coolant Temp) = 75tF (24tC).
IAT (Intake Air) = 60tF (16tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 15tF (8tC). ⇒ The monitor will not run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is greater than 13tF (7tC). H Example 2
ECT (Coolant Temp) = 70tF (21tC).
IAT (Intake Air) = 68tF (20tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 2tF (1tC). ⇒ The monitor will run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is less than 13tF (7tC). Page 14 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 Drive Pattern Preconditions The monitor will not run unless:
MIL is OFF.
Fuel level is between 1/2 to 3/4 full (for faster completion).
Altitude is 7800 feet (2400 m) or less.
ECT (Coolant Temp) is between 40tF and 95tF (4.4tC – 35tC).
IAT (Intake Air) is between 40tF and 95tF (4.4tC – 35tC).
Cold Soak Procedure has been completed. NOTE: Before starting the engine, the difference between ECT (Coolant Temp) and IAT (Intake Air) must be less than 13tF (7tC). (Refer to Examples 1 and 2 on previous page.) Drive Pattern Procedure
Connect the OBDII Scantool to DLC3 to check monitor status and preconditions.
Release the pressure in the fuel tank by removing and then reinstalling the fuel tank cap.
Start the engine and begin driving as directed. NOTE:
Do not turn the ignition off until the drive pattern is complete.
Drive on smooth roads to reduce excessive fuel sloshing. 2a. Start the engine and as soon as safely possible begin driving at approximately 45 mph (72km/h) for 5 minutes. (See illustration on previous page.) 2b. Drive the vehicle at approximately 25 mph (40 km/h) for 15 minutes and include a minimum of two stops for approximately 30 seconds. (See illustration on previous page.) The monitor should complete within approximately 20 minutes. If it does not, ensure preconditions are met and repeat the drive pattern process beginning with the Cold Soak Procedure. NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 15 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 6: EVAP Monitor (Vacuum Pressure Monitor/Intrusive Type) 3,000 rpm Idling IG SW off Soak (1a) Warm up (2a) 10 sec (2b) 15 –50 min (When the Readiness Monitor or DTC is set, this test is complete.) (2c) Cold Soak Preconditions The monitor will not run unless:
MIL is OFF.
Fuel level is between 1/2 to 3/4 full (for faster completion).
Altitude is 7800 feet (2400 m) or less. Cold Soak Procedure 1a. Let the vehicle cold soak for 8 hours or until the difference between IAT (Intake Air) and ECT (Coolant Temp) is less than 13tF (7tC). H Example 1
ECT (Coolant Temp) = 75tF (24tC).
IAT (Intake Air) = 60tF (16tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 15tF (8tC). ⇒ The monitor will not run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is greater than 13tF (7tC). H Example 2
ECT (Coolant Temp) = 70tF (21tC).
IAT (Intake Air) = 68tF (20tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 2tF (1tC). ⇒ The monitor will run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is less than 13tF (7tC). Page 16 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 Drive Pattern Preconditions The monitor will not run unless:
MIL is OFF.
Fuel level is between 1/2 to 3/4 full (for faster completion).
Altitude is 7800 feet (2400 m) or less.*
ECT (Coolant Temp) is between 40tF and 95tF (4.4tC – 35tC).
IAT (Intake Air) is between 40tF and 95tF (4.4tC – 35tC).*
Cold Soak Procedure has been completed. * For 2002 MY and later vehicles: The readiness test can be completed in cold ambient conditions (less than 40tF / 4.4tC) and/or at high altitudes (more than 7800 feet / 2400 m) if the complete drive pattern (including Cold Soak) is repeated a second time after cycling the ignition OFF. NOTE: Before starting the engine, the difference between ECT (Coolant Temp) and IAT (Intake Air) must be less than 13tF (7tC). (Refer to Examples 1 and 2 on previous page.) Drive Pattern Procedure
Connect the OBDII Scantool to DLC3 to check monitor status and preconditions.
Release the pressure in the fuel tank by removing and then reinstalling the fuel tank cap. 2a. Start the engine and allow it to idle until ECT (Coolant Temp) is 167tF (75tC) or greater. (See illustration on previous page.) 2b. Race the engine at 3,000 rpm for approximately 10 seconds. (See illustration on previous page.) 2c. Allow the engine to idle with the A/C ON (to create a slight load) for 15 – 50 minutes. (See illustration on previous page.) NOTE: If the vehicle is not equipped with A/C put a slight load on the engine by doing the following:
Securely set the parking brake.
Block the drive wheels with wheel chocks.
Allow the vehicle to idle in drive for 15 – 50 minutes. NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 17 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 7: EVAP Monitor (Without Leak Detection) 43 – 56 mph (70 – 90 km/h) Idling IG SW off Warm up ECT≥181tF 3 – 5 min (a) 3 – 5 min (b) 3 – 5 min 3 – 5 min (c) Preconditions The monitor will not run unless:
MIL is OFF.
Altitude is 7800 feet (2400 m) or less.
ECT (Coolant Temp) is 181tF (83tC) or greater.
IAT (Intake Air) is 41tF (5tC) or greater. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. a. Drive the vehicle at 43 – 56 mph (70 – 90 km/h) for a period of 3 – 5 minutes. NOTE:
Do not allow the Throttle Position (TP) to exceed 30%.
Drive with smooth throttle operation and avoid sudden acceleration. b. Stop the vehicle and let the engine idle for 3 – 5 minutes. c. Repeat steps “a” and “b” once. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” through “c.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 18 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 8: EVAP Monitor (For Prius) 50 – 65 mph (80 – 104 km/h) Idling IG SW off Soak (1a) 15 min (When the Readiness Monitor or DTC is set, this test is complete.) (2a) Cold Soak Preconditions The monitor will not run unless:
MIL is OFF.
Altitude is 7800 feet (2400 m) or less. IMPORTANT: A cold soak must be performed prior to conducting the drive pattern to complete the Internal Pressure Readiness Monitor. Cold Soak Procedure 1a. Let the vehicle cold soak for 8 hours or until the difference between IAT (Intake Air) and ECT (Coolant Temp) is less than 13tF (7tC). H Example 1
ECT (Coolant Temp) = 75tF (24tC).
IAT (Intake Air) = 60tF (16tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 15tF (8tC). ⇒ The monitor will not run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is greater than 13tF (7tC). H Example 2
ECT (Coolant Temp) = 70tF (21tC).
IAT (Intake Air) = 68tF (20tC).
Difference between ECT (Coolant Temp) and IAT (Intake Air) is 2tF (1tC). ⇒ The monitor will run because the difference between ECT (Coolant Temp) and IAT (Intake Air) is less than 13tF (7tC). Page 19 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: EVAP Monitors (Continued) March 29, 2002 Drive Pattern Preconditions The monitor will not run unless:
MIL is OFF.
Altitude is 7800 feet (2400 m) or less.
ECT (Coolant Temp) is between 40tF and 95tF (4.4tC – 35tC).
IAT (Intake Air) is between 40tF and 95tF (4.4tC – 35tC).*
Cold Soak Procedure has been completed. NOTE: Before starting the engine, the difference between ECT (Coolant Temp) and IAT (Intake Air) must be less than 13tF (7tC). (Refer to Examples 1 and 2 on previous page.) Drive Pattern Procedure
Connect the OBDII Scantool to DLC3 to check monitor status and preconditions.
Release the pressure in the fuel tank by removing and then reinstalling the fuel tank cap.
Start the engine and as soon as safely possible begin driving as directed. 2a. Drive the vehicle at 50 – 65 mph (80 – 104 km/h) for about 15 minutes. (See illustration on previous page.) NOTE:
Do not turn the ignition off until the drive pattern is complete.
Drive on smooth roads to reduce excessive fuel sloshing. If vehicle speed drops under 45 mph (72 km/h) repeat step “2a.” Page 20 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: Oxygen Monitors March 29, 2002 DRIVE PATTERN NO. 9: Oxygen Sensor Monitor (Front and Rear O2S System) Once Twice 3 times 10 times 25 mph (40 km/h) (over 900 rpm) Idling IG SW off Over 2 min (a) Over 50 sec (b) Over 40 sec (c) Over 50 sec Over 40 sec 50 sec 40 sec 50 sec (d) Preconditions The monitor will not run unless:
MIL is OFF. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. a. Start the engine and allow it to idle for 2 minutes or more. b. Drive the vehicle at 25 mph (40 km/h) or more for at least 50 seconds. Be sure engine speed remains above 900 rpm. c. Stop the vehicle and allow the engine to idle for 40 seconds or more. d. Perform steps “b” and “c” ten times. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” through “d.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 21 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: Oxygen Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 10: Oxygen/Air Fuel Ratio Sensor Monitor (Front AF Sensor and Rear O2S System) 40 – 70 mph (64 – 112 km/h) (900 – 3,200 rpm) Once 25 mph (40 km/h) (over 900 rpm) Twice 10 times Over 40 sec 40 sec Idling IG SW off Over 2 min (a) Over 3 min (b) Over 40 sec (d) Over Over 10 sec 10 sec (c) (e) Over 10 sec (f) Preconditions The monitor will not run unless:
MIL is OFF. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. a. Start the engine and allow it to idle for 2 minutes or more. b. Drive the vehicle at 40 – 70 mph (64 – 112 km/h) or more for at least 3 minutes. Be sure to maintain engine speed between 900 and 3,200 rpm. c. Stop the vehicle and allow the engine to idle for 10 seconds or more. d. Drive the vehicle at 25 mph (40 km/h) for at least 40 seconds or more. Be sure to maintain engine speed above 900 rpm. e. Stop the vehicle and allow the engine to idle for 10 seconds or more. f. Perform steps “d” and “e” ten times. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition switch OFF, then repeat steps “a” through “f.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 22 of 23 READINESS MONITOR DRIVE PATTERNS – EG003-02 Revised Readiness Monitor Drive Patterns: Oxygen Monitors (Continued) March 29, 2002 DRIVE PATTERN NO. 11: Oxygen/AF Sensor Heater Monitor 25 mph (40 km/h) Idling IG SW off 9 min (a) 2 min (b) Preconditions The monitor will not run unless:
MIL is OFF. Drive Pattern Procedure Connect the OBDII Scantool to DLC3 to check monitor status and preconditions. a. Start the engine and allow it to idle for 9 minutes. b. Drive the vehicle at 25 mph (40 km/h) or more for at least 2 minutes. If readiness status does not switch to “complete,” ensure preconditions are met, turn the ignition OFF, then repeat steps “a” and “b.” NOTE: The readiness status may not switch to “complete” after the first drive pattern trip if a Pending Code has been set (first trip for a two–trip DTC).
Pending Codes are available from the DTC Info Menu in Enhanced OBDII.
Pending Codes indicate a POTENTIAL problem was detected. A second trip is needed to confirm the DTC prior to diagnosis.
Once a second trip is completed, a current DTC will be stored. Page 23 of 23 Technical Service BULLETIN SULFUR ODOR FROM EXHAUST Models: All Models February 24, 2003 Introduction Applicable Vehicles Repair Procedure Some owners of Toyota vehicles may experience a sulfur–like or “rotten egg” odor from the exhaust system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably between gasoline brands and locations. S All Models. A sulfur odor emitted from the vehicle’s tailpipe does not necessarily indicate that there is an issue with the engine’s running condition, but is most likely directly related to the fuel. If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed: S If the MIL light is ON, check for DTCs and repair as necessary. If no trouble is found after performing the above check, recommend the customer try a different source of fuel. Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered warrantable. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ENGINE EG003-03 Title: ’99 Avalon, Camry & Solara June 11, 1999 Introduction Under certain driving conditions, some 1999 Model Year Avalon, Camry and Solaras will exhibit a false M.I.L. ON DTC P0446. A Vacuum Control Valve Assembly has been developed to prevent this condition. Production Change Information VIN RANGE MODEL FROM TO 4T1BF1#B*XU286982 4T1BF1#B*XU307913 JT2BG2#K*X0263387 JT2BG2#K*X0301683 4T1BG2#K*XU382466 4T1BG2#K*XU446663 4T1BG2#K*XU859688 4T1BG2#K*XU890371 JT2BF2#K*X0146113 JT2BF2#K*X0164251 4T1BF2#K*XU074015 4T1BF2#K*XU077714 4T1BF2#K*XU929580 4T1BF2#K*XU079278 Camry Solara 2T1CG2#P*XC055458 2T1CG2#P*XC142298 (4 Cylinder) 2T1CG2#P*XC736206 2T1CG2#P*XC766681 2T1CF2#P*XC055463 2T1CF2#P*XC142355 2T1CF2#P*XC722383 2T1CF2#P*XC766715 Avalon Camry (4 Cylinder) Camry (6 Cylinder) Camry Solara (6 Cylinder) ”#” May be a 2 or an 8. ”*” May be any number from 0 to 9 or an X. Parts Information PREVIOUS PART NUMBER N/A Warranty OPCODE Information 8602L2 CURRENT PART NUMBER 25852-20010 DESCRIPTION Vacuum Control Valve PART NAME Valve, Vacuum Control with Hoses TIME 0.5 OPN 25852-20010 T1 T2 99 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle s in-service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California and Massachusetts under the California Emission Warranty. * Warranty application is limited to correction of a problem based upon a customer s specific complaint. NOTE: Please enter the DTC P0446 in the Condition/Cause/Remedy Section when applying for Warranty Reimbursement. Toyota Supports ASE Certification Page 1of 2 ENGINE TSB DIAGNOSTIC TR OUBLE CODE P0446 Models: EG004-99 Technical Service BULLETIN Title: R E V I S E D TOYOTA DIAGNOSTIC TROUBLE CODE P0446 Repair Procedure – EG004-99 Revised 1. Verify that the Purge System is operating as specified in the Repair Manual. June 11, 1999 Figure 1 2. Raise vehicle on lift to gain access to the Purge Canister and remove the two Vacuum Lines indicated in Figure 1. Remove Save the Metal Clamps from the larger hoses for reuse. Use these two clamps on the New Hose Assembly 3. Install the New Hose Assembly as shown in Figure 2. Figure 2 Reuse the Hose Clamps removed in Step 2 on the large hose as indicated. Drain Hose Thin Hose Thick Hose to Canister Clamp must be above Hose and clamped onto Wire Harness Clamp onto Drain Hose Use Metal Clamps here Bottom of Vehicle 4. Verify that the Vacuum Hose Assembly is installed as shown in Figure 3. Figure 3 Route Larger Hose under Smaller Vacuum Hose. 5. After lowering vehicle verify that the Gas Cap is on securely. Rear of Vehicle Metal Tube attached to side of Body. Install the Two Clamps removed in Step "2" here. Page 2 of 2 Technical Service BULLETIN M.I.L. ON" P1133 Models: ’97–’99 Camry and ’99 Solara April 20, 2001 Introduction Under certain driving conditions, some 1997 – 1999 5S–FE California emission specification Camrys and 1999 5S–FE California emission specification Solaras may exhibit a M.I.L. “ON” with DTC P1133 (Air Fuel Ratio Sensor Slow Response Malfunction). An improved Air Fuel Ratio (A/F) Sensor was developed to correct this condition (See TSB EG006–99). In some rare cases, P1133 may still set after the improved A/F sensor is installed. The Engine Control Module (ECM) logic has been modified to correct this condition. Applicable Vehicles Parts Information Warranty Information S 1997 – 1999 model year Camrys with 5S–FE California emission specification. S 1999 model year Solaras with 5S–FE California emission specification. PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME 89661–3T451 89661–3T452 ECM,, 1999 AT 89661–06681 89661–06682 ECM,, 1999 MT 89661–3T271 89661–3T272 ECM,, 1998 AT 89661–06501 89661–06502 ECM,, 1998 MT 89661–3T041 89661–3T042 ECM, 1997 AT 89661–06371 89661–06372 ECM, 1997 MT 89661–3T471 89661–3T472 ECM, 1999 AT 89661–3T291 89661–3T292 ECM, 1998 AT Non Immobilizer Non–Immobilizer Immobilizer OP CODE DESCRIPTION TIME OPN T1 895011 Varied Work Code “N”. R & R ECM For DOHC 0.4 See Previous PN Above T2 99 99 Applicable Warranty*: This repair is covered under the Toyota Federal Emissions Warranty. This warranty is in effect for 96 months or 80,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 ENGINE EG004-01 Title: M.I.L. “ON” P1133 – EG004-01 Repair Procedure April 20, 2001 1. Should a M.I.L. “ON” condition with P1133 be encountered, perform diagnostic procedures as described in the Repair Manual. 2. If the problem source cannot be identified after checking all affected areas according to the Repair Manual, the cause may be an A/F Sensor or ECM logic malfunction. In this case, follow the procedure in the flowchart below to determine which part needs to be replaced. Replace the ECM only if the A/F Sensor in the vehicle was produced after August 31, 1999. DATE CODE PART NUMBER Check A/F Sensor Part Number If 89467–33010: Replace sensor with 89467–33011 If 89467–33011: Check A/F Sensor Date Code Number: If sensor was built before Aug. 31, 1999, Date Code 08U31: Replace with sensor built after Date Code 08U31. If sensor was built after Aug. 31, 1999, Date Code 08U31: Replace ECM with the improved one. A/F Sensor Date Code Number: 08 U 31 Month 08 = Aug. Year U = 1999 B = 2000 Page 2 of 2 Day Date Code Examples: 07U25 = July 25, 1999 02B15 = February 15, 2000 Technical Service BULLETIN April 27, 2001 Introduction Applicable Vehicles Contents Warranty Information EVAP SYSTEM OPERATION INFORMATION Models: All ’96 – ’01 Models This service bulletin provides supplemental information regarding the system design, operation, and diagnostics of the Early Type (Non–Intrusive) and Late Type (Intrusive) EVAP Systems found on 1996 model year and later OBD II equipped vehicles. MODEL 1996 1997 1998 1999 2000 2001 Avalon Early Early Early Early Late Late Camry Early (A/T only) Early Early Early Late Late Camry Solara N/A N/A N/A Early Late Late Celica N/A N/A Early Early Late Late Corolla N/A N/A Early Early Late Late ECHO N/A N/A N/A N/A Late Late MR2 N/A N/A N/A N/A Late Late Prius N/A N/A N/A N/A Late Late Tercel N/A Early Early Early N/A N/A 4Runner Early Early Early Early Early Late Land Cruiser N/A N/A Early Early Early Early RAV4 Early Early Early Early Early Late Sequoia N/A N/A N/A N/A N/A Late Sienna N/A N/A Early Early Early Late Tacoma Early (4WD only) Early Early Early Early Early Tundra N/A N/A N/A N/A Early Early T100 N/A Early Early N/A N/A N/A This bulletin is divided into the following sections: Early Type and Late Type EVAP System Outline 1. Early Type Description . . . . . . . . . . . . . . . . . . . . 2. Late Type Description . . . . . . . . . . . . . . . . . . . . . 3. ECHO Late Type Description . . . . . . . . . . . . . . 4. Late Type System Monitor Sequence . . . . . . Diagnostic Tips For Late Type EVAP System . . . . . . . . . . Pages 2–4 Pages 4–6 Page 6 Pages 6–9 Pages 10–14 OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 14 ENGINE EG005-01 Title: EVAP SYSTEM OPERATION INFORMATION – EG005-01 Early Type System Description April 27, 2001 Early Type (Non–Intrusive) EVAP System Overview There are a variety of EVAP systems in use with different monitoring strategies. It is essential that the EVAP system be correctly identified before beginning diagnosis. The Repair Manual is the best source for this information. The following information covers the different systems. The first system described is the Early Type (Non–Intrusive) EVAP System. Refer to the Applicable Vehicles chart for applicability information. Onboard Recovery Valve (Fill Check Valve) Vapor Pressure Sensor Vapor Pressure Sensor Three Way VSV Vacuum Check Valve Tank Valve Assembly Pressure Valve Canister To Manifold Vacuum Purge Valve Filtered Air Air Inlet Line Service Port Air Drain Valve Air Inlet Valve Air Valve Assembly Purge Operation When the engine has reached predetermined parameters (closed loop, engine temp. above 125
F, etc.), stored fuel vapors are purged from the canister whenever the purge VSV is opened by the ECM. At the appropriate time, the ECM will turn on the purge VSV. Purge VSV Fresh Air Inlet The ECM will change the duty ratio cycle of the purge VSV thus controlling purge flow volume. Purge flow volume is determined by manifold pressure and the duty ratio cycle of the purge VSV. Atmospheric pressure is allowed into the canister to ensure that purge flow is constantly maintained whenever purge vacuum is applied to the canister (see Figure 1). Page 2 of 14 Figure 1. Purge Operation EVAP SYSTEM OPERATION INFORMATION – EG005-01 Early Type System Description (Continued) April 27, 2001 ORVR Operation During refueling, low pressure above the diaphragm in the onboard recovery valve lifts allowing fuel vapors into the charcoal canister. At the same time, the air drain valve opens and the charcoal absorbs the fuel vapors (see Figure 2). Figure 2. ORVR Operation Early Type (Non–Intrusive) EVAP System DTCs EVAP Monitor Leak Operation P0440 The ECM tests for leaks by measuring EVAP system pressure in the lines, charcoal canister, and fuel tank. When the EVAP pressure is higher or lower than atmospheric pressure, the ECM concludes that no leaks are present. EVAP pressure is measured by the vapor pressure sensor. If either the tank or canister purge side is at atmospheric pressure under specific conditions, the ECM determines there is a leak. Figure 3. Fuel Tank Side of System If DTC P0440 is present, the leak is on the fuel tank side of the EVAP system. This also includes the lines between the fuel tank and part of the canister. When the Vapor Pressure sensor is measuring tank pressure, the ECM is observing changes in pressure and comparing tank pressure to atmospheric pressure. No difference in pressure indicates a leak. The ECM may take 20 minutes or more to complete testing the fuel tank side (see Figure 3). Canister Leak Detection P0446 When the ECM switches the vapor pressure VSV to canister side, the ECM measures canister pressure. A leak on the canister side can set multiple DTCs (see Figure 4). Figure 4. Canister Side of System Page 3 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Early Type System Description (Continued) April 27, 2001 Vapor Purge Flow P0441 The EVAP monitor is designed to detect: S Restricted vapor purge flow when the purge VSV is open S Inappropriate vapor purge flow when the purge VSV is closed Under normal purge conditions, pressure pulsations generated by the cycling of the purge VSV are present in the canister and detected by the Vapor Pressure sensor. Figure 5. Flow During Purge Operation Three–Way VSV P0446 The three–way VSV is connected to the Vapor Pressure sensor, canister, and fuel tank. This VSV allows the Vapor Pressure sensor to detect either canister or tank pressure. There are two modes the ECM can use to determine if the three–way VSV is malfunctioning. The three–way VSV is judged to be normal if there is pressure difference between the tank and canister when the three–way VSV is switched to look at the charcoal canister and fuel tank side of system. If there isn’t any pressure difference between the fuel tank and canister, the ECM looks for the following conditions: S During purging, pressure pulsations generated by the purge VSV are not present in the canister as detected by Vapor Pressure sensor, the three–way VSV is judged to be defective. S If there are pressure pulsations detected by the Vapor Pressure sensor present in the fuel tank, the three–way VSV is judged to be defective. Late Type System Description Late Type (Intrusive) EVAP System Overview The Late Type EVAP System, also known as the Intrusive type, was developed to meet the very stringent, mandated standard of detecting a hole 0.020 inch (0.5 mm). This system uses many of the same components as the early type EVAP system. Purge, vacuum relief, pressure relief, and ORVR operations are identical to the early type. Refer to the Applicable Vehicles chart for applicability information. The following changes were made to the Late Type EVAP System: S Vapor pressure sensor connected to the fuel tank. S Bypass VSV in the place of the three way VSV. S Canister Closed Valve (CCV) on the air inlet line. Page 4 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Late Type System Description (Continued) April 27, 2001 Late Type (Intrusive EVAP System) (Except ECHO) Onboard Recovery Valve (Fill Check Valve) Vapor Pressure Sensor Vacuum Check Valve Tank Valve Assembly Tank Pressure Valve Canister To Manifold Vacuum Purge VSV Filtered Air Canister Closed Valve Service Port Bypass VSV Air Inlet Line Air Inlet Valve Air Drain Valve Tank Side The bypass VSV and the fill check valve assembly isolates the tank pressure side from the canister side (see Figure 1). Air Valve Assembly Except ECHO Figure 1. Fuel Tank Side of System Canister Side The bypass VSV and the Fill Check valve also isolate the canister side from the tank side (see Figure 2). Except ECHO Figure 2. Canister Side of System Page 5 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Late Type System Description (Continued) April 27, 2001 ECHO Late Type (Intrusive EVAP System) The ECHO uses a Late Type EVAP System but is configured with some small differences. For the ECHO, the Canister Closed Valve is located directly on the canister. Additionally, the bypass VSV has been eliminated. Onboard Recovery Valve (Fill Check Valve) Vapor Pressure Sensor Canister Air Inlet Valve To Manifold Vacuum Purge Valve Filtered Air Canister Closed Valve Air Drain Valve Assembly Late Type System Monitor Sequence Air Valve Assembly Late Type (Intrusive) EVAP System Monitor Sequence The monitoring sequence for leak detection is different from that of the Early Type EVAP System. The Late Type applies a very small vacuum to the EVAP system. The ECM then determines if there is a problem in the system based on the vapor pressure sensor signal. Monitor Sequence (Except ECHO) Open CCV Open Closed Open Bypass Closed Closed Open Open Purge Closed Purge Closed Vapor Pressure Sensor Signal Time in Minutes Cold Start ECT/IAT Near Same Temp Negative Pressure (Vacuum) Occurs P0441 Page 6 of 14 Leak Testing CCV Bypass VSV Op Period Occurs Op P0440 P0442 P0446 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Late Type System Monitor Sequence (Continued) April 27, 2001 ECHO Monitor Sequence Open CCV Open Closed Open Open Purge Closed Purge Closed Vapor Pressure Sensor Signal Cold Start ECT/IAT Near Same Temp Negative Pressure (Vacuum) Occurs Tank & Canister Leak Check CCV Testing Monitor Operation The monitor sequence begins with a cold engine start. The IAT and ECT sensors must have approximately the same temperature reading. The ECM is constantly monitoring fuel tank pressure. As the temperature of the fuel increases, pressure slowly rises. Except ECHO Figure 1. Canister Purge The ECM will purge the charcoal canister at the appropriate time (see Figure 1). With bypass VSV closed, pressure will continue to rise in fuel tank. ECHO Figure 1. Canister Purge Page 7 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Late Type System Monitor Sequence (Continued) Purge VSV Operation – P0441 At a predetermined point, the ECM closes the CCV and opens the bypass VSV causing vacuum to increase in the entire EVAP system. The ECM continues to operate the purge VSV until the vacuum is increased to a specified point at which time the ECM closes the purge VSV (see Figure 2). If the vacuum did not increase, or if the vacuum increased beyond the specified limit, the ECM judges the purge VSV and related components to be faulty. April 27, 2001 Except ECHO Figure 2. Vacuum Application ECHO Figure 2. Vacuum Application Hole Detection P0440 and P0442 The rate of pressure increase as detected by the vapor pressure signal indicates the if there is a leak and if it is a large or small leak. After purge VSV operation, the purge VSV is turned off sealing the vacuum in the system and the ECM begins to monitor the pressure increase (see Figure 3). Some increase is normal. A very rapid, sharp increase in pressure indicates a leak in the EVAP system and sets the DTC P0440. Except ECHO Figure 3. System Sealed ECHO This monitoring method is also able to distinguish what is called the small leak detection. A pressure rise just above normal indicates a very small hole and will set the DTC P0442. Figure 3. System Sealed Page 8 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Late Type System Monitor Sequence (Continued) Vent Control, CCV Operation P0446 This stage checks the CCV and vent (air inlet side) operation. When the vapor pressure rises to a specified point, the ECM opens the CCV. Pressure will increase rapidly because of the air allowed into the system. No increase or an increase below specified rate of pressure increase indicates a restriction on the air inlet side (see Figure 4). April 27, 2001 Except ECHO Figure 4. CCV Opens ECHO Figure 4. CCV Opens Bypass VSV Operation P0446 In the next stage, the ECM closes the bypass VSV. This action blocks air entering the tank side of the system. The pressure rise on the fuel tank side is no longer as great. If there was no change in pressure, the ECM will conclude the bypass VSV did not close (see Figure 5). Except ECHO Figure 5. Bypass VSV Closes Page 9 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Diagnostic Tips for Late Type EVAP System April 27, 2001 This diagnostic process tests the EVAP System. The following diagnostic tips may be used in conjunction with the Diagnostic Procedures for EVAP DTCs listed in the Repair Manual. They may be used for all Late Type (Intrusive) EVAP Systems and for all EVAP DTCs. Refer to the Applicable Vehicles chart for applicability information. The EVAP System Pressure Test Kit (P/N 00002–6872A) and the Scan Tool can be used to diagnose the EVAP System. Measuring EVAP System pressures using the EVAP System Pressure Tester Gauge and the Scan Tool can aid in the identification of leaks in the system. System Outline (Except ECHO) Onboard Recovery Valve (Fill Check Valve) Vapor Pressure Sensor Tank Valve Assembly Vacuum Check Valve Tank Pressure Valve Canister To Manifold Vacuum Purge VSV Filtered Air Canister Closed Valve Service Port Bypass VSV Air Inlet Line Air Inlet Valve Air Valve Assembly Air Drain Valve ECHO System Outline Onboard Recovery Valve (Fill Check Valve) Vapor Pressure Sensor Air Inlet Valve Canister To Manifold Vacuum Purge VSV Filtered Air Service Port Page 10 of 14 Air Inlet Line Air Drain Valve Air Valve Assembly Canister Closed Valve EVAP SYSTEM OPERATION INFORMATION – EG005-01 Diagnostic Tips for Late Type EVAP System (Continued) April 27, 2001 Diagnostic Process Flow Chart START PRELIMINARY CHECK S Fuel level should be between 1/4 and 3/4 S Visually inspect for presence of Fuel/Gas Cap DO NOT TIGHTEN OR REMOVE! NG DO NOT PROCEED! OK SCAN TOOL SETUP A) Connect Scan Tool to DLC3 on vehicle. B) Go to the SETUP menu and select UNIT CONVERSION. C) Under VAPOR PRESSURE, Select ABS for absolute pressure, and mmHg for millimeters of mercury. This is to match the Repair Manual specifications. D) Go back to FUNCTION SELECT menu and select ENHANCED OBD II. E) Select NORMAL MODE. Then select CURRENT DATA and USER SELECT. F) Using the arrow key, select VAPOR PRESS from the DATA LIST and select YES. G) Press ENTER. You will now be able to monitor the Vapor Pressure Sensor reading. If vehicle is ECHO, go directly to “ECHO Canister and Tank Leak Check” on page 14. If vehicle is not ECHO, follow the flow chart below. PRESSURIZE EVAP SYSTEM (System Integrity Check) This test checks for leaks in the canister and fuel tank sides. The CCV and Air Inlet Lines will be checked separately. A) Clamp the air drain hose on the charcoal canister with the supplied hose pliers from the EVAP System Pressure Test Kit. B) Locate the vapor pressure sensor. If the vapor pressure sensor has two hoses connected to it, disconnect the hose between the air drain hose fitting at the vapor pressure sensor and plug the hose. C) Connect the pressure supply hose from the Pressure Test Kit to the Green EVAP System Service Port located on the EVAP Purge VSV line in the engine compartment. D) Using the directions on the inside of the EVAP System Pressure Test Kit lid, pressurize the EVAP system. Once pressurized, turn off the pump and seal the system (Pressure Hold Switch to “Closed” and Vent Switch to “Closed). E) After 30 seconds, note the pump pressure gauge reading and the Scan Tool vapor pressure sensor reading. F) Compare the readings to one of the four conditions listed below and proceed as directed. (Continued on following page) Page 11 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Diagnostic Tips for Late Type EVAP System (Continued) April 27, 2001 Diagnostic Process Flow Chart (Continued) (Continued from previous page) Pump pressure gauge and vapor pressure above atmospheric pressure (above 762 mmHg). No leak in canister or tank. Pump pressure gauge zero, vapor pressure above atmospheric pressure (above 762 mmHg). Leak is on canister side of system. Pump pressure gauge is above atmospheric pressure (above zero), vapor pressure is at 762 mmHg. Leak is on the fuel tank side of system. Pump pressure gauge at zero, vapor pressure is at 762 mmHg. The leak(s) is/are on the canister and tank sides or a leak at a point common to both sides of system. Remove hose pliers from the air drain hose on the charcoal canister before proceeding with additional checks. Remove hose pliers from the air drain hose on the charcoal canister before proceeding with additional checks. Remove hose pliers from the air drain hose on the charcoal canister before proceeding with additional checks. Remove hose pliers from the air drain hose on the charcoal canister before proceeding with additional checks. Go to CCV/Air Inlet Line Check. Go to “Canister Leak Check.” Diagram on page 13. Go to “Fuel Tank Leak Check.” Diagram on page 13. Go to “Fuel Tank Leak Check.” Diagram on page 13. CCV and Air Inlet Line Check. (Except ECHO) A) Disconnect the air inlet line from the charcoal canister. B) Using the supplied step–down brass adapter (or equivalent) connect the Pressure Supply Hose to the air inlet line. C) Using the Scan Tool Active Test, turn on the CCV. This will close the CCV. D) Pressurize the line. Once pressurized, turn off the pump and seal the line (Pressure Hold Switch to “Closed” and Vent Switch to “Closed”). Pressure should hold. If not, check CCV and connections. E) Next, using the Scan Tool, turn off the CCV. This will open the CCV. The pressure should decrease. If not, check the CCV and connections. F) After completing the test, reconnect air inlet line to charcoal canister. Go to “Return Vehicle to Service” on page 14. Page 12 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Diagnostic Tips for Late Type EVAP System (Continued) April 27, 2001 Fuel Tank Leak Check (Except ECHO) Disconnect EVAP Hose Here A. Using the supplied brass step–down adapter, disconnect the EVAP hose from the charcoal canister side as indicated above. Connect Pressure Supply hose from Pressure Test Kit to the EVAP hose and pressurize the fuel tank to 30 mmHg (4 kPa / 0.58 psi). B. Check that the internal pressure of the tank will hold for 1 minute. Check shaded areas for leaks (soapy water can be used for leak detection). If pressure holds, then perform the Canister Leak Check. C. When done, reconnect the EVAP line hose to the charcoal canister. Canister Leak Check (Except ECHO) A. Connect the Pressure Supply hose from the Pressure Test Kit to the Green EVAP System Service Port located on the EVAP Purge VSV line in the engine compartment. B. Using the directions on the inside of the EVAP System Pressure Test Kit lid, pressurize the EVAP system. Once pressurized, turn off the pump and seal the system (Pressure Hold Switch to “Closed” and Vent Switch to “Closed”) C. With system pressurized at EVAP Service Port, check shaded areas for leaks (soapy water can be used for leak detection). Page 13 of 14 EVAP SYSTEM OPERATION INFORMATION – EG005-01 Diagnostic Tips for Late Type EVAP System (Continued) April 27, 2001 ECHO Canister and Tank Leak Check A. Connect the Pressure Supply hose from the Pressure Test Kit to the Green EVAP System Service Port located on the EVAP Purge VSV line in the engine compartment. B. Using the directions on the inside of the EVAP System Pressure Test Kit lid, pressurize the EVAP system. Once pressurized, turn off the pump and seal the system (Pressure Hold Switch to “Closed” and Vent Switch to “Closed”) C. With system pressurized, check shaded areas for leaks (soapy water can be used for leak detection). Return Vehicle to Service A. After performing checks and/or repairs, be sure to reconnect all lines and verify that all plugs and hose pliers used for diagnosis have been removed. B. For additional diagnostic procedures and information, refer to the appropriate Repair Manual. Page 14 of 14 Technical Service BULLETIN GENERAL MAINTENANCE TIP Models: All ’93 – ’03 Models March 22, 2002 Introduction Applicable Vehicles Oil Filling Procedure To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These devices can place stress on the baffle, and bend or break it during the oil fill process. S All 1993 – 2003 model year Toyota vehicles. Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral damage occurs. Oil Fill Gun Valve Cover Example of Bent Oil Baffle (View From Underneath Valve Cover) Oil Baffle Bent Oil Baffle Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ENGINE EG007-02 Title: Technical Service BULLETIN M.I.L. ON" P0440, P0441 & P0446 Models: ’98 – ’99 Camry & Solara July 12, 2002 Introduction Under certain driving conditions, some 1998 – 1999 model year Camry and Solara vehicles may exhibit a M.I.L. “ON” with DTCs P0440, P0441 and P0446 stored due to an inoperative Vapor Pressure Sensor 3 way Vacuum Switching Valve (VSV). An improved Vapor Pressure Sensor VSV has been developed to correct this condition.
1998 – 1999 model year Camry & Solara vehicles. Applicable Vehicles Parts Information Required Tools & Material PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 90910–12109 90910–12271 Vapor Pressure Sensor VSV 1 TOOLS & MATERIAL PART NUMBER QUANTITY 01001271 1 01002593-005 1 Hand Operated Vacuum Pump N/A 1 Digital Volt Ohm Meter (DVOM) 09082–00050 (Or Equivalent) 1 Toyota Diagnostic Tester Kit* 12 Megabyte Diagnostic Tester Program Card with version 9.01a Software (or later)* * Essential SSTs. NOTE: Additional Diagnostic Tester Kits, Program Cards or SSTs may be ordered by calling OTC at 1-800-933-8335. Warranty Information OP CODE 178011 DESCRIPTION TIME R & R Vacuum Switching Valve (4 Cylinder) 0.4 R & R Vacuum Switching Valve (6 Cylinder) 0.2 OFP 90910 12109 90910–12109 T1 T2 72 83 Applicable Warranty*: This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 5 ENGINE EG013-02 Title: M.I.L. “ON” P0440, P0441 & P0446 – EG013-02 Inspection & Repair Procedure July 12, 2002 Test VSV Operation Using ACTIVE TEST on the Toyota Diagnostic Tester 1. Test operation of the Vapor Pressure Sensor VSV using the Toyota Diagnostic Tester in ACTIVE TEST (see screen flow in Figure 1). Figure 1: Testing Operation of Vapor Pressure Sensor VSV using ACTIVE TEST A *APPLICATION SELECT* 1: DIAGNOSIS 2: CUSTOMIZE 3: ECU REPROGRAM D SELECT DATA INJ VOL A/F CONTROL FUEL PMP SP CTL A/C CUT SIG CAN CTRL VSV TANK BYPASS VSV EVAP VSV (ALONE) FUEL PUMP/SPD LINE PRESS UP B FUNCTION SELECT FOR NORTH AMERICA 1: OBD/MOBD 2: ENHANCED OBD 3: CARB OBD II 4: BREAK–OUT BOX 5: NVH 6: AUTOPROBE 7: 02 RPM CHECK 8: SNAPSHOT REVIEW 9: SETUP 0: GAS ANALYSIS E SELECT DATA ALL USER DATA PRESS [ENTER] C DIAGNOSTIC MENU ENGINE 1: DATA LIST 2: DTC INFO 3: ACTIVE TEST 4: SNAPSHOT 5: SYSTEM CHECK 6: RESET MEMORY 7: MONITOR STATUS 8: CHECK MODE F INJECTOR 0.0ms IGN ADVANCE 5.0deg CALC LOAD 0% MAF 0gm/s ENGINE SPD 0rpm COOLANT TEMP 77.0tF INTAKE AIR 87.8tF THROTTLE POS 16% CTP SW ON VEHICLE SPD 0MPH 02S B1 S1 0.00V TANK BYPASS VSV "OFF G INJECTOR 0.0ms IGN ADVANCE 5.0deg CALC LOAD 0% MAF 0gm/s ENGINE SPD 0rpm COOLANT TEMP 77.0tF INTAKE AIR 87.8tF THROTTLE POS 16% CTP SW ON VEHICLE SPD 0MPH 02S B1 S1 0.00V TANK BYPASS VSV "ON NOTE: Vapor Pressure Sensor VSV is listed as TANK BYPASS VSV on the Diagnostic Tester. Page 2 of 5 M.I.L. “ON” P0440, P0441 & P0446 – EG013-02 Inspection & Repair Procedure (Continued) July 12, 2002 2. Locate Vapor Pressure Sensor VSV as shown in Figure 2 (or see SFI section of 1998 or 1999 Camry or Solara Repair Manual). Figure 2: Vapor Pressure Sensor VSV Components Vapor Pressure Sensor VSV Connector Vapor Pressure Sensor VSV Charcoal Canister 3. Using the Diagnostic Tester ACTIVE TEST, switch the Vapor Pressure Sensor VSV (TANK BYPASS VSV) to ON using the arrow keys. 4. Does the Vapor Pressure Sensor VSV make a “click” noise when switched to ON? YES " Go to “Test VSV for Vacuum Leaks” (page 4 and 5 of this TSB). NO " Go to Step 5. 5. Is the wiring harness connector properly connected to the Vapor Pressure Sensor VSV? YES " Go to Step 6. NO " Fix the connector, then return to Step 3. 6. Disconnect the wiring harness connector for the Vapor Pressure Sensor VSV. 7. Using a DVOM test at Pin 1 to a known good ground. (Red wire on Solara, black and yellow wire on Camry). Is battery voltage (B+) present at Pin 1 of the Vapor Pressure Sensor VSV connector when the TANK BYPASS VSV ACTIVE TEST is switched to ON? YES " Go to Step 8. NO " Perform diagnosis of power circuit. Page 3 of 5 M.I.L. “ON” P0440, P0441 & P0446 – EG013-02 Inspection & Repair Procedure (Continued) July 12, 2002 8. Using a DVOM test at Pin 2 to a known good ground. The ECM provides ground when the VSV is switched ON. (White and red wire on Solara, violet wire on Camry). Is there continuity to ground at Pin 2 of the Vapor Pressure Sensor VSV connector when the TANK BYPASS VSV ACTIVE TEST is switched to ON? YES " Replace the Vapor Pressure Sensor VSV. NO " Perform diagnosis of ground circuit. Test VSV for Vacuum Leaks 1. Locate the vacuum hose going from charcoal canister to Port F of the Vapor Pressure Sensor VSV (see Figure 3). Figure 3 Vapor Pressure Sensor Vacuum Hose Bracket PORT F Vacuum Hose Vacuum Hose Vapor Pressure Sensor VSV VSV Connector Charcoal Canister 2. Remove vacuum hose from Port F of the Vapor Pressure Sensor VSV and connect a hand–held vacuum pump to Port F using a short length of vacuum hose. 3. Apply at least 10 mm Hg vacuum to the VSV. Is a vacuum held for at least 1 minute? YES " Go to Step 4. NO " Replace the Vapor Pressure Sensor VSV. 4. Disconnect the hand–held vacuum pump and reconnect the vacuum hose from the canister to the Vapor Pressure Sensor VSV. Page 4 of 5 M.I.L. “ON” P0440, P0441 & P0446 – EG013-02 Inspection & Repair Procedure (Continued) July 12, 2002 5. Locate the vacuum hose going from charcoal canister to Port P of the Vapor Pressure Sensor VSV (see Figure 4). Figure 4 Vapor Pressure Sensor Vacuum Hose HOSE TO REMOVE Bracket Vacuum Hose Vapor Pressure Sensor VSV Vacuum Hose PORT P VSV Connector Charcoal Canister 6. Remove the vacuum hose from Port P of the Vapor Pressure Sensor VSV and connect a hand–held vacuum pump to Port P using a short length of vacuum hose. 7. Apply at least 10 mm Hg vacuum to the VSV. Is a vacuum held for at least 1 minute? YES " Go to Step 8. NO " Replace the Vapor Pressure Sensor VSV. 8. Disconnect the hand–held vacuum pump and reconnect the vacuum hose from the canister to the Vapor Pressure Sensor VSV. 9. Continue diagnosis of the EVAP system. Reference TSB EG005–01, “EVAP System Operation Information.” Page 5 of 5 SINGLE CYLINDER MISFIRES Technical Service BULLETIN Models: ’99 Avalon, Camry, Sienna & Solara December 17, 1999 Introduction Some 1999 Avalon, Camry (1MZ–FE), Sienna & Solara (1MZ–FE) vehicles may exhibit a rough idle, and or a M.I.L. “ON” condition, in which a single cylinder misfire code, or codes are present. Changes have been made in the fuel injector production process to correct this condition. Applicable Vehicles S 1999 TMMK produced Avalon, Camry (1MZ–FE), Sienna & TMMC produced Solara (1MZ–FE) vehicles built between the VIN numbers listed below. Parts Information Warranty Information MODEL STARTING VIN ENDING VIN Avalon 4T1BF1#B * XU298504 4T1BF1#B*XU319557 Camry 4T1BF2#K * XU076403 4T1BF2#K*XU081214 Camry (cont.) 4T1BF2#K * XU930024 4T1BF2#K*XU931330 Sienna 4T3ZF1#C * XU090887 4T3ZF1#C*XU122589 Solara (U.S.) 2T1CF2#P * XC111083 2T1CF2#P*XC757508 Solara (Canada) 2T1CF2#P * XC744113 2T1CF2#P*XC162681 APPLICABLE PARTS QUANTITY PART NAME 23209–0A010 6 Fuel Injector OP CODE VWC DESCRIPTION TIME OPN 895221 N R & R Fuel Injector Assembly – All 1.8 23209–0A010 T1 T2 02 56 Applicable Warranty*: This repair is covered under the Toyota Federal Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. Coverage is extended to 36 months or 50,000 miles, whichever occurs first, in the states of California, Massachusetts, and Vermont due to state emission warranty legislation. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. NOTE: Be sure to enter the DTC No. in the Condition/Cause/Remedy section, if a DTC Code appeared. Toyota Supports ASE Certification Page 1 of 2 ENGINE EG013–99 Title: SINGLE CYLINDER MISFIRE – EG013–99 Repair Procedure 1. Remove all six fuel injectors for verification of production information. Affected injectors will be labeled with a vendor part number of “23250–0A010” and have a production date code number of “828“ or lower (see illustration for number locations). 2. After determining that one or more of the injectors are affected, replace all six injectors with the above applicable part number. 3. Clear the DTC, if present, and verify that the vehicle now operates as designed. Page 2 of 2 December 17, 1999 Production Date Part Number Technical Service BULLETIN M.I.L. ON" DTC P1133 Models: ’97–’99 Camry and ’99 Solara: 5S–FE CA Spec. October 1, 1999 Introduction Under certain driving conditions, some 5S–FE equipped 1997–1999 Camry and 1999 Solara California emission specification vehicles may exhibit a M.I.L. “ON” DTC P1133. An improved Air Fuel Ratio Sensor has been developed to correct this condition. S 1997 – 1999 Camry & 1999 Solara (5S–FE) with California emission specification. Applicable Vehicles Production Change Information MODEL YEAR ORIGIN ENGINE STARTING VIN JPN JT2BG2#K*X0363615 4T1BG2#K*XU603913 1999 Camry NAP (5S–FE) 4T1BG2#K*XU918675 2000 Solara * * Parts Information Repair Procedure –– # May be a 2 or an 8. * May be any number from 0 to 9 or an X. PREVIOUS PART NUMER CURRENT PART NUMBER PART NAME 89467–33010 89467–33011 Sensor, Air Fuel S Should a M.I.L. “ON” condition with DTC P1133 be encountered, perform diagnostic procedures as described in the Repair Manual. S If the problem source cannot be identified after checking all affected areas according to the Repair Manual, the cause may be an Air/Fuel Ratio Sensor malfunction. In this case, replace the Air/Fuel Ratio Sensor with the updated part. S If the Exhaust Manifold threads are damaged by removal of the sensor, they can be repaired by the proper use of a M18 x 1.5 tap. Warranty Information OPCODE DESCRIPTION TIME OPN T1 T2 EL9006 Sensor, Air Fuel Ratio 0.3 89467–33010 99 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. Coverage is extended to 36 months or 50,000 miles, which ever occurs first, in the states of California and Massachusetts due to state emissions warranty legislation. NOTE: Please enter the DTC in the condition/Cause/Remedy section when applying for warranty reimbursement. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 ENGINE EG009–99 Title: Technical Service BULLETIN CIGARETTE LIGHTER SERVICE Models: All Models Apirl 10, 1998 Introduction Service Procedure When receiving customer complaints to repair the lighter or lighter socket, please carefully investigate the cause of the failure to prevent further occurrences. If the customer uses the wrong size lighter element or power accessory plug, damage may occur to the lighter socket. When applicable, instruct the customer to replace the lighter element with original equipment components or to use an appropriate sized accessory plug. Dimensional information included within this document will instruct you on component specifications. 1. Determine if the lighter is original equipment by using the specifications shown. a. If the vehicle has a non–genuine lighter element, it has the possibility to cause a short circuit between the lighter element and the lighter socket, which can result in an open fuse. b. A non–genuine lighter element may cause a rattle or bend the socket bimetal contacts. c. If a non–genuine lighter element is being used, advise the customer to use an original equipment element. DRAWING WITH DIMESIONS Knob 8.4 mm (0.33”) Genuine 22.5 (0.88”) FEATURES Bimetal 17.7–17.8 mm (0.697–0.7”) TYPE Ash No Problem to use. Plate Heater Element Heater Head Guard 20.7 mm (0.81”) 13 mm (0.51”) Non–Genuine 25.5 mm (1.0”) 20.8 mm (0.82”) 11 mm (0.43”) 24 mm (0.94”) Toyota Supports ASE Certification Too long an ash guard will contact bimetal (positive circuit) plate and cause fuse to melt. Excessive free play on the heater head which allows contact between heater element, socket body and bimetal plate, will cause fuse to melt. Page 1 of 2 ELECTRICAL EL002–98 Title: CIGARETTE LIGHTER SERVICE – EL002-98 b. Using a power plug larger than the given dimensions may damage the lighter socket. < 20.5 mm (0.81”) > 15 mm (0.59”) 25 – 30 mm (0.79 – 1.18”) > 2 Terminals < 20.5 mm (0.81”) a. The attached specifications in the drawing provide the maximum recommended size of accessory plug. If the customer is using an accessory plug larger than recommended, please advise the customer to use a plug of appropriate size. Recommended Accessory Plug Shape <13 mm (0.51”) 2. If the lighter element is original equipment and the lighter socket is bent or pulled out of the dash, please ask the customer about the accessory plug being used in the lighter socket. 13 mm (0.51”) Service Procedure (Continued) April 10, 1998 > 8.5 mm (0.33”) 25 – 30 mm (0.79 – 1.18”) c. If the vehicle has a power point socket, advise the customer to use this socket instead of the lighter socket. Affected Vehicles Warranty Information Page 2 of 2 S All models, all model years OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – SPEEDOMETER/TACHOMETER NEEDLE MOVEMENT Technical Service BULLETIN Models: ’99 – ’00 Camry, Corolla, Sienna, & Solara & ’00 Avalon February 11, 2000 December 13, 2002 TSB REVISION NOTICE: The information contained in this TSB was revised on December 13, 2002. The previous TSB should be discarded. Introduction Some vehicles may experience a slight, intermittent resistance to movement of the speedometer or tachometer needle near zero during the first few miles of travel. The condition can be corrected by following the repair method outlined below. NOTE: This repair does not apply to speedometers or tachometers which are permanently inoperative. Applicable Vehicles S 1999 – 2000 model year Camry, Corolla, Sienna, & Solara, and 2000 model year Avalon between the following VINs: MODEL STARTING VIN ENDING VIN Avalon 4T1BF28B * YU001171 4T1BF28B * YU030913 4T1BG2 * K * XU424095 4T1BG2 * K * YU657647 4T1BG2 * K * XU869714 4T1BG2 * K * YU957337 4T1BF2 * K * XU077249 4T1BF2 * K * YU098224 4T1BF2 * K * XU930237 4T1BF2 * K * YU940492 1NXBR1 * E * XZ171600 1NXBR1 * E * XC171600 1NXBR1 * E * YZ359500 1NXBR1 * E * YC359500 2T1BR1 * E * XC120816 2T1BR1 * E * YC291439 Sienna 4T3 * F1 * C * XU096570 4T3 * F1 * CZ * XU096570 4T3 * F1 * C * YU236332 4T3 * F1 * CZ * YU236332 Solara 2T1 * * 2 * P * XC122747 2T1 * * 2 * P * YC291165 Camry Corolla Warranty Information OP CODE MODEL DESCRIPTION TIME OFP 830011 Avalon, Camry, Corolla, Sienna, & Solara T1 R & R Speedometer Assembly 0.4 83220–XXXXX T2 73 83 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 2 ELECTRICAL EL003–00 Title: SPEEDOMETER/TACHOMETER NEEDLE MOVEMENT – EL003-02 Parts Information PREVIOUS PART NUMBER CURRENT PART NUMBER Repair Procedure Same Tachometer TOOLS & MATERIALS QUANTITY Double Sided Cotton Swab 1 Distilled Water 1 oz. 1. Remove the combination meter assembly per repair manual instructions. 2. Remove the window plate from the instrument cluster. 3. Clean the entire surface of the needle and needle stopper as illustrated. Using one end of a double sided cotton swab, clean the contact point between the pointer and the stopper pin on the speedometer and tachometer with distilled water. S Use only a new, clean cotton swab. S Use only distilled water. S Use a new swab each time a part is cleaned (one per speedometer, one per tachometer). NOTE: S After cleaning, do not touch the pointer needle or stopper pin. S Do not blow dry the pointer or stopper pin. 4. Use the opposite (dry) end of the cotton swab to dry the previously cleaned area. 5. Reassemble parts and assemble to vehicle. 6. Confirm proper working condition of speedometer and tachometer. S Confirm no foreign material entered the cluster while the window plate was removed. Page 2 of 2 PART NAME Speedometer 83220 XXXXX 83220-XXXXX Required Tools & Material Revised: December 13, 2002 February 11, 2000 Technical Service BULLETIN October 8, 1999 ENGINE IMMOBILIZER SYSTEM PRECAUTIONS Models: All Models REVISION NOTICE: The information contained in this TSB updates EL001–98 dated January 23, 1998. Introduction This bulletin applies to 1998 and newer Toyota vehicles. When using an immobilizer key containing a transponder chip, observe the following precautions while starting the engine. 1. The key ring should not rest on or be pressed against the key grip. 2. Do not place any other transponder devices on the same key ring. Such devices would include transponder equipped units used for charging fuel. 3. Do not place any other immobilizer keys on the same key ring with the key used to start the vehicle. 4. If the above precautions are not observed and an engine starting or running problem occurs, remove all items which may interfere with the ignition key transponder signal. Turn off the engine and then restart. Applicable Vehicles Warranty Information S All Toyota models equipped with an engine immobilizer system. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 ELECTRICAL EL006–99 Title: Technical Service BULLETIN April 14, 2000 Introduction HEATER CONTROL ASSEMBLY INSTRUCTIONS Models: ’97 – ’99 Camry The attached instructions have been developed to supplement the Repair Manual to assure corrrect cable routing of the heater control assembly during a service repair. PUBLICATION NUMBER 1997 Camry Repair Manual, Vol. 2 RM503U2 1998 Camry Repair Manual, Vol. 2 RM589U2 1999 Camry Repair Manual, Vol. 2 RM654U2 NOTE: For maximum heater performance the coolant ratio should be 50 to 60 percent. Applicable Vehicles Warranty Information S 1997 – 1999 model year Camry OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 4 ELECTRICAL EL007–00 Title: POOR HEATER PERFORMANCE – EL007–00 Installation Procedure April 14, 2000 A. Pull out the inner cable of the REC/FRE cable until the link of the A/C unit contacts the link stopper. View A View A Left Side Top Rear Link Should make contact here. Link Stopper B. Set the air intake selector of the heater control unit all the way to the “FRESH” position. C. Attach the REC/FRE cable to the heater control unit lever pin and clamp the outer cable to the secure clamp. NOTE: Clamp the cable while pushing the outer cable to the A/C unit assembly side. Page 2 of 4 Lever POOR HEATER PERFORMANCE – EL007–00 Installation Procedure (Continued) April 14, 2000 D. Install the heater control panel to the instrument panel with 4 screws. NOTE: Make sure air mix cable is routed outside of the brace. REC/FRE Cable (from A/C Unit) Instrument Panel Step (A) Step (C) Step (D) Air Mix Cable Top Front Side Right Side Screw (4) Page 3 of 4 POOR HEATER PERFORMANCE – EL007–00 Installation Procedure (Continued) April 14, 2000 E. Set the temperature selector of the heater control unit to the “MAX. COOL” position. MAX. COOL F. Connect the air mix cable connector to the air mix link pin on the left side of the A/C unit and clamp the outer cable to the secure clamp. NOTE: S It is unnecessary to push or pull the outer cable. S Do not bend the cable when setting the cable. S Do not move the air mix knob until you are finished clamping the outer cable. Inspection Procedure 1. Rotary Knob For Temperature Control Operate the temperature control rotary knob after setting the cables, check that there is a “thump” at the end of the travel, and no reversing force at “MAX. COOL” or “MAX. HOT” position. 2. Air Inlet Lever Operate air inlet lever after setting the cable and check that there is a “click” at the end of the travel and no reversing force at “RECIRCULATE” and “FRESH” positions. 3. Blower Switch, Air Flow Mode Switch & A/C Switch Operate each switch and make sure they are operating correctly. Page 4 of 4 Air Mix Link Technical Service BULLETIN December 4, 1998 Introduction PROGRAMMING OEM WIRELESS DOOR LOCK REMOTE TRANSMITTERS Models: ’97 – ’99 Camry This bulletin describes procedures used to program the three button remote transmitter to vehicles that are equipped with Wireless Door Lock Control. The following information applies only to the Factory Wireless Door Lock Control, not dealer or port installed options that also utilize remotes, such as VIP Keyless Entry/RS3000 or any aftermarket system. Verification of Factory Wireless Door Lock Control can easily be performed by identifying the TDS status monitor, functioning remote, or model grade. Transmitter Identification S The Remote Transmitter has LOCK, UNLOCK, and PANIC features. TDS Status Montior Indentification S The TDS Status Monitor is located in the Tachometer. NOTE: When a new remote is programmed, all previous codes are erased. Because of this, all remotes should be entered during the same programming session, otherwise a remote may no longer be registered and operate the vehicle. For Customer Satisfaction, request that any existing remote be furnished when programming a new or replacement unit. Applicable Vehicles Warranty Information S 1997 – 1999 Camrys: 1997 – 1998 All XLE (standard equipment) and some LE (optional) 1999 All XLE only OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 ELECTRICAL EL008–98 Title: PROGRAMMING OEM WIRELESS DOOR LOCK REMOTE TRANSMITTERS – EL008–98 Programing Procedure December 4, 1998 The PRG (Program) circuit of the Wireless Door Lock ECU is grounded to perform programming. This can be accomplished at a satellite location, the Mirror Control Switch (see illustration). NOTE: Up to two remotes can be programmed to operate each vehicle. Mirror Control Switch 2. Using a suitable jumper wire, connect terminal number 2, PRG (violet wire) to terminal number 10, GND (white/black) of the 10 cavity mirror control switch connector (illustrated). The vehicle confirms programming mode by requesting the power door locks to lock. Wireless Door Lock E.C.U. Violet PRG White–Black 1. With the key OUT of the ignition switch, locate and disconnect the Mirror Control Switch from the vehicle harness. Jumper Wire GND Wire Harness 3. Depress, then release, any button on the remote. The vehicle confirms registration by requesting the power door locks to lock once again. 4. To program an additional remote, repeat step 3. Program (PRG) 5. Disconnect the jumper wire to exit programming mode. Wire Harness Mirror Control Switch Connector Page 2 of 2 Technical Service BULLETIN December 20, 2002 WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: All Applicable TSB REVISION NOTICE: S February 28, 2003: In Wireless Transmitter Identification section (pages 5 and 6), Figures 5, 9, 10, 12, and 13 updated to include 2003 model year; Figure 11 updated to include 1999 and 2003 model year. S January 17, 2003: 2003 model year added to Solara in the Application Chart on page 3. S The information contained in this TSB supercedes TSB EL010–01, dated October 26, 2001. The previous TSB, EL010–01, should be discarded. Introduction Applicable Vehicles Warranty Information System Identification Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. S All applicable Toyota vehicles. OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – The following table contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. NOTE: Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in without any remotes (or one non–working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. S Look at the Trim Level of the vehicle. Higher–grade vehicles will tend to have O.E. systems, while entry–grade vehicles will tend to have VIP. For example, the 2001 Camry XLE has Factory RKE, but the LE and CE grades have VIP. S Look for a “Status Monitor” with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. S Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. S Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the “confirmation mode” and see if any “Lock/Unlock” response is received, if so, the vehicle has a factory system. Toyota Supports ASE Certification Page 1 of 6 ELECTRICAL EL008-02 Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL008-02 Revised Application Chart APPLICATION VEHICLE A l Avalon YEAR SYSTEM/REMOTE PROGRAMMING 1995 TVSS / Fig. 2 *1 TVSS Owner’s Guide 1996 – 1997 RS3000 / Fig. 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2001 RS3200 / Fig. 5 2000 VIP Manual *6 2002 – 2003 N/A N/A 1990 – 1994 1995 1996 Camry y DEALER/PORT INSTALLED 1997 TVSS / Fig. 1 *1 TVSS / Fig. 2 *1 RS3000 / Fig. Fig 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2001 RS3200 / Fig. 5 or 6 *7 2002 – 2003 1990 – 1994 TVSS / Fig. 1 *1 TVSS Owner Owner’s s Guide TSB – AX005–99 2000 VIP Manual *6 1996 – 1997 RS3000 / Fig. 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2003 RS3200 / Fig. 5 2000 VIP Manual *6 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 1998 – 2002 RS3000 / Fig. 4 2003 RS3200 / Fig. 5 Cressida 1991 – 1992 ECHO 4Runner Land Cruiser Fig. g 9 *2 RM 02 V2, BE–99 TSB – EL004–01 N/A N/A Fig 7 Fig. TSB – EL008–98 EL008 98 Fig. 11 RM 01 V2, BE–86 *2 TSB – EL004–01 Fig. 9 N/A Fig. 11 TSB – EL004–01 N/A N/A 2000 VIP Manual *6 Fig. 11 TSB – EL004–01 TDSE / Fig. 1 *1 TVSS Owner’s Guide N/A N/A 2000 – 2003 RS3200 / Fig. 5 2000 VIP Manual *6 Fig. 11 TSB – EL004–01 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 N/A N/A 1998 RS3000 / Fig. Fig 4 TSB – AX005–99 AX005 99 TSB – AX005–99 AX005 99 TSB – AX005–99 RM 02 V2, V2 BE–98 BE 98 2000 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 2003 N/A N/A 2001 – 2003 N/A N/A Fig. 11 TSB – EL004–01 1991 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide N/A N/A 1996 – 1997 RS3000 / Fig. 3 TSB – AX005–99 N/A N/A Fig. 13 RM 02 V1, DI–624 Fig. g 10 *5 RM 03, 73–16 1998 – 2002 2003 Page 2 of 6 TSB – EL003 EL003–99 99 N/A 1999 Highlander Fig. 8 PROGRAMMING TVSS Owner Owner’s s Guide TVSS / Fig. 2 *1 Corolla FACTORY INSTALLED FACTORY REMOTE TSB – AX005–99 AX005 99 1995 Celica December 20, 2002 RM 03 V2, BE–93 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL008-02 Revised Application Chart (Continued) APPLICATION DEALER/PORT INSTALLED December 20, 2002 FACTORY INSTALLED VEHICLE YEAR SYSTEM/REMOTE PROGRAMMING FACTORY REMOTE Matrix 2003 N/A N/A Fig. 11 TSB – EL004–01 TVSS Owner Owner’s s Guide N/A N/A N/A N/A N/A N/A 1991 – 1994 MR2 1995 2001 – 2003 1992 – 1994 Paseo Previa Prius RAV4 Sequoia TDSE / Fig. 1 *1 TVSS / Fig. 2 *1 RS3200 *3 / Fig.5 TVSS / Fig. 1 *1 2003 VIP Manual TVSS Owner Owner’s s Guide 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1991 – 1994 TDSE / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 TSB – AX005–99 2001 – 2003 N/A N/A Fig. 11 TSB – EL004–01 1996 – 1997 RS3000 / Fig. 3 1998 – 2000 RS3000 / Fig. 4 TSB – AX005–99 AX005 99 N/A N/A 2001 – 2003 RS3200 / Fig. 5 2000 VIP Manual *6 Fig. 11 TSB – EL004–01 2001 – 2003 N/A N/A Fig. 10 *5 RM 03 V2, BE–105 TSB – AX005–99 AX005 99 1998 1999 Sienna Solara S pra Supra T100 Tacoma PROGRAMMING 2000 Fig. 7 RS3000 / Fig. Fig 4 RS3000 / Fig.4 TSB – AX005–99 *4 TSB – EL009–98 Fig. 11 / Fig. 12 2001 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 2003 N/A N/A 1999 – 2001 RS3000 / Fig. 4 TSB – AX005–99 Fig. 11 2002–2003 N/A N/A Fig. 9 *2 1991 – 1992 TDSE / Fig. 1 *1 1995 TDSE / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1993 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 – 2001 RS3000 / Fig. 4 2002 RS3200 / Fig. 5 2000 VIP Manual *6 2003 RS3200*3 / Fig. 5 2003 VIP Manual *6 RM 02 V2, BE–87 RM 03 V2, BE–91 RM 02 V2 V2, BE BE–87 87 N/A N/A N/A N/A N/A N/A TSB – AX005–99 AX005 99 TVSS Owner Owner’s s Guide TSB – AX005–99 AX005 99 TSB – AX005–99 Page 3 of 6 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL008-02 Revised Application Chart (Continued) APPLICATION VEHICLE Tercel Tr ck Truck T ndra Tundra Page 4 of 6 DEALER/PORT INSTALLED YEAR SYSTEM/REMOTE PROGRAMMING 1991 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 2000 – 2001 RS3000 / Fig. 4 TSB – AX005–99 2002 – 2003 RS3200*3 / Fig. 5 2003 VIP Manual December 20, 2002 FACTORY INSTALLED FACTORY REMOTE PROGRAMMING N/A N/A N/A N/A N/A N/A TVSS Owner Owner’s s Guide TSB – AX005–99 AX005 99 *1 Original style TVSS/TDSE system remotes are no longer available as replacement parts. Black RS3000 remotes (Figure 3) can be used with these systems. *2 While the outward appearances are the same, there are 3 different remotes of this style (not interchangeable). Check the FCC ID Number on the back of the remote to verify correct application: S Avalon 1998 – 1999 FCC ID: HYQ1512Y / 2000 – 2003 FCC ID: HYQ12BAN S Camry/Solara 2002 – 2003 FCC ID: GQ43VT14T *3 This is a variant of the RS3200 TDS system, which does not include the security functions. The VIP manual outlines programming procedures used on these vehicles. *4 RS3200 was launched prior to the 2001 MY Change Over. Please refer to the 2000 VIP Manual if necessary. *5 While the outward appearances are the same, there are 2 different remotes of this style (not interchangeable). Check the FCC ID Number on the back of the remote to verify correct application: S 1999 – 2002 4Runner – FCC ID: HYQ1512Y S Sequoia / 2003 4Runner – FCC ID: HYQ12BAN *6 RS3200 programming procedures were sent as a supplement to the 2000 VIP Manual. This information can now be found on the TIS system. *7 The RS3200 system was only available on early production vehicles in the 2003 model year. WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL008-02 Revised Wireless Transmitter Identification December 20, 2002 DEALER or PORT INSTALLED SYSTEMS Figure 1. Figure 2. Figure 3. TVSS/TDSE 1990 – 1994 TVSS/TDSE 1995 RS3000 (BLACK) 1996 – 1997 Figure 4. Figure 5. Figure 6. RS3000 (GRAY) 1998 – 2002 RS3200* 2000 – 2003 RS3200* 2000 – 2002 * Panic Button on Back Side Page 5 of 6 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL008-02 Revised Wireless Transmitter Identification (Continued) FACTORY INSTALLED or “ORIGINAL EQUIPMENT” SYSTEMS Figure 7. Figure 8. O.E. 3 Button 1997 – 1999 O.E. 3 Button 1995 – 1997 Figure 9. Figure 10. Figure 11. O.E. 4 Button* 1998 – 2003 O.E. 4 Button* 1999 – 2003 O.E. 3 Button* 1999 – 2003 * Panic Button on Back Side Page 6 of 6 December 20, 2002 Figure 12. Figure 13. O.E. 4 Button* 1999 – 2003 O.E. In–Key 1998 – 2003 OBSOLETE PLEASE SEE EL008–02 October 26, 2001 Introduction Applicable Vehicles Warranty Information System Identification WIRELESS TRANSMITTER & PROGRAMMING GUIDE Models: All Applicable Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory Wireless systems and Toyota Port/Dealer installed systems. This bulletin will assist in identifying the system/correct remote transmitters for each vehicle, and provide the location of the most accurate programming procedure for each system. S All applicable Toyota vehicles. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – The following table contains all of the necessary information to correctly identify the type of system installed, and where to go to get programming procedures for each vehicle. NOTE: Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in without any remotes (or one non–working remote), use the following tips to help determine which type of wireless system (O.E. or PIO/DIO) the vehicle has. S Look at the Trim Level of the vehicle. Higher–grade vehicles will tend to have O.E. systems, while entry–grade vehicles will tend to have VIP. For example, the 2001 Camry XLE has Factory RKE, but the LE and CE grades have VIP. S Look for a “Status Monitor” with a glass breakage sensor and an LED externally installed into the dashboard or on the center console. Most VIP systems will have this. S Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, refer to the part label. S Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the “confirmation mode” and see if any “Lock/Unlock” response is received, if so, the vehicle has a factory system. Toyota Supports ASE Certification Page 1 of 5 ELECTRICAL Technical Service BULLETIN EL010-01 Title: WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL010-01 Application Chart APPLICATION VEHICLE A l Avalon FACTORY INSTALLED FACTORY REMOTE SYSTEM/REMOTE PROGRAMMING 1995 TVSS / Fig. 2 *1 TVSS Owner’s Guide 1996 – 1997 RS3000 / Fig. 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2001 RS3200 / Fig. 5 2000 VIP Manual *6 2002 N/A N/A 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1997 RS3000 / Fig. Fig 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2001 RS3200 / Fig. 5 or 6 2002 1990 – 1994 TVSS / Fig. 1 *1 Fig. 8 TSB – AX005–99 2000 VIP Manual *6 1996 – 1997 RS3000 / Fig. 3 1998 – 1999 RS3000 / Fig. 4 2000 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 1998 – 2002 RS3000 / Fig. 4 Cressida 1991 – 1992 TDSE / Fig. 1 *1 ECHO 2000 – 2002 RS3200 / Fig. 5 1990 – 1994 *1 4R nner 4Runner 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 1999 Highlander MR2 RS3000 / Fig. Fig 4 Fig. g 9 *2 RM 02 V2, V2 BE–99 BE 99 N/A N/A Fig 7 Fig. TSB – EL008–98 EL008 98 Fig. 11 RM 01 V2, BE–86 Fig. 9 *2 RM 02 V2, 73–8 N/A N/A Fig. 11 TSB – EL004–01 N/A N/A TVSS Owner’s Guide N/A N/A 2000 VIP Manual *6 Fig. 11 TSB – EL004–01 N/A N/A Fig 10 *5 Fig. RM 02 V2, V2 BE–98 BE 98 TSB – AX005–99 AX005 99 TSB – AX005–99 AX005 99 TVSS Owner Owner’s s Guide TSB – AX005–99 2000 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 2001 – 2002 N/A N/A Fig. 11 TSB – EL004–01 N/A N/A Fig. 13 RM 02 V1, DI–624 N/A N/A 1991 – 1994 Land Cruiser TVSS / Fig. 1 TSB – EL003 EL003–99 99 TVSS Owner Owner’s s Guide TVSS / Fig. 2 *1 Corolla PROGRAMMING TSB – AX005–99 AX005 99 1995 Celica TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 TSB – AX005–99 1998 – 2002 N/A N/A 1991 – 1994 TDSE / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 2001 – 2002 Page 2 of 5 DEALER/PORT INSTALLED YEAR 1996 Camry y October 26, 2001 RS3200 *3 / Fig.5 2000 VIP Manual *6 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL010-01 Application Chart (Continued) APPLICATION VEHICLE Paseo Previa Prius RAV4 Sequoia Sienna Solara S pra Supra T100 Tacoma Tercel Tr ck Truck Tundra October 26, 2001 DEALER/PORT INSTALLED PROGRAMMING FACTORY INSTALLED FACTORY REMOTE PROGRAMMING N/A N/A N/A N/A YEAR SYSTEM/REMOTE 1992 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1991 – 1994 TDSE / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 TSB – AX005–99 2001 – 2002 N/A N/A Fig. 11 TSB – EL004–01 1996 – 1997 RS3000 / Fig. 3 1998 – 2000 RS3000 / Fig. 4 TSB – AX005–99 AX005 99 N/A N/A 2001 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 Fig. 11 TSB – EL004–01 2001 – 2002 N/A N/A Fig. 10 *5 RM 02 V2, BE–100 1998 RS3000 / Fig. 4 1999 RS3000 / Fig. 4 2000 RS3000 / Fig.4 *4 2001 – 2002 RS3200 / Fig. 5 2000 VIP Manual *6 1999 – 2001 RS3000 / Fig. 4 TSB – AX005–99 Fig. 11 2002 N/A N/A Fig. 9 *2 1991 – 1992 TDSE / Fig. 1 *1 1995 TDSE / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1993 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1995 TVSS / Fig. 2 *1 1996 – 1997 RS3000 / Fig. 3 1998 – 2001 RS3000 / Fig. 4 2002 RS3200 / Fig. 5 2000 VIP Manual *6 1991 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 TVSS Owner Owner’s s Guide 1996 – 1997 RS3000 / Fig. 3 1998 RS3000 / Fig. 4 1990 – 1994 TVSS / Fig. 1 *1 1995 TVSS / Fig. 2 *1 2000 – 2002 RS3000 / Fig. 4 TVSS Owner Owner’s s Guide TSB – AX005–99 AX005 99 Fig. 7 TSB – AX005–99 TSB – EL009–98 Fig. 11 / Fi Fig 12 Fig. RM 02 V2, BE–87 RM 02 V2 V2, BE BE–87 87 N/A N/A N/A N/A N/A N/A N/A N/A TVSS Owner Owner’s s Guide N/A N/A TSB – AX005–99 N/A N/A TSB – AX005–99 AX005 99 TVSS Owner Owner’s s Guide TSB – AX005–99 AX005 99 TSB – AX005–99 TSB – AX005–99 AX005 99 Page 3 of 5 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL010-01 Application Chart (Continued) *1 Original style TVSS/TDSE system remotes are no longer available as replacement parts. Black RS3000 remotes (Figure 3) can be used with these systems. *2 While the outward appearances are the same, there are 3 different remotes of this style (not interchangeable). Check the FCC ID Number on the back of the remote to verify correct application: S Avalon 1998 – 1999 FCC ID: HYQ1512Y / 2000 – 2002 FCC ID: HYQ12BAN S Camry/Solara 2002 FCC ID: GQ43VT14T *3 The MR2 Spyder uses a variant of the RS3200 TDS system, which does not include the security functions. RS3200 programming procedures should be used for this vehicle. *4 RS3200 was launched prior to the 2001 MY Change Over. Please refer to the 2000 VIP Manual if necessary. *5 The Sequoia and 4Runner remotes look the same but have different FCC ID Numbers (not interchangeable): S 4Runner – FCC ID: HYQ1512Y S Sequoia – FCC ID: HYQ12BAN *6 RS 3200 programming procedures were sent as a supplement to the 2000 VIP Manual. If you require an additional copy of this information, it can be ordered from the Material Distribution Center (MDC) through your parts department: P/N 00107–00282–04. Wireless Transmitter Identification Page 4 of 5 October 26, 2001 DEALER or PORT INSTALLED SYSTEMS Figure 1. Figure 2. Figure 3. TVSS/TDSE 1990 – 1994 TVSS/TDSE 1995 RS3000 (BLACK) 1996 – 1997 Figure 4. Figure 5. Figure 6. RS3000 (GRAY) 1998 – 2002 RS3200 2000 – 2002 RS3200 2000 – 2002 WIRELESS TRANSMITTER & PROGRAMMING GUIDE – EL010-01 Wireless Transmitter Identification (Continued) October 26, 2001 FACTORY INSTALLED or “ORIGINAL EQUIPMENT” SYSTEMS Figure 7. Figure 8. O.E. 3 Button 1997 – 1999 O.E. 3 Button 1995 – 1997 Figure 9. Figure 10. Figure 11. O.E. 4 Button* 2000 – 2002 O.E. 4 Button* 1999 – 2002 O.E. 3 Button* 2000 – 2002 Figure 12. Figure 13. O.E. 4 Button* 1999 – 2002 O.E. In–Key 1998 – 2002 * Panic Button on Back Side Page 5 of 5 Technical Service BULLETIN October 6, 2000 Introduction DAYTIME RUNNING LIGHT DISABLING PROCEDURE Models: All Models Some customers may request to have the Daytime Running Lights (DRL) on their Toyota vehicle disabled. These customers may live or work in military bases or in communities that have light–sensitive gates or guardhouses. This bulletin provides instructions for disabling the feature on the Toyota vehicles listed below. If the Daytime Running Lights (DRL) have been previously disabled, the information in this bulletin can be used to enable the feature at the request of the customer. IMPORTANT: Please be sure the customer is informed that when the Daytime Running Lights (DRL) are being disabled, although it is not required by the Federal Motor Vehicle Safety Standards for safety compliance, it has been listed as a safety feature in advertising brochures. In addition, on models equipped with the Twilight Sentinel feature, the headlights will be defaulted to a manual system and will no longer function automatically. S All Models equipped with Daytime Running Lights (DRL) (see chart below). Applicable Vehicles Parts Information TOOLS & MATERIALS QUANTITY Wire Harness Repair Kit 1 NOTE: After referencing the chart, proceed to the repair procedure on the following pages. Reference Chart MODEL Avalon Camry S/D* Camry Solara* Celica* Corolla* ECHO 4Runner Land Cruiser MR2 Spyder RAV4 Sienna Tacoma Tundra * Warranty Information MODEL YEAR ECU CONNECTOR PIN# EWD PG# 1999 2000 1999 2000 1999/2000 2000 1999/2000 2000 2000 1999/2000 2000 1999/2000 1999/2000 2000 2000 DRL Main Relay Body ECU D4 B5 DRL Main Relay D6 Body ECU B6 D3 D2 1 6 23 10 23 17 23 12 D8 2 D2 D17 D4 D8 D7 12 110 99 102 96 102/96 75 84/72 67 99 90/88 69 72/70 83/81 115 95 DRL Main Relay 2 Vehicles equipped with Twilight Sentinel. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 ELECTRICAL EL011–00 Title: DAYTIME RUNNING LIGHT DISABLING PROCEDURE – EL011–00 Repair Procedure 1. Disconnect the Battery. 2. Use the locking pick tool from the wire harness repair kit and back out the terminal from the appropriate connector for the DRL Relay or Body ECU. See the Reference Chart on Page 1 of this bulletin for pin and connector information. October 6, 2000 DRL Relay or Body ECU W/H 3. Insulate the removed terminal using vinyl electrical tape. Insulate Terminal 4. Secure the wire and terminal to the outside of the wire harness using vinyl electrical tape. Tape insulated terminal to outside of wire harness. NOTE: For the 2000 MY Avalon, proceed to Step 5. For all remaining models, proceed to Step 6. 5. For 2000 model year Avalon: A. Order a new terminal with lead that is the same size and type as the terminal previously removed from the connector. (PN 82998–12690) B. Securely attach a 45 cm/ 18 in wire with an outside diameter of 2.0 mm or larger to the tail of the new terminal. Page 2 of 3 P.N. 82998–12690 DAYTIME RUNNING LIGHT DISABLING PROCEDURE – EL011–00 Repair Procedure October 6, 2000 C. Securely attach an eyelet with a hole size of 7 mm to the end of the new wire. D. Insert the new terminal with lead into the Body ECU Connector B5, previously vacated by the original terminal. E. Properly attach and route the new wire to the exterior of the existing wire harness in a manner that will not allow it to become damaged or come into contact with any other circuits. F. Securely attach the eyelet to the existing ground point located in the left kick panel area. (Ground Point IF) 6. Check that the Daytime Running Light (DRL) operation has been disabled. 7. Reassemble any interior panels that were removed to gain access to components, connectors, etc. Page 3 of 3 Technical Service BULLETIN DOOR MIRROR WIND NOISE Models: ’97 – ’99 Camry March 31, 2000 TSB Update Notice: The information contained in this TSB updates The information contained in this TSB updates BO019–99 dated December 3, 1999. Revised text is red and underlined. Introduction Applicable Vehicles Wind/road noise heard around the door mirrors of some Japan produced Camry vehicles may be caused by an improperly positioned mirror wire harness grommet and/or harness connector. S 1997 through 1999 Camry vehicles. (Japan produced only) Production Change Information Warranty Information PLANT STARTING VIN TMC JT2BG22K * X0367325 JT2BG28K * X0367352 JT2BF22K * X0227381 JT2BF28K * X0227306 OP CODE DESCRIPTION TIME BD0009 Adjust the Wire Harness Grommet and/or Connector 0.4 OPN T1 T2 87940–XXXXX–XX (LH) 59 57 87910–XXXXX–XX (RH) Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Repair Procedure 1. Carefully pry off the door speaker cover and remove the nut using a 10 mm socket that secures the speaker to the door. 2. Look through the door mirror harness access hole and check the position of the wire harness grommet and wire harness connector – the harness connector should be inside the grommet and the grommet should be fully seated in the mirror housing. Connector and Grommet Speaker Mirror Housing Connector Grommet CORRECT POSITION Toyota Supports ASE Certification Page 1 of 2 NVH NV007–00 Title: DOOR MIRROR WIND NOISE – NV007–00 Repair Procedure (Continued) March 31, 2000 Examples of improperly installed assemblies are shown below: INCORRECT POSITION A INCORRECT POSITION B Mirror Housing INCORRECT POSITION C Mirror Housing Mirror Housing Grommet Connector Grommet 3. To reposition the grommet and/or harness connector onto the mirror housing: S Remove the mirror housing (the remaining 2 nuts) from the door and carefully unclip the mirror from the housing. This will allow easier access and reinstallation of the grommet and/or harness connector. S Reposition the grommet so it is fully seated to the mirror housing. Assure the harness connector is inside the grommet. NOTE: Refer to the 1998 Camry Repair Manual pages BO–23 through BO–26. 4. Reinstall the door mirror and speaker assembly: S Secure the mirror to the housing. S Properly align and reinstall the mirror assembly to the door. Tighten the upper and forward nuts. Torque: 5.5 NSm (56 KgfScm, 49 inSlb) S Reinstall the door speaker (one nut at the lower bracket) and speaker cover onto the door as shown in the illustration. Torque: 5.5 NSm (56 KgfScm, 49 inSlb) S Assure the power mirror adjustment and the door speaker functions properly. NOTE: Do NOT mount the UPPER speaker bracket behind the nut. Page 2 of 2 Connector Connector Grommet Outside Door Mirror Rear View Mirror Connector Mirror Housing Grommet CORRECT POSITION Outside Rear View Mirror Cover Door Trim 5.5 (55, 49, ftSlbf) NSm (kgfScm, ftSlbf) INCORRECT : Specified Torque CORRECT Technical Service BULLETIN March 12, 1999 Introduction 1999 PAINT AND REFINISH FORMULA CODES Models: All 1999 Models Attached for your reference is a list of all 1999 OEM paint codes and refinish paint codes for the following paint manufacturers: BASF, DuPont, ICI Autocolor, PPG, Sherwin Williams, Sikkens, Spies–Hecker, and Standox NOTE: The body color code is on the vehicle Certification Regulation Label, located on the left front door “B” Pillar or door rear lower surface. Please contact your local paint representative for the actual paint mixing formulas or if you need help in color matching. Affected Vehicles Warranty Information Paint Codes & Color Names S All 1999 Models. OPCODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – ICI SHERWIN SPIES– COLOR CODE COLOR NAME BASF DUPONT 040 Super White TOY040 W8430 KK47 90288 35000 TOY040 17143 040 049 White Pearl TOY049 N9033 L9018 TA99G PC61B 90673 90674 40881 40882 TOY049 97746 049 051 Diamond White Pearl TOY051 L9246 L9247 PF76B TD86G 90822 90826 42872 42873 TOY051 98125 16329 051 056 Natural White TOY056 F1858 BAB5 91452 52893 TOY056 15217 056 Toyota Supports ASE Certification AUTOCOLOR PPG WILLIAMS SIKKENS HECKER STANDOX Page 1 of 5 PAINT PA002–99 Title: 1999 PAINT AND REFINISH FORMULA CODES – PA002–99 Paint Codes & Color Names (Continued) Page 2 of 5 March 12, 1999 ICI SHERWIN SPIES– COLOR CODE COLOR NAME BASF DUPONT 181 Silver Metallic TOY181 L9245 C523B 34878 44337 TOY181 98127 181 199 Alpine Silver Metallic TOY199 L9990 5TX1B 4900 48976 TOY199 70706 199 1A0 Platinum Metallic TOY1A0 N9923 6ED5B 4896 49700 TOY1A0 70809 1A0 1A2 Topaz Metallic TOY1A2 F0016 6ED9B 4898 49701 TOY1A2 70855 1A2 1A3 Silver Metallic TOY1A3 F0697 7DJ9B 35841 53001 TOY1A3 72319 1A3 1A5 Desert Dune Pearl TOY1A5 F1458 8NH3B 36090 52139 TOY1A5 72759 1A5 1B1 Champagne Pearl TOY1B1 F2186 FLT9B 5252 53074 TOY1B1 20699 1B1 1B2 Antique Sage Pearl TOY1B2 F2201 HRE5B 5324 54757 TOY1B2 73622 1B2 1B9 Quiksilver FX TOY1B9 F4996 LJC5B 5449 56738 TOY1B9 74332 1B9 1C0 Millennium Silver TOY1C0 F4928 LCJ4B 36643 56793 TOY1C0 74500 1C0 1C3 River Rock Green Mica TOY1C3 F4513 LVT2B 48703 57226 TOY1C3 74488 1C3 1C4 Silverstream Op TOY1C4 F5137 NPD6B 5560 57927 TOY1C4 74771 1C4 1C7 Thunder Gray Metallic TOY1C7 F5581 PEJ6B 5600 58581 TOY1C7 74806 1C7 1C8 Lunar Mist Metallic TOY1C8 F8569 PEJ7B 5539 58582 TOY1C8 74807 1C8 202 Black TOY202 FO220 0122 95100 57871 TOY202 72941 202 204 Black Metallic TOY204 H8645 A237B 9624 35533 TOY204 96020 204 205 Satin Black Metallic TOY205 L9024 B941B 9756 40888 TOY205 97765 205 3E5 Super Red TOY3E5 W8431 KK41 72717 35001 TOY3E5 38236 3E5 3H7 Cardinal Red TOY3H7 L9026 WJ91 73279 40890 TOY3H7 38805 3H7 3J8 Prussian Red Pearl TOY3J8 W9463 PT73B 4596 46590 TOY3J8 99827 3J8 3K4 Sunfire Red Pearl TOY3K4 W9546 PM54B 4511 46144 TOY3K4 99722 3K4 3L2 Renaissance Red TOY3L2 L9992 5TX3B 4902 48978 TOY3L2 30491 3L2 3L5 Radiant Red TOY3L5 F2688 GNK8 5287 54291 TOY3L5 33476 3L5 3M5 Sandrift Metallic TOY3M5 F3531 LCP1B 5444 56742 TOY3M5 34261 3M5 3M6 Napa Burgundy Pearl TOY3M6 F3747 LJC2B 5447 56739 TOY3M6 34262 3M6 3M8 Venetian Red Pearl TOY3M8 F4929 LCJ5B 5561 56795 TOY3M8 34300 3M8 3M9 Baroque Red Metallic TOY3M9 F4464 KWB9B 5421 56658 TOY3M9 34257 3M9 3N1 Cinnabar Pearl TOY3N1 F4483 LPC9B 5435 56752 TOY3N1 34254 3N1 3N2 Mahogany Pearl TOY3N2 F1744 LVT3B 28763 57227 TOY3N2 34317 3N2 3N5 Red Flame Metallic TOY3N5 F5138 NPD7B 5563 57928 TOY3N5 34587 3N5 3N6 Vintage Red Pearl TOY3N6 F8568 PEB8B 5525 58338 TOY3N6 34622 3N6 4J6 Sadona Sunset Metallic TOY4J6 L9028 B945B 26601 40892 TOY4J6 97753 4J6 4M4 Sierra Beige Metallic TOY4M4 H9879 4SS7B 4743 47606 TOY4M4 20157 4M4 AUTOCOLOR PPG WILLIAMS SIKKENS HECKER STANDOX 1999 PAINT AND REFINISH FORMULA CODES – PA002–99 Paint Codes & Color Names (Continued) March 12, 1999 ICI SHERWIN SPIES– COLOR CODE COLOR NAME BASF DUPONT 4M7 Oyster Pearl TOY4M7 K9968 5MK6B 27579 48841 TOY4M7 10655 4M7 4M9 Cashmere Beige Metallic TOY4M9 N9924 6ED6B 4903 49702 TOY4M9 20261 4M9 4N5 Vintage Rose Metallic TOY4N5 F2716 HYV5B 5339 54862 TOY4N5 15817 4N5 4N7 Sable Pearl TOY4N7 F3748 LJC3B 5448 56740 TOY4N7 22236 4N7 4P1 Antique Bronze Metallic TOY4P1 F4465 KWC1B 5422 56659 TOY4P1 81642 4P1 4P3 Desert Bronze Metallic LEX4P3 F7145 LVT4B 28764 57228 LEX4P3 22317 4P3 4P5 Autumn Blaze Metallic TOY4P5 F5583 PEC1B 5526 58340 TOY4P5 34623 4P5 4P6 Autumn Red Mica TOY4P6 F5139 NPD8B 5565 57929 TOY4P6 34588 4P6 578 Golden Sand Metallic TOY578 F3749 LNX6B 5457 56741 TOY578 22189 578 6M1 Dark Emerald Pearl TOY6M1 W9542 PM72B 4595 46589 TOY6M1 99746 6M1 6M3 Silver Spruce Metallic TOY6M3 W9514 D381B 4474 45931 TOY6M3 99679 6M3 6N7 Sierra Green Metallic TOY6N7 F1036 7P07B 5047 51163 TOY6N7 61391 6N7 6P2 Classic Green Pearl TOY6P2 F1850 BAA7B 5173 52889 TOY6P2 61953 6P2 6P3 Deep Jewel Grean Pearl TOY6P3 F1805 ARD3B 5166 52887 TOY6P3 61928 6P3 6P4 Surfside Green Mica TOY6P4 F2690 GNL1B 5289 54293 TOY6P4 64018 6P4 6Q7 Imperial Jade Mica TOY6Q7 F3750 KWC2B 5423 56660 TOY6Q7 68096 6Q7 6R1 Woodland Pearl TOY6R1 F7147 LVT6B 5566 57230 TOY6R1 65321 6R1 6R3 Fairway Green Pearl TOY6R3 F5140 NPD9B 5567 57930 TOY6R3 65706 6R3 760 Mystic Teal Mica TOY760 F3533 LCP2B 5445 56258 TOY760 65225 760 762 Aqua Blue Metallic TOY762 F8543 PEJ8B 5595 58693 TOY762 56812 762 8L3 Blue Velvet Pearl TOY8L3 F2239 FRC7B 5328 54032 TOY8L3 54676 8L3 8L4 Atlantis Blue Mica TOY8L4 F1898 BGT9B 19705 52994 TOY8L4 54483 8L4 8L5 Royal Sapphire Blue TOY8L5 F2728 HDJ4B 5329 54485 TOY8L5 55068 8L5 8L7 Stellar Blue Pearl TOY8L7 F2059 ETB9B 5206 53072 TOY8L7 54562 8L7 8L9 Denim Blue Mica TOY8L9 F2722 JCD1B 5443 54872 TOY8L9 55325 8L9 8M5 Mista Blue Mica TOY8M5 F3562 KBA1B 5434 56261 TOY8M5 55825 8M5 8M8 Twilight Blue Pearl TOY8M8 F7274 LXY2B 190925 57452 TOY8M8 56542 8M8 8N1 Horizon Blue Metallic TOY8N1 F5223 PEC2B 5527 58341 TOY8N1 56813 8N1 930 Blue Dusk Pearl TOY930 F2723 HRE6B 5330 54758 TOY930 40713 930 931 Frosted Iris Metallic TOY931 F2724 HRE7B 5331 54759 TOY931 40714 931 938 Mystic Purple Mica TOY938 F3532 KWB7B 5420 56656 TOY938 40930 938 AUTOCOLOR PPG WILLIAMS SIKKENS HECKER STANDOX Page 3 of 5 1999 PAINT AND REFINISH FORMULA CODES – PA002–99 Land Cruiser Cladding Codes Paint Applications & Types ICI SHERWIN SPIES– COLOR CODE COLOR NAME BASF DUPONT UCA46 Cashmere Beige Metallic TOYUCA46 H9752 D700B 27345 46754 TOYUA46 20631 UCA46 UCA76 Medium Gray Metallic TOYA76 F1114 7VT6B 35973 51188 TOY9418 72547 UCA76 UCA78 Dark Taupe Metallic TOY9420 TOYUCA78 F1116 27888 51186 80371 UCA78 7VV1B CAM AVL COLOR CODE 040 049 051 056 181 199 1A0 1A2 1A3 1A5 1B1 1B2 1B9 1C0 1C3 1C4 1C7 1C8 202 204 205 3E5 3H7 3J8 3K4 3L2 3L5 3M5 3M6 3M8 3M9 Page 4 of 5 March 12, 1999 COR SOL AUTOCOLOR CEL SNA PPG WILLIAMS RAV RAVev SIKKENS 4RN HECKER TAC STANDOX L–C 1999 PAINT AND REFINISH FORMULA CODES – PA002–99 Paint Applications & Types (Continued) COLOR CODE COR SOL CAM AVL CEL March 12, 1999 SNA RAV RAVev 4RN TAC L–C 3N1 3N2 3N5 3N6 4J6 4M4 4M7 4M9 4N5 4N7 4P1 4P3 4P5 4P6 578 6M1 6M3 6N7 6P2 6P3 6P4 6Q7 6R1 6R3 760 762 8L3 8L4 8L5 8L7 8L9 8M5 8M8 8N1 930 931 938 Page 5 of 5 Technical Service BULLETIN June 14, 2002 Introduction Applicable Vehicles Required Tools & Material REFINISHING REPLACEMENT BUMPER COVERS Models: All ’83 – ’03 Models In cases where a bumper cover is being replaced, a special preparation process is necessary to assure the refinish is customer acceptable. This bulletin provides the recommended refinishing procedure for new bumper covers. S All 1983 – 2003 model year Toyota vehicles. TOOLS & MATERIALS QUANTITY Mild Soap –– Ph neutral (no wax type) 3Mt Car Shampoo (or equivalent) Sanding Pad 3Mt ScotchBrite (Gray) 37448 Sanding Paste Wax, Grease, & Silicone Remover Plastic Part Adhesion Promoter See Paint Manufacturer’s Recommendations Primer and Paint Warranty Information Refinishing Procedure OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – 1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water. NOTE: Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface contamination or rinsing difficulty. Toyota Supports ASE Certification Page 1 of 2 PAINT PA003-02 Title: REFINISHING REPLACEMENT BUMPER COVERS – PA003-02 Refinishing Procedure (Continued) June 14, 2002 2. Scrub the bumper covers with the soap and water solution, making sure all difficult–to–reach areas are thoroughly cleaned. 3. Rinse the entire bumper cover with clean deionized water, making sure all difficult–to–reach areas are thoroughly rinsed. 4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil–less compressor may be substituted for drying with a towel. 5. Degrease the surface with a wax, grease, and silicone remover. NOTE: Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover. Carefully follow application instructions on the container label. Fish eyes or other paint irregularities may result from not following instructions. 6. Apply a generous amount of sanding paste with a gray 3Mt ScotchBrite pad. Only a gray pad should be used during the sanding process. Sand the entire bumper cover surface. Be sure all difficult–to–reach areas are thoroughly sanded. 7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult–to–reach areas are thoroughly cleaned. 8. Rinse the entire bumper with clean deionized water. Be sure all difficult–to–reach areas are thoroughly rinsed. 9. Degrease the surface with an anti–static plastic parts cleaner and a white body shop towel or paper towel. NOTE: Never use a red shop towel to wipe the surface (contains silicone). 10. Assure the bumper is firmly held in place to a steady fixture. 11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer ’s recommendations. 12. Apply plastic parts primer to the surface, according to the paint manufacturer’s recommendations. 13. Since bumpers are made of flexible plastic urethane material, use a two–part urethane finish paint system with plasticizer (flex agent) for all bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer ’s recommendations. 14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80
C (176
F.) For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective refinish paint manufacturer’s local representative. Page 2 of 2 Wash with Soap & Water Rinse & Towel Dry Degrease Step 1 Scrub with Sanding Paste Wash with Soap & Water Rinse & Towel Dry Degrease Step 2 Apply Adhesion Promoter Apply Primer Apply Top Coat Technical Service BULLETIN TWO-TONE PAINT COLOR Models: ’99 Camry Limited Edition June 11, 1999 Introduction Affected Vehicles The following information outlines the two–tone painting scheme on 1999 Camry Limited Edition. S 1999 Camry Limited Edition Production Change Information Warranty Information COLOR NO. COMBINATION TWO–TONE NAMES 2GP 4M7/1B2 Oyster Pearl/Antique Sage Pearl accent 28Y 051/4M7 Diamond White Pearl/ Oyster Pearl Accent OPCODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 PAINT PA004–99 Title: Technical Service BULLETIN January 7, 2000 Introduction 2000 TECHNICAL SERVICE BULLETIN INFORMATION Models: All Models Toyota Technical Service Bulletins (TSBs) continue to be one of the most current sources of technical information available. To ensure complete access to this reference source, use the following steps: S All 1999 Technical Service Bulletins should be relocated to a temporary binder. S Place this bulletin along with all 2000 TSBs into the emptied TSB binder. S During the month of March, all dealers will receive bound books containing all TSBs issued in 1999. Upon receipt, discard all 1999 TSBs and refer only to the bound book for reference. S Additional copies of 1994 through 2000 TSBs are available to all Toyota dealerships through the Toyota Non–Parts System (MDC NPM System) by using the following Part Number designation: TSB Part Number Prefix TSB Chapter Code Chapter Code Sequence Number Year 00406 Parts Information * – PG 001 – 99 MATERIAL DESCRIPTION PART NUMBER TSB Binder, tabs and all 2000 bulletins issued to date TSB00 New TSB Binder and tabs ONLY 00406–61012 1999 TSB Bound Book 00442–99002* 1998 TSB Bound Book 00442–98005 1997 TSB Bound Book 00442–97011 1996 TSB Bound Book 00442–97003 1995 TSB Bound Book 00401–43055 Available in March, 2000. NOTE: If you have any questions concerning Toyota Technical Service Bulletins, please contact your District Service Manager. Toyota Supports ASE Certification Page 1 of 1 PRODUCT GENERAL INFORMATION PG001–00 Title: Technical Service BULLETIN Models: All Models February 28, 2003 Introduction Corrections have been made in the repair manuals listed below. Corrections available in the last quarter are marked in red. The Toyota Technical Information system (TIS) is the best way to access up–to–date service information. NOTE: When ordering a technical publication (i.e., Repair Manual, Electrical Wiring Diagram) from the MDC, any Correction Page(s) associated with that particular Publication will automatically be included with your order. Parts Information Correction Pages are available through the Dealer Support Material Network (MDC NPM System) via the corresponding part numbers from the following table. Publication 4Runner Number 2003 4Runner . . . . . . . . RM1001–U1 . . . . . . . . . . . . . . . . . . . . . . . . . RM1001–U2 . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... . . . . . . . . . . . . . . . . . . . . . . RM1001–U1 . . . ...................................... ...................................... ...................................... ...................................... ...................................... Toyota Supports ASE Certification Page(s) Part Number 03–36 . . . . . . . . . . . . . 00400–RM100–12131 29–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 29–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 25–18 . . . . . . . . . . . . . 00400–RM100–22146 26–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 26–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 27–37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–614 to 05–616 . . 00400–RM100–12156 05–712 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–713 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–713–1 to 05–713–7 . . . . . . . . . . . . . . . . ↓ 05–724 to 05–737 . . . . . . . . . . . . . . . . . . . . . ↓ 05–811 to 05–813 . . . . . . . . . . . . . . . . . . . . . ↓ Page 1 of 4 PRODUCT GENERAL INFORMATION REPAIR MANUAL CORRECTIONS INDEX PG001-03 Title: REPAIR MANUAL CORRECTIONS INDEX – PG001-03 Publication Number February 28, 2003 Page(s) Part Number Avalon 2000 Avalon . . . . . . . . . . RM746–U2 . . . . ...................................... ...................................... ...................................... 2001 Avalon . . . . . . . . . . RM808–U2 . . . . ...................................... ...................................... ...................................... 2002 Avalon . . . . . . . . . . RM872–U2 . . . . ...................................... ...................................... ...................................... ...................................... BE–3 . . . . . . . . . . . . . 00400–RM746–2167B BE–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–3 . . . . . . . . . . . . . 00400–RM808–2166B BE–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–96 . . . . . . . . . . . . 00400–RM872–2088B BE–3 . . . . . . . . . . . . . 00400–RM872–2165B BE–4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Camry 2002 Camry . . . . . . . . . . EWD461U . . . . . ...................................... ...................................... ...................................... ...................................... ...................................... 2003 Camry . . . . . . . . . . EWD506U . . . . . ...................................... ...................................... ...................................... ...................................... ...................................... 45 . . . . . . . . . . . . . . . . 00400–EWD46–12107 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 45 . . . . . . . . . . . . . . . . 00400–EWD50–62108 77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Corolla Highlander Page 2 of 4 2003 Corolla . . . . . . . . . . EWD484U . . . . . 49 . . . . . . . . . . . . . . . . 00400–EWD48–42150 2001 Highlander . . . . . . RM837–U2 . . . . ...................................... ...................................... ...................................... 2002 Highlander . . . . . . RM918–U2 . . . . ...................................... ...................................... ...................................... 2003 Highlander . . . . . . RM987–U2 . . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... 11–15 . . . . . . . . . . . . . 00400–RM837–2140B 11–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–15 . . . . . . . . . . . . . 00400–RM918–2141B 11–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–13 . . . . . . . . . . . . . 00400–RM987–2157B 11–14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–14–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–14–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 11–27–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ REPAIR MANUAL CORRECTIONS INDEX – PG001-03 Publication Number February 28, 2003 Page(s) Part Number Matrix 2003 Matrix . . . . . . . . . . . EWD486U . . . . . . . . . . . . . . . . . . . . . . . . . . . RM940–U1 . . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... . . . . . . . . . . . . . . . . . . . . . . RM940–U2 . . . . 55 . . . . . . . . . . . . . . . . 00400–EWD48–62151 05–833 . . . . . . . . . . . . . 00400–RM940–2116 05–834 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–820 . . . . . . . . . . . . 00400–RM940–2159 05–821 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–825 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–826 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–837 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 73–9 . . . . . . . . . . . . . . 00400–RM940–2163B MR2 Spyder 2001 MR2 Spyder . . . . . RM801–U1 . . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... 2002 MR2 Spyder . . . . . RM900–U1 . . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... . . . . . . . . . . . . . . . . . . . . . . RM900–U2 . . . . DI–8 . . . . . . . . . . . . . . . 00400–RM801–2105 DI–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–184–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–184–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–8 . . . . . . . . . . . . . . . 00400–RM900–2106 DI–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–184 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–186 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–46 . . . . . . . . . . . . . 00400–RM900–2137 Prius 2001 Prius . . . . . . . . . . . . RM778–U1 . . . . DI–680 . . . . . . . . . . . . . 00400–RM778–2095 2002 Prius . . . . . . . . . . . . RM883–U1 . . . . DI–687 . . . . . . . . . . . . . 00400–RM883–2096 2003 Prius . . . . . . . . . . . . RM957–U1 . . . . DI–687 . . . . . . . . . . . . . 00400–RM957–2097 Page 3 of 4 REPAIR MANUAL CORRECTIONS INDEX – PG001-03 Publication Number February 28, 2003 Page(s) Part Number Sequoia 2003 Sequoia . . . . . . . . . RM959–U1 . . . . ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... ...................................... DI–304 . . . . . . . . . . . . 00400–RM959–12128 DI–312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–330 to DI–333 . . . . . . . . . . . . . . . . . . . . . ↓ DI–335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–360 to DI–362 . . . . . . . . . . . . . . . . . . . . . ↓ DI–372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–377–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Sienna 2001 Sienna . . . . . . . . . . EWD420U . . . . . ...................................... ...................................... ...................................... 2002 Sienna . . . . . . . . . . EWD454U . . . . . ...................................... ...................................... ...................................... 2003 Sienna . . . . . . . . . . EWD490U . . . . . ...................................... ...................................... ...................................... 37 . . . . . . . . . . . . . . . . . 00400–EWD42–2121 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 267 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 37 . . . . . . . . . . . . . . . . . 00400–EWD45–2122 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 37 . . . . . . . . . . . . . . . . 00400–EWD49–02123 64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Tacoma Tundra Page 4 of 4 2002 Tacoma . . . . . . . . . RM921–U1 . . . . DI–510 . . . . . . . . . . . . . 00400–RM921–2089 2000 Tundra . . . . . . . . . . EWD367U . . . . . ...................................... ...................................... 2001 Tundra . . . . . . . . . . EWD429U . . . . . ...................................... ...................................... 2002 Tundra . . . . . . . . . . EWD468U . . . . . ...................................... ...................................... 129 . . . . . . . . . . . . . . . 00400–EWD36–72133 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 121 . . . . . . . . . . . . . . . 00400–EWD42–92134 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 121 . . . . . . . . . . . . . . . 00400–EWD46–82135 208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ M26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Models: All Models December 31, 2000 Introduction Corrections have been made in the repair manuals listed below. Corrections available in the last quarter are marked in red, and have already been mailed to all dealers. NOTE: When ordering a technical publication (i.e. Repair Manual, Electrical Wiring Diagram) from the MDC, and Correction Page(s) associated with that particular Publication will automatically be included with your order. Parts Information Correction Pages are available through the Dealer Support Material Network (MDC NPM System) via the corresponding part numbers from the following table: Publication Number Page(s) Part Number Avalon 2001 Avalon . . . . . . . . RM746–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... DI–259 . . . . . . . . . . . . . . 00400–RM746–Z107 DI–260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–317–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–317–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Celica 2000 Celica . . . . . . . . . RM744–U1 . . . . . ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM744–U2 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... SS–45 . . . . . . . . . . . . . . 00400–RM744–9094A SS–47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–02 . . . . . . . . . . . . . . 00400–RM744–9094B SA–41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–4 . . . . . . . . . . . . . . . . 00400–RM744–Z066 EM–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ EM–12–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SF–10 . . . . . . . . . . . . . . . 00400–RM744–Z130 SF–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SF–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SF–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Toyota Supports ASE Certification Page 1 of 4 PRODUCT GENERAL INFORMATION Technical Service BULLETIN REPAIR MANUAL CORRECTIONS INDEX PG002–00 Title: REPAIR MANUAL CORRECTIONS INDEX – PG002-00 Revised Publication Number December 31, 2000 Page(s) Part Number Celica (Continued) 2001 Celica . . . . . . . . . RM818–U2 . . . . . ..................................... ..................................... ..................................... SF–10 SF–12 SF–13 SF–15 . . . . . . . . . . . . . . . 00400–RM818–Z130 ................................. ↓ ................................. ↓ ................................. ↓ ECHO 2000 ECHO . . . . . . . . RM750–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... 2001 ECHO . . . . . . . . RM816–U . . . . . . BR–16 BR–27 BR–28 BR–31 PP–50 SS–37 SS–38 BR–32 BR–32 . . . . . . . . . . . . . . . 00400–RM591–8121 ................................. ↓ ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . . 00400–RM591–8063 ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . . 00400–RM750–Z140 . . . . . . . . . . . . . . . 00400–RM816–Z140 Highlander Land Cruiser MR2 Spyder Page 2 of 4 2001 Highlander . . . . EWD442–U . . . . . 239 . . . . . . . . . . . . . . . . 00400–EWD44–2Z149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 2000 Land Cruiser . . . RM722–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM722–U2 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... DI–305 . . . . . . . . . . . . . . 00400–RM722–Z018 DI–306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–30 . . . . . . . . . . . . . . 00400–RM722–9093A SS–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–3 . . . . . . . . . . . . . . . 00400–RM722–9093B SA–37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BR–10 . . . . . . . . . . . . . . . 00400–RM722–Z038 2000 MR2 . . . . . . . . . . RM760–U . . . . . . BR–8 . . . . . . . . . . . . . . . . 00400–RM760–Z141 2001 MR2 . . . . . . . . . . RM801–U . . . . . . BR–8 . . . . . . . . . . . . . . . . 00400–RM801–Z141 REPAIR MANUAL CORRECTIONS INDEX – PG002-00 Revised Publication Number December 31, 2000 Page(s) Part Number Prius 2001 Prius . . . . . . . . . . BRM09–6E . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM778–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM778–U2 . . . . . ..................................... ..................................... ..................................... BP–17 . . . . . . . . . . . . . . 00400–BRM09–6Z112 BP–18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BP–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BP–48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BP–49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BP–54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BP–55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ PC–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–105 . . . . . . . . . . . . . . 00400–RM778–Z093 DI–106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–21 . . . . . . . . . . . . . . . 00400–RM778–Z123 DI–504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–593–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–593–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–593–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ HV–22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–661 . . . . . . . . . . . . . 00400–RM778–Z120A DI–661–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–665 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–666 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–670 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–671 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–22 . . . . . . . . . . . . . . . 00400–RM778–Z151 BE–23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–44 . . . . . . . . . . . . . . 00400–RM778–Z120B BE–46–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ RAV4 1996 RAV4 . . . . . . . . . RM447–U . . . . . . 1997 RAV4 . . . . . . . . . RM505–U . . . . . . 1998 RAV4 . . . . . . . . . RM595–U . . . . . . 1999 RAV4 . . . . . . . . . RM668–U2 . . . . . 2000 RAV4 . . . . . . . . . RM711–U2 . . . . . 2001 RAV4 . . . . . . . . . RM797–U1 . . . . . ..................................... . . . . . . . . . . . . . . . . . . . . RM797–U2 . . . . . ..................................... ..................................... SA–62 . . . . . . . . . . . . . . . 00400–RM447–Z071 SA–66 . . . . . . . . . . . . . . . 00400–RM505–Z071 SA–79 . . . . . . . . . . . . . . . 00400–RM595–Z071 SA–79 . . . . . . . . . . . . . . . 00400–RM668–Z071 SA–79 . . . . . . . . . . . . . . . 00400–RM711–Z071 DI–489 . . . . . . . . . . . . . . 00400–RM797–Z096 SS–42 . . . . . . . . . . . . . . 00400–RM797–Z106A SA–5 . . . . . . . . . . . . . . . 00400–RM797–Z106B SA–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–69 . . . . . . . . . . . . . . . 00400–RM797–Z071 Sequoia Sienna 2001 Sequoia . . . . . . . RM832–U1 . . . . . SS–31 . . . . . . . . . . . . . . . 00400–RM832–Z139 1998 Sienna . . . . . . . . RM594–U . . . . . . ..................................... ..................................... 1999 Sienna . . . . . . . . RM657–U . . . . . . ..................................... ..................................... SR–37 SR–47 SR–48 SR–37 SR–47 SR–48 . . . . . . . . . . . . . . . 00400–RM594–9095 ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . . 00400–RM657–9095 ................................. ↓ ................................. ↓ Page 3 of 4 REPAIR MANUAL CORRECTIONS INDEX – PG002-00 Revised Publication Number Page(s) December 31, 2000 Part Number Sienna (Continued) 2000 Sienna . . . . . . . . RM701–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... SR–37 . . . . . . . . . . . . . . . 00400–RM701–9095 SR–47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–387 . . . . . . . . . . . . . . 00400–RM701–Z121 DI–388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–389–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–389–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–389–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Tacoma 1998 Tacoma . . . . . . . RM576–U1 . . . . . ..................................... 1998 Tacoma Suppl. . RM614–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... 1999 Tacoma . . . . . . . RM673–U1 . . . . . ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM673–U2 . . . . . ..................................... ..................................... 2000 Tacoma . . . . . . . RM712–U1 . . . . . ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM712–U2 . . . . . ..................................... ..................................... 2001 Tacoma . . . . . . . RM835–U1 . . . . . ..................................... DI–349 . . . . . . . . . . . . . . 00400–RM576–Z105 DI–350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ PP–8 . . . . . . . . . . . . . . . . 00400–RM614–9123 PP–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–72 . . . . . . . . . . . . . . 00400–RM673–9123A DI–373 . . . . . . . . . . . . . . 00400–RM673–Z105 DI–374 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–23 . . . . . . . . . . . . . . 00400–RM673–9123B SA–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SS–73 . . . . . . . . . . . . . . 00400–RM712–9123A DI–415 . . . . . . . . . . . . . . 00400–RM712–Z105 DI–416 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–23 . . . . . . . . . . . . . . 00400–RM712–9123B SA–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–340 . . . . . . . . . . . . . . 00400–RM835–Z105 DI–341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Tundra Page 4 of 4 2000 Tundra . . . . . . . . RM682–U2 . . . . . TR–43 . . . . . . . . . . . . . . . 00400–RM682–Z055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TR–44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TR–45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Models: All Models December 24, 1999 Introduction Corrections have been made in the repair manuals listed below. Corrections available in the last quarter are marked in red, and have already been mailed to all dealers. Parts Information Correction Pages are available through the Dealer Support Material Network (MDC NPM System) via the corresponding part numbers from the following table: NOTE: When ordering a technical publication (i.e. Repair Manual, Electrical Wiring Diagram) from the MDC, and Correction Page(s) associated with that particular Publication will automatically be included with your order. Publication Number Page(s) Part Number Avalon 1999 Avalon . . . . . . . . RM598–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM656–U . . . . . . ..................................... ..................................... ..................................... BE–74 . . . . . . . . . . . . . . . 00400–RM598–8029 BE–76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–116 . . . . . . . . . . . . . . 00400–RM656–8121 DI–121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 4Runner 1998 4Runner . . . . . . RM580–U1 . . . . . ..................................... 1999 4Runner . . . . . . RM663–U2 . . . . . ..................................... DI–331 . . . . . . . . . . . . . . 00400–RM580–8087 DI–338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–49 . . . . . . . . . . . . . . . 00400–RM663–9005 BE–92 . . . . . . . . . . . . . . . 00400–RM663–8117 Camry 1998 Camry . . . . . . . . RM589–U1 . . . . . ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM589–U2 . . . . . 1999 Camry . . . . . . . . RM654–U2 . . . . . DI–107 . . . . . . . . . . . . . . 00400–RM580–8087 DI–112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–5 . . . . . . . . . . . . . . . . 00400–RM589–9002 SA–5 . . . . . . . . . . . . . . . . 00400–RM654–9002 Toyota Supports ASE Certification Page 1 of 5 PRODUCT GENERAL INFORMATION Technical Service BULLETIN REPAIR MANUAL CORRECTIONS INDEX PG002–99 Title: REPAIR MANUAL CORRECTIONS INDEX – PG002-99 REVISED Publication Number Page(s) December 24, 1999 Part Number Celica 1998 Celica . . . . . . . . . RM613–U . . . . . . ..................................... ..................................... ..................................... ..................................... 1999 Celica . . . . . . . . . RM660–U . . . . . . ..................................... ..................................... ..................................... ..................................... 2000 Celica . . . . . . . . . RM774–U1 . . . . . ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM774–U2 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... D1–90 . . . . . . . . . . . . . . . 00400–RM598–8029 D1–95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–5 . . . . . . . . . . . . . . . . 00400–RM613–9002 D1–96 . . . . . . . . . . . . . . . 00400–RM660–8121 D1–101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–116 . . . . . . . . . . . . . . 00400–RM660–8121 SA–5 . . . . . . . . . . . . . . . . 00400–RM660–9002 D1–280 . . . . . . . . . . . . . . 00400–RM774–9063 SS–47 . . . . . . . . . . . . . . 00400–RM774–9078A SS–52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–41 . . . . . . . . . . . . . . 00400–RM774–9078B SA–44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Celica 1998 Corolla . . . . . . . . RM591–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... 1999 Corolla . . . . . . . . RM655–U . . . . . . ..................................... ..................................... D1–71 . . . . . . . . . . . . . . . 00400–RM591–8121 D1–75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–181 . . . . . . . . . . . . . . 00400–RM591–8063 D1–182 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–183 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–198 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–199 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–72 . . . . . . . . . . . . . . . 00400–RM655–8121 D1–76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Page 2 of 5 REPAIR MANUAL CORRECTIONS INDEX – PG002–99 Revised Publication Corolla (Continued) Land Cruiser Number Page(s) December 24, 1999 Part Number 1999 Corolla . . . . . . . . RM665–U . . . . . . D1–91 . . . . . . . . . . . . . . . 00400–RM655–8121 1998 Land Cruiser . . . RM615–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM615–U1 . . . . . ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM615–U2 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... 1999 Land Cruiser . . . RM661–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... . . . . . . . . . . . . . . . . . . . . RM661–U2 . . . . . PP–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A PP–34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A PP–35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A PP–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A SS–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A TR–46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A D1–293 . . . . . . . . . . . . . . 00400–RM615–8046 D1–299 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–453 . . . . . . . . . . . . . . 00400–RM615–8117 SS–29 . . . . . . . . . . . . . . . 00400–RM615–9017 EM–59 . . . . . . . . . . . . . . 00400–RM615–9038 BE–74 . . . . . . . . . . . . . . . 00400–RM615–9022 BR–4 . . . . . . . . . . . . . . . . 00400–RM615–8031 SA–14 . . . . . . . . . . . . . . 00400–RM615–9017A SA–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–24 . . . . . . . . . . . . . . . 00400–RM615–9028 SR–26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–122 . . . . . . . . . . . . . . 00400–RM661–8121 D1–127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–471 . . . . . . . . . . . . . . 00400–RM661–8117 SS–30 . . . . . . . . . . . . . . . 00400–RM661–9017 BE–76 . . . . . . . . . . . . . . . 00400–RM661–9022 Page 3 of 5 REPAIR MANUAL CORRECTIONS INDEX – PG002-99 REVISED Publication Number Page(s) December 24, 1999 Part Number Land Cruiser (Continued) 1999 Land Cruiser . . . . . . . . . . . . . . . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... EM–59 . . . . . . . . . . . . . . 00400–RM661–9038 SA–15 . . . . . . . . . . . . . . 00400–RM661–9017A SA–16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–26 . . . . . . . . . . . . . . . 00400–RM661–9028 SR–28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SR–34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Sienna 1998 Sienna . . . . . . . . RM594–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... 1999 Sienna . . . . . . . . RM657–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... 2000 Sienna . . . . . . . . RM701–U . . . . . . ..................................... BO–14 . . . . . . . . . . . . . . . 00400–RM594–9023 BO–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–186 . . . . . . . . . . . . . . 00400–RM594–9065 D1–187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–219 . . . . . . . . . . . . . . 00400–RM594–8088 D1–224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–385 . . . . . . . . . . . . . . 00400–RM594–8066 D1–386 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–5 . . . . . . . . . . . . . . . . 00400–RM594–9002 BE–84 . . . . . . . . . . . . . . . 00400–RM657–9011 BO–14 . . . . . . . . . . . . . . . 00400–RM657–9021 BO–15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–219 . . . . . . . . . . . . . . 00400–RM657–9065 D1–220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–253 . . . . . . . . . . . . . . 00400–RM657–8088 D1–257 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–258 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–5 . . . . . . . . . . . . . . . . 00400–RM657–9022 D1–217 . . . . . . . . . . . . . . 00400–RM701–9065 D1–218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Page 4 of 5 REPAIR MANUAL CORRECTIONS INDEX – PG002–99 Revised Publication Number December 24, 1999 Page(s) Part Number . . . . . . . . . . . . . . 00400–RM701–9065 ................................ ↓ ................................ ↓ ................................ ↓ ................................ ↓ ................................ ↓ ................................ ↓ Sienna (Continued) 2000 Sienna . . . . . . . . RM701–U . . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... D1–221 D1–222 D1–223 D1–224 D1–225 D1–226 D1–227 Solara 1999 Solara . . . . . . . . RM649–U1 . . . . . ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... ..................................... D1–110 . . . . . . . . . . . . . . 00400–RM649–8121 D1–115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–286 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ D1–306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–5 . . . . . . . . . . . . . . . . 00400–RM594–9002 Supra 1999 Supra . . . . . . . . . RM408–U2 . . . . . ..................................... ..................................... 1996 Supra . . . . . . . . . RM444 . . . . . . . . . ..................................... ..................................... 1997 Supra . . . . . . . . . RM502 . . . . . . . . . ..................................... ..................................... 1998 Supra . . . . . . . . . RM587–U1 . . . . . . . . . . . . . . . . . . . . . . . . . RM587–U2 . . . . . ..................................... ..................................... SA–20 SA–26 SA–28 SA–18 SA–19 SA–24 SA–18 SA–19 SA–24 PP–69 SA–19 SA–28 SA–31 . . . . . . . . . . . . . . . 00400–RM408–9007 ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . . 00400–RM444–9007 ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . . 00400–RM502–9007 ................................. ↓ ................................. ↓ . . . . . . . . . . . . . . 00400–RM587–9007A . . . . . . . . . . . . . . 00400–RM587–9007B ................................. ↓ ................................. ↓ Tacoma 1998 Tacoma . . . . . . . RM576–U1 . . . . . D1–351 . . . . . . . . . . . . . . 00400–RM576–8038 Tundra 2000 Tundra . . . . . . . . RM682–U1 . . . . . SS–76 . . . . . . . . . . . . . . 00400–RM682–9077A . . . . . . . . . . . . . . . . . . . . RM682–U2 . . . . . BR–9 . . . . . . . . . . . . . . . 00400–RM682–9077B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BR–13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Page 5 of 5 Models: All Models September 30, 2002 Introduction Corrections have been made in the repair manuals listed below. Corrections available in the last quarter are marked in red, have already been mailed to all dealers, and are updated in TIS. NOTE: When ordering a technical publication (i.e., Repair Manual, Electrical Wiring Diagram) from the MDC, any Correction Page(s) associated with that particular Publication will automatically be included with your order. Parts Information Correction Pages are available through the Dealer Support Material Network (MDC NPM System) via the corresponding part numbers from the following table. Publication 4Runner Number Page(s) Part Number 2001 4Runner . . . . . . . . RM796–U1 . . . . DI–477 . . . . . . . . . . . . . 00400–RM796–2086 2002 4Runner . . . . . . . . EWD471–U . . . . 158 . . . . . . . . . . . . . . . 00400–EWD471–2050 . . . . . . . . . . . . . . . . . . . . . . RM887–U1 . . . . DI–487 . . . . . . . . . . . . . 00400–RM887–2087 Avalon 2002 Avalon . . . . . . . . . . EWD45–3U . . . . ...................................... . . . . . . . . . . . . . . . . . . . . . . RM872–U1 . . . . ...................................... 258 . . . . . . . . . . . . . . . 00400–EWD45–32038 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–232 . . . . . . . . . . . . . 00400–RM872–2054 DI–530 . . . . . . . . . . . . . 00400–RM872–2052 Camry 1998 Camry . . . . . . . . . . RM589–U2 . . . . ...................................... ...................................... 1999 Camry . . . . . . . . . . RM654–U2 . . . . ...................................... ...................................... 2000 Camry . . . . . . . . . . RM742–U2 . . . . ...................................... ...................................... 2001 Camry . . . . . . . . . . RM819–U2 . . . . ...................................... ...................................... BE–64 BE–65 BE–66 BE–65 BE–66 BE–67 BE–65 BE–66 BE–67 BE–66 BE–67 BE–68 Toyota Supports ASE Certification . . . . . . . . . . . . 00400–RM589–2005B ............................... ↓ ............................... ↓ . . . . . . . . . . . . 00400–RM654–2005B ............................... ↓ ............................... ↓ . . . . . . . . . . . . 00400–RM742–2005B ............................... ↓ ............................... ↓ . . . . . . . . . . . . 00400–RM819–2005B ............................... ↓ ............................... ↓ Page 1 of 3 PRODUCT GENERAL INFORMATION Technical Service BULLETIN REPAIR MANUAL CORRECTIONS INDEX PG002-02 Title: REPAIR MANUAL CORRECTIONS INDEX – PG002-02 Revised Publication Camry (Continued) Number 2002 Camry . . . . . . . . . . EWD46–1U . . . . . . . . . . . . . . . . . . . . . . . . . . RM881–U1 . . . . ...................................... . . . . . . . . . . . . . . . . . . . . . . RM881–U2 . . . . ...................................... ...................................... September 30, 2002 Page(s) Part Number 77 . . . . . . . . . . . . . . . . 00400–EWD46–12039 05–418 . . . . . . . . . . . . 00400–RM881–2054 05–1230 . . . . . . . . . . . 00400–RM881–2077 73–8 . . . . . . . . . . . . . . 00400–RM881–2060B 73–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 73–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Celica 2000 Celica . . . . . . . . . . . RM744–U1 . . . . DI–510 . . . . . . . . . . . . . 00400–RM744–2074 2001 Celica . . . . . . . . . . . RM818–U1 . . . . DI–511 . . . . . . . . . . . . . 00400–RM818–2075 2002 Celica . . . . . . . . . . . RM902–U1 . . . . DI–514 . . . . . . . . . . . . . 00400–RM902–2076 Corolla 2003 Corolla . . . . . . . . . . RM938–U1 . . . . 05–169 . . . . . . . . . . . . 00400–RM938–2054 ECHO Highlander Land Cruiser Prius Page 2 of 3 2000 ECHO . . . . . . . . . . RM750–U . . . . . ...................................... 2001 ECHO . . . . . . . . . . RM816–U . . . . . ...................................... 2002 ECHO . . . . . . . . . . RM884–U . . . . . ...................................... BE–66 . . . . . . . . . . . . . . 00400–RM750–2011 BE–66–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–66 . . . . . . . . . . . . . . 00400–RM816–2011 BE–66–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–66 . . . . . . . . . . . . . . 00400–RM884–2011 BE–66–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 2002 Highlander . . . . . . RM918–U1 . . . . 05–919 . . . . . . . . . . . . 00400–RM918–2053 . . . . . . . . . . . . . . . . . . . . . . RM918–U2 . . . . 82–4 . . . . . . . . . . . . . . 00400–RM918–2058B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 1998 Land Cruiser . . . . . RM615–U2 . . . . ...................................... 1999 Land Cruiser . . . . . RM661–U2 . . . . ...................................... 2000 Land Cruiser . . . . . RM722–U2 . . . . ...................................... 2001 Land Cruiser . . . . . RM795–U2 . . . . ...................................... ...................................... 2002 Land Cruiser . . . . . RM893–U2 . . . . ...................................... ...................................... BE–80 BE–81 BE–82 BE–83 BE–82 BE–83 BE–91 BE–92 BE–93 BE–91 BE–92 BE–93 . . . . . . . . . . . . 00400–RM615–2006B ............................... ↓ . . . . . . . . . . . . 00400–RM661–2006B ............................... ↓ . . . . . . . . . . . . 00400–RM722–2006B ............................... ↓ . . . . . . . . . . . . 00400–RM795–2006B ............................... ↓ ............................... ↓ . . . . . . . . . . . . 00400–RM893–2006B ............................... ↓ ............................... ↓ 2001 Prius . . . . . . . . . . . . RM778–U1 . . . . DI–654 . . . . . . . . . . . . . 00400–RM778–2072 2002 Prius . . . . . . . . . . . . RM883–U1 . . . . DI–669 . . . . . . . . . . . . . 00400–RM883–2073 REPAIR MANUAL CORRECTIONS INDEX – PG002-02 Revised Publication RAV4 Number 2001 RAV4 . . . . . . . . . . . RM797–U1 . . . . . . . . . . . . . . . . . . . . . . . . . . RM797–U2 . . . . ...................................... ...................................... ...................................... ...................................... 2002 RAV4 . . . . . . . . . . . RM891–U1 . . . . . . . . . . . . . . . . . . . . . . . . . . RM891–U2 . . . . ...................................... ...................................... ...................................... ...................................... September 30, 2002 Page(s) Part Number DI–450 . . . . . . . . . . . . . 00400–RM797–2084 BE–63 . . . . . . . . . . . . 00400–RM797–2012B BO–9 . . . . . . . . . . . . . 00400–RM797–2040B BO–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–11–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ DI–450 . . . . . . . . . . . . . 00400–RM891–2085 BE–64 . . . . . . . . . . . . 00400–RM891–2012B BO–9 . . . . . . . . . . . . . 00400–RM891–2040B BO–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BO–11–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Sequoia 2002 Sequoia . . . . . . . . . RM886–U1 . . . . DI–253 . . . . . . . . . . . . . 00400–RM886–2054 Sienna 1998 Sienna . . . . . . . . . . RM594–U . . . . . BE–59 . . . . . . . . . . . . . 00400–RM594–2013 1999 Sienna . . . . . . . . . . RM657–U . . . . . BE–60 . . . . . . . . . . . . . 00400–RM657–2013 2000 Sienna . . . . . . . . . . RM701–U . . . . . BE–60 . . . . . . . . . . . . . 00400–RM701–2013 Solara 2002 Solara . . . . . . . . . . RM882–U1 . . . . DI–446 . . . . . . . . . . . . . 00400–RM882–2054 Tacoma 2002 Tacoma . . . . . . . . . EWD478–U . . . . 71 . . . . . . . . . . . . . . . . . . . 00400–EWD–2051 ...................................... 4 .................................... ↓ Tundra 2002 Tundra . . . . . . . . . . RM885–U1 . . . . DI–371 . . . . . . . . . . . . . 00400–RM885–2054 Page 3 of 3 PRODUCT GENERAL INFORMATION PG95-006 JULY 21, 1995 ALL MODELS STANDARD BOLT TORQUE SPECIFICATIONS Page 1 of 1 The following bolt mark and class identification information is currently not included in the Standard Bolt Torque Specifications found in the Introduction section of each Toyota Repair Manual. BOLT MARK CLASS (Hexagon flange bolt or Hexagon bolt with washer) 4 Protruding Lines 9T (Hexagon flange bolt or Hexagon bolt with washer) 5 Protruding Lines 10T (Hexagon flange bolt or Hexagon bolt with washer) 6 Protruding Lines 11T SPECIFIED TORQUE FOR STANDARD BOLTS CLASS 9T 10T 11T DIAMETER mm PITCH mm SPECIFIED TORQUE HEXAGON HEAD BOLT HEXAGON FLANGE BOLT NSm kgfScm ftSlbf NSm kgfScm ftSlbf 8 1.25 34 340 25 37 380 27 10 1.25 70 710 51 78 790 57 12 1.25 125 1300 94 140 1450 105 8 1.25 38 390 28 42 430 31 10 1.25 78 800 58 88 890 64 12 1.25 140 1450 105 155 1600 116 8 1.25 42 430 31 47 480 35 10 1.25 87 890 64 97 990 72 12 1.25 155 1600 116 175 1800 130 TOYOTA MOTOR SALES U.S.A., INC. March 31, 2000 Introduction Applicable Vehicles CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING Models: All Models It is no longer necessary to fax the CA/50 State Emission Label Order Form to TMS. California (CA) and 50 State Certified underhood emission control labels (emission labels) may now be obtained through your dealership Parts Department utilizing standard replacement parts ordering procedures via the TDN. Follow the guidelines outlined in this TSB to ensure proper label application. S All model year Toyota Vehicles. We have included tables reflecting 1997 – 2000 MY CA and 50 State Emission Label part number information for your convenience. Please continue to consult the Electronic Parts Catalog (EPC) or the parts microfiche for information regarding other model years as well as Federal Emission label part numbers. NOTE: Although the California Smog Impact Fee has been discontinued, dealers are still required by regulation to verify the correct emission label is installed on the correct vehicle. REGULATIONS: The United States Clean Air Act, Title II, Sections 202, 203, 205, and 207 mandates that the emission control label must correctly match the emissions equipment on the vehicle. Any person violating this requirement is subject to applicable State penalties and a Federal civil penalty of no more than $25,000 for each instance. Personnel at franchised dealerships are authorized to affix such labels to vehicles and are, therefore, subject to this regulation and the attendant penalties. S Do not sell the labels over the counter. Always install the label on the vehicle. S Never install a California and/or 50 State Label on a vehicle that is not a California/50 State Emission Certified Vehicle. S Do not install Federal Emission labels on vehicles that are not Federal Emissions Certified. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 6 PRODUCT GENERAL INFORMATION Technical Service BULLETIN PG006–00 Title: CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING – PG006–00 Label Ordering Procedure March 31, 2000 To ensure that the emission control labels are affixed to the correct vehicle, it is necessary to follow these procedures: 1. Record the Vehicle Identification Number (VIN) from the vehicle requiring a replacement label. 2. A dealership associate (must be assigned by Parts Manager), with authorized TDN access, must confirm the emissions equipment of the vehicle by referring to the following accessory codes: S CA – California Certified S FE – 50 State Certified S RE – Federal Certified S CN – California and New York Certified 3. Once the emissions equipment information is verified, obtain the part number information by referring to the attached table for 1998 – 2000 MY vehicles or consulting the EPC/microfiche for other Toyota vehicles, including Federal Specification Vehicles. 4. Order the label through your Parts Department, using normal parts ordering procedures via the TDN. 5. When the part arrives, verify that the emission label matches the emissions equipment on the vehicle. This will ensure the correct label is affixed to the vehicle. Page 2 of 6 CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING – PG006–00 1997 MY CA/50 State Certified Emission Control Labels March 31, 2000 MODEL ENGINE NAME TRANSMISSION EMISSIONS* PART NUMBERS Tercel 5E–FE All USA 11298–11452 Paseo 5E–FE All CA 11298–11452 4A–FE All CA 11298–1D060 7A–FE All CA 11298–1D090 7A–FE All CA 11298–1D120 5S–FE All CA 11298–7A390 5S–FE M/TM CA 11298–7A330 5S–FE A/TM CA 11298–7A350 1MZ–FE All CA 11298–20110 2JZ–GE All USA 11298–46121 2JZ–GTE All USA 11298–46102 Avalon 1MZ–FE A/TM CA 11298–20110 Previa 2TZ–FZE A/TM USA 11298–76083 RAV4 3S–FE All CA 11298–7A410 3RZ–FE (2WD) All USA 11298–75220 3RZ–FE (4WD) All USA 11298–75260 5VZ–FE All CA 11298–62450 2RZ–FE (2WD) All CA 11298–75210 3RZ–FE (4WD) M/TM CA 11298–75200 3RZ–FE (4WD) All USA 11298–75220 5VZ–FE (2WD XtraCab) All USA 11298–62430 5VZ–FE (4WD RegCab) M/TM USA 11298–62430 5VZ–FE (4WD XtraCab) All CA 11298–62450 3RZ–FE (2WD) All USA 11298–75240 T 100 T–100 5VZ–FE (2WD/4WD) All CA 11298–62500 Land Cruiser 1FZ–FE A/TM USA 11298–66070 Corolla Celica Camry S pra Supra 4Runner Tacoma * CA = California Emission Specification, USA = 50 State Emission Specification Page 3 of 6 CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING – PG006–00 1998 MY CA/50 State Certified Emission Control Labels MODEL ENGINE NAME TRANSMISSION EMISSIONS* PART NUMBERS Tercel 5E–FE All CA 11298–11453 Corolla 1ZZ–FE All CA 11298–22040 Celica 5S–FE All CA 11298–7A470 5S–FE All CA 11298–7A430 1MZ–FE A/TM CA 11298–20160 1MZ–FE M/TM CA 11298–20190 Supra 2JZ–GE A/TM CA 11298–46122 Avalon 1MZ–FE A/TM CA 11298–20160 Sienna 1MZ–FE All CA 11298–20140 RAV4 3S–FE All CA 11298–7A510 3RZ–FE (2WD) All CA 11298–75320 3RZ–FE (4WD) All CA 11298–75380 5VZ–FE All CA 11298–62540 2RZ–FE (2WD) All CA 11298–75300 3RZ–FE (4WD) M/TM CA 11298–75310 3RZ–FE (4WD) A/TM CA 11298–75320 5VZ–FE (2WD) All CA 11298–62530 5VZ–FE (4WD XtraCab) All CA 11298–62540 3RZ–FE (2WD) All USA 11298–75360 T 100 T–100 5VZ–FE (2WD/4WD) All CA 11298–62580 Land Cruiser 2UZ–FE A/TM CA 11298–50200 Camry 4Runner Tacoma * Page 4 of 6 March 31, 2000 CA = California Emission Specification, USA = 50 State Emission Specification CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING – PG006–00 1999 MY CA/50 State Certified Emission Control Labels MODEL ENGINE NAME TRANSMISSION EMISSIONS* PART NUMBERS Corolla 1ZZ–FE All CA 11298–22041 Celica 5S–FE All CA 11298–7A560 5S–FE All CA 11298–7A521 1MZ–FE M/TM USA 11298–20240 1MZ–FE A/TM CA 11298–20181 5S–FE All CA 11298–7A521 1MZ–FE M/TM USA 11298–20240 1MZ–FE A/TM USA 11298–20181 Avalon 1MZ–FE All CA 11298–20181 Sienna 1MZ–FE A/TM CA 11298–20270 RAV4 3S–FE (2WD/4WD) All CA 11298–7A541 3RZ–FE (2WD/4WD) All USA 11298–75400 5VZ–FE (2WD/4WD) All CA 11298–62660 2RZ–FE (2WD) All USA 11298–75460 3RZ–FE (PreRunner/4WD) A/TM USA 11298–75470 3RZ–FE (4WD) M/TM CA 11298–75480 3RZ–FE (2WD XtraCab) A/TM USA 11298–75400 5VZ–FE (2WD XtraCab) All USA 11298–62590 5VZ–FE (PreRunner/4WD) All USA 11298–62600 2UZ–FE A/TM USA 11298–50181 Camry Camry Solara 4R nner 4Runner Tacoma Land Cruiser * March 31, 2000 CA = California Emission Specification, USA = 50 State Emission Specification Page 5 of 6 CA/50 STATE CERTIFIED EMISSION CONTROL UNDERHOOD LABEL ORDERING – PG006–00 2000 MY CA/50 State Certified Emission Control Labels March 31, 2000 MODEL ENGINE NAME TRANSMISSION EMISSIONS* PART NUMBERS ECHO 1NZ–FE All USA 11298–21010 Corolla 1ZZ–FE All USA 11298–22032 1ZZ–FE All USA 11298–22080 2ZZ–GE All USA 11298–22050 5S–FE All USA 11298–7A590 1MZ–FE M/TM USA 11298–20320 1MZ–FE A/TM CA 11298–20310 5S–FE All USA 11298–7A590 1MZ–FE M/TM USA 11298–20320 1MZ–FE A/TM CA 11298–20310 Celica Camry Camry Solara Camry Solara Convertible 5S–FE A/TM USA 11298–7A590 1MZ–FE A/TM CA 11298–20310 Camry (CNG) 5S–FNE A/TM USA 11298–7A640 Avalon 1MZ–FE A/TM USA 11298–20290 Sienna 1MZ–FE A/TM USA 11298–20340 RAV4 3S–FE (2WD/4WD) All USA 11298–7A620 3RZ–FE (2WD) All USA 11298–75550 3RZ–FE (4WD) M/TM USA 11298–75550 5VZ–FE (2WD/4WD) All USA 11298–62690 2RZ–FE (2WD) All USA 11298–75510 3RZ–FE (2WD/4WD) A/TM USA 11298–75530 M/TM USA 11298–75530 A/TM USA 11298–75550 A/TM USA 11298–75530 All USA 11298–62670 All USA 11298–62690 5VZ–FE All CA 11298–62640 2UZ–FE A/TM USA 11298–50241 2UZ–FE A/TM USA 11298–50182 4Runner Tacoma 3RZ–FE (4WD XtraCab) 3RZ–FE (4WD XtraCab) 3RZ–FE (PreRunner) 5VZ–FE (2WD XtraCab) 5VZ–FE (4WD & PreRunner) T ndra Tundra Land Cruiser * Page 6 of 6 CA = California Emission Specification, USA = 50 State Emission Specification Technical Service BULLETIN REPLACEMENT CERTIFICATION LABELS Models: All Models May 4, 2001 Introduction Replacement Certification Labels (vinyl label affixed to driver’s door or door post) may be available from Toyota providing the request meets one of the criteria listed below. Certification Label Location Applicable Vehicles Certification Label Criteria S All Toyota vehicles. 1. The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair. NOTE: S Processing a new label will be delayed significantly if the old certification label is not available. S A replacement label MAY NOT be available if the vehicle is more than 5 years old and the old label does not accompany this request. 2. The label is stolen. Procurement Procedure To request a replacement label, complete a copy of the form on the back of this bulletin. Your dealer parts account will be billed $10.00 for each replacement of a damaged or stolen label. NOTE: All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG006-01 Title: APPLICATION FOR REPLACEMENT CERTIFICATION LABEL REASON FOR REPLACEMENT ACCIDENT DAMAGE STOLEN OTHER REASON/EXPLANATION ATTACH ORIGINAL LABEL HERE PLEASE PROVIDE CORRECT VIN NOTE: Original label MUST accompany this application or order will be significantly delayed. DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD LABEL TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA 90509–2991 Technical Service BULLETIN September 26, 2003 Introduction WARRANTY PARTS MARKING PROCEDURE Models: All Models Effective September 1, 2003, all warranty parts (as indicated on the next page) must be marked in the area or location of the failure. The technician should complete this procedure after the failed part has been removed from the vehicle and before the part is placed in the 10–bin storage. (Exchanged parts and remanufactured parts are not included in this procedure.) Failed parts marking will be beneficial in detecting and resolving product and parts quality issues. This will also offer additional opportunities to make future enhancements to our parts and products. Parts are subject to random inspection in the dealership by field representatives to ensure compliance with this new policy. Failure to comply with this policy may result in a debit of the corresponding warranty claim(s). Applicable Vehicles Parts Marking Procedure S All models. All technicians must follow these procedures to ensure proper parts marking: S Wipe the part clean (no excess fluid should be present). S Indicate area of defect or failure by marking the specific part(s) with a water resistant permanent marker. Use a color that can be easily seen against the background of the part being marked. For dark surfaces the color yellow is highly recommended as well as the color black for light surfaces. S Mark the area of failure or defect by drawing a circle, a square, pointing an arrow or adhering tape with an indication of the failed or defect location. S Attach a completed Warranty Parts Tag (M/N 00404–PRETN–TAGS) to the marked part. All other parts recovery/shipping policies and procedures apply. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 3 PRODUCT GENERAL INFORMATION PG006–03 Title: WARRANTY PARTS MARKING PROCEDURE – PG006-03 Parts Marking Requirement Parts Marking List Dealers are requested to mark the location of the failure of all warranty parts that are listed below. This list is not inclusive. There may be other components that can be marked in the area of failure. All other parts that can be marked should be marked. assist grip assy headlamps audio (blemish) headliner back door garnish hoses bumper covers instrument panel safety pad sub–assy cargo cover (retractable) Interior light assemblies and covers carpet knobs, levers, handles clutch disc l/pulley pump assy clutch flywheel mirrors (side and rearview) combination meter glass navigation or VES screens console and components pillar garnish cowl assy rack and pinion/power steering gear assy cowl side trim sub–assy radiator cupholders room partition board cylinder head cover sub–assy rotors (mark where min. runout is exceeded or warped) dash panel insulator assy seat covers/cushions dashboard and trim seat tracks disc wheel soft trim display panels spare tire cover door handle assy steering column cover door moulding steering wheel door trim panel & molding tail lamps and covers emblems transmission oil pan engine oil pan visor exhaust manifold washer jar floor and cargo mats wheel cap gear shift knob wheels grills Page 2 of 3 September 26, 2003 WARRANTY PARTS MARKING PROCEDURE – PG006-03 Parts Marking List (Continued) September 26, 2003 NOTE: The following parts do not have to be marked unless the technician can determine failure and location. air induction/ejection systems fuel injection systems all computers fuel injectors alternators fuel pump audio (internal) ignition system batteries internal engine components bearings internal transmission components belts oil cooler catalytic converter power door lock switches crankshaft remanufactured parts cruise control starters distributors suspension components EGR systems valve covers engine control systems window regulators exchange parts wiper motors exhaust systems Page 3 of 3 Technical Service BULLETIN REPLACEMENT VIN PLATES Models: All Models May 4, 2001 Introduction Replacement VIN plates (metal plates riveted to dashboard) may be available from Toyota providing the request meets the criteria listed below. VIN Plate Location Applicable Vehicles Replacement VIN Plate Criteria S All Toyota vehicles. S The vehicle is in an accident and the plate is damaged. NOTE: The original plate to be replaced MUST accompany the request. NOTE: If a plate is stolen, be sure to contact the State Police or your State’s Department of Motor Vehicles (DMV). In most cases the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims. Procurement Procedure To request a replacement plate, complete a copy of the form on the back of this page. Note that the damaged VIN plate MUST accompany the request form. Your dealer parts account will be billed $10.00 for each replacement of a damaged plate. NOTE: All replacement plates for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG007-01 Title: APPLICATION FOR REPLACEMENT VIN PLATE REASON FOR REPLACEMENT ACCIDENT DAMAGE OTHER REASON/EXPLANATION PLEASE PROVIDE CORRECT VIN ATTACH DAMAGED PLATE HERE DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD PLATE TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA. 90509–2991 Technical Service BULLETIN REPLACEMENT CERTIFICATION LABELS Models: All Models January 18, 2002 TSB UPDATE NOTICE: The information contained in this TSB updates PG006–01 dated May 4, 2001. Revised text is red and underlined. The changes will take place February 1, 2002. Introduction Replacement Certification Labels (vinyl label affixed to driver’s door or door post) may be available from Toyota providing the request meets one of the criteria listed below. Certification Label Location MFD.BY:TOYOTA MOTOR MANUFACTURING CANADA INC. 10/01 GVWR 3935LB GAWR FR 1970LB RR 1985LB THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY, BUMPER, AND THEFT PREVENTION STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. XT0XX00X0X000000 PASS.CAR C/TR:3L5/FB14 MODEL:ZZE134L – DHPNKA A/TM:–04A/U341F MADE IN CANADA S26 AA01904759 Applicable Vehicles Certification Label Criteria S All Toyota vehicles. 1. The vehicle is in an accident and the label is damaged or is attached to a part that will be replaced during the repair. NOTE: S Processing a new label will be delayed significantly if the original certification label is not available. S A replacement label MAY NOT be available if the vehicle is more than 5 years old and the old label does not accompany this request. 2. The label is stolen. Procurement Procedure To request a replacement label, complete a copy of the form on the back of this bulletin. Your dealer parts account will be billed $25.00 for each replacement of a damaged or stolen label. NOTE: All replacement labels for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG008-02 Title: APPLICATION FOR REPLACEMENT CERTIFICATION LABEL REASON FOR REPLACEMENT ACCIDENT DAMAGE STOLEN OTHER MFD.BY: TOYOTAMOTOR MANUFACTURING CANADA INC. 10/01 GVWR3935LBGAWRFR1970LBRR1985LB THISVEHICLECONFORMSTOALLAPPLICABLE FEDERALMOTORVEHICLESAFETY, BUMPER, AND THEFTPREVENTIONSTANDARDS IN EFFECT ON THE DATEOFMANUFACTURESHOWNABOVE. XT0XX00X0X000000 PASS.CAR C/TR:3L5/FB14MODEL:ZZE134L–DHPNKA A/TM:–04A/U341FMADEINCANADA S26AA01904759 REASON/EXPLANATION ATTACH ORIGINAL LABEL HERE PLEASE PROVIDE CORRECT VIN NOTE: Original label MUST accompany this application or order will be significantly delayed. DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD LABEL TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA 90509–2991 Technical Service BULLETIN REPLACEMENT VIN PLATES Models: All Models January 18, 2002 TSB UPDATE NOTICE: The information contained in this TSB updates PG007–01 dated May 4, 2001. Revised text is red and underlined. The changes will take place February 1, 2002. Introduction Replacement VIN plates (metal plates riveted to dashboard) may be available from Toyota providing the request meets the criteria listed below. VIN Plate Location Applicable Vehicles Replacement VIN Plate Criteria S All Toyota vehicles. S The vehicle is in an accident and the plate is damaged. NOTE: The original plate to be replaced MUST accompany the request. NOTE: If a plate is stolen, be sure to contact the State Police or your State’s Department of Motor Vehicles (DMV). In most cases the State DMV will issue a unique number so that the original number can be included on stolen vehicle listings. If this is the case, a replacement plate is NOT available from Toyota. However, the original VIN, NOT the state issued VIN, must be used on all warranty claims. Procurement Procedure To request a replacement plate, complete a copy of the form on the back of this page. Note that the damaged VIN plate MUST accompany the request form. Your dealer parts account will be billed $25.00 for each replacement of a damaged plate. NOTE: All replacement plates for damaged and/or stolen vehicles are subject to approval by the Technical Compliance Department. If you have any specific questions, contact (310) 468–3390. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG009-02 Title: APPLICATION FOR REPLACEMENT VIN PLATE REASON FOR REPLACEMENT ACCIDENT DAMAGE OTHER REASON/EXPLANATION PLEASE PROVIDE CORRECT VIN ATTACH DAMAGED PLATE HERE DEALER INFORMATION DEALER CODE: DEALER NAME: ADDRESS: STREET ADDRESS CITY, STATE, ZIP CODE TELEPHONE: ( ) AREA CODE, TELEPHONE NUMBER CONTACT: FIRST NAME, LAST NAME MAIL (DO NOT FAX) THE COMPLETED REQUEST FORM WITH THE OLD PLATE TO: TOYOTA MOTOR SALES, U.S.A. INC. TECHNICAL COMPLIANCE DEPARTMENT, S207 19001 S. WESTERN AVENUE TORRANCE, CA. 90509–2991 Technical Service BULLETIN SUSPENSION BALL JOINT INSPECTION Models: See Applicable Models December 4, 2002 Introduction Applicable Vehicles This bulletin describes the inspection method and free play specification figures for suspension ball joints. The on–vehicle inspection methods have been standardized. S 1989 – 1992 model year Cressida vehicles. S 1989 – 1998 model year Supra vehicles. S 2001 – 2003 model year Highlander vehicles. S 1995 – 2003 model year Avalon vehicles. S 1989 – 2003 model year Camry / Camry Solara vehicles. S 1985 – 2003 model year MR2 vehicles. S 1990 – 2003 model year Celica vehicles. S 2001 – 2003 model year Prius vehicles. S 1988 – 2003 model year Corolla / Corolla Matrix vehicles. S 2000 – 2003 model year ECHO vehicles. S 1991– 1999 model year Tercel vehicles. S 1991 – 1999 model year Paseo vehicles. S 1990 – 1997 model year Previa vehicles. S 1998 – 2003 model year Sienna vehicles. S 1996 – 2003 model year RAV4 / RAV4 EV vehicles. S 1999 – 2003 model year Land Cruiser vehicles. S 2001 – 2003 model year Sequoia vehicles. S 1989 – 2003 model year 4Runner vehicles. S 2000 – 2003 model year Tundra vehicles. S 1995 – 2003 model year Tacoma vehicles. S 1989 – 1995 model year Truck vehicles. S 1993 – 1998 model year T–100 vehicles. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 8 PRODUCT GENERAL INFORMATION PG027-02 Title: SUSPENSION BALL JOINT INSPECTION – PG027-02 Inspection Information LOWER BALL JOINT OR SUSPENSION BALL JOINT MODEL Cressida (MX8#) 1989 – 1992 LOCATION Supra (JZA80) 1994 – 1998 UPPER BALL JOINT INSP. METHOD MAX. PLAY TURNING TORQUE INSP. METHOD MAX. PLAY TURNING TORQUE Front 1–(C) No Play Felt 40 in.Slbf (4.5 NSm) or Less N/A N/A N/A Rear 3 No Play Felt 31 in.Slbf (3.5 NSm) or Less 2–(A) No Play Felt 31 in.Slbf (3.5 NSm) or Less Front 1–(A) 0.4 mm 4 in.Slbf (0.5 Nm) or Less 2 (A) 2–(A) No Play Felt 31 in.Slbf (3.5 (3 5 NSm) or Less 2 (A) 2–(A) No Play Felt 31 in.Slbf (3.5 (3 5 NSm) or Less Su ra (MA70) Supra 1989 – 1994 Page 2 of 8 December 4, 2002 Rear 3 No Play Felt Front 1–(A) 0.4 mm 31 in.Slbf (3.5 NSm) or Less 27 in.Slbf (3.0 NSm) or Less Rear 1–(A) No Play Felt 31 in.Slbf (3.5 NSm) or Less Highlander (ACU2#, MCU2#) 2001 – 2003 Front 1–(C) No Play Felt 31 in.Slbf (3.5 NSm) or Less N/A N/A N/A Avalon (MCX10, 20) 1995 – 2003 Front 1–(C) No Play Felt 31 in.Slbf (3.5 NSm) or Less N/A N/A N/A Camry, Camry Solara (SV2#, VZV21, VCV10, MCV10, 20, 30 ACV 20, 30 SVX 10, 20) 1989 – 2003 Front 1–(C) No Play Felt 31 in.Slbf (3.5 NSm) or Less N/A N/A N/A SUSPENSION BALL JOINT INSPECTION – PG027-02 Inspection Information (Continued) December 4, 2002 LOWER BALL JOINT OR SUSPENSION BALL JOINT MODEL LOCATION Front MR2 (AW1#) 1985 – 1989 MR2 (SW2#) 1990 – 1996 MR2 (ZZW30) 2000 – 2003 Rear INSP. METHOD MAX. PLAY TURNING TORQUE 1–(C) No Play Felt 27 in.Slbf (3.0 NSm) or Less No Play Felt 27 in.Slbf (3.0 NSm) or Less*1 31 in.Slbf (3.5 NSm) or Less*2 1–(C)*1 3*2 Front 1 (C) 1–(C) No Play Felt Rear Front 1–(C) No Play Felt UPPER BALL JOINT INSP. METHOD MAX. PLAY TURNING TORQUE N/A N/A N/A N/A N/A N/A N/A N/A N/A 22 in.Slbf (2.5 NSm) or Less 27 in.Slbf (3.0 NSm) or Less 22 in.Slbf (2.5 NSm) or Less 9 in.Slbf (1.0 NSm) or Less Rear 3 Celica (AT180, ST18#) 1990 – 1993 Front 1–(C) No Play Felt 35 in.Slbf (4.0 NSm) or Less N/A N/A N/A Celica (AT200, ST20#, ZZT23#) 1994 – 2003 Front 1–(C) No Play Felt 44 in.Slbf (5.0 NSm) or Less N/A N/A N/A Prius (NHW11) 2001 – 2003 Front 1–(C) No Play Felt 44 in.Slbf (5.0 NSm) or Less N/A N/A N/A Corolla (AE9#, 10#) 1988 – 2003 Front 1–(C) No Play Felt 27 in.Slbf (3.0 NSm) or Less N/A N/A N/A Corolla/ Corolla Matrix (AE10#, ZZE11#, 13#) 1988 – 2003 Front 1–(C) No Play Felt 44 in.Slbf (5.0 NSm) or Less N/A N/A N/A ECHO (NCP1#) 2000 – 2003 Front 1–(C) No Play Felt 31 in.Slbf (3.5 NSm) or Less N/A N/A N/A Tercel, Paseo (EL4#, 5#) 1991 – 1999 Front 1–(C) No Play Felt 27 in.Slbf (3.0 NSm) or Less N/A N/A N/A Page 3 of 8 SUSPENSION BALL JOINT INSPECTION – PG027-02 Inspection Information (Continued) LOWER BALL JOINT OR SUSPENSION BALL JOINT MODEL LOCATION UPPER BALL JOINT INSP. METHOD MAX. PLAY TURNING TORQUE INSP. METHOD MAX. PLAY TURNING TORQUE Previa (TCR1#, 2#) 1990 – 1997 Front 1–(C) No Play Felt 35 in.Slbf (4.0 NSm) or Less N/A N/A N/A Sienna (MCL10) 1998 – 2003 Front 1–(C) No Play Felt 31 in.Slbf (3.5 NSm) or Less N/A N/A N/A Front 1–(C) No Play Felt 40 in.Slbf (4.5 NSm) or Less N/A N/A Rear 3 31 in.Slbf (3.5 NSm) or Less N/A No Play Felt RAV4 (ACA2#) 2001 – 2003 Front 1–(C) No Play Felt 44 in.Slbf (5.0 NSm) or Less N/A N/A N/A Land Cruiser 100 (UZJ100) 1999 – 2003 Front 1–(A) No Play Felt 27 in.Slbf (3.0 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less Sequoia (UCK35, 45) 2001 – 2003 Front 1–(A) 0.5 mm 22 in.Slbf (2.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less 4Runner (VZN120, 13#, RN13#, 12#) 1989 – 1995 Front 1–(C) 2.3 mm 53 in.Slbf (6.0 NSm) or Less 2–(B) No Play Felt Turns Smoothly 4Runner (RZN18#, VZN18#) 1996 – 2003 Front 1–(A) 0.5 mm 22 in.Slbf (2.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less Tundra (VCK30, 40, UCK30, 40) 2000 – 2003 Front 1–(A) 0.5 mm 22 in.Slbf (2.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less RAV4/ RAV4 EV (SXA1# (SXA1#, BEA11) 1996 – 2000 Page 4 of 8 December 4, 2002 SUSPENSION BALL JOINT INSPECTION – PG027-02 Inspection Information (Continued) December 4, 2002 LOWER BALL JOINT OR SUSPENSION BALL JOINT MODEL LOCATION UPPER BALL JOINT INSP. METHOD MAX. PLAY TURNING TORQUE INSP. METHOD MAX. PLAY TURNING TORQUE Tacoma*3 (RZN140, 150, VZN150) 1995 – 2003 Front 1–(A) 0.5 mm 40 in.Slbf (4.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less Tacoma*4 (RZN140, 150, VZN150) 1995 – 2003 Front 1–(A) 0.5 mm 31 in.Slbf (3.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less Tacoma (RZN161, 171, 19#, VZN160, 170, 195) 1995 – 2003 Front 1–(A) 0.5 mm 22 in.Slbf (2.5 NSm) or Less 2–(A) No Play Felt 40 in.Slbf (4.5 NSm) or Less Truck*5 (RN8#, 90 VZN85, 9#) 1989 – 1995 Front 1–(B) 2.3 mm 44 in.Slbf (5.0 NSm) or Less 2–(A) 2.3 mm 35 in.Slbf (4.0 NSm) or Less Truck*6 (RN8#, 90 VZN85, 9#) 1989 – 1995 Front 1–(B) 0.5 mm 44 in.Slbf (5.0 NSm) or Less 2–(A) 2.3 mm 35 in.Slbf (4.0 NSm) or Less Truck (RN10#, 11# VZN10#, 110) 1989 – 1995 Front 1–(C) 2.3 mm 53 in.Slbf (6.0 NSm) or Less 2–(B) 2.3 mm Turns Smoothly T–100 (RCK10, VCK1#) 1993 – 1998 Front 1–(A) 0.5 mm 62 in.Slbf (7.0 NSm) or Less 2–(A) 1.9 mm 35 in.Slbf (4.0 NSm) or Less T–100 (VCK2#) 1993 – 1998 Front 1–(C) 2.3 mm 53 in.Slbf (6.0 NSm) or Less 2–(B) No Play Felt (from 1995 MY) Turns Smoothly *1 Lower Ball Joint *2 Suspension Arm Ball Joint *3 With Serial Number Prior to Z718190 *4 With Serial Number After and including Z718190 *5 With Serial Number Prior to those listed in *6 *6 RN80–0087125, RN80–5130170, RN85–0004477, RN85–5046258, RN85–9010725, RN90–0014600, RN90–5047105, RN90–9002376, VZN85–0003605, VZN85–5004547, VZN90–5025989, VZN95–0025290, VZN90–0006119 Page 5 of 8 SUSPENSION BALL JOINT INSPECTION – PG027-02 On–Vehicle Inspection NOTE: S Be sure to check the table for the applicable inspection type based on the vehicle model. S Refer to the table for the standard free play values. 1. Inspect Lower Ball Joint Free Play A. Move the hub up and down by hand (most models with wishbone suspension): a. Remove the tire. b. Install the 2 lug nuts. c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the lower arm using a lever (some models with double wishbone type suspension): a. Lift up the vehicle. b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up and down. C. Move the lower arm by hand (all models with strut type suspension and some models with wishbone type suspension): a. Lift up the vehicle. b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30 kgf). Page 6 of 8 December 4, 2002 SUSPENSION BALL JOINT INSPECTION – PG027-02 On–Vehicle Inspection (Continued) December 4, 2002 2. Inspect Upper Ball Joint Free Play A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and all models using a coil spring). a. Remove the front tire. b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30 kgf). B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar). a. Lift up the vehicle. b. Place the lever under the tire, and inspect the free play while lifting the tire using a wooden stick, etc., as a fulcrum. 3. Inspect the Suspension Arm Ball Joint Free Play A. Lift up the vehicle. B. Inspect the free play while moving the control arm by hand. (Reference) Free Play Inspection Method (Gauge Installation) S Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free play. (This illustration shows how to measure free play for vehicles with double wishbone type suspension with coil spring.) 4. Inspect Ball Joint Dust Cover Check for cracks and grease leaks on the dust cover (boots). Page 7 of 8 SUSPENSION BALL JOINT INSPECTION – PG027-02 Turning Torque Inspection Inspect Ball Joint Turning Torque Move the stud back and forth 5 times, and then turn the stud continuously at 3–5 seconds per turn, and measure the turning torque at the 5th turn. HINT: Refer to the table for standard values for the turning torque. Page 8 of 8 December 4, 2002 Technical Service BULLETIN YEAR 2000 READINESS DISCLOSURE Models: All Models December 24, 1999 Introduction Based upon information we have obtained from our suppliers,1 all factory–installed systems in Toyota cars, sports utility vehicles and trucks distributed and/or sold by Toyota (“Vehicles”)2 will not be affected by the change of date from 1999 to the year 2000. Toyota anticipates no problems with past, current or future Toyota brand vehicles or Genuine Toyota parts and accessories regarding year 2000 readiness. We hope the following information is helpful to you. Please contact our Customer Service Department at 1–800–331–4331 should you have any other questions. S All Models Applicable Vehicles Warranty WARRANTY STATEMENT WITH RESPECT TO TOYOTA BRAND VEHICLES Toyota is pleased to confirm that the manufacturer’s limited express warranty and Toyota’s powertrain warranty warrant that all factory–installed systems in new Vehicles and Toyota Certified Used Vehicles shall be free of any defect arising solely due to a change in date from the year 1999 to the year 2000.3 With respect to Vehicles no longer covered under such Toyota limited express warranty, Toyota is not aware of any operational safety or functional impact the year 2000 date change would have upon any factory–installed system in Toyota Vehicles. Should Toyota become aware of any material impact to the operational safety or functionality of such systems, Toyota shall publish such information promptly. WARRANTY STATEMENT WITH RESPECT TO GENUINE TOYOTA PARTS AND ACCESSORIES Toyota is pleased to confirm that the manufacturer’s limited express warranty warrants that all new Toyota Genuine Parts and Accessories shall be free of any defect arising solely due to a change in date from the year 1999 to the year 2000. 3 With respect to products no longer covered under a Toyota limited express warranty, Toyota is not aware of any operational safety or functional impact the year 2000 date change would have upon such products. Should Toyota become aware of any material impact to the operational safety or functionality of such a product, Toyota shall publish such information promptly. 1 2 3 Toyota relies on the statements made by its suppliers and has not independently verified such information. Vehicles includes alternative fuel vehicles. Please refer to terms of limited express warranty for disclaimers, limitations and restrictions. Toyota Supports ASE Certification Page 1 of 2 PRODUCT GENERAL INFORMATION PG032–99 Title: YEAR 2000 READINESS DISCLOSURE – PG032-99 Parts & Accessories December 24, 1999 GENUINE TOYOTA PARTS AND ACCESSORIES Based upon information we have obtained from our suppliers,1 all new Genuine Toyota Parts and Accessories will not be affected by the change of date from 1999 to the year 2000. DEALER–INSTALLED AND OTHER THIRD PARTY–INSTALLED SYSTEMS/ PRODUCTS Our dealers and distributors may sell and/or install products that are not Genuine Toyota Parts and Accessories. Toyota can only determine the Year 2000 readiness status of Genuine Toyota Parts and Accessories. Therefore, the above statements do not apply to products that are not Genuine Toyota Parts and Accessories or were not installed by the factory. We encourage you to contact your dealer or other relevant third party regarding products installed on your Toyota vehicle(s) that are not Genuine Toyota Parts and Accessories and/or were not installed by the factory to determine any Year 2000 issues associated with those products. 1 Page 2 of 2 Toyota relies on the statements made by its suppliers and has not independently verified such information. April 9, 1999 Introduction SCANTOOL IMMOBILIZER KEY CODE UTILITY Models: ’98 & ’99 Avalon, Camry, Land Cruiser & Sienna ’99 Solara & 4Runner The Diagnostic Tester now incorporates a Key Code Utility Menu capable of performing the following tasks for immobilizer functions: S Key Code Registration S Key Code Erasure S Auto–Registration Closure The information contained in this bulletin will provide you with a detailed outline for the use of immobilizer functions with the Diagnostic Tester. Affected Vehicles S 1998 Avalon, Camry, Land Cruiser and Sienna. S 1998 Avalon, Camry, Land Cruiser, Sienna, Solara and 4Runner. Parts Information PART NUMBER PART NAME 01001271 Toyota Diagnostic Tester Kit 01001895–005 6.0a Diagnostic Software Card NOTE: Replacement Diagnostic Tester Kits or Software Cards may be ordered by calling OTC at 1–800–933–8335. Function Description (Key Code Utility) Key Registration This function allows the registration of additional key codes for transponder keys (Master/Sub Keys) using a Registered Master Key. Key Code Erasure This function allows the user to erase all the key codes for transponder keys except the Registered Master Key used during this function. Auto Registration Closure This function allows the user to close “Auto Registration Mode“ when less than three keys have been registered. NOTE: When a new ECU is installed, it is in the “Auto Registration Mode” from the factory. This allows Transponder Keys to automatically register as they are inserted into the Ignition Cylinder. After three Transponder Keys are registered, the ECU closes “Auto Registration Mode”. See the Repair Manual for further details. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 9 SPECIAL SERVICE TOOLS Technical Service BULLETIN SS001–99 Title: SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 April 9, 1999 Operation Procedures This section provides the procedures necessary to access the IMMOBILIZER KEY CODE UTILITY functions. Refer to the instructions below. Verify Immobilizer Key Type Before any IMMOBILIZER KEY CODE UTILITY function can be performed, the type of Transponder Key must be verified. The following steps show how to verify the Transponder Key type. 1. Connect the Diagnostic Tester to DLC3 and press the (ON) key. 2. Insert a Registered Master Key (Black Key Head) into the ignition key cylinder and turn to the ON position. HINT: A Registered Master Key is required for KEY REGISTRATION, KEY CODE ERASURE, and AUTO REGISTRATION CLOSURE. A Sub Key (Grey Key Head) will not perform these functions. 3. “From the “FUNCTION SELECT” menu (Screen A), select [1: OBD/MOBD]. 4. From the “OBD/MOBD MENU“ (Screen B), select [6: IMMOBILIZER]. 5. From the “DIAGNOSTIC MENU IMMOBILIZER” (Screen C), select [1: CURRENT DATA] Page 2 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 Verify Immobilizer Key Type (Continued) April 9, 1999 6. From the “CURRENT DATA MENU IMMOBILIZER” (Screen D), select [1: DATA LIST]. 7. From the “SELECT DATA“ menu (Screen E), select [ALL]. 8. The Transponder Key Type in the ignition cylinder will be displayed (Screen F). [MASTER] = [SUB] = [NO] = Registered Master Key Registered Sub Key Not a Registered Key, or Vehicle is not equipped with Immobilizer. NOTE: If the Transponder Key is a Master Key, proceed to [4: KEY CODE UTILITY] by pressing the (EXIT) key back to the “DIAGNOSTIC MENU IMMOBILIZER“ (Screen C). From the “DIAGNOSTIC MENU IMMOBILIZER“ (Screen C), select [4: KEY CODE UTILITY] Page 3 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 April 9, 1999 Verify Immobilizer Key Type (Continued) 9. From the “KEY CODE UTILITY” menu (Screen G), the functions listed are outlined in the next sections. Key Registration This function allows the registration of additional Key Codes for Transponder Keys (Master/Sub Keys) using a Registered Master Key. The following screens show how to perform Key Registration. NOTE: This function requires the use of one Registered Master Key. The use of a Sub Key will NOT complete Key Registration. 1. From the “KEY CODE UTILITY“ menu (Screen A), select [1: KEY REGISTRATION]. 2. Confirm the instruction on Screen B and press the (ENTER) key. Page 4 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 April 9, 1999 3. From the “KEY SELECTION” menu (Screen C), select the Transponder Key type to be registered and press the (ENTER) key. NOTE: Do not register a SUB KEY as a MASTER KEY. The SUB KEY is typically left with an attendant when the vehicle is parked. A Registered Master Key allows the user to add/erase transponder keys. 4. From “KEY SELECTION” (Screen D), confirm the type of Transponder Key to be registered and press the (ENTER) key. 5. After pressing the (YES) key, remove the Registered Master Key from the Ignition Cylinder within 20 seconds. After removing the key, press the (ENTER) key. 6. Insert the New Transponder Key into the Ignition Cylinder within 10 seconds and press the (ENTER) key. HINT: Look at the Security Indicator Light. It will begin to flash as the New Transponder Key is inserted. Page 5 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 Key Registration (Continued) April 9, 1999 7. The registration of the New Transponder Key will be completed in approximately 60 seconds. HINT: The Security Indicator continues to flash during registration. 8. Screen H will be shown at completion of registration. Confirm the Security Indicator turns OFF and press the (ENTER) key. HINT: The Security Indicator will stop flashing when Key Registration is complete. 9. Insert the New Registered Master Key into the Ignition Cylinder and turn to the ON position and press the (ENTER) key. Key Code Erasure This function allows the user to erase all the Key Codes for Transponder Keys except the Registered Master Key used during this function. The following screens show how to perform Key Code Erasure. HINT: This function requires the use of one Registered Master Key. The use of a Sub Key will NOT complete Key Code Erasure. Page 6 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 Key Code Erasure (Continued) April 9, 1999 1. From the “KEY CODE UTILITY“ menu (Screen A), select [2: KEY CODE ERASURE]. 2. Confirm the instruction on Screen B and press the (ENTER) key. 3. Confirm the instruction on Screen C and press the (YES) key. NOTE: By pressing the (YES) key, all Transponder Key Codes will be erased except the Registered Master Key in the Ignition Cylinder. HINT: After pressing the (YES) key, the Security Indicator will start to flash. 4. Pull out the Registered Master Key from the Ignition Cylinder within 10 seconds (Screen D). HINT: Security Indicator continues to flash. Page 7 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 Key Code Erasure (Continued) April 9, 1999 5. If Step 4 was completed correctly, Screen E will confirm ERASURE was sucessful. HINT: If the Erasure completed, the security indicator should still be blinking. 6. Insert the Registered Master Key into the Ignition Cylinder and turn to the ON position and press the (ENTER) key. HINT: Look at the Security Indicator Light. Inserting a Registered Master Key causes the Security Indicator to immediately stop blinking. Auto Registration Closure This function allows the user to close Auto Registration Mode when less than three keys have been registered. NOTE: When a New ECU is installed, it is in the Auto Registration Mode. This mode allows the Transponder Keys to automatically register as they are inserted into the Ignition Cylinder. See the Repair Manual for further details. CAUTION: This function requires the use of one Registered Master Key. The use of a Sub Key will NOT complete Auto Registration Closure. The use of a non–transponder key during this function may damage the ECU. 1. From the “KEY CODE UTILITY“ menu (Screen A), select [3: AUTO REG CLOSURE]. Page 8 of 9 SCANTOOL IMMOBILIZER KEY CODE UTILITY – SS001–99 Auto Registration Closure (Continued) April 9, 1999 2. Confirm the instruction on Screen B and press the (ENTER) key. 3. At “AUTO REGIST. CLOSURE” (Screen C), the Auto Registration Closure Information will be displayed. Press the (ENTER) key to finish. Page 9 of 9 September 8, 2003 Introduction SS001-03 Technical Service BULLETIN DIAGNOSTIC TESTER CONTROLLER AREA NETWORK (CAN) INTERFACE MODULE Models: All Models Over the next four model years, all Toyota vehicles will begin using an all–new diagnostic communication protocol, Controller Area Network (CAN). CAN will be introduced on the 2004 Prius this fall. A CAN Interface Module has been distributed to all dealers as an essential Special Service Tool (SST) and will allow the Diagnostic Tester to communicate with CAN–equipped vehicles. Please use the following instructions to install the new CAN Interface Module as soon as it arrives at your dealership. NOTE: S Version 10.2a or later Diagnostic Tester Software must be used to enable communication with CAN–equipped vehicles. Version 10.2a will be distributed to dealers via TIS before CAN–equipped vehicles arrive at dealers. S There is no need to remove the CAN Interface Module when working with non–CAN systems or older software versions (Version 10.1a or earlier). The Diagnostic Tester will communicate with all DLC3/J1962 based systems with the CAN Interface Module installed. S All Models Applicable Vehicles Required SSTs SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QUANTITY 01001271 1 01002744 1 01002593-005 1 Toyota Diagnostic Tester Kit* CAN Interface Module Kit* 12 Megabyte Diagnostic Tester Program Card with version 10.2a Software (or later)* * Essential SSTs. NOTE: Additional Diagnostic Tester Kits, CAN Interface Modules, Program Cards or SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 SPECIAL SERVICE TOOLS Title: DIAGNOSTIC TESTER CONTROLLER AREA NETWORK (CAN) INTERFACE – SS001-03 September 8, 2003 Installation Procedure Program Card With Version 10.2a (or Later) Software DLC Cable (P/N 02001637) CAN Interface Module Kit (P/N 01002744) Vehicle Interface Module (VIM) DLC1 (Check Connector) Cable Black Grey CAN Interface Module DLC2 (TDCL) Cable CAN Interface Module Is Used for ALL DLC3/J1962 Communication The Original DLC3 (OBDII Connector P/N 02001643) Cable Is No Longer Used. 1. Remove the original DLC3 Cable and store it in the Diagnostic Tester storage case. 2. Connect the CAN Interface Module to the DLC Cable. 3. Use the Diagnostic Tester with the CAN Module installed for all DLC3/J1962 based vehicle communication. 4. If you experience problems with the Diagnostic Tester or CAN Interface Module, please contact Toyota Special Service Tool Customer Support at 1–800–933–8335. NOTE: S There is no need to remove the CAN Interface Module when working with non–CAN systems or older software versions (Version 10.1a or earlier). The Diagnostic Tester will communicate with all DLC3/J1962 based systems with the CAN Interface Module installed. S For DLC1 and DLC2 communication you must continue to use the Vehicle Interface Module (VIM). Page 2 of 2 SPECIAL SERVICE TOOLS SS94-002 AUGUST 12, 1994 ALL MODELS WIRE HARNESS REPAIR KIT “B” Page 1 of 2 The new Wire Harness Repair Kit “B” has been released as an essential Special Service Tool (SST) to supplement the original Wire Harness Repair Kit. This kit holds an initial supply of 21 new type electrical terminals and connectors as well as the necessary supplies and small tools for most electrical repairs. The Wire Harness Repair Kit manual has been updated and now contains an illustrated catalog of all terminals and connectors available for Toyota vehicles. Connector Replacement Guidelines, a Connector/Terminal Usage Guide, and a Connector Quick Reference Chart have been added as additional reference. This manual is the only reference available which provides information on properly identifying connectors and terminals. When components/supplies need to be replaced, refer to page 21 in the manual or the reverse side of this TSB. Note: The manual is no longer available through the Toyota Non-Parts System. It is available separately under part number 410094 by calling OTC at 1-800-933-8335. TOYOTA MOTOR SALES U.S.A., INC. Page 2 of 2 WIRE HARNESS REPAIR KIT “B” PARTS REPLACEMENT ORDERING INFORMATION: The following parts can be ordered through Toyota Motor Sales on a normal parts order: Part Number Description Part Number Description 82998-12010 82998-12030 82998-12050 82998-12070 82998-12090 82998-12110 82998-12130 82998-12150 82998-12170 82998-12190 82998-12210 82998-12230 82998-12250 82998-12270 82998-12290 82998-12310 82998-12330 82998-12350 82998-12370 82998-12390 82998-12410 82998-12430 82998-12450 216824 00204-34130 00204-34137 00204-34138 Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Repair Splice Silicon Tape 18/22 Splice 14/16 Splice 10/12 Splice 82998-12470 82998-12490 82998-12020 82998-12040 82998-12060 82998-12080 82998-12100 82998-12120 82998-12140 82998-12160 82998-12180 82998-12200 82998-12220 82998-12240 82998-12260 82998-12280 82998-12300 82998-12320 82998-12340 82998-12360 82998-12380 82998-12400 82998-12420 82998-12440 82998-12460 82998-12480 82998-12500 Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Repair Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice Splice The following parts can be ordered from OTC Tool & Equipment Division, SPX Corporation, 655 Eisenhower Drive, Owatonna, Minnesota 55060: Part Number Description Part Number Description 62164 62166 310031 Tool Box Kit A (Toyota) Tool Box Kit B (Toyota) Tool Box (Lexus) Crimper (Kit A) 310032 310033 216820 216822 00002-217681 00002-217958 Wire Stripper Terminal Pick Terminal Gauge Terminal Gauge Terminal Pick Terminal Pick AMP47100-1 Crimper (Kit B) 410094 Repair Manual 310044 All remaining parts can be purchased from a local supplier. Models: All Models September 26, 1997 Introduction Parts Information When inspecting or making brake booster push rod adjustments with SST 09737–00010, it is necessary to assure proper tool configuration prior to use. The SST has a reversible center plunger that allows it to function on a wide range of Toyota vehicles. Prior to using, verify that it is configured correctly for the application by checking the master cylinder outer diameter at the point illustrated below. The dimensions for the SST, Part Number 09737–00010, are also shown in the illustrations below. PART NUMBER 09737–00010 Warranty Information PART NAME Brake Booster Push Rod Gauge (SST) OPCODE DESCRIPTION TIME OPN T1 T2 N/A Not applicable to warranty – – – – Page 1 of 1 SPECIAL SERVICE TOOLS TSB BRAKE BOOSTER PUSH ROD GAUGE (SST) SS002–97 Title: Technical Service BULLETIN 1999 SPECIAL SERVICE TOOLS Models: All ’98 & ’99 Models July 9, 1999 Introduction This TSB contains information regarding Special Service Tools (SSTs) distributed or added to the SST program during 1999 model year. Both the Essential and Available SSTs are listed by tool number, tool name, and model application. Special Service Tools can be ordered through the Toyota SST Program by calling 1–800–933–8335. Applicable Vehicles 1999 Essential Special Service Tools S All 1998 and 1999 MY Toyota Vehicles. 1999 ESSENTIAL SPECIAL SERVICE TOOLS TOOL NUMBER 09521–25021–1 09631–12090 09710–28012–01 02002–02XXX TOOL NAME APPLICATION Rear Axle Shaft Puller Attachment Land Cruiser Seal Ring Tool Land Cruiser Front Suspension Bushing Tool Set Land Cruiser Haweka Flange Plate Land Cruiser Note: XXX is Spindle Shaft Size 09950–60030–01 Replacer Set #3 09999–00310 Toyota Spare Tire Lock Kit 09999–00305 Spare Tire Lock Adapter Part of Kit # 09999–00310 (Toyota/Lexus Dual Dealers) 09268–21010–01 Toyota Supports ASE Certification Fuel Hose Puller Land Cruiser Land Cruiser, T100, Tacoma T100 Corolla (’99) Page 1 of 2 SPECIAL SERVICE TOOLS SS002–99 Title: 1999 SPECIAL SERVICE TOOLS – SS002-99 1999 Essential Special Service Tools (Cont’d) 1999 Available Special Service Tools July 9, 1999 1999 ESSENTIAL SPECIAL SERVICE TOOLS TOOL NUMBER 01001895–U05 TOOL NAME ScanTool Software (Annual Reprogramming & Site License) APPLICATION All Models 1999 ESSENTIAL SPECIAL SERVICE TOOLS TOOL NUMBER 09710–01031 TOOL NAME Upper Arm Bushing Replacer (Part of Set) APPLICATION RAV4 Part of Kit # 09710–22021 09710–22021 Upper Arm Bushing Replacer Set TOY280341 Rivet Nut Tool All Models TOY280087 Homelink Tester All Models 00002–MLR6872A Evap Tester Page 2 of 2 Land Cruiser ’99 MY with EVAP Service Port MIDTRONICS BATTERY TESTER SOFTWARE UPDATE Technical Service BULLETIN Models: All Models & Model Years Through Current June 7, 2002 Introduction The internal software of the Midtronics Battery Tester can now be periodically updated to support future models. New updates will include new battery warranty codes and testing information. The Technical Information System (TIS) will be the primary distribution method for battery tester software updates. Utilizing the new Midtronics Update Wizard (MUW) and the new essential SST (Midtronics Battery Tester Adapter), you will be able to quickly and easily update your Midtronics Battery Tester. This bulletin will show you how to use and install the Midtronics Update Wizard to update the Midtronics tester software. S All models and model years through current. Applicable Vehicles Required Tools & Material SPECIAL SERVICE TOOLS (SSTs) Midtronics Battery Tester* Midtronics Battery Tester Adapter* * Warranty Information Process Overview PART NUMBER QUANTITY 00002–MP815–T 1 00002–DMPUC 1 Essential SSTs. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – The Midtronics Battery Tester Software Update is a 2-step process: 1. Installing the Midtronics Update Wizard (MUW). The Midtronics Update Wizard (MUW) is an application that only needs to be installed on the PC one time. This bulletin will provide the steps to install the MUW. 2. Using the Midtronics Update Wizard (MUW). The Midtronics Update Wizard (MUW) will be used with each battery tester software update. The Update Wizard will walk you through each step to connect the PC to the tester and perform the update. Toyota Supports ASE Certification Page 1 of 10 SPECIAL SERVICE TOOLS SS002-02 Title: MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure: Preparation June 7, 2002 Before Installation or Use of the Midtronics Update Wizard (MUW): Steps A and B are required to begin the update process. (Refer to Figure 1.) A. Open TIS (Technical Information System) and go to the “Diagnostics” section. B. Click on the text “Midtronics Battery Tester Software.” FIGURE 1. B A Page 2 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure June 7, 2002 1. Installing the Midtronics Update Wizard (MUW). NOTE: The Midtronics Update Wizard only needs to be installed once and must be installed before the rest of the update process can take place. If this step is already complete, continue on to step 2. A. Click on the text “Install MUW.” (Figure 2.) B. The file download window will appear. Click on “Run this program from it’s current location.” C. Click the “OK” button. D. Allow the Update Wizard to perform its self–installation. This will take only a few minutes. FIGURE 2. A B C Page 3 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 2. Using the Midtronics Update Wizard (MUW). A. Click on the latest version of production software. (Figure 3.) This will begin the software update process. B. The next screen to appear will be the first screen of the software update. Click “Next” to continue. FIGURE 3. A B Page 4 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 C. Enter the serial number of the battery tester then click “OK.” (Figure 4.) FIGURE 4. C Page 5 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 D. Connect the Midtronics Battery Tester to TIS as instructed (Figure 5), then click “Next.” NOTE: Connecting the Midtronics Battery Tester to the TIS station will require the use of SST 00002–DMPUC. This is an adapter that allows the TIS RS–232 cable to plug into the Battery Tester. (Figure 5.) FIGURE 5. D Page 6 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 E. Follow the instructions to put the Midtronics Battery Tester into the correct mode (Figure 6), then click “Next.” FIGURE 6. E Page 7 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 F. Confirm the software version and click “Next.” (Figure 7.) FIGURE 7. F Figures 7–1 and 7–2 are confirmation dialogs that will pop up over the Update Information window (Figure 7) when: S The update file is an older revision level than that found in the battery tester (Figure 7–1) or S The update file is the same revision level as that found in the tester (Figure 7–2). Click the “Yes” button to clear the pop–up dialog and continue with the update. FIGURE 7–1. Page 8 of 10 FIGURE 7–2. MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 G. The Midtronics Update Wizard (MUW) will now update the Midtronics Battery Tester software. (Figure 8.) NOTE: Do not interrupt this process (it will take approximately 5 minutes). FIGURE 8. Page 9 of 10 MIDTRONICS BATTERY TESTER SOFTWARE UPDATE – SS002-02 Operation Procedure (Continued) June 7, 2002 H. Upon successful completion, the Update Results screen will display “No errors” and the update is now complete. Click on the “Exit” button. (Figure 9.) FIGURE 9. H Your Midtronics Battery Tester is now updated and ready for use. NOTE: BE SURE TO REGULARLY CHECK TIS FOR FUTURE UPDATES: S The Midtronics Battery Tester OE Stock Number Card will no longer be printed and shipped. It will be distributed through TIS from now on. S Latest versions of Tester update software will be available on TIS. Page 10 of 10 Technical Service BULLETIN RIVET NUT TOOL Models: All Models December 11, 1998 Introduction Affected Vehicles Part Number Information Toyota Motor Sales is making available a tool suitable for installing Rivet Nuts as required by some DIO accessories, such as wind deflectors, roof Racks, and running boards. The tool is available from Owatonna Tool Company, also known as OTC. S All models requiring Rivet Nuts for the installation of an accessory. OTC PART NUMBER PART NAME NOTE 00002–95161 Rivet Nut Tool Mandrels for 5, 6 and 8 mm Rivet Nuts included* * Also includes a molded plastic carrying case, not shown Ordering Procedure Warranty Information Rivet Nut Tool may be ordered by calling the OTC Order Desk at 1–800–933–8335. The introductory price for this tool is $460.00. OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 SPECIAL SERVICE TOOLS SS003–98 Title: SPECIAL SERVICE TOOLS SS95–004 NOVEMBER 10, 1995 ALL MODELS NEW OIL FILTER WRENCH Page 1 of 1 Beginning in 1996, Toyota will be standardizing the size of many of its oil filters to the three inch industry standard. This new filter size is slightly larger than the existing 75mm diameter filter presently used on many Toyota models. This larger filter will require a three inch oil filter wrench for easy removal. Three inch oil filter wrenches are readily available from parts stores and tool dealers, however, for your convenience, OTC will make this new filter wrench available under P/N 00002–17001. Dealer cost is $5.75. To order, please call OTC at 1–800–933–8335. TOYOTA MOTOR SALES U.S.A., INC. Technical Service BULLETIN December 8, 2000 Introduction Applicable Diagnostic Testers Repair Procedure DIAGNOSTIC TESTER COMMUNICATION ERROR WITH T.I.S. Models: All Models Certain Diagnostic Testers (SST P/N 02002019) may experience a communication error with the Technical Information System (T.I.S.). To correct this condition, the tester manufacturer, Vetronix Corporation, will recall and update affected units. The following explains how to determine which Diagnostic Testers may exhibit this problem and outlines the procedure to return the tester for repair. Diagnostic Testers within the serial number range below are known to experience these communication errors. STARTING SERIAL NUMBER ENDING SERIAL NUMBER 31 000000 31 000100 1. Determine the Diagnostic Tester serial number located on the back of the tester (see Figure 1). Figure 1 Back View of Diagnostic Tester 2. If the serial number is within the range listed above, call Vetronix Toyota Customer Service at 1-800-321-4889, ext. 3123, to obtain a pre-paid shipping package for the Diagnostic Tester. 3. The shipping package will arrive within 2 business days. Secure the tester in the provided package following the enclosed shipping instructions. S/N 31 000100 Diagnostic Testers are guaranteed to be returned within 3 business days from receipt at Vetronix (except over holidays). NOTE: This update will be performed free of charge. Diagnostic Testers outside of the serial number range above are not affected and do not need this repair. If a Diagnostic Tester outside this range experiences a similar problem, please call Dealer Daily Support at 1-877-DL-DAILY or Vetronix Toyota Customer Service at 1-800-321-4889, ext. 3123. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 SPECIAL SERVICE TOOLS SS004-00 Title: February 16, 2001 Introduction Models: All Applicable Models To make the steering wheel installation procedure similar for all models, the steering wheel nut tightening torque has been standardized. Applicable Vehicles Warranty Information STEERING WHEEL NUT SERVICE SPECIFICATION MODEL MODEL YEARS TERCEL EL42, 53 1991 – 1998 ECHO NCP12 2000 PASEO EL44, 54 1992 – 1997 COROLLA AE10#, ZZE110 1993 – 2001 CELICA AT180, ST18#, AT2#, ST2#, ZZT23# 1990 – 2000 MR2 SW2#, ZZW30 1991 – 1995; 2000 CAMRY SXV10, 20, MCV10, 20 1992 – 2000 CAMRY CNG SXV23 2000 – 2001 CAMRY SOLARA SXV20, MCV20 1999 – 2000 AVALON MCX10, 20 1995 – 2000 SUPRA JZA80 1993 1/2 – 1998 RAV4 SXA1# 1996 – 2000 RAV4 EV BEA11 1998 – 2000 PREVIA TRC10, 20 1991 – 1997 SIENNA MCL10 1998 – 2000 HIGHLANDER ACU20, 25, MCU20, 25 2001 4RUNNER RN12#, 13#, VZN12#, 13#, 18#, RZN180, 185 1990 – 2000 LAND CRUISER FZ80, FZJ80, UZJ100 1991 – 2000 TRUCK RN8#, 9#, 10#, 110, VZN85, 9#, 10#, 110 1989 – 1995 TACOMA RZN140, 150, 161, 171, 19#, VZN150, 160, 170, 195 1995 1/2 – 2000 T100 VCK10, 20 1993 – 1998 TUNDRA VCK30, 40, UCK30, 40 2000 OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 2 STEERING Technical Service BULLETIN ST001-01 Title: STEERING WHEEL NUT SERVICE SPECIFICATION – ST001-01 Service Information February 16, 2001 Steering Wheel Installation Nut 35 NSm (360 kgfScm, 26 ftSlbf) Steering Wheel Pad 50 NSm (510 kgfScm, 37 ftSlbf) Steering Wheel Lower No. 2 Cover Steering Wheel Steering Column Page 2 of 2 Steering Wheel Lower No. 3 Cover Technical Service BULLETIN May 22, 1998 Introduction STEERING GEAR REMOVAL/ REPLACEMENT Models: All Models equipped with SRS Airbag The following information is provided to supplement the Repair Manual procedure for removing/installing the steering gearbox or rack and pinion on vehicles equipped with a driver’s side Supplemental Restraint System (SRS) Airbag. CAUTION: When the intermediate shaft is disconnected and the steering wheel is turned freely, the SRS spiral cable may be broken. Therefore, as a precaution, make sure to pass the driver’s seat belt through the steering wheel to prevent it from turning freely, as shown below. After working on SRS/Steering components, always check the operation of the SRS Warning Light. Refer to the appropriate repair manual if any diagnostic trouble codes are recorded. Affected Vehicles Repair Procedure Tercel, Paseo, Corolla, MR2, Celica, Camry, Avalon, Supra, Previa, Sienna, RAV4, 4Runner, Tacoma, T–100 & Land Cruiser equipped with a driver’s side SRS Airbag. 1. Position the front wheels facing straight ahead. 2. Using the driver’s seat belt, set the steering wheel so that it does not turn (see Fig. 1). Fig. 1 3. Paint match marks on the intermediate shaft and control valve shaft (see Fig. 2). Match Marks 4. Remove the intermediate shaft retaining bolt and disconnect the intermediate shaft (see Fig. 2). Fig.2 Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 STEERING ST002–98 Title: Technical Service BULLETIN STEERING WHEEL NUT Models: ’94 – ’00 Camry May 12, 2000 Introduction Applicable Vehicles The steering wheel installation nut torque specification has been changed. Please update the repair manuals for the applicable vehicles. S 1994 – 2000 model year Camry 50 N m (510 kgf cm, 37 ft lbf) Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 STEERING ST002–00 Title: STEERING RACK END NOISE Technical Service BULLETIN Models: ’97 – ’00 Camry (NAP) & ’99 – ’00 Solara June 16, 2000 Introduction Some 1997 – 2000 model year Camry (NAP) and 1999 – 2000 Solara vehicles may experience a squeaking noise from the front suspension. To improve this condition, production parts have been changed. Applicable Vehicles S 1997 – 2000 model year Camry (North American Produced) S 1999 – 2000 model year Solara Production Change Information Parts Information MODEL STARTING VIN NAP Camry 4T1BG2*K*YU668756 4T1BG2*K*YU986504 4T1BF2*K*YU104860 4T1BF2*K*YU947590 Solara 2T1C*2*P*YC359722 MODEL PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME Camry and Solara 45503–09030 or 45503–39055 or 45503–39135 45503–39135 Steering Rack End Sub–Assembly HINT: A quick reference in differentiating between the previous and new parts is that the previous Rack End Shaft is BLACK and the current part is GRAY. STEERING ST004–00 Title: Previous Part (BLACK SHAFT) Current Part (GRAY SHAFT) Warranty Information OP CODE DESCRIPTION TIME 444631 R & R Power Steering Rack End Sub–Assembly (One Side) 2.2 Other Side 0.5 Combo Code A OPN 45503–09030 or 45503–39055 45503 39055 or 45503–39135 T1 T2 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 STEERING RACK END NOISE Technical Service BULLETIN Models: ’97 – ’00 Camry (NAP) & ’99 – ’00 Solara December 21, 2001 STEERING ST008-01 Title: TSB Update Notice: The information contained in this TSB updates ST004–00 dated June 16, 2000. Revised text is red and underlined. Introduction Some 1997 – 2000 model year Camry (NAP) and 1999 – 2000 Solara vehicles may experience a squeaking noise from the front suspension. To improve this condition, production parts have been changed. Applicable Vehicles S 1997 – 2000 model year Camry (North American Produced) vehicles. S 1999 – 2000 model year Solara vehicles. Production Change Information Parts Information MODEL STARTING VIN NAP Camry 4T1BG2#K#YU668756 4T1BG2#K#YU986504 4T1BF2#K#YU104860 4T1BF2#K#YU947590 Solara 2T1C#2#P#YC359722 MODEL PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME Camry and Solara 45503–09030 or 45503–39055 or 45503–39135 45503–39135 Steering Rack End Sub–Assembly NOTE: Current service parts may be GRAY or BLACK in color. Warranty Information OP CODE DESCRIPTION TIME 444631 R & R Power Steering Rack End Sub–Assembly (One Side) 2.2 Other Side 0.5 Combo Code A OPN 45503–09030 or 45503–39055 45503 39055 or 45503–39135 T1 T2 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 Technical Service BULLETIN FRONT SUSPENSION SUPPORT NOISE Models: ’97 – ’99 Avalon & ’97 – ’00 Camry January 21, 2000 TSB Update Notice: The information contained in this TSB updates SU002–99 dated September 3, 1999. Revised text is red and underlined. Introduction Applicable Vehicles Production Change Information Parts Information To eliminate a noise occurrence from the front suspension on washboard type road surfaces, the suspension support has been changed. S 1997 – 1999 Model Year Avalon and 1997 – 2000 Camry vehicles. The rubber bushing shape of the suspension support has been changed. MODEL STARTING VIN Avalon 4T1BF1*B*XU353593 JPP Camry JT2BF2*K*Y0237757 JT2BG2*K*Y0386559 NAP Camry 4T1BF2*K*YU092142 4T1BF2*K*YU934448 4T1BG2*K*YU623567 4T1BG2*K*YU925151 PREVIOUS PART NUMBER Suspension Support Coil Spring Strut CURRENT PART NUMBER PART NAME QUANTITY 48603–33020 48603–33010 Support Sub–Assembly, Front Suspension RH 1 48609–33120 48609–33110 Support Sub–Assembly, Front Suspension LH 1 48603–33020 48603–33021 Support Sub–Assembly, Front Suspension RH 1 48609–33120 48609–33121 Support Sub–Assembly, Front Suspension LH 1 Avalon Camry Warranty Information OP CODE 431451 COMBO DESCRIPTION A R & R Suspension Support (RH and LH) B Adjust Toe–In C Adjust Camber TIME OPN T1 2.1 48603–33020 T2 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 SUSPENSION SU001–00 Title: Technical Service BULLETIN March 1, 2002 Introduction Applicable Vehicles REAR BEARING O-RING SERVICE TIP Models: ’97 – ’01 Camry, ’00 – ’02 Avalon & ’99 – ’02 Solara When replacing the rear hub bearing assemblies on 1997 – 2001 model year Camry, 2000 – 2002 Avalon and 1999 – 2002 Solara vehicles, replace the O–ring. S 1997 – 2001 model year Camry vehicles. S 2000 – 2002 model year Avalon vehicles produced before the VIN shown below. S 1999 – 2002 model year Solara vehicles produced before the VIN shown below. Production Change Information Parts Information Warranty Information Repair Procedure MODEL STARTING VIN Avalon 4T1BF28B#2U223623 Solara 2T1##2#P#2C005335 PART NUMBER PART NAME 90301–63006 O–Ring OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – REMOVAL 1. Remove Rear Wheel. Torque: 103 NSm (1,050 kgfScm, 76 ftSlbf) 2. With Disc Brake: Remove Brake Caliper and Disc. A. Remove the brake caliper and disc. Torque: 47 NSm (475 kgfScm, 34 ftSlbf) B. Support the brake caliper securely. 3. With Drum Brake: Remove Brake Drum. Toyota Supports ASE Certification Page 1 of 2 SUSPENSION SU001-02 Title: REAR BEARING O–RING SERVICE TIP – SU001-02 March 1, 2002 4. Remove Rear Axle Hub. A. Remove the 4 bolts and rear axle hub. Bolt Torque: 80 NSm (820 kgfScm, 59 ftSlbf) B. Remove the O–ring. Bolt HINT: At the time of installation, coat the new O–ring with MP grease. Bolt Bolt NOTE: Please ensure that the O–ring is replaced with a new service part when installing the bearing assembly. C. With Drum Brake: Remove the bolt, and disconnect the flexible hose from the shock absorber. Torque: 29 NSm (300 kgfScm, 22 ftSlbf) D. Support the backing plate securely. 5. With ABS: Remove ABS Speed Sensor. Torque: 8.0 NSm (82 kgfScm, 71 inSlbf) INSTALLATION Installation is in the reverse order of removal. Page 2 of 2 Technical Service BULLETIN FRONT SUSPENSION SUPPORT NOISE Models: ’97 – ’99 Avalon & Camry September 3, 1999 Introduction Applicable Vehicles Modification Information To eliminate a noise occurrence from the front suspension on washboard type road surfaces, the suspension support has been changed. S 1997 – 1999 Model Year Avalon and Camry vehicles The rubber bushing shape of the suspension support has been changed. Suspension Support Coil spring Strut Parts Information Warranty Information PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QUANTITY 48603–33020 48603–33010 Support Sub–Assembly, Front Suspension RH 1 48609–33120 48609–33110 Support Sub–Assembly, Front Suspension LH 1 OP CODE 431451 GROUP DESCRIPTION A R & R Suspension Support (RH and LH) B Adjust Toe–In C Adjust Camber TIME 2.1 OPN T1 T2 48603–33020 91 99 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in–service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 1 SUSPENSION SU002–99 Title: Technical Service BULLETIN REAR ABS SPEED SENSOR REMOVAL Models: ’97 – ’00 Camry & Avalon, ’99 – ’00 Solara May 5, 2000 Introduction This bulletin provides service information regarding the removal of the ABS speed sensor prior to removal of the rear axle and rear suspension. REMINDER: Failure to remove the ABS speed sensor prior to removal of the rear axle or suspension may cause the ABS warning light to illuminate or damage the ABS speed sensor wire harness. Applicable Vehicles S 1997 – 2000 model year Camry and Avalon S 1999 – 2000 model year Solara Repair Procedure POTENTIAL AREA FOR DAMAGE 5.4 NSm (55 kgfScm, 48 inSlbf) REAR ABS SPEED SENSOR 7.8 NSm (80 kfgScm, 69 inSlbf) NOTE: Prior to removal/replacement of the rear axle, rear coil spring and rear shock absorber, be sure to remove the rear ABS speed sensor from the rear axle by removing the 3 bolts shown above. Check the speed sensor signal after installation. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable – – – – Toyota Supports ASE Certification Page 1 of 1 SUSPENSION SU002–00 Title: AUTOMATIC TRANSMISSION FLUID REQUIREMENTS Technical Service BULLETIN Models: All ’00 – ’02 Models & ’03 Corolla & Matrix May 24, 2002 Introduction Please refer to the following table for correct application of DexronR III (DexronR II) and Toyota Type T–IV Automatic Transmission Fluids or equivalent. MODEL 2000 2001 2002 2003 Avalon A541E A541E A541E N/A Camry A140E, A541E A140E, A541E U140E, U241E N/A Celica U240E, U341E U240E, U341E U240E, U341E N/A Corolla A131L, A245E A131L, A245E A131L, A245E A245E ECHO U340E U340E U340E N/A Highlander N/A U140E, U140F, U241E U140E, U140F, U241E N/A Land Cruiser A343F A343F A343F N/A U140F, U241E U140F, U241E N/A RAV4 A247E A540H Sequoia N/A A340E, A340F A340E, A340F N/A Sienna A540E A541E A541E N/A Solara A140E, A541E A140E, A541E Tacoma A340E, A340F, A43D A340E, A340F, A44D A340E, A340F, A44D N/A Tundra A340E, A340F A340E, A340F A340E, A340F N/A 4Runner A340E, A340F A340E, A340F A340E, A340F N/A Matrix N/A N/A N/A A246E Matrix N/A N/A N/A U240E Matrix N/A N/A N/A U341F Prius N/A P111 P111 N/A A140E U241E N/A LEGEND Type T–IV Fluid DexronR III (DexronR II) Parts Information Warranty Information PART NUMBER PART NAME 08886–81015 ATF Type T–IV 00718–ATF00 DexronR III (DexronR II) OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC001-02 Title: Technical Service BULLETIN REVISED DRIVE SHAFT GREASE Models: RAV4, Tercel, Corolla, Celica, Camry & Supra April 9, 1999 Introduction The greases supplied in replacement Inboard and Outboard Drive Shaft Boot Kits for the following models has been revised. With this revision, the grease compositions have been changed and are now both the same color. To correctly lubricate each joint, consult the Service Repair Manual as to which size packet of grease is designated for each Drive Shaft Joint Assembly. NOTE: Although Inboard and Outboard greases are now the same color, their compositions are different. Affected Vehicles S All RAV4, Tercel, Corolla, Celica, Camry and Supra Models. Required Tools and Material As outlined in the Service Repair Manual. Repair Procedure Refer to the appropriate Repair Manual for installation and lubrication information for Drive Shaft Joint Assemblies. Warranty Information OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC002–99 Title: TRANSMISSION OIL COOLER INSTALLATION Models: ’97 CAMRY WITH A541E ATM October 17, 1997 Introduction Towing Capacity To prevent overheating of the transmission when towing a weight of more than 1,000 pounds, a transmission oil cooler should be installed. The transmission oil cooler and required hardware for installation are available through normal parts supply. D Up to 2,000 pounds (with transmission cooler installed). Oil Cooler Tube No. 2 Oil Cooler Tube No. 1 Side Member Clip Front Suspension Member Hose Clamp Oil Cooler Assembly Fig. 1 Affected Vehicles Parts Information Warranty Information D 1997 Camrys with A541E Automatic Transmissions. PART NUMBER PART NAME QTY 32910–33040 Oil Cooler Assembly 1 32907–33050 Oil Cooler Tube No. 2 1 32907–33090 Oil Cooler Tube No. 1 1 90445–17101 180 mm (7.09”) Oil Cooler Hose 1 90445–17069 190 mm (7.48”) Oil Cooler Hose 1 90445–17139 130 mm (5.12”) Oil Cooler Hose 3 90445–17151 140 mm (5.51”) Oil Cooler Hose 1 90119–06518 Bolt 3 91611–60816 Bolt 2 90467–16013 Hose Clamp with installation clip 12 90179–06058 Nut 1 OPCODE N/A Toyota Supports ASE Certification DESCRIPTION Not applicable to warranty TIME – OPN – T1 T2 – – Page 1 of 6 TRANSMISSION & CLUTCH TSB TC003–97 Title: TRANSMISSION OIL COOLER INSTALLATION – TC003–97 Procedure October 17, 1997 1. Parts removal in preparation for cooler installation: A. Remove the 9 bolts, 2 screws and the center engine under cover. Fig. 2 Center Engine Under Cover B. Remove the engine coolant temperature switch connector and the wire clamp. Fig. 3 C. Remove battery and tray. D. Disconnect the cooling fan connector. E. Disconnect the No.1 engine coolant temperature switch wire connector. F. Remove the 2 bolts and then the cooling fan. Fig. 4 Page 2 of 6 Clamp Switch TRANSMISSION OIL COOLER INSTALLATION – TC003–97 October 17, 1997 Oil Cooler Tube No. 1 Procedure (Continued) 2. Cooler Installation: A. Install the 140 mm (5.51”) hose to the oil cooler tube No. 1 as shown. NOTE: Install the hose clamp with the hose clamp clip at the position shown, and use pliers to pull off the clip in the direction indicated by the arrow. 140 mm Hose 5 mm (0.20”) Fig. 5 B. Install the tube bracket onto the left side of the front suspension member with the 2 bolts as shown. Torque: 62 in–lbf (7 N–m / 71 kgf–cm) Fig. 6 C. Install the 130 mm (5.12”) hoses and the 180 mm (7.09”) hose to the oil cooler tube No. 2 as shown. Oil Cooler Tube No. 2 NOTE: Install the hose clamps with the hose clamp clips at the positions shown, and use pliers to pull off the clips in the direction indicated by the arrows. 180 mm Hose 130 mm Hose 5 mm (0.20”) Fig. 7 Page 3 of 6 TRANSMISSION OIL COOLER INSTALLATION – TC003–97 Procedure (Continued) October 17, 1997 D. Remove the lower side clip of the radiator side LH deflector. E. Install the tube bracket with the bolt on the side member. Torque: 62 in–lbf (7 N–m / 71 kgf–cm) F. Reinstall the lower side clip of the radiator LH deflector. Fig. 8 G. Connect the hoses from the oil cooler tube No. 2 to the oil cooler tube No.1. Oil Cooler Tube No. 1 NOTE: Install the hose clamps with the hose clamp clips at the positions shown, and use pliers to pull off the clips in the direction indicated by the arrows. Front Suspension Member 5 mm (0.20”) Fig. 9 H. Disconnect the hose from the oil cooler pipe of the radiator LH side. NOTE: Place a container below vehicle to catch any leaking ATF. Remove the other end of this hose from transaxle and discard. I. Connect the hose from oil cooler tube No.1 to the oil cooler pipe of the radiator LH side. NOTE: Install the hose clamps with the hose clamp clips at the positions shown, and use pliers to pull off the clips in the direction indicated by the arrows. Page 4 of 6 5 mm (0.20”) Fig. 10 TRANSMISSION OIL COOLER INSTALLATION – TC003–97 Procedure (Continued) October 17, 1997 J. Install the 190 mm (7.48”) hose between the oil cooler tube No.1 and transaxle oil cooler tube. NOTE: Install the hose clamps with the hose clamp clips at the positions shown, and use pliers to pull off the clips in the direction indicated by the arrows. 190 mm Hose Oil Cooler Tube No. 1 5 mm (0.20”) Fig. 11 K. Install the oil cooler onto the center brace and front cross member using the two bolts and nut as illustrated in figure 12. Torque: 65.5 in–lbf (7.4 N–m/75.5 kgf–cm) L. Connect the hoses to the pipes. NOTE: Install the hose clamps with the hose clamp clips at the positions shown, and use pliers to pull off the clips in the direction indicated by the arrows. 5 mm (0.20”) Fig. 13 Page 5 of 6 TRANSMISSION OIL COOLER INSTALLATION – TC003–97 Procedure (Continued) October 17, 1997 3. Final Assembly: A. Reconnect the coolant temperature switch connector and wire clamp as illustrated in figure 14. B. Install the cooling fan with 2 bolts. C. Reconnect the cooling fan connector and the No.1 engine temperature switch wire connector as shown in figure 15. D. Reinstall battery and tray. E. Start the engine. Fig. 15 F. With the engine at idle and the brake pedal depressed, shift the selector into all positions from “P” to “L”, and return it to the “P” position. G. Check for leaks from the hose joints. H. Add new fluid type ATF D·II or DEXRON·III (DEXRON·II). Fig. 16 NOTE: Additional capacity with cooler will be 0.38 US quarts (0.36 liters). I. Shift the selector into all positions from “P” to “L”, and return to “P”. J. Check fluid level with engine idling at normal operating temperature of 158
to 176
F (70 to 80
C) and add more fluid if required. Fig. 17 CAUTION: Do not overfill. K. Shut off the engine and reinstall the center engine under cover with 9 bolts and 2 screws as shown in figure 18. Fig. 18 Page 6 of 6 Technical Service BULLETIN June 19, 1998 Introduction Applicable Vehicles AUTOMATIC TRANSMISSION FLUID TYPE T-IV Models: All Models The introduction of Automatic Transmission Fluid type T–IV makes type T–II obsolete. Use type T–IV for all applications that specify ATF type T–II. S All vehicles with Automatic Transmissions specified to use ATF Types T–II or T–IV. TYPE OF ATF SPECIFIED ATF Dextron®–III TYPE T TYPE T–II TYPE T–IV Dextron®–II or III OK X X X TYPE T X OK X X TYPE T–II X X OK OK TYPE T–IV X X X OK X = NOT USABLE Parts Information Warranty Information SIZE NEW PART NUMBER PART NAME 4 Liter 08886–01705 ATF type T–IV OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC003–98 Title: Technical Service BULLETIN AUTOMATIC TRANSMISSION FLUIDS Models: All Models May 21, 1999 REVISION NOTICE: The information contained in this TSB updates TC003–98 dated June 19, 1998. Introduction Automatic Transmission Fluid Type T–IV now replaces Type T–II fluid. Use Type T–IV for all applications that specify ATF Type T–II. Please refer to the following table for the interchangeability between each ATF. Affected Vehicles S All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T–II and T–IV. TYPE OF ATF SPECIFIED ATF DEXTRON II OR III TYPE T TYPE T–II TYPE T–IV DEXTRON II OR III OK X X X TYPE T X OK X OK TYPE T–II X X OK OK TYPE T–IV X X X OK X = NOT USABLE NOTICE: With the exception of mixing ATF Type T with Type T–IV fluids, different types of fluids must not be mixed. Parts Information Warranty Information SIZE NEW PART NUMBER PART NAME 4 Liter 08886–01705 ATF Type T–IV OP CODE DESCRIPTION TIME OPN T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 1 TRANSMISSION & CLUTCH TC003–99 Title: TRANSMISSION & CLUTCH TC004-96 DECEMBER 20, 1996 ALL MODELS Title: AUTOMATIC TRANSMISSION SERIAL NUMBERS Page 1 of 3 Use the following tables to locate and read the original automatic transmission serial number. TRANSMISSION MODEL A4#D# A34## TRANSMISSION LOCATION SERIAL NUMBER 96 A E 00001 5-Digit Serial No. *Model Code Manufacturing Month: A thru M (“I” not used) Last 2 Digits of Manufacturing Year: 1996 A131L (AW Product) 96 A Y 00001 5-Digit Serial No. *Model Code Manufacturing Month: A thru M (“I” not used) Last 2 Digits of Manufacturing Year: 1996 A24## 96 A ZT 00001 5-Digit Serial No. *Model Code Manufacturing Month: A thru M (“I” not used) Last 2 Digits of Manufacturing Year: 1996 *See Model Code chart on Page 3. AUTOMATIC TRANSMISSION SERIAL NUMBERS TRANSMISSION TRANSMISSION LOCATION MODEL Page 2 of 3 SERIAL NUMBER 6 A 00001 50001 5-Digit Serial No. Manufacturing Month: A thru M (“I” not used) Last Digit of Manufacturing Year: 1996 A140# A130L 6 01 00001 5-Digit Serial No. Manufacturing Month: Last 2 Digits of Manufacturing Year: 1996 A131L (TMC Product) A132# F A 50001 5-Digit Serial No. Manufacturing Month: A thru M (“I” not used) *Manufacturing Year: ‘93-C, ‘94-D, ‘95-E A54#E A540H D 01 00001 5-Digit Serial No. Manufacturing Month: Manufacturing Year: A541E: ‘93-A, ‘94-B, ‘95-C A540E, A540H: ‘90-A, ‘91-B, ‘92-C A44## * NOTE: 6 A 00001 5-Digit Serial No. Manufacturing Month: A thru M (“I” not used) Last Digit of Manufacturing Year: 1996 Exception: 1991 – K, 1992 (January–March) – M, 1992 (April–December) – B Remanufactured transmissions also have an additional serial number. AUTOMATIC TRANSMISSION SERIAL NUMBERS Page 3 of 3 MODEL CODE CHART: CODE MODEL A A40 N A45DF, A44D, A45D w/o Lock-up B A40D, A40DF P A44DL, A45DF, A45DL w/Lock-up C A42D Q A44DE, A45DF, A45DE ECT, w/Lock-up D A41 R A340E, A340F w/lock-up E A343F S A340H w/Lock-up F A43D T A340E w/o Lock-up H A43DL U A341H K A42DL Y A131, A131L Z A240L, A241L, A242L, A243L, A2444L, A240E, A241E, A242E, A244E, A244F, A241H ZT A245E, A246E L A43DE, A46DE, A46DF M A42DE CODE MODEL TOYOTA SERVICE BULLETIN VOLUME 10 TRANSMISSION & REFERENCE CLUTCH NUMBER DATE 008 (REVISED) 03–22–02 MODELAE, ST, SV, VV (A131L) BR12E or BR18E (A140E) BG, EG, CG, FG, DG (A540e) ZF, GF19C TOYOTA MOTOR SALES, U.S.A., INC. Page 1 of 2 A/TM NUMBER AND LOCATION INFORMATION The purpose of this Service Bulletin is to provide information regarding the location of the A/TM numbers. NOTE: The transmission numbers must be included on the AUTOMATIC TRANSMISSION CORE INFORMATION/CREDIT REQUEST FORM when using the automatic transmission reman. program. TECHNICAL ASSURANCE DEPARTMENT TC008–89 Page 2 of 2 A/TM NUMBER AND LOCATION INFORMATION (CONT’D) TECHNICAL ASSURANCE DEPARTMENT TC008–89 O2S TEST RESULTS (MODE 05) Technical Service BULLETIN December 17, 2003 Introduction All ’96 – ’03, ’04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. S All 1996 – 2003 model year Toyota vehicles. S 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. S 2004 model year Scion xA and xB vehicles. Applicable Vehicles Function Description Models: Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking O2S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor (page 2). 2. Accessing O2S Test Results (page 3). 3. Comparing O2S Test Results to Failure Thresholds (page 4). Required SSTs SPECIAL SERVICE TOOLS (SSTs) Toyota Diagnostic Tester Kit* (or any OBDII Scantool) 12 Megabyte Diagnostic Tester Program Card with version 10.1a Software (or later)* * PART NUMBER QUANTITY 01001271 1 01002593-005 1 Essential SSTs. NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Toyota Supports ASE Certification Page 1 of 43 SPECIAL SERVICE TOOLS SS002-03 Title: O2S TEST RESULTS (MODE 05) – SS002-03 Completing O2S Readiness Monitor December 17, 2003 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. 2. Start the engine. 3. Perform the drive pattern below to run and complete the Oxygen Sensor (O2S) Monitor. O2S Monitor Drive Pattern ECT: 167
F (75
C) or more Accelerator Pedal Depressing At Least Twice At Least 8 Times Vehicle Speed Accelerator Pedal Releasing (Fuel–Cut) 48 km/h (30 mph) 6 mph (10 km/h) Idling Time 2 min. or more 40 sec or more 20 sec or more 10 sec or more 10 sec or more HINT: The O2S Monitor is completed when the following conditions are met: S Two (2) minutes or more passed after the engine start. S The Engine Coolant Temperature (ECT) is 167
F (75
C) or more. S Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. S Vehicle is in closed loop. S The fuel–cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167
F (75
C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal “off–idle” for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel–cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6 mph (10 km/h). F. Repeat steps B – E at least twice in one driving cycle. Page 2 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: S DIAGNOSTICS S CARB OBD II S O2S TEST RESULTS A list of the available oxygen sensors will be displayed. December 17, 2003 O2S TEST RESULT Screen 01 BANK 1 – SENSOR 1 01 BANK 1 – SENSOR 2 01 BANK 2 – SENSOR 1 01 BANK 2 – SENSOR 2 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select “Bank 1–Sensor 1” or Bank 2–Sensor 1” for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display “No parameter to display.” 3. Compare the test results with the values listed in the Failure Threshold Chart. TEST DATA Screen LOW SW V S S S S 0.400 V HIGH SW V S S S S 0.550 V MIN O2S V S S S S 0.100 V MAX O2S V S S S S 0.900 V TIME $81 S S S S S * 17 Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBDII scantool. Refer to your OBDII scantool operator’s manual for specific procedures. Page 3 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 Comparing O2S Test Results to Failure Thresholds December 17, 2003 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the “O2S Application Table,” pages 5 – 9 in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example below: Example: Example A. The Diagnostic Tester displays “17” as a value of the “Time $81” (see illustration). B. Find the Conversion Factor value of “Time $81” in the O2S Failure Threshold chart below. 0.3906 is specified for Time $81 in this chart. C. Multiply “17” in step “A” by 0.3906 (Conversion Factor) in step “B.” 17 x 0.3906 = 6.6 % D. If the answer is within the Standard Value of TEST LIMIT, the “Time $81” can be confirmed to be normal. LOW SW V S S S S HIGH SW V S S S S MIN O2S V S S S S MAX O2S V S S S S Time $81 Time $84 Time $85 0.400 V 0.550 V 0.035 V 0.835 V 17 84 79 NOTE: S “LOW SW V” indicates the O2S voltage when the O2S status changes from rich to lean. S “HIGH SW V” indicates the O2S voltage when the O2S status changes from lean to rich. S If the O2S voltage is lower than “LOW SW V,” the O2S status is lean. S If the O2S voltage is higher than “HIGH SW V,” the O2S status is rich. Example of O2S Failure Threshold Chart: TEST ID Time $81 DESCRIPTION OF TEST DATA Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05V CONVERSION FACTOR UNIT Multiply 0.3906 % STANDARD VALUE OF TEST LIMIT Within 60% NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, 0 s [seconds], 10.2 s, 0 and 255). Page 4 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Application Table MODEL YEAR MODEL ENGINE DRIVE TRAIN CERTIFICATION SEE CHART NO. (TSB PAGE) Avalon 1MZ–FE All 50–State 1 (p. 10) All California 2 (p. 11) All Federal 1MZ–FE All 50–State 7A–FE All 50–State 1 (p. 10) All California 2 (p. 11) All Federal 1 (p. 10) Camry y Celica 1996 5S FE 5S–FE 5S FE 5S–FE 1 (p (p. 10) Corolla ALL All 50–State 1 (p. 10) Land Cruiser 1FZ–FE All 50–State 1 (p. 10) Paseo 5E–FE All 50–State 1 (p. 10) Previa 2TZ–FZE All 50–State 1 (p. 10) RAV4 3S–FE All 50–State 2 (p. 11) Supra ALL All 50–State 1 (p. 10) Tacoma ALL All 50–State 1 (p. 10) Tercel 5E–FE All 50–State 1 (p. 10) T100 ALL All 50–State 1 (p. 10) 4Runner ALL All 50–State 1 (p. 10) Avalon 1MZ–FE All 50–State 1 (p. 10) All California 3 (p. 12) All Federal 1MZ–FE All 50–State 7A–FE All 50–State 1 (p. 10) All California 2 (p. 11) All Federal 1 (p. 10) Camry y Celica 1997 December 17, 2003 5S FE 5S–FE 5S FE 5S–FE 1 (p (p. 10) Corolla ALL All 50–State 1 (p. 10) Land Cruiser 1FZ–FE All 50–State 1 (p. 10) Paseo 5E–FE All 50–State 1 (p. 10) Previa 2TZ–FZE All 50–State 1 (p. 10) RAV4 3S–FE All 50–State 2 (p. 11) Supra ALL All 50–State 1 (p. 10) 2RZ–FE All 50–State A/T 50–State M/T, 2WD 50–State M/T, 4WD 50–State 5VZ–FE All 50–State 5E–FE All 50–State 1 (p. 10) 3RZ–FE All 50–State 1 (p. 10) 5VZ–FE All 50–State 2 (p. 11) 3RZ–FE All 50–State 1 (p. 10) 5VZ–FE All 50–State 2 (p. 11) Tacoma Tercel T100 4Runner 3RZ–FE 1 ((p. 10)) 2 (p (p. 11) Page 5 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Application Table (Continued) MODEL YEAR December 17, 2003 MODEL ENGINE Avalon 1MZ FE 1MZ–FE 5S FE 5S–FE Camry y 1MZ–FE 1998 SEE CHART NO. (TSB PAGE) All California 4 (p. 12) All Federal 1 (p. 10) All California 3 (p. 12) All Federal 2 (p. 11) California 4 (p. 12) A/T Federal 1 (p. (p 10) M/T 50–State All California 2 (p. 11) All Federal 1 (p. 10) 5S FE 5S–FE Corolla 1ZZ–FE All 50–State 2 (p. 11) Land Cruiser 2UZ–FE All 50–State 2 (p. 11) Paseo 5E–FE All 50–State 1 (p. 10) All California 3 (p. 12) RAV4 3S FE 3S–FE All Federal 2 (p. 11) Sienna 1MZ–FE All 50–State 1 (p. 10) 2JZ–GE All 50–State 2 (p. 11) 2JZ–GTE All 50–State 1 (p. 10) Tacoma ALL All 50–State 2 (p. 11) Tercel 5E–FE All 50–State 1 (p. 10) T100 ALL All 50–State 2 (p. 11) 4Runner ALL All 50–State 2 (p. 11) All California 4 (p. 12) All Federal 5 (p. 13) Avalon 1MZ FE 1MZ–FE Camry CNG 5S–FNE All 50–State 6 (p. 13) Celica 5S–FE All 50–State 5 (p. 13) Corolla 1ZZ–FE All 50–State 2 (p. 11) Land Cruiser 2UZ–FE All 50–State 2 (p. 11) Paseo 5E–FE All 50–State 1 (p. 10) All California 3 (p. 12) RAV4 3S FE 3S–FE All Federal 2 (p. 11) All California 4 (p. 12) Sienna 1MZ FE 1MZ–FE All Federal 5 (p. 13) All California 3 (p. 12) All Federal 5 (p. 13) California 4 (p. 12) 5S FE 5S–FE Solara 1MZ–FE A/T Federal M/T 50–State 5 (p. (p 13) Tacoma ALL All 50–State 2 (p. 11) Tercel 5E–FE All 50–State 1 (p. 10) 3RZ–FE All 50–State 2 (p. 11) All California 4 (p. 12) All Federal 2 (p. 11) 4Runner Page 6 of 43 CERTIFICATION Celica Supra 1999 DRIVE TRAIN 5VZ FE 5VZ–FE O2S TEST RESULTS (MODE 05) – SS002-03 O2S Application Table (Continued) MODEL YEAR December 17, 2003 MODEL ENGINE DRIVE TRAIN CERTIFICATION SEE CHART NO. (TSB PAGE) Avalon 1MZ–FE All 50–State 4 (p. 12) Camry CNG 5S–FNE All 50–State 6 (p. 13) Celica ALL All 50–State 1 (p. 10) Corolla 1ZZ–FE All 50–State 7 (p. 14) ECHO 1NZ–FE All 50–State 1 (p. 10) Land Cruiser 2UZ–FE All 50–State 2 (p. 11) MR2 1ZZ–FE All 50–State 1 (p. 10) RAV4 3S FE 3S–FE All California 4 (p. 12) All Federal 2 (p. 11) All California 4 (p. 12) All Federal 5 (p. 13) All California 4 (p. 12) All Federal 5 (p. 13) California 4 (p. 12) Sienna 1MZ FE 1MZ–FE 5S FE 5S–FE Solara 1MZ–FE 2000 2RZ FE 2RZ–FE Tacoma 3RZ FE 3RZ–FE 5VZ FE 5VZ–FE 2UZ–FE Tundra 5VZ FE 5VZ–FE 3RZ FE 3RZ–FE 4Runner 5VZ FE 5VZ–FE A/T Federal 5 (p (p. 13) M/T 50–State All California 4 (p. 12) All Federal 2 (p. 11) All California 4 (p. 12) All Federal 2 (p. 11) All California 8 (p. 15) All Federal 2 (p. 11) All 50–State 2 (p. 11) All California 8 (p. 15) All Federal 2 (p. 11) All California 4 (p. 12) All Federal 2 (p. 11) All California 8 (p. 15) All Federal 2 (p. 11) Page 7 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Application Table (Continued) MODEL YEAR MODEL ENGINE DRIVE TRAIN CERTIFICATION SEE CHART NO. (TSB PAGE) Avalon 1MZ–FE All 50–State 4 (p. 12) Camry CNG 5S–FNE All 50–State 6 (p. 13) Celica ALL All 50–State 1 (p. 10) Corolla 1ZZ–FE All 50–State 7 (p. 14) ECHO 1NZ–FE All 50–State 1 (p. 10) 1MZ–FE All 50–State 9 (p. 15) 2AZ–FE All 50–State 3 (p. 12) Land Cruiser 2UZ–FE All 50–State 1 (p. 10) MR2 1ZZ–FE All 50–State 1 (p. 10) Prius 1NZ–FXE All 50–State 11 (p. 17) RAV4 1AZ–FE All 50–State 4 (p. 12) Sequoia 2UZ–FE All 50–State 1 (p. 10) Sienna 1MZ–FE All 50–State 4 (p. 12) 5S–FE All 50–State 3 (p. 12) Highlander 2001 A/T 50–State 9 (p. 15) M/T 50–State 10 (p. 16) ALL All 50–State 4 (p. 12) 2UZ–FE All 50–State 1 (p. 10) 5VZ–FE All 50–State 4 (p. 12) 4Runner ALL All 50–State 4 (p. 12) Avalon 1MZ–FE All 50–State 4 (p. 12) 1ZZ–FE All 50–State 1 (p. 10) 2ZZ–GE All 50–State 13 (p. 19) Corolla 1ZZ–FE All 50–State 7 (p. 14) ECHO 1NZ–FE All 50–State 1 (p. 10) 1MZ–FE All 50–State 4 (p. 12) Solara Tacoma Tundra Celica Highlander 2002 1MZ FE 1MZ–FE 2AZ–FE All 50–State 3 (p. 12) Land Cruiser 2UZ–FE All 50–State 14 (p. 20) MR2 1ZZ–FE All 50–State 1 (p. 10) Prius 1NZ–FXE All 50–State 15 (p. 21) RAV4 1AZ–FE All 50–State 3 (p. 12) Sequoia 2UZ–FE All 50–State 14 (p. 20) Sienna 1MZ–FE All 50–State 4 (p. 12) 2AZ–FE All 50–State 12 (p. 18) A/T 50–State 9 (p. 15) M/T 50–State 5 (p. 13) ALL All 50–State 12 (p. 18) 2UZ–FE All 50–State 14 (p. 20) 5VZ–FE All 50–State 12 (p. 18) ALL All 50–State 12 (p. 18) Solara Tacoma Tundra 4Runner Page 8 of 43 December 17, 2003 1MZ FE 1MZ–FE O2S TEST RESULTS (MODE 05) – SS002-03 O2S Application Table (Continued) MODEL YEAR December 17, 2003 MODEL ENGINE DRIVE TRAIN CERTIFICATION SEE CHART NO. (TSB PAGE) Avalon 1MZ–FE All 50–State 16 (p. 22) All Federal 2AZ–FE M/T California A/T California 18 (p. 24) All With VVT 19 (p. 25) All Without VVT 20 (p. 26) 1ZZ–FE All 50–State 13 (p. 19) Camry y 1MZ FE 1MZ–FE Celica 2ZZ–GE All 50–State 21 (p. 27–28) Corolla 1ZZ–FE All 50–State 22 (p. 29) ECHO 1NZ–FE All 50–State 23 (p. 30–31) 1MZ–FE All 50–State 16 (p. 22) 2AZ–FE All 50–State 12 (p. 18) 2UZ–FE All 50–State 24 (p. 32–33) 1ZZ–FE All 50–State 22 (p. 29) Highlander Land Cruiser 2003 Matrix 2ZZ–GE All 50–State 21 (p. 27–28) MR2 1ZZ–FE All 50–State 13 (p. 19) Prius 1NZ–FXE All 50–State 15 (p. 21) RAV4 1AZ–FE All 50–State 25 (p. 34) Sequoia 2UZ–FE All 50–State 24 (p. 32–33) Sienna 1MZ–FE All 50–State 16 (p. 22) Solara Tacoma Tundra 4Runner 2004 17 (p. (p 23) 2AZ–FE All 50–State 17 (p. 23) 1MZ–FE All 50–State 20 (p. 26) ALL All 50–State 16 (p. 22) 2UZ–FE All 50–State 24 (p. 32–33) 5VZ–FE All 50–State 16 (p. 22) 1GR–FE All 50–State 12 (p. 18) 2UZ–FE All 50–State 26 (p. 35–36) Corolla 1ZZ–FE All 50–State 27 (p. 37–38) ECHO 1NZ–FE All 50–State 23 (p. 30–31) 2WD 50–State 27 (p. 37–38) 4WD 50–State 28 (p. 39–40) 2ZZ–GE All 50–State 29 (41–42) Matrix 1ZZ FE 1ZZ–FE Sienna 3MZ–FE All 50–State 30 (p. 43) Scion xA 1NZ–FE All 50–State 23 (p. 30–31) Scion xB 1NZ–FE All 50–State 23 (p. 30–31) Page 9 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts December 17, 2003 CHART 1: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 1 second Time $32 Time to change from Rich (≥0.55 V) to Lean (≥0.4 V) N/A Second Between 0 and 1 second If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 10 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 2: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.35 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.35 V) to Rich (≥0.55 V) N/A Second Between 0 and 1.1 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≥0.35 V) N/A Second Between 0 and 1.1 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 11 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 3: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. CHART 4: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 12 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 5: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 1.1 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 1.1 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. CHART 6: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.55 V Time $08 The maximum voltage during O2S monitoring N/A V Between 1 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 13 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 7: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 14 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 8: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.35 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.35 V) to Rich (≥0.55 V) N/A Second Between 0 and 1 second Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.35 V) N/A Second Between 0 and 1 second If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. CHART 9: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.5 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 15 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 10: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 1.1 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 1.1 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.5 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 16 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 11: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.42 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.48 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.42 V) to Rich (≥0.48 V) N/A Second Between 0 and 0.4 seconds Time $32 Time to change from Rich (≥0.48 V) to Lean (≤0.42 V) N/A Second Between 0 and 0.4 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Page 17 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 12: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≤0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 18 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 13: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 1 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 1 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.5 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 19 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 14: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.5 V Multiply 0.3906 % Between 0 and 90% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 20 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 15: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.42 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.48 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.42 V) to Rich (≥0.48 V) N/A Second Between 0 and 0.4 seconds Time $32 Time to change from Rich (≥0.48 V) to Lean (≤0.42 V) N/A Second Between 0 and 0.4 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.5 V Multiply 0.3906 % Between 0 and 80% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 10 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 21 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 16: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.5 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 22 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 17: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 55% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 23 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 18: Rear O2S (Bank 1 Sensor 2) Voltage Monitor Related DTCs: P0136 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.2 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 3) Deterioration Monitor Related DTCs: P0142 TEST ID Time $86 DESCRIPTION OF TEST DATA Average of the second impedance ratio between high– frequency and low–frequency CONVERSION FACTOR Multiply 0.0312 UNIT STANDARD VALUE OF TEST LIMIT % Between 0.7 and 1.35 If the average of the sensor impedance ratio is out of the standard value, the ECM interprets this as a malfunction. Page 24 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 19: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.5 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 95% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 25 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 20: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.5 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 80% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 26 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 21: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.8 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.8 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.4 V) time of one waveform cycle N/A Second Between 0 and 3.05 seconds Time $34 Average Rich (≥0.55 V) time of one waveform cycle N/A Second Between 0 and 3.05 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 27 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 21 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.4 V) time of one waveform cycle Average Rich (≤0.55 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.95 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.95 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 28 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 22: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.5 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 29 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 23: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.4 V) time of one waveform cycle N/A Second Between 0 and 4.5 seconds Time $34 Average Rich (≤0.55 V) time of one waveform cycle N/A Second Between 0 and 4.5 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 30 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 23 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.4 V) time of one waveform cycle Average Rich (≤0.55 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.9 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.9 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 31 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 24: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.4 V) time of one waveform cycle N/A Second Between 0 and 2.8 seconds Time $34 Average Rich (≥0.55 V) time of one waveform cycle N/A Second Between 0 and 2.8 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 32 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 24 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.4 V) time of one waveform cycle Average Rich (≤0.55 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.75 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.75 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 90% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 33 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 25: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.6 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 80% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 34 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 26: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.55 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.4 V) to Rich (≥0.55 V) N/A Second Between 0 and 0.9 seconds Time $32 Time to change from Rich (≥0.55 V) to Lean (≤0.4 V) N/A Second Between 0 and 0.9 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.4 V) time of one waveform cycle N/A Second Between 0 and 2.8 seconds Time $34 Average Rich (≥0.55 V) time of one waveform cycle N/A Second Between 0 and 2.8 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 35 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 26 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.4 V) time of one waveform cycle Average Rich (≤0.55 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.75 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.75 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 36 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 27: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.35 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.45 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.35 V) to Rich (≥0.45 V) N/A Second Between 0 and 0.6 seconds Time $32 Time to change from Rich (≥0.45 V) to Lean (≤0.35 V) N/A Second Between 0 and 0.6 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.35 V) time of one waveform cycle N/A Second Between 0 and 3 seconds Time $34 Average Rich (≥0.45 V) time of one waveform cycle N/A Second Between 0 and 3 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 37 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 27 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.35 V) time of one waveform cycle Average Rich (≤0.45 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.55 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.55 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 38 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 28: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Voltage Monitor Related DTCs: P0130, P0150, P2195, P2196, P2197 and P2198 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.35 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.45 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Response Monitor Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $31 Time to change from Lean (≤0.35 V) to Rich (≥0.45 V) N/A Second Between 0 and 0.6 seconds Time $32 Time to change from Rich (≥0.45 V) to Lean (≤0.35 V) N/A Second Between 0 and 0.6 seconds If the time required to change is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.35 V) time of one waveform cycle N/A Second Between 0 and 2 seconds Time $34 Average Rich (≥0.45 V) time of one waveform cycle N/A Second Between 0 and 2 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Page 39 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 28 (Continued): Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.35 V) time of one waveform cycle Average Rich (≤0.45 V) time of one waveform cycle CONVERSION FACTOR STANDARD VALUE OF TEST LIMIT UNIT N/A Between 0 and 0.5 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 0.5 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 40 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 29: Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Engine Idling Related DTCs: P0133 and P0153 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $33 Average Lean (≤0.4 V) time of one waveform cycle N/A Second Between 0 and 4 seconds Time $34 Average Rich (≥0.55 V) time of one waveform cycle N/A Second Between 0 and 4 seconds If the sum of Time $33 and Time $34 is out of the standard value, the ECM interprets this as a malfunction. Front O2S (Bank 1 Sensor 1 and Bank 2 Sensor 1) Frequency Monitor During Vehicle Running Related DTCs: P0133 and P0153 TEST ID Time $35 Time $36 DESCRIPTION OF TEST DATA Average Lean (≤0.4 V) time of one waveform cycle Average Rich (≥0.55 V) time of one waveform cycle CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT N/A Between 0 and 1.08 seconds Second (varies depending on feedback compensation factor) N/A Between 0 and 1.08 seconds Second (varies depending on feedback compensation factor) If the sum of Time $35 and Time $36 is out of the standard value, the ECM interprets this as a malfunction. Page 41 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 29 (Continued): Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.4 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 60% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 42 of 43 O2S TEST RESULTS (MODE 05) – SS002-03 O2S Failure Threshold Charts (Continued) December 17, 2003 CHART 30: Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Voltage Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $07 The minimum voltage during O2S monitoring N/A V Between 0 and 0.45 V Time $08 The maximum voltage during O2S monitoring N/A V Between 0.5 and 1.275 V If the sensor voltage is out of the standard value, the ECM interprets this as a malfunction. Rear O2S (Bank 1 Sensor 2 and Bank 2 Sensor 2) Element Monitor Related DTCs: P0136 and P0156 TEST ID DESCRIPTION OF TEST DATA CONVERSION FACTOR UNIT STANDARD VALUE OF TEST LIMIT Time $81 Percentage of monitoring time where Oxygen Sensor voltage is less than 0.05 V Multiply 0.3906 % Between 0 and 80% Time $84 Percentage of monitoring time where Oxygen Sensor voltage is 0.70 V or more Multiply 0.3906 % Between 20 and 100% Time $85 Maximum Rich (≥0.45 V) time Multiply 0.2621 Second Between 20 and 66.8 seconds If all the values (Time $81, Time $84 and Time $85) are out of the standard values, the ECM interprets this as a malfunction. Page 43 of 43 Technical Service BULLETIN March 1, 2004 Introduction Applicable Vehicles A/C COMPRESSOR INSTALLATION PROCEDURE Models: Applicable Models Use the following tip when installing an A/C compressor on the AZ or ZZ series engine to ensure proper belt alignment. Improper installation of the A/C compressor may result in abnormal belt noise or wear. S 1998 – Current model year Corolla vehicles. S 2000 – Current model year Celica vehicles. S 2000 – Current model year MR2 Spyder vehicles. S 2001 – Current model year Highlander vehicles equipped with 4 cylinder engine. S 2001 – Current model year RAV4 vehicles. S 2002 – Current model year Camry vehicles equipped with 4 cylinder engine. S 2002 – Current model year Solara vehicles equipped with 4 cylinder engine. S 2003 – Current model year Matrix vehicles. Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty – – – – Installation Procedure Proper Installation Improper Installation Belt Bolt NG OK Clearance A/C Compressor Toyota Supports ASE Certification Page 1 of 2 HEATING & AIR CONDITIONING AC003-04 Title: A/C COMPRESSOR INSTALLATION PROCEDURE – AC003-04 Installation Procedure (Continued) 1. AZ Series Engine: Install A/C Compressor March 1, 2004 4 Bolt 3 Bolt Push A. Loosely install the compressor (with the 3 bolts and nut or 4 bolts.) Push down on the rear side of the compressor and tighten the bolts/nut in the order shown. Torque: 24.5 NSm (250 kgfScm, 18 ftSlbf) 2 2. ZZ Series Engine: Install A/C Compressor Nut or Bolt 3 Bolt 1 Bolt Push A. Loosely install the compressor (with the 2 bolts and nut or 3 bolts). Push down on the rear side of the compressor and tighten the bolts/nut in the order shown. Torque: 29 NSm (295 kgfScm, 21 ftSlbf) 2 Page 2 of 2 Nut or Bolt 1 Bolt April 28, 2004 Applicable Avalon, Camry, Sienna & Solara Introduction Applicable Vehicles Models: Some vehicles equipped with 1MZ–FE (V6) engines without VVTi may exhibit a rough idle and/or a M.I.L. “ON” condition with a diagnostic trouble code or codes for misfire caused by an improperly operating ignition coil assembly. Production changes have been implemented to prevent this condition from occuring. S 2001 model year Japan built Camry vehicles equipped with 1MZ–FE engines (V6). S 1998–2001 model year North American built Camry vehicles equipped with 1MZ–FE engines (V6) S 1998 – 1999 model year Avalon vehicles. S 1998 – 2000 model year Sienna vehicles. S 1999 – 2002 model year Solara vehicles equipped with 1MZ–FE engines produced BEFORE the Production Change Effective VIN shown below. Production Change Information Warranty Information MODEL ENGINE PRODUCTION CHANGE EFFECTIVE VIN Solara 1MZ–FE 2T1CF2#P*2C578710 OP CODE MODEL DESCRIPTION TIME OFP T1 T2 191011 Avalon R & R Ignition Coil (one coil) 0.2 90080–19012 02 73 191011 Camry Solara Sienna R & R Ignition Coil (one coil) 03 0.3 90080 19012 90080–19012 02 73 Applicable Warranty*: This repair is covered under the Toyota Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. For California specification vehicles registered and operated in California, Maine, Massachusetts or Vermont, this repair is covered under the California Emissions Warranty, which is in effect for 36 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date. * Warranty application is limited to correction of a problem based upon a customer’s specific complaint. Toyota Supports ASE Certification Page 1 of 3 ENGINE Technical Service BULLETIN M.I.L. ON" 1MZ-FE ENGINE MISFIRE DTC P0300, P0301, P0302, P0303, P0304, P0305 OR P0306 EG008-04 Title: M.I.L. “ON” 1MZ–FE ENGINE MISFIRE DTC P0300 – P0306 – EG008-04 Parts Information Required SSTs April 28, 2004 PREVIOUS PART NUMBER CURRENT PART NUMBER PART NAME QTY 90080–19012 Same Ignition Coil Assembly 1 SPECIAL SERVICE TOOLS (SSTs) PART NUMBER QUANTITY 01001271 1 01002593-005 1 Toyota Diagnostic Tester Kit* 12 Megabyte Diagnostic Tester Program Card with version 10.2a Software (or later)* * Essential SSTs. NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Required Tools & Material Repair Procedure TOOLS & MATERIAL QUANTITY Digital Volt Ohmmeter (DVOM) 1 1. Confirm if vehicle is currently misfiring, running rough or hesitating. If YES – Go to Step 2. If NO – Review Freeze Frame Data and attempt to operate vehicle under similar driving conditions – see notes below for information that makes it more likely to duplicate misfire. NOTE: The following activities will turn off misfire detection: S Changing engine RPM greater than 150 RPM. S Changing throttle position quickly. Misfire duplication can be duplicated most readily when the engine speed and throttle angle are held nearly constant for at least 2 minutes. NOTE: When misfire monitor is active, ignition value will change on Data List. When pending misfire DTC is set, “MISFIRE RPM” and “MISFIRE LOAD” will show values. Page 2 of 3 A B IGNITION 41 CYL #1 0% CYL #2 0% CYL #3 0% CYL #4 Above 50% CYL #5 0% CYL #6 0% MISFIRE RPM 0rpm MISFIRE LOAD 0.00g/rev # CODES 1 CHECK MODE OFF MISFIRE TEST COMPL IGNITION 205 CYL #1 0% CYL #2 0% CYL #3 0% CYL #4 Above 50% CYL #5 0% CYL #6 0% MISFIRE RPM 0rpm MISFIRE LOAD 0.00g/rev # CODES 1 CHECK MODE OFF MISFIRE TEST COMPL Values Will Change From Zero M.I.L. “ON” 1MZ–FE ENGINE MISFIRE DTC P0300 – P0306 – EG008-04 Repair Procedure (Continued) April 28, 2004 2. Confirm if misfire is currently occurring on cylinder(s) identified by DTC(s) using the Diagnostic Tester while engine is idling (see below). Examining Data List For Misfire Percent A B FUNCTION SELECT FOR NORTH AMERICA 1: OBD/MOBD 2: ENHANCED OBD 3: CARB OBD II 4: BREAK–OUT BOX 5: NVH 6: AUTOPROBE 7: 02 RPM CHECK 8: SNAPSHOT REVIEW 9: SETUP 0: GAS ANALYSIS NOTICE ENHANCED OBDII COVERS VEHICLES THROUGH 2004MY. EXCEPT SEQUOIA, TUNDRA, TACOMA. FOR OTHER VEHICLES SELECT 2004 NEW MODEL OR USE CARB OBDII PRESS [ENTER] D SELECT DATA ALL USER DATA EXTEND DATA MISFIRE ATM 02 SENSOR FUEL SYS CATALYTIC EVAP C DIAGNOSTIC MENU ENGINE 1: DATA LIST 2: DTC INFO 3: ACTIVE TEST 4: SNAPSHOT 5: SYSTEM CHECK 6: RESET MEMORY 7: MONITOR STATUS 8: CHECK MODE E IGNITION 41 CYL #1 0% CYL #2 0% CYL #3 0% CYL #4 Above 50% CYL #5 0% CYL #6 0% MISFIRE RPM 0rpm MISFIRE LOAD 0.00g/rev # CODES 1 CHECK MODE OFF MISFIRE TEST COMPL Misfire on #4 Cylinder Is the cylinder(s) identified by the DTC(s) misfiring? If YES – Go to Step 3. If NO – Follow normal diagnostics for applicable DTC in Technical Information System (TIS) in applicable Repair Manual: Diagnostics: SFI: P030#. 3. Swap suspect ignition coil(s) from cylinder that is misfiring to cylinder that is not misfiring. 4. Using Diagnostic Tester, confirm that misfire is now occurring in cylinder that has suspect ignition coil(s). Has misfire followed swapped ignition coil(s)? If YES – Replace ignition coil(s) and go to Step 5. If NO – Follow normal diagnostics in Technical Information System (TIS) for applicable Repair Manual: Diagnostics: SFI: P030#. 5. Confirm misfire has been eliminated (0% at all times) using Diagnostic Tester while engine is idling. NOTE: If misfire percent is any value other than 0% at any time, then that cylinder is misfiring. Page 3 of 3 Technical Service BULLETIN Models: All Models May 18, 2004 Introduction Correction pages are available for the service publications listed below. This bulletin summarizes service publication content changes that have been released between February 2003 and March 2004. These changes have already been implemented in the Toyota Technical Information System (TIS). For the most accurate service information content, technicians are strongly encouraged to refer to TIS (http://tis.toyota.com ). Internet access is also available to Toyota service information content by subscription (http://techinfo.toyota.com ). NOTE: Inventory quantities of printed correction pages are limited, and part numbers are obsolete when supplies are exhausted. When ordering a technical publication (i.e., Repair Manual, Electrical Wiring Diagram) from the MDC, any correction page(s) associated with that particular publication which were published at the time of purchase will automatically be included with your order. Parts Information Correction pages may be ordered from the Materials Distribution Center (MDC) through Dealer Daily or by calling the MDC at 1–800–622–2033 using the corresponding part numbers from the following table. Publication Number Page(s) Part Number 4Runner 2002 4Runner . . . . . . RM887–U2 . . . 2003 4Runner . . . . . . RM1034–U . . . . . . . . . . . . . . . . . . . . . . . RM1001–U1 . . ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM1001–U2 . . ................................... ................................... ................................... ................................... BE–18, BE–19 . . . . . . . . 00400–RM887–3043B 14–31, 14–70, 14–85 . . . . 00400–RM103–2174 02–32 to 02–34 . . . . . . . . . 00400–RM100–3110 05–816, 05–817, . . . . . . 00400–RM100–3162 05–817–1, 05–817–2 . . . . . . . . . . . . . . . . . . . . . ↓ 03–46, 05–449 . . . . . . . . . 00400–RM100–3194 11–21–1 to 11–21–4 . . . 00400–RM100–2172B 27–15, 27–16 . . . . . . . . . 00400–RM100–3025B 73–23, 73–26 . . . . . . . . . 00400–RM100–3103B 30–38 . . . . . . . . . . . . . . . 00400–RM100–3110B 27–7, 27–30, 27–35 . . . 00400–RM100–3239B Avalon 2002 Avalon . . . . . . . . RM872–U2 . . . 2003 Avalon . . . . . . . . EWD487–U . . . . . . . . . . . . . . . . . . . . . . . RM953–U2 . . . ................................... ................................... BE–23, BE–24 . . . . . . . . 00400–RM872–3080B 209 . . . . . . . . . . . . . . . . . . . 00400–EWD48–3183 BE–4 to BE–6 . . . . . . . . 00400–RM953–2164B BE–102 to BE–105 . . . . 00400–RM953–2196B BE–23, BE–24 . . . . . . . . 00400–RM953–3088B Toyota Supports ASE Certification Page 1 of 5 PRODUCT GENERAL INFORMATION REPAIR MANUAL CORRECTIONS INDEX PG003-04 Title: REPAIR MANUAL CORRECTIONS INDEX – PG003-04 Publication Number May 18, 2004 Page(s) Part Number Camry 1997 Camry . . . . . . . . RM503–U2 . . . 2000 Camry . . . . . . . . RM742–U2 . . . 2002 Camry . . . . . . . . EWD461–U . . . ................................... . . . . . . . . . . . . . . . . . . . . RM881–U1 . . . ................................... . . . . . . . . . . . . . . . . . . . . RM881–U2 . . . ................................... ................................... 2003 Camry . . . . . . . . RM972–U1 . . . ................................... . . . . . . . . . . . . . . . . . . . . RM972–U2 . . . ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM1026–U . . . Celica 2004 Celica . . . . . . . . . RM1066–U1 . . DI–380 . . . . . . . . . . . . . . . . 00400–RM106–3307 Corolla ECHO Highlander Land Cruiser Page 2 of 5 2003 Corolla . . . . . . . . RM938–U1 . . . ................................... ................................... ................................... ................................... BE–69 . . . . . . . . . . . . . . . 00400–RM503–2218B BE–70 . . . . . . . . . . . . . . . 00400–RM742–2221B 38, 78, 289, . . . . . . . . . . . 00400–EWD46–2181 Overall M:5 (cont’d) . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–894, 05–895, . . . . . . 00400–RM881–3158 05–895–1, 05–895–2 . . . . . . . . . . . . . . . . . . . . . ↓ 12–10, 12–20 . . . . . . . . . 00400–RM881–3086B 14–57 . . . . . . . . . . . . . . . 00400–RM881–3142B 33–3, 33–7, 33–14 . . . . 00400–RM881–3245B 05–1008, 05–1009, . . . . 00400–RM972–3160 05–1009–1, 05–1009–2 . . . . . . . . . . . . . . . . . . . ↓ 73–8 . . . . . . . . . . . . . . . . . 00400–RM972–2183B 12–9, 12–19 . . . . . . . . . . 00400–RM972–3087B 14–54 . . . . . . . . . . . . . . . 00400–RM972–3141B 33–3, 33–7, 33–14 . . . . 00400–RM972–3246B 73–1, 73–4 . . . . . . . . . . . . 00400–RM102–3101 05–484 to 05–487 . . . . . . 00400–RM938–2160 05–421, 05–422, . . . . . . 00400–RM938–3155 05–422–1, 05–422–2 . . . . . . . . . . . . . . . . . . . . . ↓ 05–40 to 05–42, . . . . . . . 00400–RM938–3236 05–112, 05–113 . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 2002 ECHO . . . . . . . . RM884–U . . . . DI–108 . . . . . . . . . . . . . . . . 00400–RM884–3203 2003 ECHO . . . . . . . . RM984–U . . . . DI–154 . . . . . . . . . . . . . . . . 00400–RM984–3204 2002 Highlander . . . . RM918–U1 . . . ................................... ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM918–U2 . . . 2003 Highlander . . . . RM987–U1 . . . ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM987–U2 . . . ................................... 05–943, 05–962–1 . . . . 00400–RM918–3108B 05–710, 05–711, . . . . . . 00400–RM918–3156 05–711–1, 05–711–2 . . . . . . . . . . . . . . . . . . . . . ↓ 03–47 . . . . . . . . . . . . . . . . 00400–RM918–3232 32–24, 32–28 . . . . . . . . . 00400–RM918–3232B 14–56 . . . . . . . . . . . . . . . 00400–RM918–3144B 05–1028, 05–1047–1 . . . 00400–RM100–3109 05–788, 05–789, . . . . . . 00400–RM987–3153 05–789–1, 05–789–2 . . . . . . . . . . . . . . . . . . . . . ↓ 03–47 . . . . . . . . . . . . . . . . 00400–RM987–3233 73–11 . . . . . . . . . . . . . . . . 00400–RM987–2184B 14–51 . . . . . . . . . . . . . . . 00400–RM881–3143B 1999 Land Cruiser . . . RM661–U2 . . . BE–28, BE–29 . . . . . . . . 00400–RM661–3057B 2002 Land Cruiser . . . RM893–U2 . . . BE–28, BE–29 . . . . . . . . 00400–RM722–3060B REPAIR MANUAL CORRECTIONS INDEX – PG003-04 Publication Land Cruiser (Continued) Matrix Number 2003 Land Cruiser . . . EWD510–U . . . ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM966–U1 . . . . . . . . . . . . . . . . . . . . . . . RM966–U2 . . . ................................... May 18, 2004 Page(s) Part Number 71, 84, 85, 96, 97, . . . . . 00400–EWD51–2195 244, 245, 383, 387, . . . . . . . . . . . . . . . . . . . . . . ↓ 388, 396, Overall M:24 . . . . . . . . . . . . . . . . . . . . ↓ SS–23 . . . . . . . . . . . . . . . . 00400–RM966–3195 BE–95 . . . . . . . . . . . . . . . 00400–RM966–2185B BE–34, BE–35 . . . . . . . . 00400–RM966–3061B 2003 Matrix . . . . . . . . . . . RM940–U1 . . . . ...................................... ...................................... ...................................... . . . . . . . . . . . . . . . . . . . . . . RM940–U2 . . . . 05–710, 05–711, . . . 00400–RM940–3154 05–711–1, 05–711–2 . . . . . . . . . . . . . . . . . . ↓ 05–89, 05–95, . . . . . . 00400–RM940–3275 05–241, 05–247 . . . . . . . . . . . . . . . . . . . . . . ↓ 65–7 . . . . . . . . . . . . . . 00400–RM940–2205B MR2 Spyder 2001 MR2 Spyder . . . EWD424–U . . . . . . . . . . . . . . . . . . . . . . . RM801–U . . . . ................................... 2002 MR2 Spyder . . . RM900–U . . . . ................................... 2003 MR2 Spyder . . . RM967–U1 . . . ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM967–U2 . . . 61, Overall M:2 . . . . . . . . 00400–EWD42–2214 DI–180 to DI–188, . . . . . . 00400–RM801–2192 DI–188–1, DI–188–2 . . . . . . . . . . . . . . . . . . . . . ↓ BR–17 . . . . . . . . . . . . . . . . . 00400–RM900–1143 DI–189 . . . . . . . . . . . . . . . . 00400–RM900–2190 DI–245 . . . . . . . . . . . . . . . . 00400–RM967–2189 SS–35 . . . . . . . . . . . . . . . . 00400–RM967–3006 DI–121, DI–128, . . . . . . . 00400–RM967–3278 DI–134, DI–156 . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–3, SA–5, SA–7 . . . . 00400–RM967–3006B Prius 2001 Prius . . . . . . . . . . RM778–U1 . . . 2002 Prius . . . . . . . . . . RM883–U1 . . . ................................... ................................... ................................... 2003 Prius . . . . . . . . . . RM957–U1 . . . ................................... ................................... ................................... 2004 Prius . . . . . . . . . . EWD555–U . . . ................................... ................................... DI–671 . . . . . . . . . . . . . . . 00400–RM778–2095R DI–762, 766 to 769, . . . 00400–RM883–2224 774, 777 to 780, 782, . . . . . . . . . . . . . . . . . . . . ↓ 785 to 792, 794, 796 . . . . . . . . . . . . . . . . . . . . . ↓ DI–337 to DI–344 . . . . . . 00400–RM883–3241 DI–762, 766 to 769, . . . . 00400–RM957–2223 774, 777 to 780, 782, . . . . . . . . . . . . . . . . . . . . . ↓ 785 to 792, 794, 796 . . . . . . . . . . . . . . . . . . . . . ↓ DI–337 to DI–344 . . . . . . 00400–RM957–3242 20, 22, 23, 194, . . . . . . . . 00400–EWD55–3296 293, 297, 306, 343, . . . . . . . . . . . . . . . . . . . . . . ↓ Overall 4–1, 11–5 . . . . . . . . . . . . . . . . . . . . . . . . ↓ RAV4 2002 RAV4 . . . . . . . . . RM891–U1 . . . DI–18 . . . . . . . . . . . . . . . . . 00400–RM891–3091 . . . . . . . . . . . . . . . . . . . . RM891–U2 . . . BR–21 . . . . . . . . . . . . . . . 00400–RM891–1142B Sequoia 2002 Sequoia . . . . . . . RM886–U1 . . . . . . . . . . . . . . . . . . . . . . . RM886–U2 . . . 2003 Sequoia . . . . . . . EWD495–U . . . ................................... . . . . . . . . . . . . . . . . . . . . RM959–U1 . . . ................................... IN–17 . . . . . . . . . . . . . . . . . 00400–RM886–3309 BE–54 . . . . . . . . . . . . . . . 00400–RM886–3096B 37, 246, Overall M:24 . . . 00400–EWD49–2213 199, Overall M:15–4 . . . . . . 00400–EWD49–5U PP–55 . . . . . . . . . . . . . . . . 00400–RM959–2125 DI–605 . . . . . . . . . . . . . . . . 00400–RM959–2179 Page 3 of 5 REPAIR MANUAL CORRECTIONS INDEX – PG003-04 Publication Number May 18, 2004 Page(s) Part Number Sequoia (Continued) 2003 Sequoia . . . . . . . RM959–U1 . . . ................................... ................................... ................................... ................................... ................................... ................................... ................................... ................................... ................................... ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM959–U2 . . . ................................... ................................... ................................... ................................... 2004 Sequoia . . . . . . . EWD541–U . . . . . . . . . . . . . . . . . . . . . . . RM1089–U1 . . ................................... ................................... DI–600, DI–602 to . . . . . 00400–RM959–2204 DI–605, DI–608 to DI–610 . . . . . . . . . . . . . . . . . ↓ DI–308, DI–328 . . . . . . . . 00400–RM959–2206 PP–52 . . . . . . . . . . . . . . . . 00400–RM959–3137 DI–329 . . . . . . . . . . . . . . . . 00400–RM959–3179 DI–128, DI–129, . . . . . . . 00400–RM959–3271 DI–135, DI–136, DI–142, . . . . . . . . . . . . . . . . . ↓ DI–143, DI–163, DI–164 . . . . . . . . . . . . . . . . . . ↓ PP–35 . . . . . . . . . . . . . . . . 00400–RM959–3228 SS–38 . . . . . . . . . . . . . . . . 00400–RM959–3260 IN–17 . . . . . . . . . . . . . . . . . 00400–RM959–3310 DI–300, DI–304, . . . . . . . . 00400–RM959–3311 DI–404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ SA–98 . . . . . . . . . . . . . . . 00400–RM959–2125B BE–140 . . . . . . . . . . . . . . 00400–RM959–2179B SR–12, BE–24 . . . . . . . . 00400–RM959–2206B BE–58 . . . . . . . . . . . . . . . 00400–RM959–3094B SA–90 . . . . . . . . . . . . . . . 00400–RM959–3137B 199, Overall M:15–4 . . . . 00400–EWD54–3214 IN–17 . . . . . . . . . . . . . . . . . 00400–RM108–3312 DI–446, DI–450, . . . . . . . 00400–RM108–3313 DI–550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Sienna 2002 Sienna . . . . . . . . RM871–U2 . . . ................................... 2003 Sienna . . . . . . . . EWD490–U . . . . . . . . . . . . . . . . . . . . . . . RM954–U2 . . . ................................... 2004 Sienna . . . . . . . . EWD524–U . . . ................................... . . . . . . . . . . . . . . . . . . . . RM1025–U1 . . ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM1025–U2 . . ................................... ................................... ................................... ................................... BE–23, BE–24 . . . . . . . . 00400–RM871–3081B SR–3 . . . . . . . . . . . . . . . . 00400–RM871–3132B 193 . . . . . . . . . . . . . . . . . . . 00400–EWD49–3208 SR–3 . . . . . . . . . . . . . . . . 00400–RM954–3133B BE–23, BE–24 . . . . . . . . 00400–RM954–3082B 96, 97, 126, . . . . . . . . . . . 00400–EWD52–3184 127, Overall M:1 . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–304, 05–355, . . . . . . 00400–RM102–3126 05–359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 05–865, 05–866, . . . . . . 00400–RM102–3163 05–866–1, 05–866–2 . . . . . . . . . . . . . . . . . . . . . ↓ 73–23, 73–26 . . . . . . . . . 00400–RM102–3102B 14–1 . . . . . . . . . . . . . . . . . 00400–RM102–3134B 28–2, 28–3, 28–4 . . . . . 00400–RM102–3135B 82–3 to 82–6, . . . . . . . . 00400–RM102–3186B 82–6–1, 82–6–2 . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Solara 2003 Solara . . . . . . . . RM955–U1 . . . DI–287 . . . . . . . . . . . . . . . . 00400–RM955–3219 2004 Solara . . . . . . . . EWD554–U . . . 168 to 170, . . . . . . . . . . 00400–EWD554–3294 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall M:15–1 . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ Page 4 of 5 REPAIR MANUAL CORRECTIONS INDEX – PG003-04 Publication Tacoma Tundra Number May 18, 2004 Page(s) Part Number 2002 Tacoma . . . . . . . RM921–U2 . . . BE–40 . . . . . . . . . . . . . . . 00400–RM921–3084B . . . . . . . . . . . . . . . . . . . . RM921–U1 . . . DI–323 . . . . . . . . . . . . . . . . 00400–RM921–3218 2003 Tacoma . . . . . . . RM1002–U2 . . BE–40 . . . . . . . . . . . . . . . 00400–RM100–3085B 2002 Tundra . . . . . . . . RM885–U2 . . . 2003 Tundra . . . . . . . . EWD491–U . . . ................................... ................................... ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM956–U1 . . . ................................... ................................... . . . . . . . . . . . . . . . . . . . . RM956–U2 . . . 2004 Tundra . . . . . . . . EWD567–U . . . ................................... ................................... BE–52 to BE–56 . . . . . . 00400–RM885–3105B 139, 240, . . . . . . . . . . . . 00400–EWD49–12136 Overall M:30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 31, 33, 235, 261, . . . . . . 00400–EWD49–2216 Overall M:29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ 176, Overall M:18–5 . . . . 00400–EWD49–3210 SS–79 . . . . . . . . . . . . . . . . 00400–RM956–3258 DI–115, DI–117, . . . . . . . 00400–RM956–3282 DI–316, DI–318 . . . . . . . . . . . . . . . . . . . . . . . . . . ↓ BE–57 to BE–60 . . . . . . 00400–RM956–3106B 230, 446, . . . . . . . . . . . . . 00400–EWD56–3209 Overall M:19–5, M:49–4 . . . . . . . . . . . . . . . . . . . ↓ 21, 94, 210, 515 . . . . . . . 00400–EWD56–3298 Page 5 of 5 BR–1 BRAKE – BRAKE SYSTEM BRAKE SYSTEM BR0A9–01 PRECAUTION 1. 2. 3. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. Author: Date: 2024 BR–2 BRAKE – TROUBLESHOOTING TROUBLESHOOTING BR0AA–03 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom CAUSE PAGE 1. Fluid leaks for brake system 2. Air in brake system 3. Piston seals (Worn or damaged) Low pedal or spongy pedal 4. Rear brake shoe clearance (Out of adjustment) 5. Master cylinder (Faulty) 6. Booster push rod (Out of adjustment) 1. 2. 3. 4. 5. Brake pedal freeplay (Minimal) Parking brake lever travel (Out of adjustment) Parking brake wire (Sticking) Rear brake shoe clearance (Out of adjustment) Pad or lining (Cracked or distorted) 6. Piston (Stuck) Brake drag 7. Piston (Frozen) 8. Anchor, return or tension spring (Faulty) 9. Booster push rod (Out of adjustment) 10.Vacuum leaks for booster system 11.Master cylinder (Faulty) 1. Piston (Stuck) 3. Piston (Frozen) 4. Disc (Scored) 5. Pad or lining (Cracked or distorted) Author: BR–5 BR–8 BR–35 BR–21 BR–31 BR–36 BR–24 BR–31 BR–39 BR–24 BR–31 BR–39 BR–31 BR–45 BR–20 BR–18 BR–9 BR–24 BR–31 BR–39 BR–21 BR–31 BR–36 BR–24 BR–31 BR–39 BR–24 BR–39 BR–21 BR–31 BR–36 2. Pad or lining (Oily) Brake pull DI–536 BR–4 BR–24 BR–31 BR–39 BR–35 BR–9 BR–20 Date: 2025 BR–3 BRAKE – TROUBLESHOOTING 1. Fluid leaks for brake system 2. Air in brake system 3. Pad or lining (Worn) 4. Pad or lining (Cracked or distorted) Hard pedal but brake inefficient 5. Rear brake shoe clearance (Out of adjustment) 6. Pad or lining (Oily) 7. Pad or lining (Glazed) 8. Disc (Scored) 9. Booster push rod (Out of adjustment) 10.Vacuum leaks for booster system 1. Pad or lining (Cracked or distorted) BR–21 BR–31 BR–36 BR–24 BR–39 BR–24 BR–39 BR–21 BR–36 BR–24 BR–39 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–31 BR–45 BR–21 BR–36 BR–31 BR–45 2. Installation bolt (Loose) 3. Disc (Scored) 4. Pad support plate (Loose) 5. Sliding pin (Worn) Noise from brakes 6. Pad or lining (Dirty) 7. Pad or lining (Glazed) 8. Anchor, return or tension spring (Faulty) 9. Anti–squeal shim (Damaged) 10.Shoe hold–down spring (Damaged) Author: DI–536 BR–4 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–35 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–24 BR–39 BR–20 BR–18 Date: 2026 BR–4 BRAKE – BRAKE FLUID BRAKE FLUID BR0AB–03 BLEEDING F05595 F05596 HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid level in the reservoir after bleeding each wheel. Add fluid, if necessary. Fluid: SAEJ1703 or FMVSS No.116 DOT 3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the 2 brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) (d) Block off the outlet plugs with your fingers, and release the brake pedal. Repeat (b) and (c) 3 or 4 times. F05597 3. R00252 CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the other end of the tube in a half–full container of brake fluid. NOTICE: Bleed air of the rear brake first. If front brake is bled first, rear brake air cannot be bled. 4. BLEED BRAKE LINE (a) Slowly depress the brake pedal several times. (b) While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. (c) Repeat this procedure until there are no more air bubbles in the fluid. Torque: (Bleeder plug) 8.3 N·m (85 kgf·cm, 74 in.·lbf) 5. REPEAT PROCEDURE FOR EACH WHEEL Author: Date: 2027 BR–5 BRAKE – BRAKE PEDAL BRAKE PEDAL Stop Light Switch BR0YH–01 ON–VEHICLE INSPECTION 1. 2. (a) (b) Push Rod (c) (d) (e) (f) (g) Pedal Height R00954 (h) (i) (j) (k) 3. (a) Pedal Freeplay R00935 (b) CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 152.0 – 162.0 mm (5.984 – 6.378 in.) IF NECESSARY, ADJUST PEDAL HEIGHT Disconnect the connector from the stop light switch. Loosen the stop light switch lock nut and remove the stop light switch. Loosen the push rod lock nut. Adjust the pedal height by turning the pedal push rod. Tighten the push rod lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Install the stop light switch and turn it until it lightly contacts the pedal stopper. Push in the brake pedal 5–15 mm (0.20–0.59 in.), turn the stop light switch to lock the nut in the position where the stop light goes off. Connect the connector to the stop light switch. After installation, push in the brake pedal 5–15 mm (0.20–0.59 in.), check that stop light lights up. Connect the connector to the stop light switch. After adjusting the pedal height, check the pedal freeplay. CHECK PEDAL FREEPLAY Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. Push in the pedal by hand until the resistance begins to be felt, then measure the distance. Pedal freeplay: 1 – 6 mm (0.04 – 0.24 in.) HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1 – 6 mm (0.04 – 0.24 in.) at the pedal. If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. Stop light switch clearance: 0.5 – 2.4 mm (0.020 – 0.094 in.) Author: Date: 2028 BR–6 BRAKE Pedal Reserve Distance – BRAKE PEDAL 4. (a) (b) CHECK PEDAL RESERVE DISTANCE Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 70 mm (2.76 in.) If the reserve distance is incorrect, troubleshoot the brake system. R00934 Author: Date: 2029 BR–7 BRAKE – BRAKE PEDAL BR0YI–01 COMPONENTS A/T: Lower Panel Insert Wave Washer No.1 Lower Panel Clevis Pin Brake Pedal Bracket Stop Light Switch Cruise Control ECU 13 (130, 9) Clip 5.0 (51, 44 in.·lbf)
Bushing Front Opening Cover 13 (130, 9) M/T: Return Spring 39 (400, 29)
Bushing Collar Pedal Pad Cushion Plate Pedal Pad Brake Pedal Brake Pedal Cowl Side Trim Inside Scuff Plate N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease F07004 Author: Date: 2030 BR–8 BRAKE – PARKING BRAKE LEVER PARKING BRAKE LEVER BR0AD–03 ON–VEHICLE INSPECTION W03254 Lock Nut Adjusting Nut W03255 1. CHECK THAT PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 5 – 8 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE LEVER TRAVEL HINT: Before adjusting the parking brake lever travel, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 2 on page BR–35 or step 1 on page BR–48. (a) Remove the console box. (b) Loosen the lock nut and adjust the adjusting nut until the lever travel is correct. (c) Tighten the lock nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (d) Install the console box. Author: Date: 2031 BR–9 BRAKE – BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER BR0AE–02 COMPONENTS w/o ABS Brake Booster Master Cylinder 15 (155, 11) w/ ABS (& TRAC) 2–way
Gasket 3–way 13 (130, 9) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19120 w/ TRAC Cap Strainer Reservoir Set Screw 1.7 (18, 16 in.·lbf) Straight Pin Reservoir Grommet Spring Spring Grommet No. 1 Piston No. 2 Piston Cylinder Body N·m (kgf·cm, ft·lbf) : Specified torque Lithium soap base glycol grease W03569 Author: Date: 2032 BR–10 BRAKE – BRAKE MASTER CYLINDER w/o ABS Cap Strainer Reservoir Reservoir Set Screw 1.7 (18, 16 in.·lbf) Snap Ring Grommet Grommet No. 2 Piston and Spring
Gasket No. 1 Piston and Spring Cylinder Body 10 (100, 7) Stopper Bolt Cap w/ ABS Strainer Reservoir Reservoir Set Screw 1.7 (18, 16 in.·lbf) Snap Ring Grommet Grommet No. 2 Piston and Spring Cylinder Body No. 1 Piston and Spring
Gasket 10 (100, 7) Stopper Bolt N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease Z19122 Author: Date: 2033 BR–11 BRAKE – BRAKE MASTER CYLINDER BR0AF–03 REMOVAL 1. SST W04697 R11405 DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. DISCONNECT BRAKE LINES (a) w/ ABS (& TRAC): Using SST, disconnect the 4 brake lines. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) (b) w/o ABS: Using SST, disconnect the 5 brake lines. SST 09023–00100 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 4. REMOVE MASTER CYLINDER Remove the 2 nuts, and pull out the 2 or 3–way, master cylinder and gasket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Author: Date: 2034 BR–12 BRAKE – BRAKE MASTER CYLINDER BR0AG–02 DISASSEMBLY 1. (a) (b) 2. 3. REMOVE RESERVOIR Remove the set screw and pull out the reservoir. Torque: 1.7 N·m (18 kgf·cm, 16 in.·lbf) Remove the cap and strainer from the reservoir. REMOVE 2 GROMMETS Except w/ TRAC: PLACE CYLINDER IN VISE 4. w/o TRAC: REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Soft Jows R11406 5. Soft Jows (a) R11407 w/o TRAC: REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. (b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle. NOTICE:
If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.
At the time of reassembly, please refer to the following item. Be careful not to damage the rubber lips on the pistons. (c) Place a rag and 2 wooden blocks on the work table, and lightly tap the cylinder flange against the block edges until the No. 2 piston drops out of the cylinder. HINT: Make sure that the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). A R12236 Author: Date: 2035 BR–13 BRAKE 6. (a) – BRAKE MASTER CYLINDER w/ TRAC: REMOVE 2 PISTONS AND SPRINGS Push in the piston with a screwdriver, and remove the 2 straight pins by turning over the cylinder body. HINT: Tape the screwdriver tip before use. (b) Remove the 2 pistons and springs by hand, pulling straight out, not at an angle. W03570 NOTICE:
If pulled out and installed at an angle, there is a possibility that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage the rubber lips on the pistons. HINT: At the time of reassembly, insert the pistons with elliptic hole facing vertically. W03590 Author: Date: 2036 BR–14 BRAKE – BRAKE MASTER CYLINDER BR0AH–01 INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. Author: Date: 2037 BR–15 BRAKE – BRAKE MASTER CYLINDER BR0AI–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–12). NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page BR–9). Author: Date: 2038 BR–16 BRAKE – BRAKE MASTER CYLINDER BR0AJ–02 INSTALLATION Installation is in the reverse order of removal (See page BR–11). HINT:
Before installation, adjust length of the brake booster push rod (See page BR–20).
After installation, fill the brake reservoir with brake fluid, bleed the brake system and check for leaks (See page BR–4).
Check and adjust brake pedal (See page BR–5). Author: Date: 2039 BR–17 BRAKE – BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY BR0AK–03 ON–VEHICLE INSPECTION 1. (a) (b) BR2237 GOOD NO GOOD 3rd 1st 2nd BR2238 OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. (a) AIR TIGHTNESS CHECK Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for 30 seconds, the booster is air tight. Author: Date: 2040 BR–18 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AL–03 COMPONENTS Brake Booster Master Cylinder w/ ABS (& TRAC) 15 (155, 11)
Gasket Pin
Gasket Clip 2–way 3–way 25 (260, 19) Clevis 13 (130, 9) 13 (130, 9) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Z19121 Author: Date: 2041 BR–19 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AM–03 REMOVAL 1. 5. 6. REMOVE AIR CLEANER COVER WITH AIR CLEANER HOSE REMOVE MASTER CYLINDER (See page BR–11) REMOVE CHARCOL CANISTER DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER REMOVE PEDAL RETURN SPRING REMOVE CLIP AND CLEVIS PIN 7. (a) (b) REMOVE BRAKE BOOSTER, GASKET AND CLEVIS Remove the 4 nuts and clevis. Pull out the brake booster and gasket. 2. 3. 4. F06431 Author: Date: 2042 BR–20 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AN–03 INSTALLATION 1. (a) (b) (c) (d) (e) (f) 2. (a) (b) SST Gasket (c) F03521 SST (d) (e) 3. 4. 5. R11347 6. 7. 8. 9. 10. INSTALL BRAKE BOOSTER Install the booster and a new gasket. Install the clevis to the operating rod. Install and torque the booster installation nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install the clevis, and torque the lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. Install the pedal return spring. ADJUST LENGTH OF BOOSTER PUSH ROD Install a new gasket on the master cylinder. Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. SST 09737–00010 Turn the SST upside down, and set it on the booster. SST 09737–00010 Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) Adjust the booster push rod length until the push rod lightly touches the pin head. INSTALL CHARCOAL CANISTER TO ORIGINAL POSITION INSTALL MASTER CYLINDER (See page BR–16) INSTALL AIR CLEANER COVER WITH AIR CLEANER HOSE CONNECT VACUUM HOSE TO BRAKE BOOSTER FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–4) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR–5) DO OPERATIONAL CHECK (See page BR–17) Author: Date: 2043 BR–21 BRAKE – FRONT BRAKE PAD FRONT BRAKE PAD BR0AO–03 COMPONENTS 5S–FE engine: 34 (350, 25) Anti–squeal Shim Inner Anti–squeal Shim Anti–squeal Spring Outer Pad Pad Support Plate Inner Pad 1MZ–FE engine: 34 (350, 25) Anti–squeal Shim Inner Anti–squeal Shim Pad Wear Indicator Plate Outer Pad Pad Support Plate Inner Pad F07224 F06983 N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F07225 Author: Date: 2044 BR–22 BRAKE – FRONT BRAKE PAD BR0AP–03 REPLACEMENT F07213 R02874 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace the pads if they are not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Remove the bolt and flexible hose from the bracket. (b) 5S–FE engine: Hold the sliding pin on the bottom and loosen the installation bolt, and remove the installation bolt. (c) 1MZ–FE engine: Remove the bottom side installation bolt. (d) Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose from the caliper. 4. 5S–FE engine: REMOVE 2 ANTI–SQUEAL SPRINGS 5. REMOVE 2 BRAKE PADS 6. REMOVE 4 ANTI–SQUEAL SHIMS 7. 1MZ–FE engine: REMOVE PAD WEAR INDICATOR PLATE 8. 1MZ–FE engine: REMOVE 2 PAD SUPPORT PLATES 9. 5S–FE engine: REMOVE 4 PAD SUPPORT PLATES NOTICE: The anti–squeal springs and support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 10. CHECK DISC THICKNESS AND RUNOUT (See page BR–28) 11. INSTALL 2 OR 4 PAD SUPPORT PLATES 12. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti–squeal shims and wear indicator plates must be replaced together with the pads. Author: Date: 2045 BR–23 BRAKE – FRONT BRAKE PAD (a) R00595 1MZ–FE engine: Install a pad wear indicator plate on the inner pad. (b) Apply disc brake grease to both sides of the inner anti– squeal shims (See page BR–21). (c) Install the 2 anti–squeal shims on each pad. (d) Install inner pad with the pad wear indicator plate facing upward. (e) Install inner pad. (f) Install outer pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. (g) 5S–FE engine: Install the 2 anti–squeal springs. 13. (a) (b) R02981 INSTALL CALIPER Draw out a small amount of brake fluid from the reservoir. Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper. (d) 5S–FE engine: Hold the sliding pin and torque the installation bolt. (e) 1MZ–FE engine: Install the installation bolt. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (f) Install the flexible hose and bolt to the bracket. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) 14. INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 15. DEPRESS BRAKE PEDAL SEVERAL TIMES 16. CHECK THAT FLUID LEVEL IS AT MAX LINE Author: Date: 2046 BR–24 BRAKE – FRONT BRAKE CALIPER FRONT BRAKE CALIPER BR0AQ–02 COMPONENTS 5S–FE engine: Caliper Torque Plate 29 (300, 21) 107 (1,090, 79) 34 (350, 25) Disc Bleeder Plug 8.3 (85, 74 in.·lbf) 29 (300, 21)
Gasket Sliding Pin
Dust Boot Piston Piston Seal Boot Set Ring Sliding Pin Pad Support Plate
Sliding Bushing
Dust Boot Anti–squeal Shim Anti–squeal Spring Outer Pad Inner Anti–squeal Shim Inner Pad N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease Disc brake grease F07212 Author: Date: 2047 BR–25 BRAKE – FRONT BRAKE CALIPER 1MZ–FE engine: Caliper 29 (300, 21) 107 (1,090, 79) Torque Plate 34 (350, 25) Disc Bleeder Plug 8.3 (85, 74 in.·lbf) 29 (300, 21)
Gasket Sliding pin
Sliding Bushing Piston
Dust Boot Set Ring Piston Seal Boot Sliding Pin Pad Support Plate
Dust Boot Pad Wear Indicator Plate Inner Pad Outer Pad Inner Anti–squeal Shim Anti–squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease Disc Brake grease F07226 Author: Date: 2048 BR–26 BRAKE – FRONT BRAKE CALIPER BR0AR–03 REMOVAL 1. 2. (a) R02840 REMOVE FRONT WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) HINT: At the time of installation, please refer to the following item. Install the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 3. REMOVE CALIPER (a) 5S–FE engine: Hold the sliding pin and loosen the 2 installation bolts, and remove the installation bolts. (b) 1MZ–FE engine: Remove the 2 installation bolts. Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) 4. 5S–FE engine: REMOVE 2 ANTI–SQUEAL SPRINGS 5. REMOVE 2 BRAKE PADS WITH ANTI–SQUEAL SHIMS 6. 1MZ–FE engine: REMOVE 2 PAD SUPPORT PLATES 7. 5S–FE engine: REMOVE 4 PAD SUPPORT PLATES Author: Date: 2049 BR–27 BRAKE – FRONT BRAKE CALIPER BR0AS–03 DISASSEMBLY 1. REMOVE SET RING AND CYLINDER BOOT Using a screwdriver, remove the set ring and cylinder boot from the caliper. R00121 2. (a) REMOVE PISTON Place a piece of cloth or similar, between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. R00122 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. R00123 R02877 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. NOTICE: At the time of reassembly, please refer to the following item. Insert the sliding pin with sliding bushing into the bottom side (5S–FE engine) or top side (1MZ–FE engine). (b) Using a screwdriver and hammer, tap out the 2 dust boots. HINT: At the time of reassembly, please refer to the following item. Use a 22 mm (5S–FE engine) or 24 mm (1MZ–FE engine) socket wrench and tap in 2 new dust boots into the torque plate. NOTICE: At the time of reassembly, please refer to the following item. Check that the metal plate portion of the dust boot fits snugly in the torque plate. Author: Date: 2050 BR–28 BRAKE – FRONT BRAKE CALIPER BR0AT–03 INSPECTION F06988 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine: 12.0 mm (0.472 in.) 1MZ–FE engine: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the minimum thickness or less, or if the pad has severe and uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) Replace the disc if the disc’s thickness is at the minimum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. R02878 R02879 3. MEASURE DISC RUNOUT Using a dial indicator, measure disc runout 10 mm (0.39 in.) away from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If the disc’s runout is the maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA–10). If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a ”On–Car” brake lathe. 4. (a) (b) R02880 (c) (d) (e) (f) IF NECESSARY, ADJUST DISC RUNOUT Remove the torque plate from the knuckle. Remove the hub nuts and the disc. Reinstall the disc in the position turned 1/5 from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Repeat (b) until the disc has been installed on the 3 remaining hub positions. If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. Install the torque plate and torque the mounting bolts. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) Author: Date: 2051 BR–29 BRAKE – FRONT BRAKE CALIPER BR0AU–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–27). NOTICE: Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR–24). Author: Date: 2052 BR–30 BRAKE – FRONT BRAKE CALIPER BR0AV–02 INSTALLATION Installation is in the reverse order of removal (See page BR–26). HINT:
After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4).
Check for leaks. Author: Date: 2053 BR–31 BRAKE – REAR DRUM BRAKE REAR DRUM BRAKE BR0AW–03 COMPONENTS Bleeder Plug Plug Adjuster 8.3 (85, 74 in.·lbf) 10 (100, 7) Wheel Cylinder Spring Boot Inspection Hole Plug
Cup
C–washer Parking Brake Lever Piston Automatic Adjusting Lever E–ring Pin Adjuster Rear Shoe Adjusting Lever Spring Front Shoe Anchor Spring Cup N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease High temperature grease Shoe Hold–down Spring W03258 Author: Date: 2054 BR–32 BRAKE – REAR DRUM BRAKE BR0AX–03 REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than the minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL BR1532 3. (a) R00285 REMOVE BRAKE DRUM Release the parking brake lever and remove the brake drum. HINT: If the brake drum cannot be removed easily, do the following steps. (b) Insert a bent wire or equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster. (c) Using a screwdriver, reduce the brake shoe adjustment by turning the adjuster. 4. (a) REMOVE FRONT SHOE Using SST, disconnect the return spring. SST 09703–30010 (b) Using SST, remove the shoe hold–down spring, 2 cups and pin. SST 09718–00010 Disconnect the anchor spring from the front shoe and remove the front shoe. Remove the anchor spring from the rear shoe. SST BR1534 (c) (d) SST BR1535 Author: Date: 2055 BR–33 BRAKE – REAR DRUM BRAKE 5. (a) SST R00248 Z03633 REMOVE REAR SHOE Using SST, remove the shoe hold–down spring, 2 cups and pin. SST 09718–00010 (b) Using a screwdriver, disconnect the parking brake cable from the anchor plate. (c) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe together with adjuster. NOTICE: Do not allow oil or grease on the rubbing face. 6. REMOVE ADJUSTER FROM REAR SHOE (a) Remove the adjusting lever spring. (b) Remove the adjuster together with the return spring. 7. REMOVE AUTOMATIC ADJUSTING LEVER AND PARKING BRAKE LEVER (a) Remove the E–ring. (b) Remove the automatic adjusting lever. (c) Remove the C–washer. (d) Remove the parking brake lever. 8. (a) SST (b) BR1540 9. (a) (b) (c) REMOVE WHEEL CYLINDER Using SST, disconnect the brake line. Use a container to catch the brake fluid. Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) SST 09751–36011 Remove the 2 bolts and the wheel cylinder. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) DISASSEMBLE WHEEL CYLINDER Remove the 2 boots. Remove the 2 pistons and springs. Remove the 2 piston cups. Author: Date: 2056 BR–34 BRAKE – REAR DRUM BRAKE INSPECTION BR1542 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Using a ruler, measure the shoe lining thickness. Standard thickness: 5.0 mm (0.197 in.) Minimum thickness: 1.0 mm (0.039 in.) If the thickness is less than the minimum, or shows signs of uneven wear, replace the brake shoes. HINT: If any of the brake shoes have to be replaced, replace all of the rear brake shoes in order to maintain even braking. BR0AY–03 3. MEASURE BRAKE DRUM INSIDE DIAMETER Using brake drum gauge or equivalent, measure the inside diameter of the drum. Standard inside diameter: 228.6 mm (9.000 in.) Maximum inside diameter: 230.6 mm (9.079 in.) If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. F06408 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. BR1543 Author: Date: 2057 BR–35 BRAKE – REAR DRUM BRAKE BR0AZ–02 INSTALLATION Installation is in the reverse order of removal (See page BR–32). NOTICE: Apply lithium soap base glycol grease and high temperature grease to the parts indicated by the arrows (See page BR–31). 1. AFTER INSTALLATION, FILL BRAKE RESERVOIR WITH BRAKE FLUID, BLEED BRAKE SYSTEM (See page BR–4) 2. CHECK FOR LEAKS 3. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM (a) Move the parking brake lever of the rear shoe back and forth. Check that the adjuster turns. If the adjuster does not turn, check for incorrect installation of the rear brake. (b) Adjust the adjuster length as short as possible. W01679 (c) (d) Align the adjusting hole on the brake drum and the largest hole on the axle carrier, install the brake drum. Pull the parking brake lever all the way up until a clicking sound can no longer be heard. BR1553 4. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the drum. (b) Measure the brake drum inside diameter and diameter between the brake shoes. Check that the difference between the diameters is the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 in.) If incorrect, check the parking brake system. F06423 Author: Date: 2058 BR–36 BRAKE – REAR BRAKE PAD REAR BRAKE PAD BR0B0–03 COMPONENTS Pad Support Plate Anti–squeal Shim Inner Anti–squeal Shim Inner Pad Outer Pad 29 (300, 21) 20 (200, 14) Pad Support Plate Anti–squeal Shim Inner Anti–squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque Disc brake grease F02610 Author: Date: 2059 BR–37 BRAKE – REAR BRAKE PAD BR0B1–03 REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) R00591 R00514 R10387 3. LIFT UP CALIPER (a) Remove the bolt and flexible hose from the bracket. (b) Remove the installation bolt from the torque plate. (c) Lift up the caliper and suspend it securely. HINT: Do not disconnect the flexible hose. 4. REMOVE 2 BRAKE PADS 5. REMOVE 4 ANTI–SQUEAL SHIMS 6. REMOVE 4 PAD SUPPORT PLATES NOTICE: The support plates can be used again provided that they have sufficient rebound, no deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. 7. CHECK DISC THICKNESS AND RUNOUT (See page BR–42) 8. INSTALL 4 PAD SUPPORT PLATES 9. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti–squeal shims must be replaced together with the pads. (a) Apply disc brake grease to both side of the inner anti– squeal shims (See page BR–36). (b) Install the 2 anti–squeal shims on each pad. (c) Install 2 pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 10. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper and torque the installation bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (d) Install the flexible hose and bolt to the bracket. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) Author: Date: 2060 BR–38 BRAKE 11. 12. 13. – REAR BRAKE PAD INSTALL REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DEPRESS BRAKE PEDAL SEVERAL TIMES CHECK THAT FLUID LEVEL IS AT MAX LINE Author: Date: 2061 BR–39 BRAKE – REAR BRAKE CALIPER REAR BRAKE CALIPER BR0B2–03 COMPONENTS 29 (300, 21) 20 (200, 14)
Gasket 29 (300, 21) 47 (475, 34) Caliper Torque Plate Disc Plug Bleeder Plug 8.3 (85, 74 in.·lbf) Dust Boot Main Pin Boot Piston Seal Piston Main Pin Boot Dust Boot 26 (270, 20) Set Ring Sliding Bushing Anti–squeal Shim Inner Anti–squeal Shim Pad Support Plate Inner Pad Outer Pad Inner Anti–squeal Shim Anti–squeal Shim N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Lithium soap base glycol grease Disc brake grease W03262 Author: Date: 2062 BR–40 BRAKE – REAR BRAKE CALIPER BR0B3–03 REMOVAL 1. 2. (a) W03263 REMOVE REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) DISCONNECT FLEXIBLE HOSE Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) HINT: At the time of installation, please refer to the following item. Insert the flexible hose lock securely in the lock hole in the caliper. (b) Use a container to catch the brake fluid as it drains out. 3. REMOVE CALIPER (a) Remove the installation bolt. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (b) Remove the caliper from the torque plate. 4. REMOVE 2 BRAKE PADS WITH 4 ANTI–SQUEAL SHIMS 5. REMOVE 4 PAD SUPPORT PLATES NOTICE: At the time of installation, please refer to the following item. There should be no oil or grease adhering to the friction surfaces of the pads or disc. 6. REMOVE MAIN PIN Loosen the main pin installation bolt and remove the main pin. Torque: 26 N·m (270 kgf·cm, 20 ft·lbf) W03264 Author: Date: 2063 BR–41 BRAKE – REAR BRAKE CALIPER BR0B4–02 DISASSEMBLY R00520 1. REMOVE SLIDING BUSHING 2. REMOVE 2 DUST BOOTS 3. REMOVE MAIN PIN BOOT NOTICE: Ensure that the boots are secured firmly to the bushing and caliper grooves. 4. REMOVE CYLINDER BOOT SET RING AND BOOT (See step 1 on page BR–27) 5. REMOVE PISTON (See step 2 on page BR–27) 6. REMOVE PISTON SEAL (See step 3 on page BR–27) Author: Date: 2064 BR–42 BRAKE – REAR BRAKE CALIPER BR0B5–02 INSPECTION 1. W03265 MEASURE PAD LINING THICKNESS (See step 1 on page BR–28) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) 2. MEASURE DISC THICKNESS (See step 2 on page BR–28) Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) 3. MEASURE DISC RUNOUT (See step 3 on page BR–28) Maximum disc runout: 0.15 mm (0.0059 in.) If the disc’s runout is maximum value or greater, check the bearing play in the axial direction and check the axle hub runout (See page SA–52). If the bearing play and axle hub runout are not abnormal, adjust the disc runout or grind it on a ”On–Car” brake lathe. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the 2 bolts and torque plate. (b) Remove the hub nuts and the disc. Reinstall the disc in the position turned 1/5 from its original position on the hub. Install and torque the hub nuts. Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.15 mm (0.0059 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.15 mm (0.0059 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Author: Date: 2065 BR–43 BRAKE – REAR BRAKE CALIPER BR0B6–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–41). NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR–24). Author: Date: 2066 BR–44 BRAKE – REAR BRAKE CALIPER BR0B7–02 INSTALLATION Installation is in the reverse order of removal (See page BR–40). HINT:
After installation, fill the brake reservoir with brake fluid and bleed the brake system (See page BR–4).
Check for leaks. Author: Date: 2067 BR–45 BRAKE – PARKING BRAKE PARKING BRAKE BR0B8–03 COMPONENTS Guide Plate Shoe Strut Adjuster Shim Spring Rear Disc Brake Assembly
C–washer Parking Brake Lever 47 (475, 34) Pin Rear Shoe Shoe Return Spring Pin Front Shoe Disc Adjuster Tension Spring Shoe Hold–down Spring Plug N·m (kgf·cm, ft·lbf) : Specified torque Shoe Hold–down Spring Cup
Non–reusable part High temperature grease W03275 Author: Date: 2068 BR–46 BRAKE – PARKING BRAKE BR0B9–03 DISASSEMBLY 1. 2. (a) (b) W03265 REMOVE REAR WHEEL Torque: 103 N·m (1.050 kgf·cm, 76 ft·lbf) REMOVE REAR DISC BRAKE ASSEMBLY Remove the 2 mounting bolts and remove the disc brake assembly. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Suspend the disc brake securely. Ensure that the hose is not stretched. 3. REMOVE DISC Release the parking brake lever and remove the disc. HINT: If the disc cannot be removed easily, turn the shoe adjuster until the wheel turns freely. R00309 4. REMOVE SHOE RETURN SPRINGS Using needle–nose pliers, remove the shoe return springs. 5. REMOVE FRONT SHOE ADJUSTER AND TENSION SPRING (a) Slide out the front shoe and remove the shoe adjuster. (b) Remove the shoe strut with the spring. (c) Remove the shoe hold–down spring cups, spring and pin. (d) Disconnect the tension spring and remove the front shoe. BR3948 6. (a) (b) (c) (d) REMOVE REAR SHOE Slide out the rear shoe. Remove the tension spring from the rear shoe. Remove the shoe hold–down spring cups, spring and pin. Using needle–nose pliers, disconnect the parking brake cable from the parking brake shoe lever. R00310 Author: Date: 2069 BR–47 BRAKE – PARKING BRAKE BR0BA–02 INSPECTION 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS (See step 2 on page BR–34) Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) 3. MEASURE DISC INSIDE DIAMETER (See step 3 on page BR–34) Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT (See step 4 on page BR–34) 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) Shim Clearance R00343 If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) – 6. (a) IF NECESSARY, REPLACE SHIM Using a screwdriver, remove the C–washer and shim. (b) (c) Install the correct size shim with a new C–washer. Remeasure the clearance. R00312 R00313 Author: Date: 2070 BR–48 BRAKE – PARKING BRAKE BR0BB–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–46). NOTICE: Apply high temperature grease to the parts indicated by the arrows (See page BR–45). 1. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the hole plug. (c) Contract (d) (e) 2. (a) (b) Expand BR0823 (c) 3. Turn the adjuster and expand the shoes until the disc locks. Return the adjuster 8 notches. Install the hole plug. SETTLING PARKING BRAKE SHOES AND DISC With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbf) of force. Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road for about 400 meters (0.25 mile) in this condition. Repeat this procedure 2 or 3 times. RECHECK AND ADJUST PARKING BRAKE LEVER TRAVEL (See page BR–8) Author: Date: 2071 BR–49 BRAKE – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) BR0BC–03 INSPECTION SST SST W04698 1. 2. 3. INSTALL LSPV GAUGE (SST) SST 09709–29018 BLEED AIR FROM FLUID PRESSURE GAUGE RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER OR CALIPER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 2,452 kPa (25 kgf/cm2, 356 psi) 2,452 kPa (25 kgf/cm2, 356 psi) 7,845 kPa (80 kgf/cm2, 1,138 psi) 4,413 kPa (45 kgf/cm2, 640 psi) 2,942 kPa (30 kgf/cm2, 427 psi) 2,942 kPa (30 kgf/cm2, 427 psi) 7,845 kPa (80 kgf/cm2, 1,138 psi) 5,982 kPa (61 kgf/cm2, 868 psi) 5S–FE engine: 1MZ–FE engine: If the rear brake cylinder pressure is incorrect, replace the P valve assembly. 4. REMOVE LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM (See page BR–4) 5. CHECK FOR LEAKS Author: Date: 2072 BR–50 BRAKE – ABS ACTUATOR (DENSO Made) ABS ACTUATOR (DENSO Made) BR0BD–02 ON–VEHICLE INSPECTION W03244 HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the operation of sub–wire harness G according to the instructions on pages DI–502 and DI–507. If the solenoid and/or pump motor relay are abnormal, replace the relay and inspect the actuator operation again. 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10 – 14 V 2. DISCONNECT CONNECTORS Disconnect the 2 connectors from the actuator. 3. CONNECT ACTUATOR CHECKER (SST) (a) Connect the actuator checker (SST) to the actuator side wire harness via the sub–wire harness (SST), as shown. SST 09990–00150, 09990–00250, 09990–00300, 09990–00360 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (–) terminal. Connect the black cable of the sub–wire harness to the battery negative (–) terminal or body ground. Sub–Wire Harness G (SST) ABS Actuator Checker (SST) Sub–Wire Harness L (SST) ABS Actuator Sub–Wire Harness I (SST) R09422 Author: Date: 2073 BR–51 BRAKE (c) 4. (a) (b) (c) – ABS ACTUATOR (DENSO Made) Place the ”SHEET P” (SST) on the actuator checker. SST SST 09990–00430 INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to ”FRONT LH” position. Push and hold in the MOTOR switch for a few seconds. F07214 (d) Depress the brake pedal and hold it until step (g) is completed. (e) Push the MAIN push switch, and check that the brake pedal does not go down. NOTICE: Do not keep the MAIN push switch pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. W03269 (g) (h) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. Release the brake pedal. W03270 (i) (j) (k) (l) (m) Push and hold in the MOTOR switch for a few seconds. Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. Release the brake pedal. Turn the selector switch to ”REAR RH” position. Repeat (c) to (j), checking the actuator operation similarly. W03268 (n) Similarly, inspect ”REAR LH” and ”FRONT RH” position. HINT: When inspecting ”FRONT RH” position, push the FRONT RH switch instead of the MAIN push switch, and you can inspect in any selector switch position. W03271 Author: Date: 2074 BR–52 BRAKE – ABS ACTUATOR (DENSO Made) (o) (p) 5. W03267 Push and hold in the MOTOR switch for a few seconds. Stop the engine. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET P” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator. SST 09990–00150, 09990–00250, 09990–00300, 09990–00360, 09990–00430 6. CONNECT CONNECTORS Connect the 2 connectors to the actuator. 7. CLEAR DTC (See page DI–493) Author: Date: 2075 BR–53 BRAKE – ABS ACTUATOR (DENSO Made) BR0BE–02 COMPONENTS 15 (155, 11) 5.4 (55, 48 in.·lbf) ABS Actuator 19 (195, 14) A/C Tube Clamp Bracket Cushion Holder Cushion 19 (195, 14) Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque W03266 Author: Date: 2076 BR–54 BRAKE – ABS ACTUATOR (DENSO Made) BR0BF–02 REMOVAL SST W03243 1. REMOVE RIGHT FRONT FENDER LINER 2. REMOVE A/C TUBE CLAMP BRACKET BOLT 3. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS actuator. SST 09751–36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) 4. REMOVE ABS ACTUATOR ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 2 blots, 2 nuts and ABS actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 5. REMOVE ABS ACTUATOR (a) Remove the 2 nuts and ABS actuator from actuator bracket. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the 2 holders and 3 cushions from the ABS actuator. Author: Date: 2077 BR–55 BRAKE – ABS ACTUATOR (DENSO Made) BR0BG–02 INSTALLATION Installation is in the reverse order of removal (See page BR–54). HINT:
After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4).
Check for leaks. Author: Date: 2078 BR–56 BRAKE – ABS ACTUATOR (BOSCH Made) ABS ACTUATOR (BOSCH Made) BR0BH–03 COMPONENTS 15 (155, 11) 9.0 (92, 80 in.·lbf) Holder ABS Actuator (w/ ECU) 19 (195, 14) Cushion A/C Tube Clamp Bracket Cushion 19 (195, 14) Actuator Bracket N·m (kgf·cm, ft·lbf) : Specified torque W03327
2.6 (27, 23 in.·lbf) ECU Actuator N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F07215 Author: Date: 2079 BR–57 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BI–03 REMOVAL SST 1. REMOVE RIGHT FRONT FENDER LINER 2. REMOVE A/C TUBE CLAMP BRACKET BOLT 3. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS actuator. SST 09751–36011 Torque: 15 N·m (155 kgf·cm, 11 ft·lbf) W03324 Release Bar W03325 4. DISCONNECT CONNECTOR Pull out the release bar, and disconnect the connector. 5. REMOVE ABS ACTUATOR ASSEMBLY Remove the 2 bolts, 2 nuts and ABS actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 6. REMOVE ABS ACTUATOR (a) Remove the 2 nuts and ABS actuator. Torque: 9.0 N·m (92 kgf·cm, 80 in.·lbf) (b) Remove the 2 holders and 3 cushions from the ABS actuator. Author: Date: 2080 BR–58 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BJ–02 DISASSEMBLY W03326 1. DISCONNECT CONNECTOR Disconnect the connector, and remove the wire harness from the harness guide. 2. REMOVE ECU (a) Using a T20 torx wrench, loosen the 6 screws. Torque: 2.6 N·m (27 kgf·cm, 23 in.·lbf) NOTICE:
When removing the ECU from the actuator, it must be removed it upward.
At the time of reassembly, tighten the screws according to the order shown on the left. (b) Remove the ECU from the actuator. NOTICE: Protect the actuator in order to prevent sealing surface from getting dirty and causing damage on the valve body. If the dirt and the like are stuck to the sealing surface, use plastic tools or soft objects to remove the dirt. Do not use chemical solvents. Author: Date: 2081 BR–59 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BK–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–58). Author: Date: 2082 BR–60 BRAKE – ABS ACTUATOR (BOSCH Made) BR0BL–02 INSTALLATION Installation is in the reverse order of removal (See page BR–57). HINT:
After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4).
Check for leaks. Author: Date: 2083 BR–61 BRAKE – ABS & TRAC ACTUATOR ABS & TRAC ACTUATOR BR07A–06 ON–VEHICLE INSPECTION HINT: Using the ABS actuator checker (SST), check the operation of the actuator. If the actuator does not operate, check the operation of sub–wire harness G according to the instructions on pages DI–584 and DI–587. If the solenoid and/or pump motor relay are abnormal, replace the relay and inspect the actuator operation again. 1. W03246 INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10 – 14 V 2. DISCONNECT CONNECTORS Disconnect the 2 connectors from the actuator. 3. CONNECT ABS ACTUATOR CHECKER (SST) (a) Connect the actuator checker (SST) to the actuator side wire harness via the sub–wire harness (SST), as shown. SST 09990–00150, 09990–00250, 09990–00360, 09990–00450 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (–) terminal. Connect the black cable of the sub–wire harness to the battery negative (–) terminal or body ground. Sub – Wire Harness G (SST) Sub – Wire harness L (SST) ABS Actuator Checker (SST) FF TRC Connector FR TRC Connector White Connector Sub – Wire harness P (SST) ABS & TRAC Actuator *: Connect the white connector with the labeled (FF TRC) connector. W03897 Author: Date: 2084 BR–62 BRAKE (c) 4. (a) (b) (c) – ABS & TRAC ACTUATOR Place the ”SHEET A” (SST) on the actuator checker. SST 09990–00163 INSPECT BRAKE ACTUATOR OPERATION Start the engine, and run it at idle. Turn the selector switch of the actuator checker to ”FRONT RH” position. Push and hold in the MOTOR switch for a few seconds. BR1811 (d) Depress the brake pedal and hold it until step (g) is completed. (e) Push the POWER SWITCH, and check that the brake pedal does not go down. NOTICE: Do not keep the POWER SWITCH pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. R00324 (g) (h) Push and hold in the MOTOR switch for a few seconds, and check that the pedal returns. Release the brake pedal. R00325 (i) (j) (k) (l) (m) Push and hold in the MOTOR switch for a few seconds. Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. Release the brake pedal. Turn the selector switch to ”FRONT LH” position. Repeat (c) to (j), checking the actuator operation similarly. R00326 (n) Similarly, inspect ”REAR RH” and ”REAR LH” position. HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position. BR1813 Author: Date: 2085 BR–63 BRAKE – ABS & TRAC ACTUATOR (o) (p) 5. BR1811 Push and hold in the MOTOR switch for a few seconds. Stop the engine. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET A” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator. SST 09990–00150, 09990–00163, 09990–00250, 09990–00360, 09990–00450 6. CONNECT CONNECTORS Connect the 2 connectors to the actuator. 7. CLEAR DTC (See page DI–574) Author: Date: 2086 BR–64 BRAKE – ABS & TRAC ACTUATOR BR077–04 COMPONENTS 15 (155, 11) 5.4 (55, 48 in.·lbf) 20 (200, 14) ABS & TRAC Actuator 19 (195, 14) A/C Tube Clamp Bracket Cushion Holder Cushion 19 (195, 14) N·m (kgf·cm, ft·lbf) Actuator Bracket : Specified torque W03272 Author: Date: 2087 BR–65 BRAKE – ABS & TRAC ACTUATOR BR078–03 REMOVAL SST W03245 1. REMOVE RIGHT FRONT FENDER LINER 2. REMOVE A/C TUBE CLAMP BRACKET BOLT 3. DISCONNECT BRAKE LINES Using SST, disconnect the 6 brake lines from the ABS & TRAC actuator. SST 09751–36011 Torque: 10 mm nut 15 N·m (155 kgf·cm, 11 ft·lbf) 12 mm nut 20 N·m (200 kgf·cm, 14 ft·lbf) 4. REMOVE ABS & TRAC ACTUATOR ASSEMBLY (a) Disconnect the 2 connectors. (b) Remove the 2 blots, 2 nuts and ABS & TRAC actuator assembly. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) 5. REMOVE ABS & TRAC ACTUATOR (a) Remove the 2 nuts and ABS & TRAC actuator from actuator bracket. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (b) Remove the 2 holders and 3 cushions from the ABS & TRAC actuator. Author: Date: 2088 BR–66 BRAKE – ABS & TRAC ACTUATOR BR079–03 INSTALLATION Installation is in the reverse order of removal (See page BR–65). HINT:
After installation, fill the brake reservoir with brake fluid and bleed the brake system. (See page BR–4)
Check for leaks. Author: Date: 2089 BR–67 BRAKE – FRONT SPEED SENSOR FRONT SPEED SENSOR BR0BQ–03 COMPONENTS 5.4 (55, 48 in.·lbf) 29 (300, 21) Front Speed Sensor N·m (kgf·cm, ft·lbf) : Specified torque 7.8 (80, 69 in.·lbf) W03273 Author: Date: 2090 BR–68 BRAKE – FRONT SPEED SENSOR BR0BR–03 REMOVAL 1. (a) (b) DISCONNECT SPEED SENSOR CONNECTOR Remove the fender liner. Disconnect the speed sensor connector. 2. (a) REMOVE SPEED SENSOR Remove the bolt, flexible hose and speed sensor harness clamp from the shock absorber. Torque: 29 N·m (300 kgf·cm, 21 ft·lbf) Remove the resin clip and clamp bolt holding the sensor harness to the body. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the speed sensor from the steering knuckle. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) R00327 (b) (c) W04507 Author: Date: 2091 BR–69 BRAKE – FRONT SPEED SENSOR BR0BS–02 INSTALLATION Installation is in the reverse order of removal (See pageBR–68). HINT: After installation, check the speed sensor signal (See page DI–493, DI–539). Author: Date: 2092 BR–70 BRAKE – REAR SPEED SENSOR REAR SPEED SENSOR BR0BT–03 COMPONENTS 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) 7.8 (80, 69 in.·lbf) Rear Speed Sensor N·m (kgf·cm, ft·lbf) : Specified torque W03274 Author: Date: 2093 BR–71 BRAKE – REAR SPEED SENSOR BR0BU–03 REMOVAL 1. (a) (b) DISCONNECT SPEED SENSOR CONNECTOR Remove the seat cushion and side seatback (See page BO–114 or BO–119). Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. R00330 2. (a) (b) REMOVE SPEED SENSOR Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the speed sensor from the axle carrier. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) W04508 Author: Date: 2094 BR–72 BRAKE – REAR SPEED SENSOR BR0BV–02 INSTALLATION Installation is in the reverse order of removal (See page BR–71). HINT: After installation, check the speed sensor signal (See page DI–493, DI–539). Author: Date: 2095 SA–1 SUSPENSION AND AXLE – TROUBLESHOOTING TROUBLESHOOTING SA077–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page 1. Tire (Worn or improperly inflated) 2. Wheel alignment (Incorrect) Wander/pulls 3. Steering linkage (Loosen or worn) 4. Hub bearings (Worn) 5. Suspension parts (Worn) 6. Steering gear (Out of adjustment or broken) 1. Vehicle (Overloaded) 2. Spring (Weak) – SA–33 SA–56 SA–33 SA–56 Bottoming 3. Shock absorber (Worn) 1. Tire (Worn or improperly inflated) 2. Stabilizer bar (Bent or broken) SA–2 SA–47 SA–69 SA–33 SA–56 Sways/pitches 3. Shock absorber (Worn) 1. Tire (Worn or improperly inflated) 2. Wheels (Out of balance) 3. Shock absorber (Worn) Front wheel shimmy 4. Wheel alignment (Incorrect) 5. Ball joints (Worn) 6. Hub bearings (Worn) 7. Steering linkage (Loosen or worn) 8. Steering gear (Out of adjustment or broken) Abnormal tire wear 1. Tire (Worn or improperly inflated) 2. Wheels (Out of balance) 3. Suspension parts (Worn) 4. Shock absorber (Worn) Author: SA–2 SA–4 SA–7 – SA–10 – – SA–2 SA–2 SA–33 SA–56 SA–4 SA–7 SA–43 SA–10 – – SA–2 SA–2 – SA–33 SA–56 Date: 1952 SA–2 SUSPENSION AND AXLE – TIRE AND WHEEL TIRE AND WHEEL SA078–01 INSPECTION 1. (a) INSPECT TIRE Check the tires for wear and proper inflation pressure. Cold inflation pressure: Normal driving Tire size R03031 Front, Rear kPa (kgf/cm2 or bar, psi) P195/70R14 90S, 90H 210 (2.1, 30) P205/65R15 92H *1 220 (2.2, 32) *2 200 (2.0, 29) *1: For all loads including full rated loads *2: For reduced loads (1 to 4 passengers) Trailer towing Tire size Front, Rear kPa (kgf/cm2 or bar, psi) P195/70R14 90S *1 210 (2.1, 30) *2 240 (2.4, 36) P205/65R15 92H *1 220 (2.2, 32) *2 240 (2.4, 36) *1: For driving under 160 km/h (100 mph) *2: For driving at 160 km/h (100 mph) or over (b) Check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less 2. ROTATING TIRES HINT: See the illustration for where to rotate each tire. Front R15157 3. (a) (b) INSPECT WHEEL BALANCE Check and adjust the Off–the–car balance. If necessary, check and adjust the On–the–car balance. Imbalance after adjustment: 8.0 g (0.018 lb) or less R07928 Author: Date: 1953 SA–3 SUSPENSION AND AXLE 4. (a) (b) W03084 5. 6. 7. 8.


– TIRE AND WHEEL CHECK WHEEL BEARING LOOSENESS Check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) Check the axle hub deviation. Maximum: 0.05 mm (0.0020 in.) CHECK FRONT SUSPENSION FOR LOOSENESS CHECK STEERING LINKAGE FOR LOOSENESS CHECK BALL JOINT FOR LOOSENESS CHECK SHOCK ABSORBER WORKS PROPERLY Check for oil leaks Check mounting bushings for wear Check front and rear of the vehicle for bounce Author: Date: 1954 SA–4 SUSPENSION AND AXLE – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Front SA079–01 INSPECTION 1. MEASURE VEHICLE HEIGHT Tire size Front*1 mm (in.) Rear*2 195/70R14 212 (8.35) 264 (10.39) 205/65R15 215 (8.46) 266 (10.49) mm (in.) *1: W03085 Rear Front measuring point Measure from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure from the ground to the center of the strut rod mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specification. If the vehicle height is not within the specification, try to adjust it by pushing down on or lifting the body. R03030 2. INSTALL CAMBER–CASTER–KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION 5S–FE 1MZ–FE Left–right error –0°36’ ± 45’ (–0.6° ± 0.75°) 45’ (0.75°) or less –0°37’ ± 45’ (–0.62° ± 0.75°) 45’ (0.75°) or less Left–right error 2°10’ ± 45’ (2.17° ± 0.75°) 45’ (0.75°) or less 2°11’ ± 45’ (2.18° ± 0.75°) 45’ (0.75°) or less 13°01’ ± 45’ (13.02° ± 0.75°) 45’ (0.75°) or less 13°04’ ± 45’ (13.07° ± 0.75°) 45’ (0.75°) or less Camber Z03382 Caster Steering axis inclination Left–right error HINT: If the caster and steering axis inclination are not within the specification, after the camber has correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. A 4. B D INSPECT TOE–IN Toe–in (Total) Front A + B: 0° ± 12’ (0° ± 0.2°) C – D: 0 ± 2 mm (0 ± 0.08 in.) If the toe–in is not within the specification, adjust it at the rack ends. C SA3213 Author: Date: 1955 SA–5 SUSPENSION AND AXLE – FRONT WHEEL ALIGNMENT 5. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe–in. (a) Remove the front wheels and speed sensor clamp. (b) Remove the 2 nuts on the lower side of the shock absorber. (c) Coat the threads of the nuts with engine oil. (d) Temporarily install the 2 nuts. W03086 (e) (f) (g) (h) HINT: Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) Install the front wheels. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Check the camber.

Try to adjust the camber to the center value. Adjusting value for the set bolts is 6’ – 30’ (0.1° – 0.5°). If the camber is not within the specification, using the table below, estimate for how much additional camber adjustment will be required, and select the camber adjusting bolt. 1 2 Adjusting Bolt Set Bolt Bolt 90105–15001 90105–15004 90105–15005 1 Dot F02267 Adjusting Value 1 2 1 2 90105–15006 2 Dots 3 Dots 1 1 2 2 15’ 30’ 45’ 1°00’ 1°15’ 1°30’ F01195 (i) Follow the above mentioned steps again. Between step (b) and (c), exchange 1 or 2 selected bolts. HINT: When exchanging the 2 bolts, exchange 1 bolt for each time. Author: Date: 1956 SA–6 SUSPENSION AND AXLE 6. (a) (b) (c) – FRONT WHEEL ALIGNMENT ADJUST TOE–IN Remove the boot clamps. Loosen the tie rod end lock nuts. Turn the left and right rack ends an equal amount to adjust the toe–in. HINT:

W03088 (d) Try to adjust the toe–in to the center value. Make sure that the length of the left and right rack ends is the same. Rack end length difference: 1.5 mm (0.059 in.) or less Torque the tie rod end lock nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Place the boot on the seat and install the clip it. (e) HINT: Make sure that the boots are not twisted. A B B 7. INSPECT WHEEL ANGLE Turn the steering wheel fully, and measure the turning angle. A Front A: Inside B: Outside SA0028 Tire size Inside wheel Outside wheel 195/70R14 37°12’ ± 2° (37.2° ± 2°) 32°21’ (32.45°) 205/65R15 35°47’ ± 2° (35.78° ± 2°) 31°25’ (31.42°) If the wheel angles differ from the specification, check the left and right rack end length. Author: Date: 1957 SA–7 SUSPENSION AND AXLE – REAR WHEEL ALIGNMENT REAR WHEEL ALIGNMENT SA07A–01 INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle height: See page SA–4 NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to specification. 2. INSTALL CAMBER – CASTER – KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions on the equipment manufacturer. 3. INSPECT CAMBER Camber Left–right error 5S–FE 1MZ–FE –0°42’ ± 45’ (–0.7° ± 0.75°) 45’ (0.75°) or less –0°45’ ± 45’ (–0.75° ± 0.75°) 45’ (0.75°) or less HINT: Camber in not adjustable, it measurement is not within the specifications, inspect the suspension parts for damaged and/ or worn–out parts and replace them as necessary. A D 4. B INSPECT TOE–IN Toe–in (Total) Front A + B: 0°24’ ± 12’ (0.4° ± 0.2°) C – D: 4 ± 2 mm (0.16 ± 0.08 in.) If the toe–in is not within the specification, adjust it at the No.2 lower suspension arm. C SA3213 5. (a) ADJUST TOE–IN Measure the length of the left and right No.2 lower suspension arms. No.2 lower suspension arm length difference: 1 mm (0.04 in.) or less If the left–right difference is larger than the specification, adjust the length. W03090 Author: Date: 1958 SA–8 SUSPENSION AND AXLE (b) (c) – REAR WHEEL ALIGNMENT Loosen the lock nuts. Turn the left and right lower suspension arms an equal amount to adjust toe–in. HINT:

(d) W03091 Try to adjust the toe–in to the center value. One turn of the each adjusting tube will adjust the toe–in about 36’ (0.6°, 6.7 mm, 0.264 in.). Torque the lock nuts. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) Author: Date: 1959 SA–9 SUSPENSION AND AXLE – FRONT AXLE HUB FRONT AXLE HUB SA07B–01 COMPONENTS Front Shock Absorber 211 (2,150, 156) Tie Rod End Front Drive Shaft 8.0 (82, 71 in.·lbf) Brake Caliper 107 (1,090,79) ABS Speed Sensor Hub Bolt 49 (500, 36)
Cotter pin
Cotter pin Lock Cap Disc Lower Suspension Arm 294 (3,000, 217)
Snap Ring 127 (1,300, 94)
Cotter pin Steering Knuckle
Dust Deflector Dust Cover
Bearing 123 (1,250, 90) Axle Hub Lower Ball Joint N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 8.3 (85, 74 in.·lbf) W03092 Author: Date: 1960 SA–10 SUSPENSION AND AXLE – FRONT AXLE HUB SA07C–01 REMOVAL 1. 2. (a) (b) REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) CHECK BEARING BACKLASH AND AXLE HUB DEVIATION Remove the 2 bolts, brake caliper and disc. Support the brake caliper securely. (c) W03084 W03093 Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the bearing. (d) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If the deviation exceeds the maximum, replace the bearing. (e) Install the disc, 2 bolts and brake caliper. Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf) 3. REMOVE DRIVE SHAFT LOCK NUT (a) Remove the cotter pin and lock cap. (b) With applying the brakes, remove the nut. Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf) (c) Remove the brake caliper and disc. 4. w/ ABS: REMOVE ABS SPEED SENSOR AND WIRE HARNESS CLAMP Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) 5. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK ABSORBER Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) HINT:

Do not remove the bolts. At the time of installation, coat the nut’s thread with engine oil. 6. DISCONNECT TIE ROD END FROM STEERING KNUCKLE Remove the cotter pin and nut. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) Using SST, disconnect the tie rod end from the steering knuckle. SST 09610–20012 W03139 (a) (b) SST W03094 Author: Date: 1961 SA–11 SUSPENSION AND AXLE – FRONT AXLE HUB 7. W03095 DISCONNECT LOWER BALL JOINT FROM LOWER ARM Remove the 2 nuts and bolt. Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) 8. REMOVE STEERING KNUCKLE WITH AXLE HUB (a) Remove the 2 bolts on the lower side of the shock absorber. (b) Remove the steering knuckle with the axle hub. NOTICE: Be careful not to damage the oil seal with drive shaft. Author: Date: 1962 SA–12 SUSPENSION AND AXLE – FRONT AXLE HUB SA07D–01 DISASSEMBLY SST 1. REMOVE DUST DEFLECTOR Using a screwdriver, remove the dust deflector. 2. REMOVE LOWER BALL JOINT (a) Remove the cotter pin and nut. (b) Using SST, remove the lower ball joint. SST 09628–62011 R08859 3. (a) SST REMOVE AXLE HUB Using SST, remove the axle hub. SST 09520–00031 R00789 (b) Using SST and a press, remove the inner race (outside) from the axle hub. SST 09950–00020, 09950–60010 (09951–00400), 09950–70010 (09951–07100) 4. REMOVE DUST COVER Using a torx wrench (T30), remove the 4 bolts and dust cover. SST W02110 SST 5. (a) (b) (c) REMOVE BEARING FROM STEERING KNUCKLE Using snap ring pliers, remove the snap ring. Place the inner race on the outside of the bearing. Using SST and a press, remove the bearing. SST 09310–35010, 09527–17011 SST R11486 Author: Date: 1963 SA–13 SUSPENSION AND AXLE – FRONT AXLE HUB SA07E–01 REASSEMBLY SST 1. (a) R00792 INSTALL BEARING Using SST and a press, install a new bearing to the steering knuckle. SST 09608–32010 (b) Using snap ring pliers, install a new snap ring. 2. INSTALL DUST COVER Place the dust cover and using a torx wrench (T30), torque the 4 bolts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) 3. INSTALL FRONT AXLE HUB Using SST and a press, install the axle hub. SST 09310–35010, 09608–32010 4. INSTALL LOWER BALL JOINT (a) Install the lower ball joint and torque the nut. Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) (b) Install a new cotter pin. SST SST R08860 5. INSTALL DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316–60011 (09316–00011, 09316–00041), 09608–32010 HINT: Align the holes for the ABS speed sensor in the dust deflector and steering knuckle. SST SST Z19236 Author: Date: 1964 SA–14 SUSPENSION AND AXLE – FRONT AXLE HUB SA07F–01 INSTALLATION Installation is in the reverse order of removal (See page SA–10). AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI–493 or DI–539) AND FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 1965 SA–15 SUSPENSION AND AXLE – FRONT WHEEL HUB BOLT FRONT WHEEL HUB BOLT SA07G–01 REPLACEMENT SST W03096 1. REMOVE FRONT WHEEL 2. REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 bolts, brake caliper and disc. (b) Support the brake caliper securely. 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09628–10011 4. INSTALL HUB BOLT Install a washer and nut to the hub bolt as shown in the illustration, and install the hub bolt by torquing the nut. 5. INSTALL BRAKE DISC AND CALIPER Install the disc, 2 bolts and brake caliper. 6. INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) W03097 Author: Date: 1966 SA–16 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (5S–FE) FRONT DRIVE SHAFT (5S–FE) SA08P–01 COMPONENTS Fender Apron Seal Drive Shaft(RH)
Lock Bolt 32 (330, 24) Fender Apron Seal
Snap Ring Drive Shaft(LH) Tie Rod End
Snap Ring
Boot Clamp Lower Suspension Arm 49 (500, 36)
No.2 Dust Deflector
Cotter pin Outbord Joint Shaft 127 (1,300, 94)
Snap Ring
Boot Lock Cap 294 (3,000, 217)
Boot LH Inboard Joint Shaft Tripod Inboard Joint Shaft
Dust Cover
Snap Ring
Dust Cover
Center Bearing N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F03274 Author: Date: 1967 SA–17 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (5S–FE) SA08Q–01 REMOVAL SST FA1535 NOTICE: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST. SST 09608–16042 (09608–02021, 09608–02041) 1. REMOVE FRONT WHEEL AND FRONT FENDER APRON SEAL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. (a) (b) 3. 4. 5. W03093 REMOVE DRIVE SHAFT LOCK NUT Remove the cotter pin and lock cap. With applying the brakes, remove the nut. Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf) DRAIN GEAR OIL (M/T) or ATF (A/T) DISCONNECT TIE ROD END FROM STEERING KNUCKLE (See page SA–10) DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM (See page SA–10) 6. (a) DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub. NOTICE: Cover the drive shaft boot with cloth to protect it from damage. (b) Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub. W03142 Author: Date: 1968 SA–18 SUSPENSION AND AXLE LH W03143 FRONT DRIVE SHAFT (5S–FE) 7. REMOVE LH DRIVE SHAFT (a) Using a brass bar and hammer, remove the drive shaft. HINT: At the time of installation, please refer to the following items.
Coat gear oil to the inboard joint shaft and differential case sliding surface.
Before installing the drive shaft, set the snap ring with its opening side facing downward.
Whether or not the inboard joint shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in.
After installation, check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction.
After installation, check that the drive shaft cannot be removed by hand. (b) Using a screwdriver, remove the snap ring from the inboard joint shaft. 8. (a) RH – REMOVE RH DRIVE SHAFT Remove the bearing lock bolt. Torque: 32 N·m (330 kgf·cm, 24 ft·lbf) Using pliers, remove the snap ring and drive shaft. (b) HINT: At the time of installation, coat gear oil to the inboard joint shaft and differential case sliding surface. W03144 Author: Date: 1969 SA–19 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (5S–FE) SA08R–01 DISASSEMBLY 1. (a) (b) (c) N00191 (d) 2. (a) (b) CHECK DRIVE SHAFT Check to see that there is no play in the outboard joint shaft. Check to see that the inboard joint shaft slides smoothly in the thrust direction. Check to see that there is no remarkable play in the radial direction of the inboard joint shaft. Check for damage to boots. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS Using pliers, draw the hooks together and remove the large inboard joint boot clamp. Using a side cutter, cut the small inboard and 2 outboard joint boot clamps and remove them. 3. (a) Matchmarks FA1615 REMOVE INBOARD JOINT SHAFT Place matchmarks on the tripod, inboard and outboardjoint shafts. NOTICE: Do not punch the marks. (b) Remove the inboard joint shaft from the outboard joint shaft. 4. REMOVE TRIPOD (a) Using a snap ring expander, remove the snap ring. (b) Using a snap ring expander, temporarily slide the snap ring toward the outboard joint shaft side. (c) (d) Matchmarks Place matchmarks on the outboard joint shaft and tripod. Using a brass bar and hammer, remove the tripod from the outboard joint shaft. (e) Using a snap ring expander, remove the snap ring. 5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS Slide out the 2 boots. NOTICE: Do not disassemble the outboard joint. SA1443 Author: Date: 1970 SA–20 SUSPENSION AND AXLE 6.
SST – FRONT DRIVE SHAFT (5S–FE) REMOVE DUST COVER (LH drive shaft) Using SST and a press, remove the dust cover from the inboard joint shaft. SST 09950–00020 R09716
(RH drive shaft) Using a press, remove the dust cover from the inboard joint shaft. SA1446 7. SST (a) (b) RH DRIVE SHAFT: DISASSEMBLE INBOARD JOINT SHAFT Using SST and a press, remove the dust cover. SST 09950–00020 Using a snap ring expander, remove the snap ring. R09717 (c) (d) 8. (a) (b) Using a press, remove the bearing. Remove the snap ring. REMOVE NO.2 DUST DEFLECTOR Mount outboard joint shaft in a soft jaw vise. Using a screwdriver and hammer, remove the No.2 dust deflector. NOTICE: Be careful not to damage the ABS speed sensor rotor. SA1451 Author: Date: 1971 SA–21 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (5S–FE) SA08S–01 REASSEMBLY 1. INSTALL NO.2 DUST DEFLECTOR Using SST and a press, install a new No.2 dust deflector. SST 09309–36010, 09316–20011 SST R15532 2. (a) (b) (c) RH DRIVE SHAFT: ASSEMBLE INBOARD JOINT SHAFT Install a new snap ring to the inboard joint shaft. Using a press, install a new bearing. Using a snap ring expander, install a new snap ring. FA1888 (d) 1.0 mm (0.039 in.) Using SST, an extension bar and press, install a new dust cover. SST 09506–35010 HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration. SST → → FA1971 3.
INSTALL DUST COVER (LH drive shaft) Using a press, install a new dust cover. SA1459
(RH drive shaft) Using a press, install a new dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specification, as shown in the illustration. 86 – 87mm (3.39 – 3.43 in.) FA1889 Author: Date: 1972 SA–22 SUSPENSION AND AXLE Inboard Joint Boot Outboard Joint Boot 4. – FRONT DRIVE SHAFT (5S–FE) TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS HINT:
Vinyl tape F01747 Before installing the boots, wrap the spline of the drive shaft in vinyl tape to prevent the boots from being damaged.
Before installing the boots, place 3 new clamps to the small boot ends and large end (wheel side) and then install boots to drive shaft. 5. INSTALL TRIPOD (a) Using a snap ring expander, install a new snap ring. (b) Place the beveled side of the tripod axial spline toward the outboard joint shaft. (c) Align the matchmarks placed before removal. (d) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft. NOTICE: Do not tap the roller. (e) Using a snap ring expander, install a new snap ring. 6. INSTALL BOOT TO OUTBOARD JOINT SHAFT Before assembling the boot, coat the outboard joint and boot with grease in the boot kit. Grease capacity: (Color = Black) 100 – 120 g (3.5 – 4.2 oz.) 7. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT (a) Coat the inboard joint and boot with grease in the boot kit. Grease capacity: (Color = Yellow ocher) 125 – 155 g (4.4 – 5.5 oz) (b) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft. (c) Install the boot to the inboard joint shaft. 8. (a) (b) ASSEMBLE BOOT CLAMPS TO BOTH BOOTS Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length LH 609.2 ± 2.0 mm (23.984 ± 0.079 in.) RH 867.3 ± 2.0 mm (34.146 ± 0.079 in.) R00764 Author: Date: 1973 SA–23 SUSPENSION AND AXLE (c) (d) – FRONT DRIVE SHAFT (5S–FE) Holding the clamp near the closing hooks, using pliers, position the holes in the clamp’s free end over the closing hooks. Secure clamp by drawing the closing hooks together. F00615 (e) (f) Secure the preplaced 3 clamps onto the boots. Place SST onto the clamp. SST 09521–24010 (g) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST R10353 (h) Clearance 9. Using SST, adjust the clearance of the clamp. SST 09240–00020 Clearance: A : 1.9 mm (0.075 in.) or less B : 1.5 – 2.5 mm (0.059 – 0.098 in.) C : 3.0 – 4.0 mm (0.118 – 0.157 in.) CHECK DRIVE SHAFT (See page SA–19) SST A B C F00616 Author: Date: 1974 SA–24 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (5S–FE) SA08T–01 INSTALLATION Installation is in the reverse order of removal (See page SA–17). AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI–493 or DI–539) AND FRONT WHEEL ALIGNMENT(See page SA–4) Author: Date: 1975 SA–25 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) FRONT DRIVE SHAFT (1MZ–FE) SA07H–01 COMPONENTS Fender Apron Seal Drive Shaft(RH)
Snap Ring Fender Apron Seal
Lock Bolt 32 (330, 24)
Snap Ring Drive Shaft(LH) Tie Rod End Outbord Joint Shaft 49 (500, 36) Lower Suspension Arm
Boot Clamp
Cotter pin
No.2 Dust Deflector Lock Cap 127 (1,300, 94) 294 (3,000, 217)
Boot
Snap Ring Inboard Joint Shaft LH Inboard Joint Shaft
Dust Cover
Center Bearing
Dust Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part W03141 Author: Date: 1976 SA–26 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) SA07I–01 REMOVAL (See page SA–17) Author: Date: 1977 SA–27 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) SA07J–01 DISASSEMBLY 1. (a) (b) (c) R14967 (d) 2. (a) (b) CHECK DRIVE SHAFT Check to see that there is no play in the outboard joint shaft. Check to see that the inboard joint shaft slides smoothly in the thrust direction. Check to see that there is no remarkable play in the radial direction of the inboard joint shaft. Check for damage to boots. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS Using pliers, draw the hooks together and remove the large inboard joint boot clamp. Using a side cutter, cut the small inboard and 2 outboard joint boot clamps and remove them. 3. matchmarks W03190 REMOVE INBOARD JOINT SHAFT FROM OUTBOARD JOINT SHAFT (a) Place matchmarks on the inboard and outboard joint shafts. NOTICE: Do not punch the marks. (b) Using a snap ring expander, pull out the outboard joint shaft expanding the snap ring. 4. REMOVE INBOARD AND OUTBOARD JOINT BOOTS Slide out the 2 boots. 5. REMOVE DUST COVER
(LH drive shaft) Using a screwdriver and hammer, remove the dust cover from the inboard joint shaft.
(RH drive shaft) Using a press, remove the dust cover from the inboard joint shaft. SA0689 6. (a) SST (b) RH DRIVE SHAFT: DISASSEMBLE INBOARD JOINT SHAFT Using SST and a press, remove the dust cover. SST 09950–00020 Using a snap ring expander, remove the snap ring. R09717 Author: Date: 1978 SA–28 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) (c) (d) 7. (a) (b) Using a press, remove the bearing. Remove the snap ring. REMOVE NO.2 DUST DEFLECTOR Mount outboard joint shaft in a soft jaw vise. Using a screwdriver and hammer, remove the No.2 dust deflector. NOTICE: Be careful not to damage the ABS speed sensor rotor. SA1451 Author: Date: 1979 SA–29 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) SA07K–01 REASSEMBLY 1. INSTALL NO.2 DUST DEFLECTOR Using SST and a press, install a new No.2 dust deflector. SST 09309–36010, 09316–20011 SST W02121 2. SST (a) (b) (c) RH DRIVE SHAFT: ASSEMBLE INBOARD JOINT SHAFT Install a new snap ring to the inboard joint shaft. Using SST and a press, install a new bearing. SST 09223–56010 Using a snap ring expander, install a new snap ring. W03193 (d) SST Using SST and a press, install a new dust cover. SST 09223–56010 W03316 3. INSTALL DUST COVER (LH drive shaft) Using SST and a press, install a dust cover. SST 09223–56010, 09555–55010
SST SST W03145
(RH drive shaft) Using SST and a press, install a new dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specification, as shown in the illustration. SST 09223–56010 SST 100.5 mm (3.957 in.) W03194 Author: Date: 1980 SA–30 SUSPENSION AND AXLE Inboard Joint Boot Outboard Joint Boot 4. – FRONT DRIVE SHAFT (1MZ–FE) TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS HINT:
Vinyl Tape W03195 Before installing the boots, wrap the spline of the drive shaft in vinyl tape to prevent the boots from being damaged.
Before installing the boots, place 3 new clamps to the small boot ends and large end (wheel side) and then install boots to drive shaft. 5. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT Align the matchmarks placed at removal, and using a snap ring expander, put in the inboard joint shaft expanding the snap ring. 6. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity: (Color = Black) 105 – 125 g (3.7 – 4.4 oz.) 7. INSTALL BOOT TO INBOARD JOINT SHAFT (a) Pack the inboard joint and boot with grease in the boot kit. Grease capacity: (Color = Gray) Joint side: 142.5 – 157.5 g (5.0 – 5.6 oz.) Boot side: 52.5 – 57.5 g (2.1 – 2.3 oz.) (b) Install the boot to the inboard joint shaft. 8. (a) (b) W03196 (c) (d) ASSEMBLE BOOT CLAMPS TO BOTH BOOTS Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: M/T LH 601.5 ± 2.0 mm (23.681 ± 0.079 in.) RH 871.6 ± 2.0 mm (34.315 ± 0.079 in.) A/T LH 586.0 ± 2.0 mm (23.071 ± 0.079 in.) RH 881.6 ± 2.0 mm (34.709 ± 0.079 in.) Holding the clamp near the closing hooks, using pliers, position the holes in the clamp’s free end over the closing hooks. Secure clamp by drawing the closing hooks together. R14973 Author: Date: 1981 SA–31 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) (e) (f) Secure the preplaced 3 clamps onto the boots. Place SST onto the clamp. SST 09521–24010 (g) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST R10353 (h) Clearance 9. Using SST, adjust the clearance of the clamp. SST 09240–00020 Clearance: A : 1.9 mm (0.075 in.) or less B : 1.5 – 2.5 mm (0.059 – 0.098 in.) C : 3.0 – 4.0 mm (0.118 – 0.157 in.) CHECK DRIVE SHAFT (See page SA–27) SST A B C F02023 Author: Date: 1982 SA–32 SUSPENSION AND AXLE – FRONT DRIVE SHAFT (1MZ–FE) SA07L–01 INSTALLATION Installation is in the reverse order of removal (See page SA–26). AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI–493 or DI–539) AND FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 1983 SA–33 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER SA07M–05 COMPONENTS 80 (820, 59)
49 (500, 36) Suspension Support No. 2 Suspension Support Bearing Spring Bumper Spring Upper Seat Lower Insulator Upper Insulator Stabilizer Bar Link 39 (400, 29) Shock Absorber with Coil Spring Coil Spring 211 (2,150, 156) Shock Absorber Front Drive Shaft ABS Speed Sensor Wire Harness Clamp
Dust Deflector Tie Rod End 29 (300, 22) 8.0 (82, 71 in.·lbf)
Cotter Pin 107 (1,090, 79) ABS Speed Sensor 123 (1,250, 90) 49 (500, 36) Disc Lock Cap 206 (2,100, 152) Brake Caliper
Cotter Pin
Cotter Pin Lower Suspension Bushing Stopper Lower Ball joint 294 (3,000, 217) 206 (2,100, 152) 206 (2,100, 152) Lower Suspension Arm 127 (1,300, 94) 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F06530 Author: Date: 1984 SA–34 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA07N–01 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS (w/ ABS) AND CLAMP FROM SHOCK ABSORBER Remove the bolt, flexible hose and ABS wire harness clamp. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) 3. DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER (See page SA–48) 4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE (a) Remove the 2 nuts and bolts on the lower side of the shock absorber. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) (b) Remove the shock absorber from the steering knuckle. HINT: At the time of installation, coat the nut’s threads with engine oil. 5. REMOVE SHOCK ABSORBER WITH COIL SPRING Remove the 3 nuts, suspension support No.2 and shock absorber with the coil spring. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) HINT: At the time of installation rotate the suspension support and set it in the direction, as shown in the illustration. To Outside Z19346 Author: Date: 1985 SA–35 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA07O–01 DISASSEMBLY SST SST W03198 REMOVE COIL SPRING (a) Install 2 nuts and a bolt to the bracket at the lower portion of the shock absorber and secure it in a vise. (b) Using SST, compress the coil spring. SST 09727–30021 NOTICE:
When holding the shock absorber with the coil spring removed, do not hold it by the spring lower seat. Also, do not knock the spring lower seat.
Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (c) SST (d) W03199 Using SST to hold the suspension support, remove the nut. SST 09729–22031 Remove these parts from the shock absorber:
Suspension support
Bearing
Spring upper seat
Upper insulator
Coil spring
Lower insulator
Spring bumper Author: Date: 1986 SA–36 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA07P–01 INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sound. NOTICE: When discarding the shock absorber, see DISPOSAL on page SA–37. W03646 Author: Date: 1987 SA–37 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA0II–01 DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to remove the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. W03648 Author: Date: 1988 SA–38 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA07R–01 REASSEMBLY 1. SST W03200 W03201 INSTALL LOWER INSULATOR ONTO SHOCK ABSORBER 2. INSTALL SPRING BUMPER TO PISTON ROD 3. INSTALL COIL SPRING (a) Using SST, compress the coil spring. SST 09727–30021 NOTICE: Do not use an impact wrench. It will damage the SST. HINT: Use 2 of the same type of SST. (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring lower seat. 4. INSTALL SPRING UPPER SEAT AND INSULATOR (a) Align the ’OUT’ mark of spring upper seat with the mark of the upper insulator. (b) Install the spring upper seat with upper insulator to the shock absorber with the mark facing the outside of the vehicle. (c) Install the bearing and suspension support. (d) SST W03199 Using SST to hold the suspension support, install a new nut. SST 09729–22031 Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) (e) Remove the SST from the coil spring. SST 09727–30021 NOTICE: Check that the bearing fits into the recess in the suspension support. Author: Date: 1989 SA–39 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA07S–01 INSTALLATION Installation is in the reverse order of removal (See page SA–34). AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 1990 SA–40 SUSPENSION AND AXLE – FRONT LOWER SUSPENSION ARM FRONT LOWER SUSPENSION ARM SA07T–04 COMPONENTS 80 (820, 59)
49 (500, 36) Suspension Support No. 2 Suspension Support Bearing Spring Bumper Spring Upper Seat Lower Insulator Upper Insulator Stabilizer Bar Link 39 (400, 29) Shock Absorber with Coil Spring Coil Spring 211 (2,150, 156) Shock Absorber Front Drive Shaft ABS Speed Sensor Wire Harness Clamp
Dust Deflector Tie Rod End 29 (300, 22) 8.0 (82, 71 in.·lbf)
Cotter Pin 107 (1,090, 79) ABS Speed Sensor 123 (1,250, 90) 49 (500, 36) Disc Lock Cap 206 (2,100, 152) Brake Caliper
Cotter Pin
Cotter Pin Lower Suspension Bushing Stopper Lower Ball joint 294 (3,000, 217) 206 (2,100, 152) 206 (2,100, 152) Lower Suspension Arm 127 (1,300, 94) 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F06530 Author: Date: 1991 SA–41 SUSPENSION AND AXLE – FRONT LOWER SUSPENSION ARM SA07U–01 REMOVAL 1. REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt. Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) W03202 3. (a) REMOVE LOWER SUSPENSION ARM Remove the 2 bolts on the front side of the lower suspension arm. Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf) (b) Remove the bolt and nut on the rear side of the lower suspension arm. Torque: 206 N·m (2,100 kgf·cm, 152 ft·lbf) Remove the lower suspension arm. Remove the lower suspension arm bushing stopper from the lower suspension arm shaft. W03203 (c) (d) W03204 Author: Date: 1992 SA–42 SUSPENSION AND AXLE – FRONT LOWER SUSPENSION ARM SA07W–01 INSTALLATION Installation is in the reverse order of removal (See page SA–41). AFTER INSTALLATION, CHECK FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 1993 SA–43 SUSPENSION AND AXLE – FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT SA07X–05 COMPONENTS 80 (820, 59)
49 (500, 36) Suspension Support No. 2 Suspension Support Bearing Spring Bumper Spring Upper Seat Lower Insulator Upper Insulator Stabilizer Bar Link 39 (400, 29) Shock Absorber with Coil Spring Coil Spring 211 (2,150, 156) Shock Absorber Front Drive Shaft ABS Speed Sensor Wire Harness Clamp
Dust Deflector Tie Rod End 29 (300, 22) 8.0 (82, 71 in.·lbf)
Cotter Pin 107 (1,090, 79) ABS Speed Sensor 123 (1,250, 90) 49 (500, 36) Disc Lock Cap 206 (2,100, 152) Brake Caliper
Cotter Pin
Cotter Pin Lower Suspension Bushing Stopper Lower Ball joint 294 (3,000, 217) 206 (2,100, 152) 206 (2,100, 152) Lower Suspension Arm 127 (1,300, 94) 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F06530 Author: Date: 1994 SA–44 SUSPENSION AND AXLE – FRONT LOWER BALL JOINT SA07Y–01 REMOVAL SST 1. 2. (a) (b) (c) REMOVE STEERING KNUCKLE WITH AXLE HUB (See page SA–10) REMOVE LOWER BALL JOINT Using a screwdriver, remove the dust deflector. Remove the cotter pin and nut. Using SST, remove the lower ball joint. SST 09628–62011 R08859 Author: Date: 1995 SA–45 SUSPENSION AND AXLE – FRONT LOWER BALL JOINT SA07Z–01 INSPECTION N00208 INSPECT BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously one turn each 2 – 4 seconds and take the torque reading on the 5th turn. Turning torque: 1.0 – 3.4 N·m (10 – 35 kgf·cm, 8.7 – 30 in.·lbf) Author: Date: 1996 SA–46 SUSPENSION AND AXLE – FRONT LOWER BALL JOINT SA080–01 INSTALLATION 1. (a) (b) INSTALL LOWER BALL JOINT Install the lower ball joint and tighten the nut. Torque:123 N·m (1,250 kgf·cm, 90 ft·lbf) Install a new cotter pin. R08850 SST SST R08861 2. INSTALL NEW DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316–60011 (09316–00011, 09316–00041), 09608–32010 HINT: Align the holes for the ABS speed sensor in the dust deflector and steering knuckle. 3. INSTALL STEERING KNUCKLE WITH AXLE HUB (See page SA–13) 4. CHECK ABS SPEED SENSOR SIGNAL (See page DI–493 or DI–539) AND FRONT WHEEL ALIGNMENT (See page SA–4) Author: Date: 1997 SA–47 SUSPENSION AND AXLE – FRONT STABILIZER BAR FRONT STABILIZER BAR SA081–01 COMPONENTS 19 (195, 14) 19 (195, 14) Bracket Stabilizer Bar Link Bushing Bracket Bushing Stabilizer Bar Link 39 (400, 29) 39 (400, 29) Stabilizer Bar 39 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable torque W03207 Author: Date: 1998 SA–48 SUSPENSION AND AXLE – FRONT STABILIZER BAR SA082–01 REMOVAL 1. W03208 REMOVE LEFT AND RIGHT FRONT WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE LEFT AND RIGHT STABILIZER BAR LINKS Remove the 4 nuts and 2 links. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: If the ball joint turns together with the nut, use a 5 mm hexagon wrench to hold the stud. 3. W03209 REMOVE LEFT AND RIGHT BRACKETS AND BUSHINGS Remove the 4 bolts, 2 brackets and bushings. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: At the time of installation, please refer to the following item. Install the bushing to the inside of the bushing on the stabilizer bar. 4. REMOVE STABILIZER BAR Remove the stabilizer bar from the left hand side. NOTICE: Be careful not to damage the pressure feed tube. Author: Date: 1999 SA–49 SUSPENSION AND AXLE – FRONT STABILIZER BAR SA083–01 INSPECTION Z00340 INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously one turn each 2 – 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Author: Date: 2000 SA–50 SUSPENSION AND AXLE – FRONT STABILIZER BAR SA084–01 INSTALLATION Installation is in the reverse order of removal (See page SA–48). Author: Date: 2001 SA–51 SUSPENSION AND AXLE – REAR AXLE HUB REAR AXLE HUB SA085–01 COMPONENTS DRUM BRAKE 29 (300, 22) Flexible Hose Rear Axle Hub 80 (820, 59)
O–Ring Reused Nut : 196 (2,000, 145) New Nut : 255 (2,600, 188) No.2 Lower Suspension Arm Hub Bolt Brake Drum Rear Axle Carrier 181 (1,850, 134) 47 (475, 134) No.1 Lower Suspension Arm Brake Caliper ABS Speed Sensor 80 (820, 59)
O–Ring 8.0 (82, 71 in.·lbf) 113 (1,150, 83) Disc Hub Bolt Strut Rod Rear Axle Hub N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part W03210 Author: Date: 2002 SA–52 SUSPENSION AND AXLE – REAR AXLE HUB SA086–01 REMOVAL 1. 2. (a) (b) 3. REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) w/ DISC BRAKE: REMOVE BRAKE CALIPER AND DISC Remove the brake caliper and disc. Torque: 47 N·m (475 kgf·cm, 34 ft·lbf) Support the brake caliper securely. w/ DRUM BRAKE: REMOVE BRAKE DRUM 4. R10948 CHECK BEARING BACKLASH AND AXLE HUB DEVIATION (a) Using a dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If the backlash exceeds the maximum, replace the axle hub with the bearing. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.07 mm (0.0028 in.) If the deviation exceeds the maximum, replace the axle hub with the bearing. 5. (a) REMOVE REAR AXLE HUB Remove the 4 bolts and rear axle hub. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) Remove the O–ring. (b) HINT: At the time of installation, coat a new O–ring with MP grease. Z00206 Author: Date: 2003 SA–53 SUSPENSION AND AXLE (c) (d) 6. 7. (a) A A B W03211 – REAR AXLE HUB w/ Drum brake: Remove the bolt, and disconnect the flexible hose from the shock absorber. Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) Support the backing plate securely. w/ ABS: REMOVE ABS SPEED SENSOR Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) REMOVE REAR AXLE CARRIER Loosen the 3 nuts. Torque: Nut A: Reused nut: 196 N·m (2,000 kgf·cm, 145 ft·lbf) New nut: 255 N·m (2,600 kgf·cm, 188 ft·lbf) Nut B: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: At the time of installation, please refer to the following items.
If reusing the 2 nuts, coat the nut’s threads with engine oil.
After stabilizing the suspension, torque the nuts. (b) R11165 Remove the bolt and nut, and disconnect the strut rod from the rear axle carrier. NOTICE: When removing/installing bolt, stop the nut from rotating and loosen/torque the bolt. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) (c) Remove the 2 nuts and bolts on the lower side of the shock absorber. (d) Remove the nut, bolt and No.2 lower suspension arm. (e) Remove the rear axle carrier. Author: Date: 2004 SA–54 SUSPENSION AND AXLE – REAR AXLE HUB SA087–01 INSTALLATION Installation is in the reverse order of removal (See page SA–52). AFTER INSTALLATION, CHECK ABS SPEED SENSOR SIGNAL (See page DI–493 or DI–539) AND REAR WHEEL ALIGNMENT (See page SA–7) Author: Date: 2005 SA–55 SUSPENSION AND AXLE – REAR WHEEL HUB BOLT REAR WHEEL HUB BOLT SA088–01 REPLACEMENT SST 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC OR DRUM (See page SA–52) 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09628–10011 Z00212 4. INSTALL HUB BOLT Install a washer and nut to the hub bolt, as shown in the illustration, and install the hub bolt by tightening the nut. 5. INSTALL REAR DISC OR DRUM 6. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Z00213 Author: Date: 2006 SA–56 SUSPENSION AND AXLE – REAR SHOCK ABSORBER REAR SHOCK ABSORBER SA089–01 COMPONENTS Rear Side Seatback 49 (500, 36) Suspension Support Coil Spring Spring Bumper Cap 39 (400, 29) 18 (185, 13) Lower Insulator Stabilizer Bar link Shock Absorber Assembly Shock Absorber 5.5 (56, 49 in.·lbf) ABS Wire Harness 39 (400, 29) Reused nut : 196 (2,000, 145) New nut : 255 (2,600, 188) 29 (300, 22) Flexible Hose N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part W03212 Author: Date: 2007 SA–57 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08A–01 REMOVAL 1. 2. REMOVE REAR SIDE SEATBACK (See page BO–113 or BO–118) REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 3. REMOVE FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS (w/ ABS) FROM SHOCK ABSORBER Remove the 2 bolts, flexible hose bracket and ABS wire harness clamp. Torque: Flexible hose: 29 N·m (300 kgf·cm, 22 ft·lbf) ABS wire: 5.5 N·m (56 kgf·cm, 49 in.·lbf) R00749 4. 5. (a) R10288 W03213 DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER (See page SA–70) REMOVE SHOCK ABSORBER WITH COIL SPRING Loosen the 2 nuts on the lower side of the shock absorber. Torque: Reused nut: 196 N·m (2,000 kgf·cm, 145 ft·lbf) New nut: 255 N·m (2,600 kgf·cm, 188 ft·lbf) HINT: At the time of installation, coat the nut’s threads with engine oil. (b) Support the rear axle carrier with a jack. (c) Remove the cap. (d) Loosen the nut in the middle of the suspension support. NOTICE: Do not remove it. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) (e) Remove the 3 nuts of the suspension support. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (f) Lower the rear axle carrier and remove the 2 bolts. (g) Remove the shock absorber with the coil spring. Author: Date: 2008 SA–58 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08B–01 DISASSEMBLY SST W03214 REMOVE COIL SPRING (a) Install 2 nuts and a bolt to the bracket at the lower part of the shock absorber and secure it in a vise. (b) Using SST, compress the coil spring. NOTICE: Do not use an impact wrench. It will damage the SST. SST 09727–30021 (c) Remove the suspension support nut. (d) Remove these parts from the shock absorber:
Suspension support
Coil spring
Lower insulator
Spring bumper Author: Date: 2009 SA–59 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08C–01 INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sound. NOTICE: When discarding the shock absorber, see DISPOSAL on page SA–60. W03646 Author: Date: 2010 SA–60 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA0IJ–01 DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown in the illustration to remove the gas inside. CAUTION: The discharged gas is harmless, but be careful of chips which may fly up when drilling. W03647 Author: Date: 2011 SA–61 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08E–01 REASSEMBLY 1. 2. 3. (a) INSTALL LOWER INSULATOR INSTALL SPRING BUMPER TO PISTON ROD INSTALL COIL SPRING Using SST, compress the coil spring. SST 09727–30021 NOTICE: Do not use an impact wrench. It will damage the SST. SST R00911 (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the spring lower seat. R00912 4. (a) I (b) Outside (c) R00823 INSTALL SUSPENSION SUPPORT Install the suspension support to the piston rod and temporarily tighten a new nut. Rotate the suspension support and set it in the direction shown in the illustration. Remove the SST. SST 09727–30021 HINT: After removing SST, again check the direction of the suspension support. Author: Date: 2012 SA–62 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08F–01 INSTALLATION Installation is in the reverse order of removal (See page SA–57). AFTER INSTALLATION, CHECK REAR WHEEL ALIGNMENT (See page SA–7) Author: Date: 2013 SA–63 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD REAR LOWER SUSPENSION ARM AND STRUT ROD SA08G–01 COMPONENTS Suspension member Suspension Member Lower Stopper No.2 LOWER SUSPENSION ARM RH LH 56 (570, 41) 56 (570, 41) 51 (520, 38) 38 (390, 28) 51 (520, 38) Adjusting Tube Suspension Member Lower Stopper Sub–Assembly Adjusting Tube 181 (1,850, 134) Suspension Arm Washer No.2 Lower Suspension Arm 181 (1,850, 134) No.1 Lower Suspension Arm 113 (1,150, 83) Parking Brake Cable 39 (400, 29) 5.4 (55, 48 in.·lbf) Parking Brake Cable Clamp Stabilizer Bar Link Stabilizer Bar Strut Rod 113 (1,150, 83) Stabilizer Bar Link Bushing Clip Heat Insulator
Gasket Bracket Bushing Bracket 19 (195, 14) 56 (570, 41)
Gasket Exhaust Center Pipe
56 (570, 41) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable torque W03215 Author: Date: 2014 SA–64 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA08H–01 REMOVAL 1. 2. 3. (a) (b) W03216 Rear B A A W03219 REMOVE NO.2 LOWER SUSPENSION ARM Remove the 3 nuts, suspension arm washer and washers. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: At the time of installtion, after stabilizing the suspension, torque the nuts. (b) Remove the No.2 lower suspension arm. HINT: At the time of installtion, face the paint mark to the rearward. 5. REMOVE LEFT AND RIGHT STABILIZER BRACKETS (See page SA–70) 6. (a) (b) B REMOVE STRUT ROD Remove the bolt and disconnect the parking brake cable. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Remove the 2 bolts and nuts. Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) HINT: At the time of installtion,after stabilizing the suspension, torque the bolts. (c) Remove the strut rod. 4. (a) W03217 REMOVE REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE EXHAUST CENTER PIPE 5S–FE Engine: (See page EM–114) 1MZ–FE Engine: (See page EM–111) (c) REMOVE NO.1 LOWER SUSPENSION ARM Support the suspension member with a jack. Remove the 4 nuts, 2 bolts and suspension member lower stoppers. Torque: Bolt: 51 N·m (520 kgf·cm, 38 ft·lbf) Nut A: 51 N·m (520 kgf·cm, 38 ft·lbf) Nut B: 38 N·m (390 kgf·cm, 28 ft·lbf) Lower the suspension member. Author: Date: 2015 SA–65 SUSPENSION AND AXLE (d) – REAR LOWER SUSPENSION ARM AND STRUT ROD Remove the No.1 lower suspension arm with the 2 bolts and washer. HINT: At the time of installtion, face the paint mark to the rearward. Rear W03220 Author: Date: 2016 SA–66 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA08I–01 DISASSEMBLY DISASSEMBLE NO.2 LOWER SUSPENSION ARM (a) Loosen the 2 lock nuts. (b) Turn and disassemble the No.2 lower suspension arm. (c) Remove the lock nuts from the No.2 lower suspension arm. W03221 Author: Date: 2017 SA–67 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA08J–01 REASSEMBLY ASSEMBLE NO.2 LOWER SUSPENSION ARM (a) Install the 2 lock nuts to the No.2 lower suspension arm. (b) Turn the adjusting tube and assemble the No.2 lower suspension arm. W03222 HINT: When assembling the No.2 lower suspension arm, make sure that the length of A and B shown in the illustration is the same. Maximum difference: 3.0 mm (0.118 in.) A B W03223 (c) Adjust the No.2 lower suspension arm length by turning the adjusting tube. Arm length: 512.3 mm (20.169 in.) Temporarily tighten the 2 lock nuts. (d) HINT: After adjusting the rear wheel alignment, torque the lock nuts (See page SA–7). Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) W03224 Author: Date: 2018 SA–68 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA08K–01 INSTALLATION Installation is in the reverse order of removal (See page SA–64). AFTER INSTALLATION, CHECK REAR WHEEL ALIGNMENT (See page SA–7) Author: Date: 2019 SA–69 SUSPENSION AND AXLE – REAR STABILIZER BAR REAR STABILIZER BAR SA08L–01 COMPONENTS Suspension member Suspension Member Lower Stopper No.2 LOWER SUSPENSION ARM RH LH 56 (570, 41) 56 (570, 41) 51 (520, 38) 38 (390, 28) 51 (520, 38) Adjusting Tube Suspension Member Lower Stopper Sub–Assembly Adjusting Tube 181 (1,850, 134) Suspension Arm Washer No.2 Lower Suspension Arm 181 (1,850, 134) No.1 Lower Suspension Arm 113 (1,150, 83) Parking Brake Cable 39 (400, 29) 5.4 (55, 48 in.·lbf) Parking Brake Cable Clamp Stabilizer Bar Link Stabilizer Bar Strut Rod 113 (1,150, 83) Stabilizer Bar Link Bushing Clip Heat Insulator
Gasket Bracket Bushing Bracket 19 (195, 14) 56 (570, 41)
Gasket Exhaust Center Pipe
56 (570, 41) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable torque W03215 Author: Date: 2020 SA–70 SUSPENSION AND AXLE – REAR STABILIZER BAR SA08M–01 REMOVAL 1. REMOVE REAR WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 2. REMOVE LEFT AND RIGHT STABILIZER BAR LINKS Remove the 4 nuts and 2 links. HINT: If the ball joint turns together with the nut, use a 5 mm hexagon wrench to hold the stud. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 3. REMOVE HEAT INSULATOR Remove the 3 bolts, clip and heat insulator. W03225 4. REMOVE LEFT AND RIGHT BRACKETS AND BUSHINGS Remove the 4 bolts, 2 brackets and bushings. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: At the time of installation, install the bushing to the portion outside the bushing on the stabilizer bar. 5. REMOVE STABILIZER BAR W03226 Author: Date: 2021 SA–71 SUSPENSION AND AXLE – REAR STABILIZER BAR SA08N–01 INSPECTION Z00340 INSPECT STABILIZER BAR LINK BALL JOINT FOR ROTATION CONDITION (a) As shown in the illustration, flip the ball joint stud back and forth 5 times, before installing the nut. (b) Using a torque wrench, turn the nut continuously one turn each 2 – 4 seconds and take the torque reading on the 5th turn. Turning torque: 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Author: Date: 2022 SA–72 SUSPENSION AND AXLE – REAR STABILIZER BAR SA08O–01 INSTALLATION Installation is in the reverse order of removal (See page SA–70). Author: Date: 2023 SA–1 SUSPENSION AND AXLE – FRONT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Front: SA1DP–03 INSPECTION 1. MEASURE VEHICLE HEIGHT Vehicle height: Tire size Front*1 mm (in.) 205/65R15 218 (8.58) Rear*2 mm (in.) 270 (10.63) *1: Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the front side strut rod mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Rear: F08080 2. INSTALL CAMBER–CASTER–KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: Right–left error –0°36’ ± 45’ (–0.6° ± 0.75°) 45’ (0.75°) or less Right–left error 2°10’ ± 45’ (2.17° ± 0.75°) 45’ (0.75°) or less Right–left error 13°01’ ± 45’ (13.02° ± 0.75°) 45’ (0.75°) or less Camber Z03382 Caster Steering axis inclination If the caster and steering axis inclination are not within the specified values, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 4. ADJUST CAMBER NOTICE: After the camber has been adjusted, inspect the toe–in. (a) Remove the front wheel and ABS speed sensor clamp. Author: Date: 508 SA–2 SUSPENSION AND AXLE (b) – FRONT WHEEL ALIGNMENT Remove the 2 nuts on the lower side of the shock absorber. Coat the threads of the nuts with engine oil. Temporarily install the 2 nuts. (c) (d) F04031 (e) (f) (g) (h) HINT: Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required. Tighten the nuts. Torque: 211 N·m (2,150 kgf·cm, 156 ft·lbf) Install the ABS speed sensor clamp and front wheel. Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) Check the camber.
Try to adjust the camber to the center of the specified value.
Adjusting value for the set bolts is 6’ – 30’ (0.1° – 0.5°). If the camber is not within the specified value, using the following table, estimate how much additional camber adjustment will be required, and select the camber adjusting bolt. 1 2 Adjusting Bolt Set Bolt Bolt 90105–15001 90105–15004 90105–15005 90105–15006 1 Dot 3 Dots F04048 Adjusting Value 1 2 1 2 2 Dots 1 2 1 2 15’ 30’ 45’ 1°00’ 1°15’ 1°30’ F01195 (i) Do the steps mentioned above again. Between step (b) and (c), replace 1 or 2 selected bolts. HINT: When replacing the 2 bolts, replace 1 bolt for each time. Author: Date: 509 SA–3 SUSPENSION AND AXLE A – FRONT WHEEL ALIGNMENT 5. INSPECT TOE–IN Toe–in: B D Toe–in (total) Front A + B: 0° ± 12’ (0° ± 0.2°) C – D: 0 ± 2 mm (0 ± 0.08 in.) If the toe–in is not within the specified value, adjust it at the rack ends. 6. ADJUST TOE–IN (a) Using pliers, remove the rack boot set clips. C SA3213 (b) (c) Loosen the tie rod end lock nuts. Turn the right and left rack ends by an equal amount to adjust the toe–in. HINT: Try to adjust the toe–in to the center of the specified value. F02245 (d) (e) (f) F02246 A B B Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 in.) or less Torque the tie rod end lock nuts. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) Place the boots on the seats and using pliers, install the clips. HINT: Make sure that the boots are not twisted. 7. INSPECT WHEEL ANGLE Turn the steering wheel fully, and measure the turning angle. Wheel turning angle: A Front Inside wheel 35°50’ ± 2° (35.84° ± 2°) Outside wheel: Reference 31°28’ (31.47°) If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths. A: Inside B: Outside SA0028 Author: Date: 510 SA–4 SUSPENSION AND AXLE – FRONT AXLE HUB FRONT AXLE HUB SA07B–05 COMPONENTS Front Shock Absorber 211 (2,150, 156) Tie Rod End Front Drive Shaft 107 (1,090, 79) 8.0 (82, 71 in.·lbf) Brake Caliper ABS Speed Sensor Hub Bolt
Cotter pin 49 (500, 36)
Cotter pin Lock Cap Lower Suspension Arm Disc
Snap Ring 294 (3,000, 217) 127 (1,300, 94)
Cotter pin Steering Knuckle
Dust Deflector Dust Cover
Bearing 123 (1,250, 90) Axle Hub Lower Ball Joint N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 8.3 (85, 74 in.·lbf) F08042 Author: Date: 511 SA–5 SUSPENSION AND AXLE – FRONT DRIVE SHAFT FRONT DRIVE SHAFT SA08P–02 COMPONENTS Fender Apron Seal Drive Shaft (RH)
Lock Bolt 32 (330, 24) Fender Apron Seal
Snap Ring Drive Shaft (LH) Tie Rod End
Snap Ring
Boot Clamp Lower Suspension Arm 49 (500, 36)
No. 2 Dust Deflector
Cotter pin Outbord Joint Shaft RH: 127 (1,300, 94) Lock Cap
Snap Ring
Boot 294 (3,000, 217)
Boot LH: Inboard Joint Shaft Tripod Inboard Joint Shaft
Dust Cover
Snap Ring
Dust Cover
Center Bearing N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F03274 Author: Date: 512 SA–6 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA1JR–01 REMOVAL SST FA1535 NOTICE:
The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with SST. SST 09608–16042 (09608–02021, 09608–02041)
After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the ABS speed sensor rotor serration on the drive shaft. 1. REMOVE FRONT WHEEL AND FRONT FENDER APRON SEAL 2. DRAIN ATF 3. (a) (b) 4. (a) REMOVE DRIVE SHAFT LOCK NUT Remove the cotter pin and lock cap. While applying the brakes, remove the nut. DISCONNECT TIE ROD END FROM STEERING KNUCKLE Remove the cotter pin and nut. W03093 (b) Using SST, disconnect the tie rod end from the steering knuckle. SST 09610–20012 SST W03094 5. DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the bolt and 2 nuts, and disconnect the lower suspension arm from the lower ball joint. W03095 SA–7 SUSPENSION AND AXLE – FRONT DRIVE SHAFT 6. (a) DISCONNECT DRIVE SHAFT FROM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. (b) Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub. W03142 7. (a) REMOVE LH DRIVE SHAFT Using a hub nut wrench and wooden block or an equivalent, remove the drive shaft. (b) Using a screwdriver, remove the snap ring from the inboard joint shaft. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. LH: R00647 8. REMOVE RH DRIVE SHAFT (a) Remove the bearing lock bolt. (b) Using pliers, remove the snap ring and drive shaft. NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. RH: W03144 SA–8 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA1EA–02 DISASSEMBLY 1. (a) (b) (c) N00191 (d) 2. (a) B A (b) (c) CHECK DRIVE SHAFT Check to see that there is no remarkable play in the outboard joint. Check to see that the inboard joint slides smoothly in the thrust direction. Check to see that there is no remarkable play in the radial direction of the inboard joint. Check the boots for damage. REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS Using pliers, pinch the claw A and B to compress the large inboard joint boot clamp and remove it. Using a side cutter, cut the small inboard joint boot clamp and remove it. Using a side cutter, cut the 2 outboard joint boot clamps and remove them. F06526 3. (a) Matchmarks FA1615 Matchmarks SA1443 REMOVE INBOARD JOINT SHAFT Place matchmarks on the tripod, inboard and outboard joint shafts. NOTICE: Do not punch the marks. (b) Remove the inboard joint shaft from the outboard joint shaft. 4. REMOVE TRIPOD (a) Using a snap ring expander, remove the inboard joint side snap ring. (b) Using a snap ring expander, temporarily slide the outboard joint side snap ring toward the outboard joint side. (c) Place matchmarks on the outboard joint shaft and tripod. NOTICE: Do not punch the marks. (d) Using a brass bar and hammer, remove the tripod from the outboard joint shaft. NOTICE: Do not tap the roller. (e) Using a snap ring expander, remove the snap ring. SA–9 SUSPENSION AND AXLE – FRONT DRIVE SHAFT 5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS Slide out the 2 boots. NOTICE: Do not disassemble the outboard joint. 6. LH drive shaft: REMOVE DUST COVER Using SST and a press, remove the dust cover from the inboard joint shaft. SST 09950–00020 SST R09716 7. (a) RH drive shaft: DISASSEMBLE INBOARD JOINT SHAFT Using a press, remove the transaxle side dust cover from the inboard joint shaft. SA1446 (b) (c) Using SST and a press, remove the bearing side dust cover. SST 09950–00020 Using a snap ring expander, remove the snap ring. (d) (e) Using a press, remove the bearing. Remove the snap ring. SST R09717 SA1451 SA–10 SUSPENSION AND AXLE 8. (a) (b) – FRONT DRIVE SHAFT REMOVE NO. 2 DUST DEFLECTOR Mount the outboard joint shaft in a soft jaw vise. Using a screwdriver and hammer, remove the No. 2 dust deflector. NOTICE: Be careful not to damage the ABS speed sensor rotor. F06452 SA–11 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA1EB–02 REASSEMBLY 1. INSTALL NO. 2 DUST DEFLECTOR Using SST and a press, install a new No. 2 dust deflector. SST 09309–36010, 09316–20011 2. RH drive shaft: ASSEMBLE INBOARD JOINT SHAFT (a) Install a new snap ring to the inboard joint shaft. SST R15532 Steel Plate (b) (c) Using a steel plate and press, install a new bearing. Using a snap ring expander, install a new snap ring. (d) Using SST, an extension bar and press, install a new bearing side dust cover. SST 09506–35010 FA1888 1.0 mm (0.039 in.) HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration. SST → → FA1971 (e) Steel Plate Using a steel plate and press, install a new transaxle side dust cover until the distance from the tip of the inboard joint shaft to the dust cover falls within the specified value, as shown in the illustration. 86 – 87mm (3.39 – 3.43 in.) FA1889 3. LH drive shaft: INSTALL DUST COVER Using a press, install a new dust cover. SA1459 SA–12 SUSPENSION AND AXLE Inboard Joint Boot Outboard Joint Boot 4. – FRONT DRIVE SHAFT TEMPORARILY INSTALL OUTBOARD AND INBOARD JOINT BOOTS AND NEW BOOT CLAMPS HINT:
Vinyl tape F01747 Before installing the boots, wrap the spline of the outboard joint shaft with vinyl tape to prevent the boots from being damaged.
Before installing the boots, place 3 new clamps to the small boot ends and large boot end (outboard joint side). 5. INSTALL TRIPOD (a) Using a snap ring expander, install a new snap ring. (b) Place the beveled side of the tripod axial spline toward the outboard joint. (c) Align the matchmarks placed before removal. (d) Using a brass bar and hammer, tap in the tripod to the outboard joint shaft. NOTICE: Do not tap the roller. (e) Using a snap ring expander, install a new snap ring. 6. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint and boot with grease in the boot kit. Grease capacity (Color = Black): 100 – 120 g (3.5 – 4.2 oz.) 7. INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT (a) Pack the inboard joint and boot with grease in the boot kit. Grease capacity (Color = Yellow ocher): 125 – 155 g (4.4 – 5.5 oz.) (b) Align the matchmarks placed before removal, and install the inboard joint shaft to the outboard joint shaft. (c) Temporarily install the boot to the inboard joint shaft. 8. (a) (b) CHECK DRIVE SHAFT LENGTH Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: R00764 LH 609.2 ± 2.0 mm (23.984 ± 0.079 in.) RH 842.9 ± 2.0 mm (33.185 ± 0.079 in.) SA–13 SUSPENSION AND AXLE 9. (a) (b) C 10. B C’ A (a) – FRONT DRIVE SHAFT Large inboard joint boot clamp: INSTALL BOOT CLAMP TO INBOARD JOINT SHAFT BOOT Place the large inboard joint boot clamp. Using pliers, pinch the claw A and B to compress the clamp and engage the claw C and C’. Others: INSTALL BOOT CLAMPS TO BOTH BOOTS Secure the preplaced 3 clamps onto the boots. F06527 (b) Place SST onto the clamp. SST 09521–24010 (c) Tighten the SST so that the clamp is pinched. NOTICE: Do not overtighten the SST. SST R10353 (d) Clearance 11. SST A B C F00616 Using SST, adjust the clearance of the clamp. SST 09240–00020 Clearance: A : 1.9 mm (0.075 in.) or less B : 1.5 – 2.5 mm (0.059 – 0.098 in.) C : 3.0 – 4.0 mm (0.118 – 0.157 in.) CHECK DRIVE SHAFT (See page SA–8) SA–14 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA1EC–02 INSTALLATION 1. LH drive shaft: INSTALL DRIVE SHAFT TO TRANSAXLE (a) Install a new snap ring to the inboard joint shaft. (b) Coat the gear oil to the inboard joint shaft and differential case sliding surface. (c) Set the snap ring with opening side facing downward. (d) Using a brass bar and hammer, install the drive shaft. NOTICE: Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle. HINT: Whether the inboard joint shaft is in contact with the pinion shaft or not can be known from the sound or feeling when driving it in. (e) Check that there is 2 – 3 mm (0.08 – 0.12 in.) of play in the axial direction. (f) Check that the drive shaft cannot be removed by hand. 2. RH drive shaft: INSTALL DRIVE SHAFT TO TRANSAXLE (a) Install the drive shaft. NOTICE: Be careful not to damage the dust cover of the drive shaft and oil seal lip of the transaxle. (b) Using pliers, install a new snap ring. (c) Install a new bearing lock bolt. Torque: 32 N·m (330 kgf·cm, 24 ft·lbf) 3. CONNECT DRIVE SHAFT TO AXLE HUB NOTICE: Be careful not to damage the boot and ABS speed sensor rotor. 4. CONNECT LOWER SUSPENSION ARM TO LOWER BALL JOINT Torque: 127 N·m (1,300 kgf·cm, 94 ft·lbf) 5. CONNECT TIE ROD END TO STEERING KNUCKLE (a) Connect the tie rod end to the steering knuckle. (b) Install the nut and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) 6. INSTALL DRIVE SHAFT LOCK NUT (a) While applying brakes, install the nut. Torque: 294 N·m (3,000 kgf·cm, 217 ft·lbf) (b) Install the lock cap and a new cotter pin. If the holes for the cotter pin are not aligned, tighten the nut further up to 60°. 7. FILL AND CHECK ATF (See page DI–133) 8. INSTALL FRONT FENDER APRON SEAL 9. INSTALL FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 10. CHECK FRONT WHEEL ALIGNMENT (See page SA–1) 11. CHECK ABS SPEED SENSOR SIGNAL (See page DI–177) SA–15 SUSPENSION AND AXLE – FRONT LOWER BALL JOINT FRONT LOWER BALL JOINT SA07X–06 COMPONENTS 80 (820, 59)
49 (500, 36) Suspension Support No. 2 Suspension Support Bearing Spring Bumper Spring Upper Seat Lower Insulator Upper Insulator Stabilizer Bar Link 39 (400, 29) Shock Absorber with Coil Spring 211 (2,150, 156) Coil Spring Shock Absorber Front Drive Shaft Tie Rod End ABS Speed Sensor Wire Harness Clamp
Dust Deflector 29 (300, 22) 8.0 (82, 71 in.·lbf)
Cotter Pin 107 (1,090, 79) ABS Speed Sensor 123 (1,250, 90) 49 (500, 36) Disc Lock Cap 206 (2,100, 152) Brake Caliper
Cotter Pin
Cotter Pin Lower Suspension Bushing Stopper Lower Ball joint 294 (3,000, 217) 206 (2,100, 152) 206 (2,100, 152) Lower Suspension Arm 127 (1,300, 94) 127 (1,300, 94) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F08043 Author: Date: 522 SA–16 SUSPENSION AND AXLE – REAR AXLE HUB REAR AXLE HUB SA085–04 COMPONENTS Reused Nut : 196 (2,000, 145) New Nut : 255 (2,600, 188) No. 2 Lower Suspension Arm No. 1 Lower Suspension Arm Rear Axle Carrier 181 (1,850, 134) 29 (300, 22) Flexible Hose 80 (820, 59) Rear Axle Hub ABS Speed Sensor 8.0 (82, 71 in.·lbf)
O–Ring 113 (1,150, 83) Hub Bolt Strut Rod Brake Drum N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F08044 Author: Date: 523 SA–17 SUSPENSION AND AXLE – REAR SHOCK ABSORBER REAR SHOCK ABSORBER SA1EZ–03 COMPONENTS Rear Seatback 42 (430, 31) 42 (430, 31) Rear Seat Cushion Cap
49 (500, 36) 39 (400, 29) Collar Suspension Support Spring Bumper Stabilizer Bar Link Reused nut: 196 (2,000, 145) New nut: 255 (2,600, 188) Shock Absorber with Coil Spring 39 (400, 29) Coil Spring Lower Insulator 5.4 (55, 48 in.·lbf) ABS Speed Sensor Wire Harness Flexible Hose 29 (300, 22) Shock Absorber N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F08045 Author: Date: 524 SA–18 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA08A–03 REMOVAL 1. 2. REMOVE REAR SEATBACK AND REAR SEAT CUSHION (See page BO–22) REMOVE REAR WHEEL 3. DISCONNECT FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS CLAMP FROM SHOCK ABSORBER Remove the 2 bolts and disconnect the flexible hose bracket and ABS wire harness clamp. F08046 4. F08047 DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER Remove the nut and stabilizer bar link. HINT: If the ball joint turns together with the nut, use a 5 mm hexagon wrench to hold the stud. 5. REMOVE SHOCK ABSORBER WITH COIL SPRING (a) Loosen the 2 nuts on the lower side of the shock absorber. (b) Remove the cap. (c) Loosen the nut in the center of the suspension support. NOTICE: Do not remove it. HINT: If not disassembling the shock absorber, it is not necessary to loosen the nut. (d) Remove the 3 nuts and shock absorber with the coil spring. F08081 SA–19 SUSPENSION AND AXLE – REAR SHOCK ABSORBER SA1F5–02 INSTALLATION 1. (a) (b) INSTALL SHOCK ABSORBER WITH COIL SPRING Install the 3 nuts and shock absorber with the coil spring. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Install the shock absorber with the coil spring, 2 bolts and nuts. Torque: Reused nut: 196 N·m (2,000 kgf·cm, 145 ft·lbf) New nut: 255 N·m (2,600 kgf·cm, 188 ft·lbf) HINT: If reusing the 2 nuts, coat the threads of the 2 nuts with engine oil. (c) Torque the nut in the center of the suspension support. Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) HINT: If the shock absorber has not been disassembled, it is not necessary to torque the nut. (d) Install the cap. 2. CONNECT STABILIZER BAR LINK Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. 3. CONNECT FLEXIBLE HOSE AND ABS SPEED SENSOR WIRE HARNESS CLAMP Torque: Flexible hose: 29 N·m (300 kgf·cm, 22 ft·lbf) ABS speed sensor wire harness: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 4. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 5. INSTALL REAR SEATBACK AND REAR SEAT CUSHION (See page BO–25) 6. CHECK REAR WHEEL ALIGNMENT (See Pub. No. RM654U on page SA–7) SA–20 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD REAR LOWER SUSPENSION ARM AND STRUT ROD SA1F6–02 COMPONENTS Suspension Member 56 (570, 41) Suspension Arm Washer Adjusting Tube 181 (1,850, 134) No. 2 Lower Suspension Arm 181 (1,850, 134) 113 (1,150, 83) No. 1 Lower Suspension Arm 5.4 (55, 48 in.·lbf) Strut Rod 113 (1,150, 83) Parking Brake Cable N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part F08049 Author: Date: 527 SA–21 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA1JS–01 REMOVAL 1. 2. (a) REMOVE REAR WHEEL REMOVE STRUT ROD Remove the bolt and disconnect the parking brake cable. (b) Remove the 2 bolts, nuts and strut rod. NOTICE: Loossen the bolt since the nut cannot be rotated. F08073 3. (a) (b) REMOVE NO. 2 LOWER SUSPENSION ARM Remove the 3 nuts, suspension arm washer and washer. Remove the No. 2 lower suspension arm and washer. F08074 4. REMOVE NO. 1 LOWER SUSPENSION ARM Remove the 2 bolts with the washer and No. 1 lower suspension arm. F08075 SA–22 SUSPENSION AND AXLE – REAR LOWER SUSPENSION ARM AND STRUT ROD SA1JT–01 INSTALLATION 1. INSTALL NO. 1 LOWER SUSPENSION ARM Install the No. 1 lower suspension arm, washer and 2 bolts. HINT: Face the paint mark to the rearward. Rear F08076 2. (a) Rear INSTALL NO. 2 LOWER SUSPENSION ARM Install the No. 2 lower suspension arm, washer and nut to the axle carrier. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT:

(b) F08051 (c) Face the paint mark to the rearward. After stabilizing the suspension, torque the nut. Install the washer and connect the No. 2 lower suspension arm to the suspension member. Install the suspension arm washer and 2 nuts. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) HINT: After stabilizing the suspension, torque the nut. 3. F08050 INSTALL STRUT ROD Torque: 113 N·m (1,150 kgf·cm, 83 ft·lbf) NOTICE: Torque the bolt since the nut cannot be rotated. HINT: After stabilizing the suspension, torque the bolt. 4. CONNECT PARKING BRAKE CABLE Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 5. INSTALL REAR WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 6. CHECK REAR WHEEL ALIGNMENT (See Pub. No. RM654U on page SA–7) SA–23 SUSPENSION AND AXLE – REAR STABILIZER BAR REAR STABILIZER BAR SA1FB–02 COMPONENTS Stabilizer Bar Stabilizer Bar Link 39 (400, 29) 39 (400, 29) Bushing 19 (195, 14) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part 19 (195, 14) Stabilizer Bar Bracket F08077 Author: Date: 530 SA–24 SUSPENSION AND AXLE – REAR STABILIZER BAR SA08M–02 REMOVAL 1. REMOVE RIGHT AND LEFT STABILIZER BAR LINKS (a) Remove the 2 nuts and link. HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. (b) Employ the same manner described above to the other side. F08048 2. (a) (b) 3. F08078 REMOVE RIGHT AND LEFT BRACKETS AND BUSHINGS Remove the 2 bolts, bracket and bushings. Employ the same manner described above to the other side. REMOVE STABILIZER BAR SA–25 SUSPENSION AND AXLE – REAR STABILIZER BAR SA1FE–02 INSTALLATION Bushing Stopper F08079 1. INSTALL STABILIZER BAR 2. INSTALL RIGHT AND LEFT BUSHINGS AND STABILIZER BAR BRACKETS Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) HINT: Install the bushing to the outside of the bushing stopper on the stabilizer bar. 3. INSTALL RIGHT AND LEFT STABILIZER BAR LINKS Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) HINT: If the ball joint turns together with the nut, use a hexagon (5 mm) wrench to hold the stud. ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–1 Overview of instruments and controls
Instrument panel overview
Instrument cluster overview
Indicator symbols on the instrument panel 1 ’99camry U Instrument panel overview 1. Rear view mirror remote control levers 2. Side defroster outlets 3. Side vents 4. Instrument cluster 5. Center vents 6. Glove box 7. Electric moon roof switch and personal light 8. Garage door opener box or miscellaneous box 9. Power door lock switches 10. Power window switches 11. Cup holders 12. Cup holder or rear ashtray 13. Parking brake lever 14. Automatic transmission selector lever or manual transmission gear shift lever 15. Auxiliary box 16. Hood lock release lever 2 ’99camry U 1. Power rear view mirror control switch 2. Headlight and turn signal switch 3. Wiper and washer switches 4. Clock 5. Emergency flasher switch 6. Car audio 7. Rear window and outside rear view mirror defoggers switch 8. Air conditioning controls 9. Front ashtray 10. Power outlet 11. Cigarette lighter 12. Ignition switch 13. Cruise control switch 14. Tilt steering lock release lever 15. Traction control system off switch 16. Instrument panel light control knob 3 ’99camry U Instrument cluster overview 1. Engine coolant temperature gauge 4. Speedometer 7. Tachometer 2. Service reminder indicators and indicator lights 5. Odometer and two trip meters 8. Trip meter reset knob 6. Theft deterrent system/Engine immobiliser system indicator light 9. Low fuel level warning light 3. Fuel gauge 4 ’99camry U Indicator symbols on the instrument panel (type A) (type A) Brake system warning light∗1 Anti-lock brake system warning light∗1 (type B) (type B) Seat belt reminder light∗1 Open door warning light∗1 Discharge warning light∗1 Rear light failure warning light∗1 Malfunction indicator lamp∗1 SRS airbag warning light∗1 Low oil pressure warning light∗1 Low windshield washer fluid level warning light∗1 5 ’99camry U Traction light∗1 control system off indicator/warning Automatic transmission indicator lights Slip indicator light Turn signal indicator lights Headlight high beam indicator light ∗1 : ∗2 : Overdrive–off indicator light Cruise control indicator light∗2 6 For details, see ”Service reminder indicators and warning buzzers” in Chapter 1–5. If this light flashes, see ”Cruise control” in Chapter 1–6. ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Keys (without engine immobiliser system) Chapter 1–2 Keys and Doors
Keys
Engine immobiliser system
Side doors
Power windows
Trunk lid
Hood
Theft deterrent system
Fuel tank cap
Electric moon roof Your vehicle is supplied with two kinds of key. 1. Master key—This key works in every lock. 2. Sub key—This key will not work in the glove box and trunk. To protect things locked in the glove box or trunk when you have your vehicle parked, leave the sub key with the attendant. KEY NUMBER PLATE Your key number is shown on the plate. Keep the plate in a safe place such as your wallet, not in the vehicle. If you should lose your keys or if you need additional keys, duplicates can be made by a Toyota dealer using the key number. We recommend you to write down the key number and keep it in safe place. Since the doors and trunk lid can be locked without a key, you should always carry a spare master key in case you accidentally lock your keys inside the vehicle. 7 ’99camry U Keys (with engine immobiliser system) To protect things locked in the trunk when you have your vehicle parked, leave the sub key with the attendant. Since the door can be locked without a key, you should always carry a spare master key in case you accidentally lock your keys inside the vehicle. Your vehicle is supplied with the two kinds of key. 1. Master key (black)—This key works in every lock. Your Toyota dealer will need it to make you a new key with built–in transponder chip. 2. Sub key (gray)—This key will not work in the glove box and trunk. The master key and sub key each have a transponder chip in their key head which is very important for the system function, so be careful not to lose these keys. If you make your own duplicate key, you will not be able to cancel the system or start the engine. 8 NOTICE When using a key containing a transponder chip, observe the following precautions:  When starting the engine, do not use the key with a key ring resting on the key grip and do not press the key ring against the key grip. Otherwise the engine may not start, or may stop soon after it starts. ’99camry U  Do not cover the key grip with any material that cuts off electromagnetic waves.  Do not knock the key hard against other objects.  Do not leave the key exposed to high temperatures for a long period, such as on the dashboard and hood under the direct sunlight.  Do not put the key in water or wash it in an ultrasonic washer.  When starting the engine, do not use the key with other transponder keys around (including keys of other vehicles) and do not press other key plates against the key grip. Otherwise the engine may not start, or may stop soon after it starts. If this happens, remove the key once and then insert it again after taking off other transporter keys (including keys of other vehicles) from the ring or while gripping or covering them with your hand to start the engine.  Do not bend the key grip.  Do not use the key with electromagnetic materials. 9 ’99camry U Engine immobiliser system KEY NUMBER PLATE Your key number is shown on the plate. Keep the plate in a safe place such as your wallet, not in the vehicle. If you should lose your keys or if you need additional keys, duplicates can be made by a Toyota dealer using the key number. We recommend you to write down the key number and keep it in safe place. The engine immobiliser system is a theft prevention system. When you insert the key in the ignition switch, the transporter chip in the key’s head transmits an electronic code to the vehicle. The engine will start, only when the electronic code in the chip corresponds to the registered ID code for the vehicle. The system is automatically set when the key is removed from the ignition switch. The indicator light will start flashing every 1 second to show the system is set. If either of the following indicator conditions occurs, contact your Toyota dealer.
The indicator light stays on except when the theft deterrent system is setting or activating. (See ”Theft deterrent system”)
The indicator light does not start flashing when the key is removed from the ignition switch.
The indicator light flashes unsteady. 10 ’99camry U Inserting the registered key in the ignition switch automatically cancels the system, which enables the engine to start. The indicator light will go off. For your Toyota dealer to make you a new key with built–in transporter chip, your dealer will need your key number and master key. However, there is a limit to the number of additional keys your Toyota dealer can make for you. If you make your own duplicate key, you will not be able to cancel the system or start the engine. For vehicles sold in U.S.A. FCC ID: MOZ RI–4ATY MADE IN JAPAN This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. For vehicles sold in Canada This device complies with RSS–210 of Industry Canada. Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. CAUTION Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. 11 ’99camry U Side doors LOCKING AND UNLOCKING WITH KEY Insert the key into the keyhole and turn it. LOCKING AND UNLOCKING WITH INSIDE LOCK BUTTON Driver’s side Move the lock button. To lock: Turn the key forward. To unlock: Turn the key backward. To lock: Push the knob forward. To unlock: Pull the knob backward. Vehicles with power door lock system—All the doors lock and unlock simultaneously with either front door. In the driver’s door lock, turning the key once will unlock the driver’s door and twice in succession will unlock all the doors simultaneously. Closing the door with the lock knob in the lock position will also lock the door. Be careful not to lock your keys in the vehicle. Vehicles with power door lock system—The door cannot be locked if you leave the key in the ignition switch. Passenger’s side 12 ’99camry U LOCKING AND UNLOCKING WITH POWER DOOR LOCK SWITCH CAUTION Push the switch. Before driving, be sure that the doors are closed and locked, especially when small children are in the vehicle. Along with the proper use of seat belts, locking the doors helps prevent the driver and passengers from being thrown out from the vehicle during an accident. It also helps prevent the doors from being opened unintentionally. To lock: Push the switch on the front side. To unlock: Push the switch on the rear side. All the doors lock or unlock simultaneously. REAR DOOR CHILD–PROTECTORS Move the lock lever to the ”LOCK” position as shown on the label. This feature allows you to lock a rear door so it can be opened from the outside only, not from inside. We recommend using this feature whenever small children are in the vehicle. 13 ’99camry U —Wireless remote control Your vehicle has a wireless remote control system that can lock or unlock all the doors, or activate the theft deterrent system from a distance within approximately 1 m (3 ft.) of the vehicle. LOCKING DOORS AND UNLOCKING THE To lock and unlock all the doors, push the switches of the transmitter slowly and securely. Locking operation To lock: Push the ”LOCK” switch. All the doors are locked simultaneously. At this time, parking lights, side marker lights and tail lights flash. Check to see that the doors are securely locked. If any of the doors is not securely closed, or if the key is in the ignition switch, locking cannot be performed by the ”LOCK” switch. To unlock: Push the ”UNLOCK” switch once to unlock the driver’s door alone. Pushing the switch twice within 3 seconds unlocks all the doors simultaneously. At this time, parking lights, side marker lights and tail lights flash twice. Unlocking operation 14 You have 30 seconds to open a door after using the wireless remote unlock feature. If a door is not opened by then, all the doors will be automatically locked again. If the ”LOCK” or ”UNLOCK” switch is kept pressed in, the locking or unlocking operation is not repeated. Release the button and then push again. ’99camry U WIRELESS REMOTE CONTROL TRANSMITTER The wireless remote control transmitter is an electronic component. Observe the following instructions in order not to cause damage to the transmitter.
Do not leave the transmitter on places where the temperature becomes high such as on the dashboard.
Do not disassemble it.
Avoid knocking it hard against other objects or dropping it. ”PANIC” SWITCH Pushing the ”PANIC” switch blows the horn intermittently and flashes the headlights and tail lights. The ”PANIC” switch is used to deter vehicle theft when you witness anyone attempting to break into or damage your vehicle. The alarm will last for one minute. To stop alarm midway, push the ”PANIC” switch once again, unlock any door with the key or transmitter, or turn the ignition key from the ”LOCK” to ”ON” position. The ”PANIC” mode does not work when the key is inserted in the ignition switch.
Avoid putting it in water. You can use up to 2 wireless remote control transmitters for the same vehicle. Contact your Toyota dealer for detailed information. If the wireless remote control transmitter does not actuate the doors or alarm, or operate from a normal distance: REPLACING TRANSMITTER BATTERIES For replacement, use DURACELL DL2016 batteries or equivalent. CAUTION Special care should be taken that small children do not swallow the removed transmitter batteries or components. NOTICE When replacing the terminal batteries, be careful not to lose the components. Replace the transmitter batteries by the following procedures:
Check for closeness to a radio transmitter such as a radio station or an airport which can interfere with normal operation of the transmitter.
The batteries may have been consumed. Check the batteries in the transmitter. To replace the batteries, see ”Replacing transmitter batteries”. 15 ’99camry U 1. Using a coin or equivalent, open the transmitter case. 2. Remove the discharged transmitter batteries. NOTICE Do not bend the terminals. 3. Put new transmitter batteries with negative (–) side up. Close the transmitter case securely. NOTICE  Make sure the positive side and negative side of the transmitter batteries should be faced correctly.  Be careful not to bend the electrode of the transmitter batteries insertion and that dust or oils do not adhere to the transmitter case.  Close the transmitter case securely. 16 ’99camry U Power windows After replacing batteries, check that the transmitter operates properly. If the transmitter still does not operate properly, contact your Toyota dealer. If you lose your transmitter, contact your Toyota dealer as soon as possible to avoid the possibility of theft, or an accident. MODEL/FCC ID: GQ43VT7T ISC: 1470 K1361 MADE IN U.S.A. This complies with Part 15 of the FCC rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. The windows can be operated with the switch on each door. The power windows work when the ignition switch is in the ”ON” position. Key off operation: If both front doors are closed, they work for 45 seconds even after the ignition switch is turned off. They stop working when either front door is opened. Automatic operation (to open only): Push the switch completely down and then release it. The window will fully open. To stop the window partway, lightly pull the switch up and then release it. OPERATING THE DRIVER’S WINDOW Use the switch on the driver’s door. Normal operation: The window moves as long as you hold the switch. To open: Lightly push down the switch. To close: Pull up the switch. 17 ’99camry U Window lock button CAUTION To avoid serious personal injury, you must do the following.
Always make sure the head, hands OPERATING DOWS THE PASSENGERS’ WIN- Use the switches on the passengers’ doors. The driver’s door also has switches that control the passengers’ windows. The window moves as long as you hold the switch. To open: Push down the switch. To close: Pull up the switch. If you push in the window lock button on the driver’s door, the passengers’ windows cannot be operated. 18 and other parts of the body of all occupants are kept completely inside the vehicle before you close the power windows. If someone’s neck, head or hands gets caught in a closing window, it could result in a serious injury. When anyone closes the power windows, be sure that they operate the windows safely.
When small children are in the vehicle, never let them use the power window switches without supervision. Use the window lock button to prevent them from making unexpected use of the switches.
Never leave small children alone in the vehicle, especially with the ignition key still inserted. They could use the power window switches and get trapped in a window. Unattended children can become involved in serious accidents. ’99camry U Trunk lid— —Lock release lever CAUTION Keep the trunk lid closed while driving. This not only keeps the luggage from being thrown out but also prevents exhaust gases from entering the vehicle. To open the trunk lid from the outside, insert the master key and turn it clockwise. To open the trunk lid from the driver’s seat, pull up on the lock release lever. See ”Luggage stowage precautions” in Part 2 for precautions to observe for loading luggage. To close the trunk lid, lower it and press down on it. After closing the trunk lid, try pulling it up to make sure it is securely closed. 19 ’99camry U —Luggage security system This system deactivates the lock release lever so that things locked in the trunk can be protected. 1. Push down the security lock levers to lock the rear seatbacks. On vehicles with built–in child restraint, only the left seatback has a lock lever and can be lowered. The right seatback cannot be folded down. After locking the rear seatbacks, try folding them down to make sure they are securely locked, otherwise someone could get into the trunk by folding down a rear seat. 20 Hood 2. After closing the trunk lid, insert the master key and turn it counterclockwise to deactivate the lock release lever. After closing the trunk lid, try pulling it up to make sure it is securely locked. To open the hood: 1. Pull the hood lock release lever. The hood will spring up slightly. CAUTION Before driving, be sure that the hood is closed and securely locked. Otherwise, the hood may open unexpectedly while driving and an accident may occur. ’99camry U Theft deterrent system 2. In front of the vehicle, pull up the auxiliary catch lever and lift the hood. 3. Hold the hood open by inserting the support rod into the slot. Before closing the hood, check to see that you have not forgotten any tools, rags, etc. and return the support rod to its clip
this prevents rattles. Then lower the hood make sure it locks into place. If necessary, press down gently on the front edge to lock it. To deter the vehicle theft, The system is designed to give an alarm if any of the doors, trunk or hood is forcibly unlocked or the battery terminal is disconnected and then reconnected when the vehicle is locked. The alarm blows the horn intermittently and flashes the headlights and tail lights. CAUTION After inserting the support rod into the slot, make sure the rod supports the hood securely from falling down on to your head or body. 21 ’99camry U The system will automatically be set after 30 seconds. When the system is set, the indicator light will start flashing again. 4. After making sure the indicator light starts flashing, you may leave the vehicle. Never leave anyone in the vehicle when you set the system, because unlocking from the inside will activate the system. WHEN THE SYSTEM IS SET Activating the system SETTING THE SYSTEM 1. Turn the ignition key to the ”LOCK” position and remove it. The system will give the alarm under the following conditions:
If any of the doors is unlocked or if the trunk or hood is forcibly opened without the key or wireless remote control transmitter The indicator light will start flashing every 1 second when the key is removed from the ignition switch. (See ”Engine immobiliser system” for details.)
If the battery terminal is disconnected 2. Have all passengers get out of the vehicle. The indicator light will come on when the system is activating. 3. Close and lock all the doors, trunk and hood. The indicator light will come on when all the doors, trunk and hood are closed and locked. 22 and then reconnected If any of the door is unlocked without the key or wireless remote control transmitter and the key is not in the ignition switch, all the doors will be automatically locked again. After one minute, the alarm will automatically stop and the indicator light will starts flashing again. Reactivating the alarm Once set, the system automatically resets the alarm after the alarm stops. The alarm will activate again under the same circumstances described in ”Activating the system”. Stopping the alarm The alarm will be stopped by the following three ways:
Turn the ignition key from the ”LOCK” to ”ON” position.
Unlock any of the doors with the key or wireless remote control transmitter.
Open the trunk with the key. These ways cancel the system at the same time. ’99camry U Fuel tank cap TESTING THE SYSTEM 1. Open all the windows. 2. Set the system as described above. The doors should be locked with the key or wireless remote control transmitter. Be sure to wait until the indicator light goes off or starts flashing. 3. Unlock any door from the inside. The system should activate the alarm. 4. Stopping the alarm as described above. 5. Repeat this operation for the other doors, trunk and hood. When testing on the hood, also check that the system is activated when the battery terminal is disconnected and then reconnected. If the system does not work properly, have it checked by your Toyota dealer. 1. To open the fuel filler door, pull the lever up. When refueling, turn off the engine. CAUTION
Do not smoke, cause sparks or allow open flames when refueling. The fumes are flammable.
When opening the cap, do not remove the cap quickly. In hot weather, fuel under pressure could cause injury by spraying out of the filler neck if the cap is suddenly removed. 2. To remove the fuel tank cap, turn the cap slowly counterclockwise, then pause slightly before removing it. After removing the cap, hang it on the cap hanger. It is not unusual to hear a slight swoosh when the cap is opened. When installing, turn the cap clockwise till you hear a click. If the cap is not tightened securely, the malfunction indicator lamp comes on. Make sure the cap is tightened securely. 23 ’99camry U Electric moon roof The indicator lamp goes off after driving several times. If the indicator lamp does not go off, contact your Toyota dealer as soon as possible. To operate the moon roof, use the switches beside the personal light. The moon roof works when the ignition switch is in the ”ON” position. However, if all the doors are closed, it works for 45 seconds even after the ignition switch is turned off. It stops working when any of the doors is opened. CAUTION
Make sure the cap is tightened securely to prevent fuel spillage in case of an accident. Sun shade operation— The sun shade can be opened or closed by hand.
Use only a genuine Toyota fuel tank cap for replacement. It has a built– in check valve to reduce fuel tank vacuum. Sliding operation— Sliding operation To open: Push the switch on the ”SLIDE OPEN” side. The roof will fully open. To stop the roof partway, push the switch on either the ”SLIDE OPEN” or ”TILT UP” side briefly. The sun shade will be opened together with the roof. To close: Push the switch on the ”TILT UP” side. As a precaution when closing, the roof stops at the three–quarters closed position before fully closing. Therefore, release the switch and then push it again to close it completely. Tilting operation 24 ’99camry U Tilting operation— To tilt up: Push the switch on the ”TILT UP” side. To lower: Push the switch on the ”SLIDE OPEN” side. You may stop the moon roof at any desired position. The roof will move while the switch is being pushed and stop when released except to slide open. CAUTION To avoid serious personal injury, you must do the following.
While the vehicle is moving, always keep the head, hands and other parts of the body of all occupants away from the roof opening. Otherwise, you could be seriously injured if the vehicle stops suddenly or if the vehicle is involved in an accident.
Always make sure nobody places his/her head, hands and other parts of the body in the roof opening before you close the roof. If someone’s neck, head or hands gets caught in the closing roof, it could result in a serious injury. When anyone closes the roof, first make sure it is safe to do so.
Never leave small children alone in the vehicle,e specially with the ignition key still inserted. They could use the moon roof switches and get trapped in the roof opening. Unattended children can become involved in serious accidents.
Never sit on top of the vehicle around the roof opening. 25 ’99camry U 26 ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–3 Seats, Seat belts, Steering wheel and Mirrors
Seats
Front seats
Fold–down rear seat
Head restraints
Seat belts Seats
Anti–glare inside rear view mirror
Sun visors While the vehicle is being driven, all vehicle occupants should have the seatback upright, sit well back in the seat and properly wear the seat belts provided. CAUTION
Do not drive the vehicle unless the occupants are properly seated. Do not allow sitting on top of a folded–down seatback, or in the luggage compartment. Persons not properly seated and not properly restrained by seat belts can be severely injured in the event of emergency braking or a collision.
During driving, do not allow passengers to stand up or move around between seats. Severe injuries can occur in the event of emergency braking or a collision.
SRS driver and front passenger airbags
SRS side airbags
Child restraint
Tilt steering wheel
Outside rear view mirrors 27 ’99camry U Front seats— —Front seat precautions (with SRS side airbags) CAUTION The SRS side airbags are installed in the driver and front passenger seats. Observe the following precautions.
Do not lean against the front door when the vehicle is in use. The side airbag inflates with considerable speed and force; you may be killed or seriously injured.
Do not modify or replace the seats or surface of the front seats with the side airbags. Such changes may disable the system or cause the side airbags to inflate, resulting in death or serious injury. Consult your Toyota dealer.
Do not use accessories for the seats which cover the parts where the side airbags should inflate. Such accessories may prevent the side airbags from activating correctly, causing death or serious injury. 28 —Seat adjustment precautions Adjust the driver’s seat so that the foot pedals, steering wheel and instrument panel controls are within easy reach of the driver. CAUTION
Adjustments should not be made while the vehicle is moving, as the seat may unexpectedly move and cause the driver to lose control of the vehicle.
When adjusting the seat, be careful not to hit the seat against a passenger or luggage.
After adjusting the seat position, try sliding it forward and backward to make sure it is locked in position.
After adjusting the seatback, exert body pressure to make sure it is locked in position.
Do not put objects under the seats. The objects may interfere with the seat–lock mechanism or unexpectedly push up the seat position adjusting lever; the seat may suddenly move, causing the driver to lose control of the vehicle.
While adjusting the seat, do not put your hands under the seat or near the moving parts. You may catch and injure your hands or fingers. ’99camry U —Adjusting front seats (manual seat) 1. SEAT POSITION ADJUSTING LEVER Pull the lever up. Then slide the seat to the desired position with slight body pressure and release the lever. 2. SEATBACK LEVER ANGLE ADJUSTING 3. SEAT CUSHION HEIGHT ADJUSTING KNOB Turn the knob either way. 4. SEAT LUMBAR SUPPORT ADJUSTING LEVER Pull the lever upward or downward. Lean forward and pull the lever up. Then lean back to the desired angle and release the lever. CAUTION To reduce the risk of sliding under the lap belt during a collision, avoid reclining the seatback any more than needed. The seat belts provide maximum protection in a frontal or rear collision when the driver and the passenger are sitting up straight and well back in the seats. If you are reclined, the lap belt may slide past your hips and apply restraint forces directly to the abdomen. Therefore, in the event of a frontal collision, the risk of personal injury may increase with increasing recline of the seatback. 29 ’99camry U —Adjusting front seats (power seat) 1. SEAT POSITION AND SEAT CUSHION HEIGHT ADJUSTING SWITCH Move the control switch in the desired direction. Releasing the switch will stop the seat at that position. Do not place anything under the front seats. It might interfere with the seat–lock mechanism. 2. SEATBACK SWITCH ANGLE ADJUSTING Move the control switch in the desired direction. Releasing the switch will stop the seatback at that position. CAUTION To reduce the risk of sliding under the lap belt during a collision, avoid reclining the seatback any more than needed. The seat belts provide maximum protection in a frontal or rear collision when the driver and the passenger are sitting up straight and well back in the seats. If you are reclined, the lap belt may slide past your hips and apply restraint forces directly to the abdomen. Therefore, in the event of a formal collision, the risk of personal injury may increase with increasing recline of the seatback. 3. SEAT LUMBAR SUPPORT ADJUSTING LEVER Pull the lever upward or downward 30 ’99camry U Fold–down rear seat CAUTION When returning the seatback to the upright position:
Make sure the seat belts are not twisted or caught in the seatback and are arranged in the proper position and are ready to use.
Make sure the seatback is securely locked by pushing forward and rearward on the top of the seatback. 1. Pull up the seatback security lock lever 1 to the unlock position. 2. Pull up the lock release button 2. 3. Fold down the seatback. Each seatback may be folded separately. On vehicles with built–in child restraint, only the left seatback can be folded down. This will enlarge the trunk as far as the seatbacks. See ”Luggage stowage precautions” in Part 2 for precautions to observe for loading luggage. NOTICE Make sure the luggage loaded in the enlarged trunk will not damage the webbing of the rear center seat belt when the left seatback is folded down. 31 ’99camry U Seat belts— —Seat belt precautions Head restraints For your safety and comfort, adjust the head restraint before driving. To raise: Pull it up. To lower: Push it down while pressing the lock release button. On some models, you can also move the head restraint forward or backward. If such adjustment is desired, pull or push on the top of the head restraint. Front The head restraint is most effective when it is close to your head. Therefore, using a cushion on the seatback is not recommended. CAUTION
Adjust the center of the head restraint so that it is closest to the top of your ears.
After adjusting the head restraint, make sure it is locked in position.
Do not drive with the head restraints removed. Rear 32 Toyota strongly urges that the driver and passengers in the vehicle be properly restrained at all times with the seat belts provided. Failure to do so could increase the chance of injury and/or the severity of injury in accidents. Child. Use a child restraint system appropriate for the child until the child becomes large enough to properly wear the vehicle’s seat belts. See ”Child restraint” for details. If a child is too large for a child restraint system, the child should sit in the rear seat and must be restrained using the vehicle’s seat belt. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat. If a child must sit in the front seat, the seat belts should be worn properly. If an accident occurs and the seat belts are not worn properly, the force of the rapid inflation of the airbag may cause death or serious injury to the child. ’99camry U Do not allow the child to stand up or kneel on either rear or front seats. An unrestrained child could suffer serious injury or death during emergency braking or a collision. Also, do not let the child sit on your lap. It does not provide sufficient restraint. Pregnant woman. Toyota recommends the use of a seat belt. Ask your doctor for specific recommendations. The lap belt should be worn securely and as low as possible over the hips and not on the waist. Injured person. Toyota recommends the use of a seat belt. Depending on the injury, first check with your doctor for specific recommendations. CAUTION Persons should ride in their seats properly wearing their seat belts whenever the vehicle is moving. Otherwise, they are much more likely to suffer serious bodily injury or death in the event of sudden braking or a collision. When using the seat belts, observe the following:
Use the belt for only one person at
Keep the belts clean and dry. If they need cleaning, use a mild soap solution or lukewarm water. Never use bleach, dye, or abrasive cleaners—they may severely weaken the belts. (See ”Cleaning the interior” in Part 5.)
Replace the belt assembly (including bolts) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. a time. Do not use a single belt for two or more people—even children.
Avoid reclining the seatbacks too much. The seat belts provide maximum protection when the seatbacks are in the upright position. (Refer to the seat adjustment instructions.)
Be careful not to damage the belt webbing or hardware. Take care that they do not get caught or pinched in the seat or doors.
Inspect the belt system periodically. Check for cuts, fraying, and loose parts. Damaged parts should be replaced. Do not disassemble or modify the system. 33 ’99camry U —Front and rear seat belts If the seat belt cannot be pulled out of the retractor, firmly pull the belt and release it. You will then be able to smoothly pull the belt out of the retractor. When a passenger’s shoulder belt is completely extended and is then retracted even slightly, the belt is locked in that position and cannot be extended. This feature is used to hold the child restraint system securely. (For details, see ”Child restraint” in this chapter.) To free the belt again, fully retract the belt and then pull the belt out once more. Adjust the seat as needed (front seats only) and sit up straight and well back in the seat. To fasten your belt, pull it out of the retractor and insert the tab into the buckle. CAUTION Seat belts with an adjustable shoulder anchor—
After inserting the tab, make sure Adjust the shoulder anchor position to your size. You will hear a click when the tab locks into the buckle.
Do not insert coins, clips, etc. in The seat belt length automatically adjusts to your size and the seat position. The retractor will lock the belt during a sudden stop or on impact. It also may lock if you lean forward too quickly. A slow, easy motion will allow the belt to extend, and you can move around freely. 34 the tab and buckle are locked and that the belt is not twisted. the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, immediately contact your Toyota dealer. Do not use the seat until the seat belt is fixed. It cannot protect an adult occupant or your child from injury. To raise: Slide the anchor up. To lower: Push in the lock release button and slide the anchor down. After adjustment make sure the anchor is locked in position. ’99camry U CAUTION CAUTION Take up slack Always make sure the shoulder belt is positioned across the center of your shoulder. The belt should be kept away from your neck, but not falling off your shoulder. Failure to do so could reduce the amount of protection in an accident and cause serious injures in a collision. Too high lap belts and loose–fitting belts both could cause serious injuries due to sliding under the lap belt during a collision or other unintended result. Keep the lap belt positioned as low on hips as possible.
For your safety, do not place the Keep as low on hips as possible Adjust the position shoulder belts.
High–positioned shoulder belt under your arm. of the Position the lap belt as low as on your hips—not on your waist, just it to a snug fit by pulling the portion upward through the latch lap and possible then adshoulder plate. 35 ’99camry U —Seat belt extender If your seat belt curely because it personalized seat able from your charge. cannot be fastened seis not long enough, a belt extender is availToyota dealer free of Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring the heaviest coat you expect to wear for proper measurement and selection of length. Additional ordering information is available at your Toyota dealer. To release the belt, press the buckle–release button and allow the belt to retract. If the belt does not retract smoothly, pull it out and check for kinks or twists. Then make sure it remains untwisted as it retracts. CAUTION When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury.
Never use the seat belt extender if you can fasten the seat belt without it. 36
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. ’99camry U —Front seat belt pretensioners CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the seat belt extender is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the ”PRESS” signs on the buckle–release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle–release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. normally, immediately contact your Toyota dealer. Do not use the seat until the seat belt is fixed. It cannot protect an adult occupant or your child from injury. The driver and front passenger’s seat belt pretensioners are designed to be activated in response to a severe frontal impact. When the airbag sensor detects the shock of a severe frontal impact, the front seat belt is quickly drawn back in by the retractor so that the belt snugly restrains the front seat occupants. The seat belt pretensioners are activated even with no passenger in the front seat. When not in use, remove the extender and store in the vehicle for future use. 37 ’99camry U When a seat belt pretensioner is activated, an operating noise may be heard and a small amount of smoke–like gas may be released. This gas is harmless and does not indicate that a fire is occurring. Once the seat belt pretensioner has been activated, the seat belt retractor remains locked. CAUTION This indicator comes on when the ignition key is turned to the ”ACC” or ”ON” position. It goes off after about 6 seconds. This means the front seat belt pretensioners are operating properly. This warning light system monitors the front airbag sensors, airbag sensor assembly, seat belt pretensioner assembly, warning light, interconnecting wiring and power sources. (For details, see ”Service reminder indicators and warning buzzers” in Chapter 1–5.) 38 The seat belt pretensioner system mainly consists of the following components and their locations are shown in the illustration. 1. Front airbag sensors 2. SRS airbag warning light 3. Seat belt pretensioner assemblies 4. Airbag sensor assembly The seat belt pretensioner is controlled by the airbag sensor assembly. The airbag sensor assembly consists of a safing sensor and airbag sensor. Do not modify, remove, strike or open the front seat belt pretensioner assemblies, airbag sensor or surrounding area or wiring. Doing any of these may cause sudden operation of the front seat belt pretensioners or disable the system, which could result in serious injury. Failure to follow these instructions can result in serious injuries. ’99camry U
If either front seat belt does not retract NOTICE or can not be pulled out due to a malfunction or activation of the pretensioner. Do not perform any of the following changes without consulting your Toyota dealer. Such changes can interfere with proper operation of the seat belt pretensioners in some cases.
The front seat belt pretensioner assembly or surrounding area has been damaged.
The front and side parts of the vehicle  Installation of electronic items such as a mobile two–way radio, cassette tape player or compact disc player (shaded in the illustration) were involved in an accident that did not cause the seat belt pretensioners to operate.  Repairs on or near the front seat belt retractor assemblies  Modification of the suspension system
The front seat belt pretensioner assem-  Attachment of a grille guard (bull bar, kangaroo bar, etc.), snowplow, winches or any other equipment to the front end This front seat belt pretensioner system has a service reminder indicator to inform the driver of operating problems. If either of the following conditions occurs, this indicates a malfunction of the airbags or pretensioners. Contact your Toyota dealer as soon as possible to service the vehicle.  Repairs made on or near the front fenders, front end structure or console ignition key is turned to the ”ACC” or ”ON” position, or remains on.  Modification of the front end structure bly is scratched, cracked, or otherwise damaged.
The light does not come on when the
The light comes on or flashes while driving. 39 ’99camry U SRS driver and front passenger airbags CAUTION A driver or front passenger too close to the steering wheel or dashboard during airbag deployment can be killed or seriously injured. Toyota strongly recommends that:
The driver sit as far back as possible from the steering wheel while still maintaining control of the vehicle.
The front passenger sit as far back The SRS (Supplemental Restraint System) airbags are designed to provide further protection for the driver and front passenger when added to the primary protection provided by the seat belts. In response to a severe frontal impact, the SRS airbags work together with the seat belts to help prevent or reduce injury by inflating, in order to decrease the likelihood of the driver’s or front passenger’s head or chest directly hitting the steering wheel or dashboard. The passenger airbag is activated even with no passenger in the front seat. Be sure to wear your seat belt. 40 as possible from the dashboard.
All vehicle occupants be properly restrained using the available seat belts. This indicator comes on when the ignition key is turned to the ”ACC” or ”ON” position. It goes off after about 6 seconds. This means the SRS airbags are operating properly. The SRS airbag warning light system monitors the front airbag sensors, airbag sensor assembly, inflators, warning light, interconnecting wiring and power sources. (For details, see ”Service reminder indicators and warning buzzers” in Chapter 1–5.) ’99camry U If the severity of the impact is below the above threshold level, the SRS airbags may not deploy. However, this threshold velocity will be considerably higher if the vehicle strikes an object, such as a parked vehicle or sign pole, which can move or deform on impact, or if it is involved in an underride collision (e.g. a collision in which the nose of the vehicle ”underrides”, or goes under, the bed of a truck, etc.). The SRS airbag system is designed to activate in response to a severe frontal impact within the shaded area between the arrows in the illustration. There may be the case that the SRS airbag will not activate with such an impact in which the occupant wearing the seat belt correctly would not get serious injury. It is possible with collision severity at the marginal level of airbag sensor detection and activation that only one of your vehicle’s two airbags will deploy. For the safety of all occupants, be sure to always wear seat belts. Collision from rear Collision from the side Vehicle rollover The SRS airbags are not designed to inflate if the vehicle is subjected to a side or rear impact, if it rolls over, or if it is involved in a low–speed frontal collision. The SRS airbags will deploy if the severity of the impact is above the designed threshold level, comparable to an approximate 25 km/h (15 mph) collision when impacting straight into a fixed barrier that does not move or deform. 41 ’99camry U Hitting a curb, edge of pavement or hard material In a severe frontal impact, sensors detect deceleration and the system triggers the airbag inflators. Then a chemical reaction in the inflators momentarily fills the airbags with non–toxic gas to help restrain the forward motion of the occupants. Falling into or jumping over a deep hole Landing hard or vehicle falling The SRS airbags may deploy if a serious impact occurs to the underside of your vehicle. Some examples are shown in the illustration. The SRS airbag system mainly consists of the following components and their locations are shown in the illustration. 1. Front airbag sensors 2. SRS airbag warning light 3. Airbag module for passenger (airbag and inflator) 4. Airbag sensor assembly 5. Airbag module for driver (airbag and inflator) The airbag sensor assembly consists of a safing sensor and airbag sensor. 42 When the airbags inflate, they produce a fairly loud noise and release some smoke and residue along with non–toxic gas. This does not indicate a fire. This gas is normally harmless, however, for those who have delicate skin, it may cause minor skin irritation. Be sure to wash off any residue as soon as possible to prevent minor skin irritation. Deployment of the airbags happens in a fraction of a second, so the airbags must inflate with considerable force. While the system is designed to reduce serious injuries, it may also cause minor burns or abrasions and swellings. Parts of the airbag module (steering wheel hub, dashboard) may be hot for several minutes, but the airbags themselves will not be hot. The airbags are designed to inflate only once. ’99camry U A crash severe enough to inflate the airbags may break the windshield as the vehicle buckles. In vehicles with a passenger airbag the windshield may also be damaged by absorbing some of the force of the inflating airbag. CAUTION
The SRS airbag system is designed only as a supplement to the primary protection of the driver side and front passenger side seat belt systems. The front seat occupants can be killed or seriously injured by an inflating airbag if they do not wear the available seat belts. During sudden braking just before a collision, an unrestrained driver or front passenger can move forward into direct contact with or close proximity to the airbag which may then deploy during the collision. To obtain maximum protection in an accident, the driver and all passengers in the vehicle must wear their seat belts. Wearing a seat belt during an accident reduces the chances of death or serious injuries or being thrown out of the vehicle. For instructions and precautions concerning the seat belt system, see ”Seat belts” in this chapter.
Improperly seated and/or restrained infants and children can be killed or seriously injured by a deploying airbag. An infant or child who is too small to use a seat belt should be properly secured using a child restraint system. Toyota strongly recommends that all infants and children be placed in the rear seat of the vehicle and properly restrained. The rear seat is the safest for infants and children. For instructions concerning the installation of a child restraint system, see ”Child restraint” in this chapter. 43 ’99camry U
For instructions concerning the installation of a child restraint system, see ”Child restraint” in this chapter. Move seat fully back
Never put a rear–facing child re-
A forward–facing child restraint sys- straint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child. tem should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. On vehicles with side airbags, do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates, and the impact could cause death or serious injury to the child. 44 ’99camry U
Do not sit on the edge of the seat
Do not allow a child to stand up,
Do not put objects or your pets on or lean over the dashboard when the vehicle is in use. The airbags inflate with considerable speed and force; you may be killed or seriously injured. Sit up straight and well back in the seat, and always use your seat belt. or to kneel on the front passenger seat. The airbag inflates with considerable speed and force; the child may be killed or seriously injured. or in front of the dashboard or steering wheel pad that houses the airbag system. They might restrict inflation or cause death or serious injury as they are projected rearward by the force of deploying airbags. Likewise, the driver and front passenger should not hold things in their arms or on their knees.
Do not hold a child on your lap or in your arms. Use a child restraint system in the rear seat. For instructions concerning the installation of a child restraint system, see ”Child restraint” in this chapter. 45 ’99camry U
Do not modify or remove any wiring. Do not modify, remove, strike or open any components such as the steering wheel column cover, front passenger airbag cover, front passenger airbag, airbag sensor assembly. Doing any of these may cause sudden SRS airbag inflation or disable the system, which could result in death or serious injury. Failure to follow these instructions can result in death or serious injuries. NOTICE Do not perform any of the following changes without consulting your Toyota dealer. Such changes can interfere with proper operation of the SRS airbag system in some cases.  Installation of electronic items such as a mobile two–way radio, cassette tape player or compact disc player  Modification of the suspension system  Modification of the front end structure  Attachment of a grille guard (bull bar, kangaroo bar, etc.), snowplow, winches or any other equipment to the front end  Repairs made on or near the front fenders, front end structure, console, steering column, steering wheel or dashboard near the front passenger airbag 46 This SRS airbag system has a service reminder indicator to inform the driver of operating problems. If either of the following conditions occurs, this indicates a malfunction of the airbags. Contact your Toyota dealer as soon as possible to service the vehicle.
The light does not come on when the ignition key is turned to the ”ACC” or ”ON” position, or remains on.
The light comes on while driving. ’99camry U SRS side airbags NOTICE Do not disconnect the battery cables before contacting your Toyota dealer. In the following cases, contact your Toyota dealer as soon as possible:
The SRS airbags have been inflated.
The front part of the vehicle (shaded in the illustration) were involved in an accident that did not cause the SRS airbags to inflate.
The pad section of the steering wheel or front passenger airbag cover (shaded in the illustration) is scratched, cracked, or otherwise damaged. The SRS (Supplemental Restraint System) side airbags are designed to provide further protection for the driver and front passenger when added to the primary protection provided by the seat belts. In response to a severe side impact, the SRS side airbags work together with the seat belt to help prevent or reduce injury by inflating, in order to decrease the impact mainly on the driver’s or front passenger’s chest. The SRS side airbag on the passenger seat is activated even with no passenger in the front seat. Be sure to wear your seat belt. 47 ’99camry U CAUTION SRS side airbags inflate with considerable force. To avoid potential death or serious injury during inflation of a side airbag, Toyota strongly recommends that the driver and front passenger;
Wear their seat belt
Remain properly seated with their back against the seat at all times. This indicator comes on when the ignition key is turned to the ”ACC” or ”ON” position. It goes off after about 6 seconds. This means the SRS side airbags are operating properly. The warning light system monitors the airbag sensor assembly, inflators, warning light, interconnecting wiring and power sources. (For details, see ”Service reminder indicators and warning buzzers” in Chapter 1–5.) 48 The SRS side airbags may not inflate if the vehicle is subjected to a collision from the side at an angle, or a collision to the side of the vehicle body other than the passenger compartment shown in the illustration, which impact is not severe enough for the passenger compartment. ’99camry U There may be the case that the SRS side airbags will not activate with such an impact in which the occupant wearing the seat belt correctly would not get serious injury. Collision from the rear The SRS side airbags are designed to inflate when the passenger compartment gets a severe impact from the side. For the safety of all occupants, be sure to always wear seat belts. Collision from the front Vehicle rollover The SRS side airbags are not designed to inflate if the vehicle is subjected to a front or rear impact, if it rolls over, or if it is involved in a low–speed side collision. The SRS side airbag system mainly consists of the following components and their locations are shown in the illustration. 1. SRS airbag warning light 2. Side airbag modules (airbag and inflator) 3. Side airbag sensor assemblies 4. Airbag sensor assembly The SRS side airbag system is controlled by the airbag sensor assembly. The airbag sensor assembly consists of a safing sensor and airbag sensor. 49 ’99camry U In a severe side impact, the side airbag sensor triggers the side airbag inflators. Then a chemical reaction in the inflators momentarily fills the airbags with non–toxic gas to help restrain the lateral motion of the occupants. When the airbags inflate, they produce a fairly loud noise and release some smoke and residue along with non–toxic gas. This does not indicate a fire. This gas is normally harmless, however, for those who have delicate skin, it may cause minor skin irritation. Be sure to wash off any residue as soon as possible to prevent minor skin irritation. Deployment of the airbags happen in a fraction of a second, so the airbags must inflate with considerable force. While the system is designed to reduce serious injuries, it may also cause minor burns or abrasions and swellings. Front seats may be hot for several minutes, but the airbags themselves will not be hot. The airbags are designed to inflate only once. 50 CAUTION
The SRS side airbag system is designed only as a supplement to the primary protection of the driver side and front passenger side seat belt systems. The front seat occupants can be killed or seriously injured by an inflating airbag if they do not wear the available seat belts. During sudden braking just before a collision, an unrestrained driver or front passenger can move sideward into direct contact with or close proximity to the airbag which may then deploy during the collision. To obtain maximum protection in an accident, the driver and all passengers in the vehicle must wear their seat belts. Wearing a seat belt during an accident reduces the chances of death or serious injuries or being thrown out of the vehicle. For instructions and precautions concerning the seat belt system, see ”Seat belts” in this chapter.
Improperly seated and/or restrained infants and children can be killed or seriously injured by a deploying airbag. An infant or child who is too small to use a seat belt should be properly secured using a child restraint system. Toyota strongly recommends that all infants and children be placed in the rear seat of the vehicle and properly restrained. The rear seat is the safest for infants and children. For instructions concerning the installation of a child restraint system, see ”Child restraint” in this chapter.
Do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates and the impact could cause death or serious injury to the child. For instructors concerning the installation of a child restraint system, see ”Child restraint” in this chapter. ’99camry U
Do not use accessories for the seats which cover the parts where the side airbags should inflate. Such accessories may prevent the side airbags from activating correctly, causing death or serious injury.
Do not modify or replace the seats or surface of the front seats with the side airbags. Such changes may disable the system or cause the side airbags to inflate, resulting in death or serious injury. Consult your Toyota dealer.
Do not lean against the front door
Do not attach a cup holder or any when the vehicle is in use. The side airbag inflates with considerable speed and force; you may be killed or seriously injured. other device on or around the door. When the side airbag inflates, the cup holder or any other device will be thrown with great force or the side airbag may not activate correctly, resulting in death or serious injury. Likewise, the driver and front passenger should not hold things in their arms or on their knees.
Do not apply excessive weight to the outer side of the front seats on vehicles with side airbags.
The child head should not be leaned against the vicinity of the part where the side airbag activates. Failure to follow these instructions can result in death or serious injuries. 51 ’99camry U NOTICE Do not perform any of the following changes without consulting your Toyota dealer. Such changes can interfere with proper operation of the SRS airbag system in some cases.  Installation of electronic items such as a mobile two–way radio, cassette tape player or compact disc player  Modification of the suspension system  Modification of the side structure of the passenger compartment  Repairs made on or near the console or front seat This SRS side airbag system has a service reminder indicator to inform the driver of operating problems. If either of the following conditions occurs, this indicates a malfunction of the airbags. Contact your Toyota dealer as soon as possible to service the vehicle.
The light does not come on when the ignition key is turned to the ”ACC” or ”ON” position, or remains on.
The light comes on or flashes while driving. 52 In the following cases, contact your Toyota dealer as soon as possible:
The SRS side airbags have been inflated.
The portion of the doors (shaded in the illustration) were involved in an accident that did not cause the SRS side airbags to inflate.
The surface of the seats with the side airbag (shaded in the illustration) is scratched, cracked, or otherwise damaged. ’99camry U Child restraint— —Child restraint precautions NOTICE Do not disconnect the battery cables before contacting your Toyota dealer. Toyota strongly urges the use of child restraint systems for children small enough to use them. The laws of all fifty states in the U.S.A. and Canada now require the use of a child restraint system. Your vehicle conforms to SAEJ1819. If a child is too large for a child restraint system, the child should sit in the rear seat and must be restrained using the vehicle’s seat belt. See ”Seat belts” for details. CAUTION
For effective protection in automobile accidents and sudden stops, children must be properly restrained using a seat belt or child restraint system depending on the age and size of the child. Holding a child in your arms is not a substitute for a child restraint system. In an accident, the child can be crushed against the windshield, or between you and the vehicle’s interior.
Toyota strongly urges use of a proper child restraint system which conforms to the size of the child, and is put on the rear seat. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat.
Never put a rear–facing child restraint system on the front seat. In the event of an accident, the force of the rapid inflation of the airbag can cause death or serious injury if a rear–facing child restraint system is put on the front seat.
Unless it is unavoidable, do not put a child restraint front seat. system on the 53 ’99camry U —Child restraint system
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. Do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates, and the impact could cause death or serious injury to the child.
Make sure that you have complied with all installation instructions provided by the child restraint manufacturer and that the system is properly secured. 54 A child restraint system for a small child or baby must itself be properly restrained on the seat with the lap portion of the lap/shoulder belt. You must carefully consult the manufacturer’s instructions which accompany your child restraint system. To provide proper restraint, use a child restraint system following the manufacturer’s instructions about the appropriate age and size of the child for the restraint system. Install the child restraint system correctly following the instructions provided by its manufacturer of the system. General directions are also provided under the following illustrations. The child restraint system should be installed on the rear seat. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat. CAUTION
Never put a rear–facing child restraint system on the front seat. In the event of an accident, the force of the rapid inflation of the airbag can cause death or serious injury if a rear–facing child restraint system is put on the front seat.
Unless it is unavoidable, do not put a child restraint front seat. system on the
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. Do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates, and the impact could cause death or serious injury to the child. ’99camry U
After installing the child restraint system, make sure it is secured in place following the manufacturer’s instructions. If it is not restrained securely, it may cause death or serious injury to the child in the event of a sudden stop or accident. When not using the child restraint system, keep it secured with the seat belt or place it in the trunk or somewhere other than the passenger compartment. This will prevent it from injuring passengers in the event of a sudden stop or accident. For instructions about how to install the anchor bracket, see ”Top strap anchors and locations”. If your child restraint system does not provide any of the necessary parts, you can purchase the following items from your Toyota dealer.
CRS installation kit (Part No. 04731–22012)—contains 1 bolt, 3 types of spacers and 1 locking clip.
Bolt (Part No. 91511–60830) Your vehicle has anchors for securing the top strap of a child restraint system. The anchor nuts are welded beneath the sheet metal to permit installation of an anchor bracket for a child restraint system. To install an anchor bracket, use an 8 mm
30 mm
1.25 mm coarse thread metric bolt and 15 mm (0.6 in.) spacer. Note that the bolts accompanying many child restraint systems are not metric. You can damage the anchor nuts on your vehicle if you force bolts with different thread into the anchor nuts. 55 ’99camry U —Built–in child restraint The built–in child restraint system mainly consists of a child seat integrated in the rear seat and 5–point seat belts. Refer to the illustration to become familiar with the parts of the system. This child restraint system conforms to U.S. Motor Vehicle Safety Standard No.213 and Canada Motor Vehicle Safety Standard No.213.4. 1. Shoulder belts 2. Head restraint lock release button 3. Storage bag (for the head restraint and upper pad) 4. Head restraint and upper pad (for the rear seat) 5. Maximum shoulder height indicator label 6. Removable pad 7. Seat belt buckle 8. Seat belt release strap (black) 9. Seat belt adjustment strap (gray tab) 10. Child seat cushion 11. Seat belt buckle release button 12. Seat belt tabs 13. Owner’s manual supplement 14. Shoulder belt clip 56 ’99camry U This child restraint is designed for use only by children who weigh between 10 and 30 kg (22.1 and 66.1 pounds), and whose height is between 85 and 127 cm (33.5 and 50.0 inches). The child should be at least one year old and must be capable of sitting upright alone and whose shoulder height is at or below the maximum shoulder height indicator. It is important to use a rear–facing child restraint until the child is about a year old. A rear–facing restraint gives the child’s head, neck and body the support they would need in a crash. See ”—Child restraint system” for more information. If your child’s shoulders are above the indicator position, do not use the built– in child restraint. Your child should use the vehicle’s seat belts. According to accident statistics, children are safer when properly restrained in the rear seat than in the front seat.
Keep the belts clean and dry. If CAUTION Make sure the child is securely restrained with the built–in child restraint. WARNING! Failure to follow the manufacturer’s instructions on the use of this child restraint system can result in your child striking the vehicle’s interior during a sudden stop or crash. Snugly adjust the belts provided with this child restraint around your child. When using the built–in child straint, observe the following: re-
Use the belts for only one child at a time. Do not use the belts for two or more children.
Be careful not to damage the belt webbing or hardware. Take care that they do not get caught or pinched in the seatback. they need cleaning, use a mild soap solution or lukewarm water. Never use bleach, dye, or abrasive cleaners—they may severely weaken the belts.
Replace the built–in child restraint assembly if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious.
Do not use a separate child restraint system over the built–in child restraint. opened
When the built–in child restraint is in use, do not use the adult lap and shoulder belt instead of the built–in child restraint seat belt as it can cause severe injury to the child in a sudden stop or crash.
Inspect the belt system periodically. Check for cuts, fraying, and loose parts. Damaged parts should be replaced. Do not disassemble or modify the child restraint belt system. 57 ’99camry U 1. Remove the head restraint and upper pad by pressing the head restraint lock release button and pulling up the head restraint and upper pad. Lower the child seat cushion. 2. Insert the head restraint and upper pad into the storage bag. Then place the storage bag into the trunk by attaching with Velcro. CAUTION Do not use the built–in child restraint with the head restraint and upper pad installed. When using the built–in child restraint, the head restraint and upper pad should be stored in the trunk. 58 3. While pulling the seat belt release strap (black), pull both shoulder belts together. Pull the seat belt release strap from above at about 45 angle to the child seat cushion. If the shoulder belts cannot be pulled out, return the child seat cushion to an almost closed position, firmly pull the seat belt release strap and at the same time pull both shoulder belts, then lower the child seat cushion again. ’99camry U 4. Compress the shoulder belt clip to separate the right and left shoulder belts. 5. Pull down the seatback part of the removable pad. Make sure the child’s shoulders are at or below the maximum shoulder height indicator label. 6. Press the removable pad against the fastener tapes and install the pad to the seatback. Make sure the belts go through the slots in the pad. The removable pad is attached by fastener tapes. CAUTION CAUTION If your child’s shoulders are above the maximum shoulder height indicator label, do not use the built–in child restraint. Your child should use the adult lap and shoulder belt. If you have removed the removable pad for cleaning etc., do not use the built–in child restraint without the pad. 59 ’99camry U
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tabs and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your Toyota dealer immediately. Do not use the built–in child restraint until the seat belt is fixed. 7. Sit the child on the child seat. Place a shoulder belt over each shoulder. Insert the tabs into the buckle. CAUTION
When the built–in child restraint is in use, do not use the adult lap and shoulder belt instead of the built–in child restraint seat belt as it can cause severe injury to the child in a sudden stop or crash.
After inserting the tabs, make sure the tabs and buckle are locked and that the shoulder belts and buckle strap are not twisted. 60 8. Fasten the shoulder belt clip. The purpose of the clip is to keep the shoulder belts positioned correctly on the shoulders. CAUTION An unfastened shoulder belt clip will not help keep the belts on the child’s shoulders. In a sudden stop or crash, the child may go too far forward and be seriously injured. Make sure the belt clip is fastened at all times. ’99camry U 9. Pull the seat belt adjustment strap (gray tab) firmly until the shoulder belts are snugly adjusted around the child’s shoulders. You should not be able to put more than two fingers between a shoulder belt and the child’s chest. After adjusting the shoulder belt tightness, move the shoulder belt clip 5 to 8 cm (2 to 3 in.) below the child’s chin. On each belt, the shoulder part should be centered on the child’s shoulder. The belts should be away from the child’s face and neck, but not falling off the child’s shoulders. 10. To release the child from the seat belts, separate the shoulder belts then press the buckle release button. Move both belts off the child’s shoulders. 11. To store the built–in child restraint, fasten the shoulder belt clip and return the seat belt buckle using the fastener tapes. Fold up the seat belt adjustment strap (gray tab) in the seat so that the edge of the strap does not come out the raised child restraint seat cushion. Raise the child restratraint seat cushion and reinstall the head restraint and upper pad correctly by inserting the posts into the holes. 61 ’99camry U —Types of child restraint system CAUTION Before using the vehicle’s seat belt, make sure the head restraint and upper pad is reinstalled. Do not occupy this position unless the head restraint and upper pad is reinstalled as serious injury may result. Child restraint systems are classified into the following 3 types depending on the child’s age and size. (A) Infant seat (B) Convertible seat (C) Booster seat Install the child restraint system following the instructions provided by its manufacturer. (A) Infant seat (B) Convertible seat 62 ’99camry U —Installation with 3–point type seat belt (C) Booster seat (A) INFANT SEAT INSTALLATION An infant seat is used in rear–facing position only. CAUTION
Never put a rear–facing child restraint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child. 63 ’99camry U CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function
Do not put a rear–facing child restraint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. 64 1. Run the lap and shoulder belt through or around the infant seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Keep the lap portion of the belt tight. normally, it cannot protect your child from injury. Contact your Toyota dealer immediately. Do not use the seat until the seat belt is fixed. ’99camry U 2. Fully extend the shoulder belt to put it in the lock mode. When the belt is then retracted even slightly, it cannot be extended. To hold the infant seat securely, make sure the belt is in the lock mode before letting the belt retract. 3. While pressing against the seat let the shoulder it will go to hold ly. the infant seat firmly cushion and seatback, belt retract as far as the infant seat secure- CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 65 ’99camry U 4. To remove the infant seat, press the buckle–release button and allow the belt to retract completely. The belt will move freely again and be ready to work for an adult or older child passenger. 66 (B) CONVERTIBLE SEAT INSTALLATION A convertible seat is used in forward– facing and rear–facing position depending on the child’s age and size. When installing, follow the manufacturer’s instructions about the applicable child’s age and size as well as directions for installing a child restraint system. CAUTION
Never put a rear–facing child restraint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child. ’99camry U Move seat fully back
A forward–facing child restraint sys-
Do not put a rear–facing child re- tem should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. Do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates, and the impact could cause death or serious injury to the child. straint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. 1. Run the lap and shoulder belt through or around the convertible seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Keep the lap portion of the belt tight. 67 ’99camry U CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your Toyota dealer immediately. Do not use the seat until the seat belt is fixed. 2. Fully extend the shoulder belt to put it in the lock mode. When the belt is then retracted even slightly, it cannot be extended. To hold the convertible seat securely, make sure the belt is in the lock mode before letting the belt retract. 68 3. While pressing the convertible seat firmly against the seat cushion and seatback, let the shoulder belt retract as far as it will go to hold the convertible seat securely. ’99camry U CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 4. To remove the convertible seat, press the buckle–release button and allow the belt to retract completely. The belt will move freely again and be ready to work for an adult or older child passenger. (C) BOOSTER SEAT INSTALLATION A booster seat is used in forward–facing position only. 69 ’99camry U CAUTION
Always make sure the shoulder belt is positioned across the center of child’s shoulder. The belt should be kept away from child’s neck, but not falling off child’s shoulder. Failure to do so could reduce the amount of protection in an accident and cause serious injuries in a collision.
High–positioned Move seat fully back CAUTION A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. Do not allow the child to lean against the front door or around the front door even if the child is seated in the child restraint system. It is dangerous if the side airbag inflates, and the impact could cause death or serious injury to the child. 70 1. Sit the child on a booster seat. Run the lap and shoulder belt through or around the booster seat and child following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Make sure the shoulder belt is correctly across the child’s shoulder and that the lap belt is positioned as low as possible on child’s hips. See ”Seat belts” for details. lap belts and loose–fitting belts both could cause serious injuries due to sliding under the lap belt during a collision or other unintended result. Keep the lap belt positioned as low on hips as possible.
For child’s safety, do not place the shoulder belt under child’s arm.
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle. ’99camry U —Top strap anchors and locations
If the seat belt does not function normally, it cannot protect your child from injury. Contact your Toyota dealer immediately. Do not use the seat until the seat belt is fixed. 2. To remove the child restraint system, press the buckle–release button and allow the belt to retract. If your child restraint system requires the use of a top strap, latch the hook onto the anchor bracket and tighten the top strap. See the following instructions to install the anchor bracket. 71 ’99camry U Bolt Anchor bracket Anchor bracket Bolt Bolt Anchor bracket 345 mm (13.6 in.) Spacer Spacer Spacer 100 mm (4.0 in.) 100 mm (4.0 in.) 185 mm (7.3 in.) TYPE A Outside anchors— TYPE B On the filler panel behind the rear seat a. Remove the cap as shown in the illustration. On the filler panel behind the rear seat b. Insert a 15 mm (0.6 in.) spacer and tighten down the anchor bracket for your child restraint system with a bolt. Torque the bolt to 16.5—24.7 N⋅m (1.68—2.52 kgf⋅m, 12.2—18.2 ft⋅lbf). a. Using the illustration as a guide, run your fingers across the trim of the filler panel itself to locate the position of the holes underneath. Center anchor— a. Using the illustration as a guide, run your fingers across the trim of the filler panel itself to locate the position of the holes underneath. b. Make a hole in the covering directly above the hole in the filler panel. c. Insert a 15 mm (0.6 in.) spacer and tighten down the anchor bracket for your child restraint system with a bolt. Torque the bolt to 16.5—24.7 N⋅m (1.68—2.52 kgf⋅m, 12.2—18.2 ft⋅lbf). 72 Center anchor— b. Make a hole in the covering directly above the hole in the filler panel. c. Insert a 15 mm (0.6 in.) spacer and tighten down the anchor bracket for your child restraint system with a bolt. Torque the bolt to 16.5—24.7 N⋅m (1.68—2.52 kgf⋅m, 12.2—18.2 ft⋅lbf). ’99camry U Tilt steering wheel To comply with Canadian Motor Vehicle Safety Standards, this model sold in Canada is provided with a bracket set in the glovebox, designed for use with any of the 3 anchor locations shown in the illustration. If your child restraint system does not provide any of the necessary parts, ask your Toyota dealer. (See ”—Child restraint system”.) Outside anchors— a. Should you select to use the outer anchor positions, please contact your Toyota dealer for proper modifications to the filler panel. b. After modifications have been made to the filler panel, insert a 15 mm (0.6 in.) spacer and tighten down the anchor bracket for your child restraint system with a bolt. Torque the bolt to 16.5—24.7 N⋅m (1.68—2.52 kgf⋅m, 12.2—18.2 ft⋅lbf). To change the steering wheel angle, hold the steering wheel, pull up the lock release lever, tilt the steering wheel to the desired angle and release the lever. When the steering wheel is in a low position, it will spring up as you release the lock release lever. c. Securely latch the hook of the top strap onto the anchor bracket and make sure the hook does not make contact with the filler panel. 73 ’99camry U Outside rear view mirrors— CAUTION CAUTION
Do not adjust the steering wheel
Do not adjust the mirror while the while the vehicle is moving. vehicle is moving. It may cause the driver to mishandle the vehicle and an accident may occur resulting in personal injuries.
After adjusting the steering wheel, try moving it up and down to make sure it is locked in position.
Since the mirror surfaces can get hot, keep your hands off them when the defogger switch is on. Adjust the mirror so that you can just see the side of your vehicle in the mirror. Be careful when judging the size or distance of any object seen in the outside rear view mirror on the passenger’s side. It is a convex mirror with a curved surface. Any object seen in a convex mirror will look smaller and farther away than when seen in a flat mirror. On some models, when you push the rear window defogger switch, the heater panels in the outside rear view mirrors will quickly clear the mirror surface. 74 ’99camry U —Rear view mirror remote control —Power rear view mirror control NOTICE If ice should jam the mirror, do not operate the control or scrape the mirror face. Use a spray de–icer to free the mirror. To adjust the rear view mirror, simply operate the control lever. NOTICE If ice should jam the mirror, do not operate the control or scrape the mirror face. Use a spray de–icer to free the mirror. To adjust a mirror, use the switches. 1. Master switch—To select the mirror to be adjusted Place the switch at ”L” (left) or ”R” (right). 2. Control switch—To move the mirror Push the switch in the desired direction. Mirror can be adjusted when key is in the ”ACC” or ”ON” position. 75 ’99camry U Anti–glare inside rear view mirror Sun visors— CAUTION Do not adjust the mirror while the vehicle is moving. It may cause the driver to mishandle the vehicle and an accident may occur resulting in personal injuries. Adjust the mirror so that you can just see the rear of your vehicle in the mirror. To block out glare, move the sun visor. To reduce glare from the headlights of the vehicle behind you during night driving, operate the lever on the lower edge of the mirror. To block out glare from the side—Swing down the sun visor, remove it from the hook and swing it to the lateral side (position 2). Daylight driving—Lever at position 1 If glare comes from obliquely behind you, extend the plate at the end of the visor (to position 3 or 4). The reflection in the mirror has greater clarity at this position. Night driving—Lever at position 2 Remember that by reducing glare you also lose some rear view clarity. 76 To block out glare from the front—Swing down the sun visor (position 1). ’99camry U —Vanity mirrors CAUTION Do not extend the plate at the end of the sun visor when the visor is in the position 1. It can cover the anti–glare inside rear view mirror and obstruct the rear view. To use the vanity mirrors, swing down the sun visor and open the cover. On some models, the vanity light comes on when you open the cover. 77 ’99camry U 78 ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Headlights and turn signals NOTICE To prevent the battery from being discharged, do not leave the lights on for a long period when the engine is not running. Chapter 1–4 Lights, Wipers and Defogger Daytime running light system The headlights turn on at reduced intensity when the parking brake is released with the engine started, even with the light switch in the ”OFF” position. They will not go off until the ignition switch is turned off.
Headlights and turn signals
Emergency flashers
Instrument panel light control
Interior light
Ignition switch light
Personal light
Windshield wipers and washer
Rear window and outside rear view mirror defoggers HEADLIGHTS To turn on the following lights: Twist the headlight/turn signal lever knob. Position 1—Parking, tail, license plate, side marker and instrument panel lights Position above 2—Headlights and all of the The lights automatically turn off when the driver’s door is opened with the ignition turned off. To turn them on again, turn the key to the ”ON” position or actuate the headlight switch. If you are going to park for over one week, make sure the headlight switch is off. To turn on the other exterior lights and instrument panel lights, twist the knob to the position 1. Twist the knob to the position 2 to turn the headlights to full intensity for driving at night. The headlights automatically turn to full intensity in the twilight even with the light switch in the ”OFF” position. 79 ’99camry U The daytime running light control sensor is on the top of the passenger’s side instrument panel. Do not place anything on the instrument panel, and/or do not affix anything on the windshield to block this sensor. High–Low beams—For high beams, turn the headlights on and push the lever away from you (position 1). Pull the lever toward you (position 2) for low beams. TURN SIGNALS The headlight high beam indicator light (blue light) on the instrument panel will tell you that the high beams are on. The key must be in the ”ON” position. Flashing the high (position 3)—Pull the back. The high beam when you release the beam headlights lever all the way headlights turn off lever. You can flash the high beam headlights with the knob turned to ”OFF”. 80 To signal a turn, push the headlight/ turn signal lever up or down to position 1. The lever automatically returns after you make a turn, but you may have to return it by hand after you change lanes. To signal a lane change, move the lever up or down to the pressure point (position 2) and hold it. If the turn signal indicator lights (green lights) on the instrument panel flash faster than normal, a front or rear turn signal bulb is burned out. ’99camry U Emergency flashers Instrument panel light control NOTICE To prevent the battery from being discharged, do not leave the switch on longer than necessary when the engine is not running. To turn on the push the switch. emergency flashers, To adjust the brightness of the instrument panel lights, turn the knob. All the turn signal lights will flash. To turn them off, push the switch once again. Turn on the emergency flashers to warn other drivers if your vehicle must be stopped where it might be a traffic hazard. Always pull as far off the road as possible. The turn signal light switch will not work when the emergency flashers are operating. 81 ’99camry U Interior light Ignition switch light Personal light To turn on the interior light, slide the switch. For easy access to the ignition switch, the ignition switch light comes on when any of the doors are opened. To turn on the personal light, push the switch. To turn it off, push the switch once again. The interior light switch has the following positions: ”ON”—Keeps the light on all the time. ”OFF”—Turns the light off. ”DOOR”—Turns the light on when any of the door is opened. The light goes off when all the doors are closed. On some models, the light remains on for some time after all of the doors are closed. 82 The light remains on for a certain time after all the doors are closed. Vehicles with power door lock system —When all the doors are locked or the ignition switch is turned to ”ACC”, ”ON” after all the doors are closed, the light fades out. ’99camry U Windshield wipers and washer Rear window and outside rear view mirror defoggers To squirt washer fluid, pull the lever toward you. If the windshield wipers are off, they will operate a couple of times after the washer squirts. For instructions on adding washer fluid, see ”Adding washer fluid” in Chapter 7–3. In freezing weather, warm the windshield with the defroster before using the washer. This will help prevent the washer fluid from freezing on your windshield, which can block your vision. To turn on the windshield wipers, move the lever to the desired setting. The key must be in the ”ON” position. Lever position Speed setting Position 1 Intermittent Position 2 Slow Position 3 Fast With interval adjuster: The ”INT TIME” band lets you adjust the wiping time interval when the wiper lever is in the intermittent position (position 1). Twist the band upward to increase the time between sweeps, and downward to decrease it. NOTICE Do not operate the wipers if the windshield is dry. It may scratch the glass. To defog or defrost the rear window, push the switch. The key must be in the ”ON” position. The thin heater wires on the inside of the rear window will quickly clear the surfaces. An indicator light will illuminate to indicate the defogger is operating. On some models, heater panels in the outside rear view mirrors will also quickly clear the surfaces. Push the switch once again to turn the defogger off. The system will automatically shut off after the defogger has operated about 15 minutes. 83 ’99camry U CAUTION Since the mirror surfaces can get hot keep your hands off them when the defogger switch is on. Make sure you turn the defoggers off when the surfaces are clear. Leaving the defoggers on for a long time could cause the battery to discharge, especially during stop–and–go driving. The defoggers are not designed for drying rain water or for melting snow. If the outside rear view mirrors are heavily coated with ice, use a spray de–icer before operating the switch. NOTICE When cleaning the inside of the rear window, be careful not to scratch or damage the heater wires. 84 ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–5 Gauges, Meters and Service reminder indicators
Fuel gauge
Engine coolant temperature gauge
Tachometer
Odometer and two trip meters
Service reminder indicators and warning buzzers Fuel gauge On inclines or curves, due to the movement of fuel in the tank, the fuel gauge needle may fluctuate or the low fuel level warning light may come on earlier than usual. If the fuel tank is completely empty, the malfunction indicator lamp comes on. Fill the fuel tank immediately. Low fuel level warning light The indicator lamp goes off after driving several times. If the indicator lamp does not go off, contact your Toyota dealer as soon as possible. The gauge works when the ignition switch is on and indicates the approximate quantity of fuel remaining in the tank. Nearly full—Needle at ”F” Nearly empty—Needle at ”E” It is a good idea to keep the tank over 1/4 full. This fuel gauge has a non–return type needle which remains at the last indicated position when the ignition switch is turned off. If the fuel level approaches ”E” or the low fuel level warning light comes on, fill the fuel tank as soon as possible. 85 ’99camry U Engine coolant temperature gauge Tachometer
Idling for a long period with the air conditioning on in stop–and–go traffic.
Towing a trailer. NOTICE  Do not remove the thermostat in the engine cooling system as this may cause the engine to overheat. The thermostat is designed to control the flow of coolant to keep the temperature of the engine within the specified operating range. The gauge indicates the engine coolant temperature when the ignition switch is on. The engine operating temperature will vary with changes in weather and engine load. If the needle moves into the red zone, your engine is too hot. If your vehicle overheats, stop your vehicle and allow the engine to cool. Your vehicle may overheat during severe operating conditions, such as:
Driving up a long hill on a hot day.
Reducing speed or stopping after high speed driving. 86  Do not continue driving with an overheated engine. See ”If your vehicle overheats” in Part 4. The tachometer indicates engine speed in thousands of rpm (revolutions per minute). Use it while driving to select correct shift points and to prevent engine lugging and overrevving. Driving with the engine running too fast causes excessive engine wear and poor fuel economy. Remember, in most cases the slower the engine speed, the greater the fuel economy. NOTICE Do not let the indicator needle get into the red zone. This may cause severe engine damage. ’99camry U Service reminder indicators and warning buzzers Odometer and two trip meters 3. Trip meter reset knob—It can reset the two trip meters to zero, and also change the meter display. To change the meter display, quickly push and release the knob. The meter display changes in the order from the odometer to trip meter A to trip meter B, then back to the odometer each time you push. This meter displays the odometer and two trip meters. 1. Odometer—It shows the total distance the vehicle has been driven. 2. Two trip meters—They show two different distances independently driven since the last time each trip meter was set to zero. You can use one trip meter to calculate the fuel economy and the other to measure the distance on each trip. All trip meter data is cancelled if the electrical power source is disconnected. To reset the trip meter A to zero, display the meter A reading, then push and hold the knob until the meter is set to zero. The same process can be applied for resetting the trip meter B. Do this . If the indicator or buzzer comes on... ( a) (type A) If parking brake is off, stop and check. (type B) (b) Fasten seat belts. (Indicator and buzzer) (c) Stop and check. (d) Take vehicle to Toyota dealer. (e) Low fuel level warning light Fill up tank. 87 ’99camry U If the indicator or buzzer comes on... Do this. If the indicator or buzzer comes on... Do this. (a) Brake System Warning Light This light has the following functions: Parking brake reminder (f) (g) (type A) Stop and check . (k) Add washer fluid. If this light is on, make sure the parking brake is fully released. The light should go off. Take vehicle to Toyota dealer immediately. (l) Take vehicle to Toyota dealer. Low brake fluid level warning (type B) (h) (m) Close all doors. (i) Replace bulb. (j) Take vehicle to Toyota dealer immediately. Key reminder buzzer Remove key. If this light comes on and stays on while you are driving, slow down and pull off the road. Then stop the vehicle carefully. Remember that stopping distance and pedal effort may be increased. There may be a problem somewhere in the brake system. Check the fluid level of the see– through reservoir. To make sure the parking brake has not caused the warning light to come on, check to see that the parking brake is fully released. If the brake fluid level is low... At a safe place, test your brakes by starting and stopping.
If you judge that the brakes still work adequately, drive cautiously to your nearest dealer or shop for repairs.
If the brakes are not working, have the vehicle towed in for repairs. (For towing information, see Part 4.) 88 ’99camry U It is dangerous to continue driving normally when the brake fluid level is low. If the brake fluid level is correct... Have the warning system checked by your Toyota dealer. (b) Seat Belt Reminder Light and Buzzer Once the ignition key is turned to ”ON” or ”START”, the reminder light and buzzer come on if the driver’s seat belt is not fastened. Unless the driver fastens the belt, the light stays on and the buzzer stops after about 4 to 8 seconds. (c) Discharge Warning Light This light warns that the battery is being discharged. If it comes on while you are driving, there is a problem somewhere in the charging system. The engine ignition will continue to operate, however, until the battery is discharged. Turn off the air conditioning, blower, radio, etc., and drive directly to the nearest Toyota dealer or repair shop. (f) Low Oil Pressure Warning Light NOTICE CAUTION Do not continue driving if the engine drive belt is broken or loose. (d) Malfunction Indicator Lamp This lamp cases. comes on in the following a. The fuel tank is completely empty. (See ”Fuel gauge” in Chapter 1–5 for instructions.) b. The fuel tank cap is not tightened securely. (See ”Fuel tank cap” in Chapter 1–2 for instructions.) c. There is a problem somewhere in your engine or automatic transmission electrical system. If it comes on while you are driving in case c, have your vehicle checked/repaired by your Toyota dealer as soon as possible. (e) Low Fuel Level Warning Light This light warns that the engine oil pressure is too low. If it flickers or stays on while you are driving, pull off the road to a safe place and stop the engine immediately. Call a Toyota dealer or qualified repair shop for assistance. The light may occasionally flicker when the engine is idling or it may come on briefly after a hard stop. There is no cause for concern if it then goes out when the engine is accelerated slightly. The light may come on when the oil level is extremely low. It is not designed to indicate low oil level, and the oil level must be checked using the level dipstick. NOTICE Do not drive the vehicle with the warning light on—even for one block. It may ruin the engine. This light comes on when the fuel level in the tank becomes nearly empty. Fill up the tank as soon as possible. On inclines or curves, due to the movement of fuel in the tank, the low fuel level warning light may come on earlier than usual. 89 ’99camry U (g) ”ABS” Warning Light This light warns that there is a problem somewhere in your anti–lock brake system. If the light comes on while you are driving, have your vehicle checked by your Toyota dealer as soon as possible. The light will come on when the ignition key is turned to the ”ON” position. After a few seconds, the light will go off. When the ”ABS” warning light is on (and the brake system warning light is off), the brake system operates conventionally but anti–lock brake system is not assisting brake performance so that the wheels can lock–up during sudden braking or braking on slippery road surfaces. (h) Open Door Warning Light This light remains on until all the doors and back door are completely closed. (i) Rear Light Failure Warning Light If this light comes on when the headlight switch is turned on (at the first or second clickstop), it indicates that one or more of the tail lights are burned out. If it comes on when the brake pedal is depressed, one or more stop lights are burned out. Have defective bulbs replaced as soon as possible. (j) SRS Airbag Warning Light This light will come on when the ignition key is turned to the ”ACC” or ”ON” position. After about 6 seconds, the light will go off. This means the systems of the airbag and front seat belt pretensioner are operating properly. The warning light system monitors the front airbag sensors, airbag sensor assembly, seat belt pretensioner assemblies, inflators, warning light, interconnecting wiring and power sources. The light warns that the windshield washer fluid level is too low. Add washer fluid at your earliest opportunity. (For instructions, see ”Adding washer fluid” in Chapter 7–3.) (l) ”TRAC OFF” Indicator/Warning Light This light is turned seconds. operating comes on when the ignition key to ”ON”, and will go off after 3 This means that the system is properly. If one of the following conditions occurs, this indicates a malfunction somewhere in the parts monitored by the warning light system. Contact your Toyota dealer as soon as possible to service the vehicle.
The light remains on more than 3 seconds after the ignition switch is turned on. If either of the following conditions occurs, this indicates a malfunction somewhere in the parts monitored by the warning light system. Contact your Toyota dealer as soon as possible to service the vehicle.
The light comes on while driving even
The light does not come on when the
The light flashes. ignition key is turned to the ”ACC” or ”ON” position or remains on.
The light comes on or flashes while driving. 90 (k) Low Windshield Washer Fluid Level Warning Light if the ”TRAC pushed. OFF” switch is not ’99camry U (m) Key Reminder Buzzer This buzzer reminds you to remove the key when you open the driver’s door with the ignition key in the ”ACC” or ”LOCK” position. CHECKING SERVICE REMINDER INDICATORS (except the low fuel level warning light and low windshield washer fluid level warning light) If any service reminder indicator or warning buzzer does not function as described above, either the bulb is burned out or the circuit is in need of repair. Have it checked by your Toyota dealer as soon as possible. 1. Apply the parking brake. 2. Open one of the doors. The open door warning light should come on. 3. Close the door. The open door warning light should go off. 4. Turn the ignition key to ”ACC”. The SRS airbag warning light should come on. It goes off after about 6 seconds. 5. Turn the ignition key to ”ON”, but do not start the engine. All the service reminder indicators except the open door warning light, SRS airbag warning light and low windshield washer fluid level warning light should come on. The ”ABS” warning light goes off after a few seconds. 91 ’99camry U 92 ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Ignition switch with steering lock You must push in the key to turn the key from ”ACC” to the ”LOCK” position. On vehicles with an automatic transmission, the selector lever must be put in the ”P” position before pushing the key. Vehicles with engine immobiliser system— Once you remove the key, the engine immobiliser system is automatically set. (See ”Engine immobiliser system” in Chapter 1–2.) Chapter 1–6 Ignition switch, Transmission and Parking brake
Ignition switch with steering lock
Automatic transmission
Manual transmission
Parking brake
Cruise control ”START”—Starter motor on. The key will return to the ”ON” position when released. For starting tips, see Part 3. ”ON”—Engine on and all accessories on. This is the normal driving position. ”ACC”—Accessories such as the radio operate, but the engine is off. When starting the engine, the key may seem stuck at the ”LOCK” position. To free it, first be sure the key is pushed all the way in, and then rock the steering wheel slightly while turning the key gently. CAUTION For manual transmission: Never remove the key when the vehicle is moving, as this will lock the steering wheel and result in loss of steering control. If you leave the key in the ”ACC” or ”LOCK” position and open the driver’s door, a buzzer will remind you to remove the key. ”LOCK”—Engine is off and the steering wheel is locked. The key can be removed only at this position. 93 ’99camry U NOTICE Do not leave the key in the ”ON” position if the engine is not running. The battery will discharge and the ignition could be damaged. 94 ’99camry U Automatic transmission Lock release button To prevent misshifting Parking, engine starting and key removal postition Reverse position Overdrive switch For selecting either a three–speed or four–speed transmission ON position (Shifting into overdrive possible) Neutral position Normal driving position Position for engine braking Position for stronger engine braking than that in ”2” position With the brake pedal depressed, shift while holding the lock release button in. (The ignition switch must be in ”ON” position.) Shift while holding the lock release button in OFF position (Shifting into overdrive not possible) ”O/D OFF” indicator light shows the overdrive switch is in OFF position Shift normally Vehicles with cruise controlWhen the cruise control is being used, even if you downshift the transmission by turning off the overdrive switch, engine braking will not be applied because the cruise control is not cancelled. For ways to decrease the vehicle speed, see ”Cruise control” in this chapter. 95 ’99camry U Your automatic transmission has a shift lock system to minimize the possibility of incorrect operation. This means you can only shift out of ”P” position when the brake pedal is depressed (with the ignition switch in ”ON” position and the lock release button depressed). (a) Normal driving 1. Start the engine as instructed in ”How to start the engine” in Part 3. The transmission must be in ”P” or ”N”. 2. With your foot holding down the brake pedal, shift the selector lever to ”D”. In ”D” position, the automatic transmission system will select the most suitable gear for the running conditions such as normal cruising, hill climbing, hard towing, etc. Always turn the overdrive switch on for better fuel economy and quieter driving. If the engine coolant temperature is low, the transmission will not shift into overdrive gear even with the overdrive switch on. CAUTION Never put your foot on the accelerator pedal while shifting. 96 3. Release the parking brake and brake pedal. Depress the accelerator pedal slowly for smooth starting. (b) Using engine braking To use engine braking, you can downshift the transmission as follows:
Turn off the overdrive switch. The ”O/D OFF” indicator light will come on and the transmission will downshift to the third gear.
Shift into the ”2” position. The transmission will downshift to the second gear when the vehicle speed drops down to or lower than the following speed, and more powerful engine braking will be obtained. 5S–FE engine . . . 106 km/h (65 mph) 1MZ–FE engine . . 122 km/h (75 mph)
Shift into the ”L” position. The transmission will downshift to the first gear When the vehicle speed drops down to or lower than the following speed, and maximum engine braking will be applied. 5S–FE engine . . . 1MZ–FE engine . . 46 km/h (28 mph) 55 km/h (34 mph) Vehicles with cruise controlWhen the cruise control is being used, even if you downshift the transmission by turning off the overdrive switch, engine braking is not applied because the cruise control is not cancelled. For ways to decrease the vehicle speed, see ”Cruise control” in this chapter. CAUTION Be careful when downshifting on a slippery surface. Abrupt shifting could cause the vehicle to spin or skid. (c) Using ”2” and ”L” positions The ”2” and ”L” positions are used for strong engine braking as described previously. With the selector lever in ”2” or ”L”, you can start the vehicle in motion as with the lever in ”D”. With the selector lever in ”2”, the vehicle will start in the first gear and automatically shift to the second gear. With the selector lever in ”L”, the transmission is engaged in the first gear. ’99camry U NOTICE  Be careful not to overrev the engine. Watch the tachometer to keep engine rpm from going into the red zone. The approximate maximum allowable speed for each position is given below for your reference: ”2” . . . . . . . . . 125 km/h (77 mph) ”L” . . . . . . . . . . 69 km/h (42 mph)  Do not continue hill climbing or hard towing for a long time in the ”2” or ”L” position. This may cause severe automatic transmission damage from overheating. To prevent such damage, ”D” position should be used in hill climbing or hard towing. (e) Parking 1. Bring the vehicle to a complete stop. 2. Pull the parking brake lever up fully to securely apply the parking brake. 3. With the brake pedal pressed down, shift the selector lever to the ”P” position. CAUTION While the vehicle is moving, never attempt to move the selector lever into ”P” position under any circumstances. Serious mechanical damage and loss of vehicle control may result. CAUTION Always keep your foot on the brake pedal while stopped with the engine running. This prevents the vehicle from creeping. NOTICE Do not hold the vehicle on an upgrade with the accelerator pedal. It can cause the transmission to overheat. Always use the brake pedal or parking brake. (f) Good driving practice
If the transmission is repeatedly up- (d) Backing up 1. Bring the vehicle to a complete stop. 2. With the brake pedal held down with your foot, shift the selector lever to the ”R” position. NOTICE Never shift into reverse while the vehicle is moving. shifted and downshifted between the third gear and overdrive when climbing a gentle slope, the overdrive switch should be turned off. Be sure to turn the switch on immediately afterward.
When towing a trailer, in order to maintain engine braking efficiency, do not use overdrive. 97 ’99camry U Manual transmission (g) Rocking your vehicle if stuck CAUTION If your vehicle becomes stuck in snow, mud, sand, etc., then you may attempt to rock your vehicle free by moving it forward and backward. Do not attempt this procedure if people or objects are anywhere near the vehicle. During the rocking operation the vehicle may suddenly move forward or backward as it becomes unstuck, causing injury or damage to nearby people or objects. NOTICE If you rock your vehicle, observe the following precautions to prevent damage to the transmission and other parts.  Do not depress the accelerator pedal while shifting the selector lever or before the transmission is completely shifted to forward or reverse gear.  Do not race the engine and avoid spinning the wheels. 98  If your vehicle remains stuck after rocking the vehicle several times, consider other ways such as towing. (h) If you cannot shift the selector lever out of ”P” position If you cannot shift the selector lever from ”P” position even though the brake pedal is depressed, use the shift lock override button. For instructions, see ”If you cannot shift automatic transmission selector lever” in Part 4. The shift pattern is conventional as shown above. Press the clutch pedal down fully while shifting, and then release it slowly. Do not rest your foot on the pedal while driving, because it will cause clutch trouble. And do not use the clutch to hold the vehicle when stopped on an uphill grade—use the parking brake. Recommended shifting speeds The transmission is fully synchronized and upshifting or downshifting is easy. For the best compromise between fuel economy and vehicle performance, you should upshift or downshift at the following speeds: ’99camry U Parking brake 1 2 3 4 to to to to 2 3 4 5 gear or 2 or 3 or 4 or 5 to to to to 1 2 3 4 km/h 24 40 64 72 (mph) (15) (25) (40) (45) Downshift to the appropriate gear if acceleration is needed when you are cruising below the above downshifting speeds. Upshifting too soon or downshifting too late will cause lugging, and possibly pinging. Regularly revving the engine to maximum speed in each gear will cause excessive engine wear and high fuel consumption. Maximum allowable speeds To get on a highway or to pass slower traffic, maximum acceleration may be necessary. Make sure you observe the following maximum allowable speeds in each gear: gear 1 2 3 km/h 52 93 147 Good driving practice
If it is difficult to shift into reverse, put the transmission in neutral, release the clutch pedal momentarily, and then try again.
When towing a trailer, in order to maintain engine braking efficiency, do not use the fifth gear. CAUTION Be careful when downshifting on a slippery surface. Abrupt shifting could cause the vehicle to spin or skid. Type A NOTICE Make sure the vehicle is completely stopped before shifting into reverse. (mph) (32) (57) (91) NOTICE Do not downshift if you are going faster than the maximum allowable speed for the next lower gear. Type B 99 ’99camry U Cruise control When parking, firmly apply the parking brake to avoid inadvertent creeping. To set: Pull up the lever. For better holding power, first depress the brake pedal and hold it while setting the brake. To release: Pull up the lever slightly, press the thumb button, and lower. The cruise control allows you to cruise the vehicle at a desired speed over 40 km/h (25 mph) even with your foot off the accelerator pedal. To remind you that the parking brake is set, the parking brake reminder light in the instrument panel remains on until you release the parking brake. Your cruising speed can be maintained up or down grades within the limits of engine performance, although a slight speed change may occur when driving up or down the grades. On steeper hills, a greater speed change will occur so it is better to drive without the cruise control. CAUTION CAUTION Before driving, be sure the parking brake is fully released and the parking brake reminder light is off.
To help maintain maximum control of your vehicle, do not use the cruise control when driving in heavy or varying traffic, or on slippery (rainy, icy or snow–covered) or winding roads.
Avoid vehicle speed increases when driving downhill. If the vehicle speed is too fast in relation to the cruise control set speed, cancel the cruise control then downshift the transmission to use engine braking to slow down. 100 TURNING ON THE SYSTEM To operate the cruise control, press the ”CRUISE ON–OFF” button. This turns the system on. The indicator light in the instrument panel shows that you can now set the vehicle at a desired cruising speed. Another press will turn the system completely off. CAUTION To avoid accidental cruise control engagement, keep the ”CRUISE ON– OFF” switch off when not using the cruise control. ’99camry U If you need acceleration—for example, when passing—depress the accelerator pedal enough for the vehicle to exceed the set speed. When you release it, the vehicle will return to the speed set prior to the acceleration. CAUTION For manual transmission: SETTING AT A DESIRED SPEED On vehicles with automatic transmission, the transmission must be in ”D” before you set the cruise control speed. Bring your vehicle to the desired speed, push the lever down in the ”SET/COAST” direction and release it. This sets the vehicle at that speed. If the speed is not satisfactory, tap the lever up for a faster speed, or tap it down for a slower speed. Each tap changes the set speed by 1.6 km/h (1.0 mph). You can now take your foot off the accelerator pedal. While driving with the cruise control on, do not shift to neutral without depressing the clutch pedal, as this may cause engine racing or overrevving. CANCELLING THE PRESET SPEED You can cancel the preset speed by: a. Pulling the lever in the ”CANCEL” direction and releasing it. b. Depressing the brake pedal. c. Depressing the clutch pedal (manual transmission). If the preset speed automatically cancels out other than for the above cases, have your vehicle checked by your Toyota dealer at the earliest opportunity. RESETTING AT A FASTER SPEED Push the lever up in the ”RES/ACC” direction and hold it. Release the lever when the desired speed is attained. While the lever is held up, the vehicle will gradually gain speed. However, a faster way to reset is to accelerate the vehicle and then push the lever down in the ”SET/COAST” direction. RESETTING AT A SLOWER SPEED Push the lever down in the ”SET/COAST” direction and hold it. Release the lever when the desired speed is attained. While the lever is held down, the vehicle speed will gradually decrease. However, a faster way to reset is to depress the brake pedal and then push the lever down in the ”SET/COAST” direction. If the vehicle speed falls below about 40 km/h (25 mph), the preset speed will automatically cancel out. If the vehicle speed drops 16 km/h (10 mph) below the preset speed,the preset speed will also automatically cancel out. 101 ’99camry U On vehicles with automatic transmission, even if you turn off the overdrive switch, with the cruise control on, engine braking will not be applied because the cruise control is not cancelled. To decrease the vehicle speed, reset to a slower speed with the cruise control lever or depress the brake pedal. If you use the brake pedal, cruise control is cancelled. RESUMING THE PRESET SPEED If the preset speed is cancelled by pulling the control lever or by depressing the brake pedal or clutch pedal, pushing the lever up in the ”RES/ACC” direction will restore the speed set prior to cancellation. However, once the vehicle speed falls below about 40 km/h (25 mph), the preset speed will not be resumed. CRUISE CONTROL FAILURE WARNING If the ”CRUISE” indicator light in the instrument cluster flashes when using the cruise control, press the ”CRUISE ON– OFF” button to turn the system off and then press it again to turn it on. If any of the following conditions then occurs, there is some trouble in the cruise control system. 102
The indicator light does not come on.
The indicator light flashes again.
The indicator light goes out after it comes on. If this is the case, contact your Toyota dealer and have your vehicle inspected. ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Car audio system— —Reference Chapter 1–7 Car audio system and Air conditioning system Car audio system  Reference Type 1: AM· FM ETR radio/cassette player/ compact disc auto changer controller Type 3: AM· FM ETR radio/cassette player/ compact disc auto changer controller Type 2: AM· FM ETR radio/compact disc player/compact disc auto changer controller Type 4: AM·FM ETR radio/cassette player/compact disc player/compact disc auto changer controller  Using your audio system: some basics  Using your audio system: controls and features  Car audio system operating hints Air conditioning system  Controls  Air flow selector settings  Operating tips  Side vents 103 ’99camry U —Using your audio system: some basics This section describes some of the basic features on Toyota audio systems. Some information may not pertain to your system. TONE AND BALANCE Your audio system works when the ignition key is in the ”ACC” or ”ON” position. Tone TURNING THE SYSTEM ON AND OFF Push ”PWR·VOL”, ”PWR/VOL” or ”VOL/ PWR” to turn the audio system on and off. Type 5: AM·FM ETR radio/cassette player/compact disc player/compact disc auto changer controller Push ”AM”, ”FM”, ”AM·FM”, ”TAPE” or ”CD” to turn on that function without pushing ”PWR·VOL”, ”PWR/VOL” or ”VOL/ PWR”. You can turn on each player by inserting a cassette tape or compact disc. You can turn off each player by ejecting the cassette tape or compact disc. If the audio system was previously off, then the entire audio system will be turned off when you eject the cassette tape or compact disc. If the another function was previously playing, it will come on again. SWITCHING BETWEEN FUNCTIONS Push ”AM”, ”FM”, ”AM·FM”, ”TAPE” or ”CD” if the system is already on but you want to switch from one function to another. 104 For details about your system’s tone and balance controls, see the description of your own system. How good an audio program sounds to you is largely determined by the mix of the treble, midrange, and bass levels. In fact, different kinds of music and vocal programs usually sound better with different mixes of treble, midrange, and bass. Balance A good balance of the left and right stereo channels and of the front and rear sound levels is also important. Keep in mind that if you are listening to a stereo recording or broadcast, changing the right/left balance will increase the volume of one group of sounds while decreasing the volume of another. ’99camry U YOUR RADIO ANTENNA NOTICE Attaching the film (especially conductive or metallic type) on the rear glass will noticeably reduce the sensitivity of the radio. YOUR CASSETTE PLAYER When you insert a cassette, the exposed tape should be to the right. NOTICE Do not oil any part of the player and do not insert anything other than cassette tapes into the slot, or the tape player may be damaged. YOUR COMPACT DISC PLAYER When you insert a disc, gently push it in with the label side up. (The player will automatically eject a disc if the label side is down.) The compact disc player will play from track 1 through the end of the disc. Then it will play from track 1 again. NOTICE Never try to disassemble or oil any part of the compact disc player. Do not insert anything except a compact disc into the slot. 8 cm (3 in.) compact disc singles Your compact disc player does not need an adaptor to play compact disc singles. Compact disc singles are about 8 cm (3 in.) in diameter–smaller than standard discs. After you eject a compact disc single, do not insert a standard 12 cm (5 in.) disc until ”DISC” disappears from the display. NOTICE Do not use an adaptor for compact disc singles—it could cause tracking errors or interfere with the ejection of compact discs. 105 ’99camry U —Using your audio system: controls and features
Type 1 Details of specific buttons, controls and features are described in the alphabetical listing that follows. 106 ’99camry U 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see ”TUNE” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show ”AM”, ”FM1” or ”FM2” when you push ”AM” or ”FM”). (Eject button) Push this button to eject a cassette. After you turn the ignition to ”LOCK”, you will be able to eject a cassette but you will not be able to reinsert it. (Reverse/Fast forward buttons) Cassette Player Push the fast forward button to fast forward a cassette tape. ”FF” will appear on the display. Push the reverse button to rewind a tape. ”REW” will appear on the display. To stop the tape while it is fast forwarding, push the fast forward button or ”TAPE”; to stop the tape while it is rewinding, push the reverse button or ”TAPE”. If a tape side rewinds completely, the cassette player will stop and then play that same side. If a tape fast forwards completely, the cassette player will play the other side of the tape, using the auto–reverse feature. Compact Disc Player If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. AM Push ”AM” to switch the AM band. ”AM” will appear on the display. If the audio system is off, you can turn on the radio by pushing ”AM”. Also, push ”AM” to switch from cassette or compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— This knob is used to adjust the tone manually. For low–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAS” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”BAS –5” to ”BAS 5”. For high–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”TRE –5” to ”TRE 5”. 107 ’99camry U Sound balance adjustment function— CD (Compact Disc) This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. Push ”CD” to switch from radio or cassette operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing ”CD”. In both cases, a disc must already be loaded in the player. For front/rear adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from ”FAd F7” to ”FAd R7”. For left/right adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAL” appears on the display. Then turn the knob to adjust the left/right balance. The display will show the range from ”BAL L7” to ”BAL R7”. If ”Err 3” or ”Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push ”CD”, the system changes between single disc player and automatic changer. If ”OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the player malfunctions, your audio system will display one of the six following error messages. DISC 
If ”WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. By using this button, you can select a disc you wish to listen to. If ”Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. 108 If ”Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If the malfunction is not rectified, take your vehicle to your Toyota dealer. Compact disc auto changer only— Push either side of the button until the number of the disc you want to listen to appears on the display. ’99camry U Dolby B NR∗ If you are listening to a tape that was recorded with Dolby B Noise Reduction, push the button marked with the double–D symbol. The double–D symbol will appear on the display. Push the button again to turn off Dolby B NR. The Dolby NR mode reduces tape noise by about 10 dB. For best sound reproduction, play your tapes with this button on or off according to the mode used for recording the tape. ∗ : Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation. ”DOLBY” and the double D symbol are trademarks of Dolby Laboratories Licensing Corporation. FM RAND (Random) Push ”FM” to switch the FM band. ”FM1” or ”FM2” will appear on the display. This system allows you to set twelve FM stations, two for each button. There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. If the audio system is off, you can turn on the radio by pushing ”FM”. Also, push ”FM” to switch from cassette or compact disc operation to radio operation. PROG (Program) Push ”PROG” to select the other side of a cassette tape. The display indicates which side is currently selected (” ” indicates top side, ” ” indicates bottom side). Auto–reverse feature: After the cassette player reaches the end of a tape side, it automatically reverses and begins to play the other side. This is true whether the cassette was playing or fast forwarding. Random playing for the tracks on a disc: Quickly push and release ”RAND”. ”RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the ”RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold ”RAND” until you hear a beep. ”D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push ”RAND” a second time. 109 ’99camry U RPT (Repeat) SCAN Compact disc player There are two repeat features—you can either replay a disc track or a whole compact disc. Radio There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Repeating a track: Quickly push and release ”RPT” while the track is playing. ”RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. Compact disc auto changer only— Repeating a disc: Push and hold ”RPT” until you hear a beep. ”D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. This process will be continued until you push the button again to turn off the repeat feature. 110 You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold ”SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push ”SCAN” a second time. To scan all the frequencies: Quickly push and release ”SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push ”SCAN” a second time. Scanning for the tracks on a disc: Quickly push and release ”SCAN”. ”SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the ”SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. Compact disc auto changer only— Scanning for the first tracks of all the discs in the magazine: Push and hold ”SCAN” until you hear a beep. ”D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the ”SCAN” a second time. If the player has scanned all the discs, it will stop scanning. ’99camry U ST (Stereo reception) display TUNE Your radio automatically changes to stereo reception when a stereo broadcast is received. ”ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. Tuning TAPE In the seek mode, the radio finds and plays the next station up or down the station band. Push ”TAPE” to switch from radio or compact disc operation to cassette operation. If the audio system is off, you can turn on the cassette player by pushing ”TAPE”. In both cases, a cassette must already be loaded in the player. TRACK (Track up/down Compact disc player button): By using this button, you can skip up or down to a different track. Your Toyota has an electronic tuning radio (ETR). Push and release the ”
” (up) or ”” (down) side of ”TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) Seeking To seek a station, push and hold the ”
” or ”” side of ”TUNE” until you hear a beep. Do this again to find another station. VOL/PWR (Volume/Power) Push ”VOL/PWR” to turn the audio system on and off. Turn ”VOL/PWR” to adjust the volume. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. 111 ’99camry U
Type 2 Details of specific buttons, controls, and features are described in the alphabetical listing that follows. 112 ’99camry U 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see ”TUNE” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show ”AM”, ”FM1” or ”FM2” when you push ”AM” or ”FM”). (Eject button) Push this button to eject a compact disc. After you turn the ignition to ”LOCK”, you will be able to eject a disc but you will not be able to reinsert it. (Reverse/Fast forward buttons) If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. AM⋅FM Push ”AM⋅FM” to switch between the AM and FM bands. ”AM”, ”FM1” or ”FM2” will appear on the display. These systems allow you to set twelve FM stations, two for each button. If the audio system is off, you can turn on the radio by pushing ”AM⋅FM”. Also, push ”AM⋅FM” to switch from compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— This knob is used to adjust the tone manually. For low–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAS” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”BAS –5” to ”BAS 5”. With middle–pitch tone— For middle–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”Mld” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”Mld –5” to ”Mld 5”. For high–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”TRE –5” to ”TRE 5”. 113 ’99camry U Sound balance adjustment function— CD (Compact Disc) This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. Push ”CD” to switch from radio operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing ”CD”. In both cases, a disc must already be loaded in the player. For front/rear adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from ”FAd F7” to ”FAd R7”. For left/right adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAL” appears on the display. Then turn the knob to adjust the left/right balance. The display will show the range from ”BAL L7” to ”BAL R7”. 114 If ”Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If ”Err 3” or ”Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push ”CD”, the system changes between built–in single disc player and automatic changer. If ”OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the player malfunctions, your audio system will display one of the six following error messages. DISC 
If ”WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. By using this button, you can select a disc you wish to listen to. If ”Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. Push ”PWR/VOL” to turn the audio system on and off. Turn ”PWR/VOL” to adjust the volume. If the malfunction is not rectified, take your vehicle to your Toyota dealer. Compact disc auto changer only— Push either side of the button until the number of the disc you want to listen to appears on the display. PWR/VOL (Power/Volume) ’99camry U RAND (Random) RPT (Repeat) SCAN There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. There are two repeat features—you can either replay a disc track or a whole compact disc. Radio Random playing for the tracks on a disc: Quickly push and release ”RAND”. ”RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the ”RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold ”RAND” until you hear a beep. ”D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push ”RAND” a second time. Repeating a track: Quickly push and release ”RPT” while the track is playing. ”RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. Compact disc auto changer only— Repeating a disc: Push and hold ”RPT” until you hear a beep. ”D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. This process will be continued until you push the button again to turn off the repeat feature. You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold ”SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push ”SCAN” a second time. To scan all the frequencies: Quickly push and release ”SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push ”SCAN” a second time. 115 ’99camry U Compact disc player ST (Stereo reception) display TUNE (Tuning) There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Your radio automatically changes to stereo reception when a stereo broadcast is received. ”ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. Tuning TRACK (Track up/down Compact disc player In the seek mode, the radio finds and plays the next station up or down the station band. Scanning for the tracks on a disc: Quickly push and release ”SCAN”. ”SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the ”SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. Compact disc auto changer only— Scanning for the first tracks of all the discs in the magazine: Push and hold ”SCAN” until you hear a beep. ”D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the ”SCAN” a second time. If the player has scanned all the discs, it will stop scanning. 116 button): By using this button, you can skip up or down to a different track. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. Your Toyota has an electronic tuning radio (ETR). Push and release the ”
” (up) or ”” (down) side of ”TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) Seeking To seek a station, push and hold the ”
” or ”” side of ”TUNE” until you hear a beep. Do this again to find another station. ’99camry U
Type 3 Details of specific buttons, controls, and features are described in the alphabetical listing that follows. 117 ’99camry U 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see ”TUNE” or ”SEEK” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show ”AM”, ”FM1” or ”FM2” when you push ”AM” or ”FM”). (Eject button) Push this button to eject a cassette. After you turn the ignition to ”LOCK”, you will be able to eject a cassette but you will not be able to reinsert it. 118 (Reverse/Fast forward buttons) Cassette Player Push the fast forward button to fast forward a cassette tape. ”FF” will appear on the display. Push the reverse button to rewind a tape. ”REW” will appear on the display. To stop the tape while it is fast forwarding, push the fast forward button or ”TAPE”; to stop the tape while it is rewinding, push the reverse button or ”TAPE”. If a tape side rewinds completely, the cassette player will stop and then play that same side. If a tape fast forwards completely, the cassette player will play the other side of the tape, using the auto–reverse feature. Compact Disc Player If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. AM Push ”AM” to switch the AM band. ”AM” will appear on the display. If the audio system is off, you can turn on the radio by pushing ”AM”. Also, push ”AM” to switch from cassette or compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— This knob is used to adjust the tone manually. For low–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAS” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”BAS –5” to ”BAS 5”. For middle–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”Mld” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”Mld –5” to ”Mld 5”. ’99camry U For high–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”TRE –5” to ”TRE 5”. Sound balance adjustment function— This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. For front/rear adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from ”FAd F7” to ”FAd R7”. For left/right adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAL” appears on the display. Then turn the knob to adjust the left/right balance. The display will show the range from ”BAL L7” to ”BAL R7”. CD (Compact Disc) Push ”CD” to switch from radio or cassette operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing ”CD”. In both cases, a disc must already be loaded in the player. If ”Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If ”Err 3” or ”Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push ”CD”, the system changes between single disc player and automatic changer. If ”OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the player malfunctions, your audio system will display one of the six following error messages. DISC 
If ”WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. By using this button, you can select a disc you wish to listen to. If the malfunction is not rectified, take your vehicle to your Toyota dealer. Compact disc auto changer only— Push either side of the button until the number of the disc you want to listen to appears on the display. If ”Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. 119 ’99camry U Dolby B NR∗ If you are listening to a tape that was recorded with Dolby B Noise Reduction, push the button marked with the double–D symbol. The double–D symbol will appear on the display. Push the button again to turn off Dolby B NR. The Dolby NR mode reduces tape noise by about 10 dB. For best sound reproduction, play your tapes with this button on or off according to the mode used for recording the tape. ∗ : Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation. ”DOLBY” and the double D symbol are trademarks of Dolby Laboratories Licensing Corporation. FM Push ”FM” to switch the FM band. ”FM1” or ”FM2” will appear on the display. This system allows you to set twelve FM stations, two for each button. If the audio system is off, you can turn on the radio by pushing ”FM”. Also, push ”FM” to switch from cassette or compact disc operation to radio operation. 120 MTL (Metal) Display RAND (Random) If a metal or chrome equivalent cassette tape is put in the cassette player, the player will automatically adapt to it and ”MTL” will appear on the display. There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. PROG (Program) Push ”PROG” to select the other side of a cassette tape. The display indicates which side is currently selected (” ” indicates top side, ” ” indicates bottom side). Auto–reverse feature: After the cassette player reaches the end of a tape side, it automatically reverses and begins to play the other side. This is true whether the cassette was playing or fast forwarding. Random playing for the tracks on a disc: Quickly push and release ”RAND”. ”RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the ”RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold ”RAND” until you hear a beep. ”D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push ”RAND” a second time. ’99camry U RPT (Repeat) Compact disc auto changer only— Cassette Player Repeating a disc: Push and hold ”RPT” until you hear a beep. ”D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. This process will be continued until you push the button again to turn off the repeat feature. Push ”RPT” while the track is playing. ”RPT” will appear on the display. When the track ends, it will automatically be rewound and replayed. This process will be continued until you push the button again to turn off the repeat feature. There must be at least 3 seconds of blank space between tracks in order for the repeat feature to work correctly. Compact Disc Player There are two repeat features—you can either replay a disc track or a whole compact disc. Repeating a track: Quickly push and release ”RPT” while the track is playing. ”RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. SCAN Radio You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold ”SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push ”SCAN” a second time. To scan all the frequencies: Quickly push and release ”SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push ”SCAN” a second time. Compact disc player There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Scanning for the tracks on a disc: Quickly push and release ”SCAN”. ”SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the ”SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. 121 ’99camry U Compact disc auto changer only— Cassette Player Scanning for the first tracks of all the discs in the magazine: Push and hold ”SCAN” until you hear a beep. ”D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the ”SCAN” a second time. If the player has scanned all the discs, it will stop scanning. By using this button, you can skip up or down to a different track. SEEK (Seeking) Radio In the seek mode, the radio finds and plays the next station up or down the station band. To seek a station, push and hold the ”
” or ”” side of ”TUNE” until you hear a beep. Do this again to find another station. The track number you select is not valid if it is higher than the number of tracks remaining on the current cassette side. You can skip up tp nine tracks at a time.  After the beginning of the tape is Push the up or down side of the button. ”FF 1” or ”REW 1” will appear on the display.  After the end of the tape is reached, Next, push either side of until the number on the the number of tracks you you push the button ten feature will be turned off. the track button display reaches want to skip. If times, the skip When counting the number of tracks you want to rewind, remember to count the current track as well. For example, if you want to rewind to a song that is two before the song you are listening to, push on the down side of the button until ”REW 3” appears on the display. If you have pushed the track button more than you wanted to, push the other side of the button. The track number will be reduced. reached, the player will automatically start playing the same side. the player will automatically reverse sides and start playing the other side. There must be at least 3 seconds of blank space between tracks for the track button to work correctly. In addition, the feature may not work well with some spoken word, live, or classical recordings. SKIP The skip feature allows you to fast forward past long stretches of blank tape. This is especially useful at the end of cassettes. Push ”SKIP”. ”SKIP” will appear on the display. The cassette player will keep track of how much blank space it plays. Any time it has played about 10 seconds of blank tape, it will automatically fast forward to the next track and begin to play. Push the button a second time to turn off the skip feature. 122 ’99camry U ST (Stereo reception) display TUNE (Tuning) Your radio automatically changes to stereo reception when a stereo broadcast is received. ”ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. Your Toyota has an electronic tuning radio (ETR). Push and release the ”
” (up) or ”” (down) side of ”TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) TAPE VOL/PWR (Volume/Power) Push ”VOL/PWR” to turn the audio system on and off. Turn ”VOL/PWR” to adjust the volume. Push ”TAPE” to switch from radio or compact disc operation to cassette operation. If the audio system is off, you can turn on the cassette player by pushing ”TAPE”. In both cases, a cassette must already be loaded in the player. TRACK (Track up/down Compact disc player button): By using this button, you can skip up or down to a different track. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. 123 ’99camry U
Type 4 Details of specific buttons, controls, and features are described in the alphabetical listing that follows. 124 ’99camry U 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see ”TUNE” or ”SEEK” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show ”AM”, ”FM1” or ”FM2” when you push ”AM” or ”FM”). (Eject button) Push the cassette tape eject button to eject a cassette. Push the compact disc eject button to eject a compact disc. After you turn the ignition to ”LOCK”, you will be able to eject a cassette or disc but you will not be able to reinsert it. (Reverse/Fast forward buttons) Cassette Player Push the fast forward button to fast forward a cassette tape. ”FF” will appear on the display. Push the reverse button to rewind a tape. ”REW” will appear on the display. To stop the tape while it is fast forwarding, push the fast forward button or ”TAPE”; to stop the tape while it is rewinding, push the reverse button or ”TAPE”. AM⋅FM Push ”AM⋅FM” to switch between the AM and FM bands. ”AM”, ”FM1” or ”FM2” will appear on the display. These systems allow you to set twelve FM stations, two for each button. If the audio system is off, you can turn on the radio by pushing ”AM⋅FM”. Also, push ”AM⋅FM” to switch from cassette or compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— If a tape side rewinds completely, the cassette player will stop and then play that same side. If a tape fast forwards completely, the cassette player will play the other side of the tape, using the auto–reverse feature. This knob is used to adjust the tone manually. Compact Disc Player The display will show the range from ”BAS –5” to ”BAS 5”. If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. For low–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAS” appears on the display. Then turn the knob to suit your preference. For middle–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”Mld” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”Mld –5” to ”Mld 5”. 125 ’99camry U For high–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”TRE –5” to ”TRE 5”. Sound balance adjustment function— This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. For front/rear adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from ”FAd F7” to ”FAd R7”. For left/right adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAL” appears on the display. Then turn the knob to adjust the left/right balance. The display will show the range from ”BAL L7” to ”BAL R7”. 126 CD (Compact Disc) Push ”CD” to switch from radio or cassette operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing ”CD”. In both cases, a disc must already be loaded in the player. If ”Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If ”Err 3” or ”Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push ”CD”, the system changes between built–in single disc player and automatic changer. If ”OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the player malfunctions, your audio system will display one of the six following error messages. DISC 
If ”WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. By using this button, you can select a disc you wish to listen to. If ”Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. If the malfunction is not rectified, take your vehicle to your Toyota dealer. Compact disc auto changer only— Push either side of the button until the number of the disc you want to listen to appears on the display. ’99camry U Dolby B NR∗ If you are listening to a tape that was recorded with Dolby B Noise Reduction, push the button marked with the double–D symbol. The double–D symbol will appear on the display. Push the button again to turn off Dolby B NR. The Dolby NR mode reduces tape noise by about 10 dB. For best sound reproduction, play your tapes with this button on or off according to the mode used for recording the tape. PROG (Program) Push ”PROG” to select the other side of a cassette tape. The display indicates which side is currently selected (” ” indicates top side). side, ” ” indicates bottom Auto–reverse feature: After the cassette player reaches the end of a tape side, it automatically reverses and begins to play the other side. This is true whether the cassette was playing or fast forwarding. ∗ : Dolby noise reduction manufactured under license from PWR⋅VOL (Power⋅Volume) Dolby Laboratories Licensing Corporation. ”DOLBY” and the double D symbol are trademarks of Dolby Laboratories Licensing Corporation. Push ”PWR⋅VOL” to turn the audio system on and off. Turn ”PWR⋅VOL” to adjust the volume. MTL (Metal) Display If a metal or chrome equivalent cassette tape is put in the cassette player, the player will automatically adapt to it and ”MTL” will appear on the display. RAND (Random) There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. Random playing for the tracks on a disc: Quickly push and release ”RAND”. ”RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the ”RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold ”RAND” until you hear a beep. ”D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push ”RAND” a second time. RPT (Repeat) Cassette Player Push ”RPT” while the track is playing. ”RPT” will appear on the display. When the track ends, it will automatically be rewound and replayed. This process will be continued until you push the button again to turn off the repeat feature. There must be at least 3 seconds of blank space between tracks in order for the repeat feature to work correctly. 127 ’99camry U Compact Disc Player SCAN Compact disc player There are two repeat features—you can either replay a disc track or a whole compact disc. Radio There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Repeating a track: Quickly push and release ”RPT” while the track is playing. ”RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. Compact disc auto changer only— Repeating a disc: Push and hold ”RPT” until you hear a beep. ”D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. This process will be continued until you push the button again to turn off the repeat feature. 128 You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold ”SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push ”SCAN” a second time. To scan all the frequencies: Quickly push and release ”SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push ”SCAN” a second time. Scanning for the tracks on a disc: Quickly push and release ”SCAN”. ”SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the ”SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. Compact disc auto changer only— Scanning for the first tracks of all the discs in the magazine: Push ”SCAN” until you hear a beep. ”D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the ”SCAN” a second time. If the player has scanned all the discs, it will stop scanning. ’99camry U SEEK (Seeking) Radio In the seek mode, the radio finds and plays the next station up or down the station band. To seek a station, push and hold the ”
” or ”” side of ”TUNE” until you hear a beep. Do this again to find another station. Cassette Player By using this button, you can skip up or down to a different track. When counting the number of tracks you want to rewind, remember to count the current track as well. For example, if you want to rewind to a song that is two before the song you are listening to, push on the down side of the button until ”REW 3” appears on the display. If you have pushed the track button more than you wanted to, push the other side of the button. The track number will be reduced. You can skip up tp nine tracks at a time. The track number you select is not valid if it is higher than the number of tracks remaining on the current cassette side. Push the up or down side of the button. ”FF 1” or ”REW 1” will appear on the display. reached, the player will automatically start playing the same side. Next, push either side of until the number on the the number of tracks you you push the button ten feature will be turned off. the track button display reaches want to skip. If times, the skip  After the beginning of the tape is  After the end of the tape is reached, the player will automatically reverse sides and start playing the other side. There must be at least 3 seconds of blank space between tracks for the track button to work correctly. In addition, the feature may not work well with some spoken word, live, or classical recordings. SKIP The skip feature allows you to fast forward past long stretches of blank tape. This is especially useful at the end of cassettes. Push ”SKIP”. ”SKIP” will appear on the display. The cassette player will keep track of how much blank space it plays. Any time it has played about 10 seconds of blank tape, it will automatically fast forward to the next track and begin to play. Push the button a second time to turn off the skip feature. ST (Stereo reception) display Your radio automatically changes to stereo reception when a stereo broadcast is received. ”ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. 129 ’99camry U TAPE Push ”TAPE” to switch from radio or compact disc operation to cassette operation. If the audio system is off, you can turn on the cassette player by pushing ”TAPE”. In both cases, a cassette must already be loaded in the player. TRACK (Track up/down Compact disc player button): By using this button, you can skip up or down to a different track. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. TUNE (Tuning) Your Toyota has an electronic tuning radio (ETR). Push and release the ”
” (up) or ”” (down) side of ”TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) 130 ’99camry U
Type 5 Details of specific buttons, controls, and features are described in the alphabetical listing that follows. 131 ’99camry U 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see ”TUNE” or ”SEEK” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show ”AM”, ”FM1” or ”FM2” when you push ”AM” or ”FM”). (Eject button) Push the cassette tape eject button to eject a cassette. Push the compact disc eject button to eject a compact disc. After you turn the ignition to ”LOCK”, you will be able to eject a cassette or disc but you will not be able to reinsert it. (Reverse/Fast forward buttons) Cassette Player Push the fast forward button to fast forward a cassette tape. ”FF” will appear on the display. Push the reverse button to rewind a tape. ”REW” will appear on the display. To stop the tape while it is fast forwarding, push the fast forward button or ”TAPE”; to stop the tape while it is rewinding, push the reverse button or ”TAPE”. AM⋅FM Push ”AM⋅FM” to switch between the AM and FM bands. ”AM”, ”FM1” or ”FM2” will appear on the display. These systems allow you to set twelve FM stations, two for each button. If the audio system is off, you can turn on the radio by pushing ”AM⋅FM”. Also, push ”AM⋅FM” to switch from cassette or compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— If a tape side rewinds completely, the cassette player will stop and then play that same side. If a tape fast forwards completely, the cassette player will play the other side of the tape, using the auto–reverse feature. This knob is used to adjust the tone manually. Compact Disc Player The display will show the range from ”BAS –5” to ”BAS 5”. If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. For low–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAS” appears on the display. Then turn the knob to suit your preference. For high–pitch tone adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from ”TRE –5” to ”TRE 5”. 132 ’99camry U Sound balance adjustment function— CD (Compact Disc) This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. Push ”CD” to switch from radio or cassette operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing ”CD”. In both cases, a disc must already be loaded in the player. For front/rear adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from ”FAd F7” to ”FAd R7”. For left/right adjustment, push ”AUDIO CONTROL / MODE” repeatedly until ”BAL” appears on the display. Then turn the knob to adjust the left/right balance. The display will show the range from ”BAL L7” to ”BAL R7”. If ”Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If ”Err 3” or ”Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push ”CD”, the system changes between built–in single disc player and automatic changer. If ”OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the player malfunctions, your audio system will display one of the six following error messages. DISC 
If ”WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. By using this button, you can select a disc you wish to listen to. If the malfunction is not rectified, take your vehicle to your Toyota dealer. Compact disc auto changer only— Push either side of the button until the number of the disc you want to listen to appears on the display. If ”Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. 133 ’99camry U Dolby B NR∗ If you are listening to a tape that was recorded with Dolby B Noise Reduction, push the button marked with the double–D symbol. The double–D symbol will appear on the display. Push the button again to turn off Dolby B NR. The Dolby NR mode reduces tape noise by about 10 dB. For best sound reproduction, play your tapes with this button on or off according to the mode used for recording the tape. PROG (Program) Push ”PROG” to select the other side of a cassette tape. The display indicates which side is currently selected (” ” indicates top side). side, ” ” indicates bottom Auto–reverse feature: After the cassette player reaches the end of a tape side, it automatically reverses and begins to play the other side. This is true whether the cassette was playing or fast forwarding. ∗ : Dolby noise reduction manufactured under license from PWR⋅VOL (Power⋅Volume) Dolby Laboratories Licensing Corporation. ”DOLBY” and the double D symbol are trademarks of Dolby Laboratories Licensing Corporation. Push ”PWR⋅VOL” to turn the audio system on and off. Turn ”PWR⋅VOL” to adjust the volume. MTL (Metal) Display If a metal or chrome equivalent cassette tape is put in the cassette player, the player will automatically adapt to it and ”MTL” will appear on the display. RAND (Random) There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. Random playing for the tracks on a disc: Quickly push and release ”RAND”. ”RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the ”RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold ”RAND” until you hear a beep. ”D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push ”RAND” a second time. RPT (Repeat) Cassette Player Push ”RPT” while the track is playing. ”RPT” will appear on the display. When the track ends, it will automatically be rewound and replayed. This process will be continued until you push the button again to turn off the repeat feature. There must be at least 3 seconds of blank space between tracks in order for the repeat feature to work correctly. 134 ’99camry U Compact Disc Player SCAN Compact disc player There are two repeat features—you can either replay a disc track or a whole compact disc. Radio There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Repeating a track: Quickly push and release ”RPT” while the track is playing. ”RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. Compact disc auto changer only— Repeating a disc: Push and hold ”RPT” until you hear a beep. ”D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. This process will be continued until you push the button again to turn off the repeat feature. You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold ”SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push ”SCAN” a second time. To scan all the frequencies: Quickly push and release ”SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push ”SCAN” a second time. Scanning for the tracks on a disc: Quickly push and release ”SCAN”. ”SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the ”SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. Compact disc auto changer only— Scanning for the first tracks of all the discs in the magazine: Push ”SCAN” until you hear a beep. ”D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the ”SCAN” a second time. If the player has scanned all the discs, it will stop scanning. 135 ’99camry U SEEK (Seeking) Radio In the seek mode, the radio finds and plays the next station up or down the station band. To seek a station, push and hold the ”
” or ”” side of ”TUNE” until you hear a beep. Do this again to find another station. Cassette Player By using this button, you can skip up or down to a different track. When counting the number of tracks you want to rewind, remember to count the current track as well. For example, if you want to rewind to a song that is two before the song you are listening to, push on the down side of the button until ”REW 3” appears on the display. If you have pushed the track button more than you wanted to, push the other side of the button. The track number will be reduced. You can skip up tp nine tracks at a time. The track number you select is not valid if it is higher than the number of tracks remaining on the current cassette side. Push the up or down side of the button. ”FF 1” or ”REW 1” will appear on the display. reached, the player will automatically start playing the same side. Next, push either side of until the number on the the number of tracks you you push the button ten feature will be turned off. 136 the track button display reaches want to skip. If times, the skip  After the beginning of the tape is  After the end of the tape is reached, the player will automatically reverse sides and start playing the other side. There must be at least 3 seconds of blank space between tracks for the track button to work correctly. In addition, the feature may not work well with some spoken word, live, or classical recordings. SKIP The skip feature allows you to fast forward past long stretches of blank tape. This is especially useful at the end of cassettes. Push ”SKIP”. ”SKIP” will appear on the display. The cassette player will keep track of how much blank space it plays. Any time it has played about 10 seconds of blank tape, it will automatically fast forward to the next track and begin to play. Push the button a second time to turn off the skip feature. ST (Stereo reception) display Your radio automatically changes to stereo reception when a stereo broadcast is received. ”ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. ’99camry U —Car audio system operating hints TAPE Push ”TAPE” to switch from radio or compact disc operation to cassette operation. If the audio system is off, you can turn on the cassette player by pushing ”TAPE”. In both cases, a cassette must already be loaded in the player. TRACK (Track up/down Compact disc player button): By using this button, you can skip up or down to a different track. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. TUNE (Tuning) Your Toyota has an electronic tuning radio (ETR). Push and release the ”
” (up) or ”” (down) side of ”TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) NOTICE To ensure the correct audio system operation:  Be careful not to spill beverages over the audio system.  Do not put anything other than a cassette tape or Compact Disc into the slot. RADIO RECEPTION Usually, a problem with radio reception does not mean there is a problem with your radio—it is just the normal result of conditions outside the vehicle. For example, nearby buildings and terrain can interfere with FM reception. Power lines or telephone wires can interfere with AM signals. And of course, radio signals have a limited range, and the farther you are from a station, the weaker its signal will be. In addition, reception conditions change constantly as your vehicle moves. FM Fading and drifting stations—Generally, the effective range of FM is about 40 km (25 miles). Once outside this range, you may notice fading and drifting, which increase with the distance from the radio transmitter. They are often accompanied by distortion. Multi–path—FM signals are reflective, making it possible for two signals to reach your antenna at the same time. If this happens, the signals will cancel each other out, causing a momentary flutter or loss of reception. Static and fluttering—These occur when signals are blocked by buildings, trees, or other large objects. Increasing the bass level may reduce static and fluttering. Station swapping—If the FM signal you are listening to is interrupted or weakened, and there is another strong station nearby on the FM band, your radio may tune in the second station until the original signal can be picked up again. Here are some common reception problems that probably do not indicate a problem with your radio: 137 ’99camry U AM Use high–quality cassettes. Fading—AM broadcasts are reflected by the upper atmosphere—especially at night. These reflected signals can interfere with those received directly from the radio station, causing the radio station to sound alternately strong and weak.  Low–quality cassette tapes can cause Station interference—When a reflected signal and a signal received directly from a radio station are very nearly the same frequency, they can interfere with each other, making it difficult to hear the broadcast.  Do not use a cassette if it has been Static—AM is easily affected by external sources of electrical noise, such as high tension power lines, lightening, or electrical motors. This results in static.  Store cassettes in their cases and out CARING FOR YOUR CASSETTE PLAYER AND TAPES For high performance from your cassette player and tapes: Clean the tape head and other parts regularly.  A dirty tape head or tape path can decrease sound quality and tangle your cassette tapes. The easiest way to clean them is by using a cleaning tape. (A wet type is recommended.) 138 many problems, including poor sound, inconsistent playing speed, and constant auto–reversing. They can also get stuck or tangled in the cassette player. damaged or tangled or if its label is peeling off.  Do not leave a cassette in the player if you are not listening to it, especially if it is hot outside. of direct sunlight.  Avoid using cassettes with a total playing time longer than 100 minutes (50 minutes per side). The tape used in these cassettes is thin and could get stuck or tangled in the cassette player. CARING FOR YOUR PLAYER AND DISCS COMPACT DISC  Use only compact discs labeled as shown.  Extremely high temperatures can keep your compact disc player from working. On hot days, use the air conditioning to cool the vehicle interior before you listen to a disc.  Bumpy roads or other vibrations may make your compact disc player skip. ’99camry U  If moisture gets into your compact disc CAUTION player, you may not hear any sound even though your compact disc player appears to be working. Remove the disc from the player and wait until it dries. Compact disc players use invisible laser beam which could cause hazardous radiation exposure if directed outside the unit. Be sure to operate the player correctly as instructed.  Handle compact discs carefully, especially when you are inserting them. Hold them on the edge and do not bend them. Avoid getting fingerprints on them, particularly on the shiny side.  Dirt, scrapes, warping, pin holes, or other disc damage could cause the player to skip or to repeat a section of a track. (To see a pin hole, hold the disc up to the light.)  Remove discs from the compact disc player when you are not listening to them. Store them in their plastic cases away from moisture, heat, and direct sunlight. To clean a compact disc: Wipe it with a soft, lint–free cloth that has been dampened with water. Wipe in a straight line from the center to the edge of the disc (not in circles). Dry it with another soft, lint–free cloth. Do not use a conventional record cleaner or anti–static device. A new disc may have rough edges on its inner and outer perimeter. Remove the rough edges by pressing the side of a ball–point pen or pencil against the inner and outer perimeter of the disc as shown. If you continue to play a disc with rough edges, flakes will fall on to the signal side of the disc and cause sound skipping or other problems. 139 ’99camry U Air conditioning system— —Controls 1. ”A/C” Button 2. Air Intake Selector 3. Air Flow Selector 4. Temperature Selector 5. Fan Speed Selector 140 ’99camry U Fan speed selector For details about air flow selector settings, see the illustration after ”A/C” button. Turn the knob to adjust the fan speed—to the right to increase, to the left to decrease. Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Temperature selector Turn the knob to adjust the temperature— to the right to warm, to the left to cool. Air flow selector Turn the knob to select the vents used for air flow. 1. Panel—Air flows mainly instrument panel vents. from the 2. Bi–level—Air flows from both the floor vents and the instrument panel vents. 3. Floor—Air flows mainly from the floor vents. 4. Floor/Windshield—Air flows mainly from the floor vents and windshield vents. 5. Windshield—Air flows mainly from the windshield vents. 141 ’99camry U ”A/C” button To turn on the air conditioning, press the ”A/C” button. The ”A/C” button indicator will come on. To turn the air conditioning off, press the button again. If the ”A/C” button indicator flashes, there is a problem in the air conditioning system and the air conditioning automatically shuts off. If this happens, take your vehicle to a Toyota dealer for service. Air intake selector Move the lever to select the air source. 1. Recirculate—Recirculates the air inside the vehicle. 2. Fresh—Draws outside air into the system. 142 ’99camry U —Air flow selector settings —Operating tips  To cool off your Toyota after it has been parked in the hot sun, drive with the windows open for a few minutes. This vents the hot air, allowing the air conditioning to cool the interior more quickly.  Make sure the air intake grilles in front of the windshield are not blocked (by leaves or snow, for example).  On humid days, do not blow cold air on the windshield. The windshield could fog up because of the difference in air temperature on the inside and outside of the windshield.  Keep the area under the front seats clear to allow air to circulate throughout the vehicle.  On cold days, move the fan speed to ”HI” for a minute to help clear the intake ducts of snow or moisture. This can reduce the amount of fogging on the windows. 143 ’99camry U Heating Air conditioning Defogging For best results, set controls to: For best results, set controls to: The inside of the windshield Fan speed—Any setting except ”OFF” Temperature—Towards WARM (red zone) Air intake—FRESH (outside air) Air flow—FLOOR Air conditioning—OFF Fan speed—Any setting except ”OFF” Temperature—Towards COLD (blue zone) Air intake—FRESH (outside air) Air flow—PANEL Air conditioning—ON  For quick heating, select recirculated  For quick cooling, move the air intake air for a few minutes. To keep the windows from fogging, select fresh after the vehicle interior has been warmed. selector to recirculate for a few minutes.  Press the ”A/C” button on for dehumidified heating.  Choose floor/windshield air flow to heat the vehicle interior while defrosting or defogging the windshield. 144 Ventilation For best results, set controls to: Fan speed—Any setting except ”OFF” Temperature—Towards COLD (blue zone) Air intake—FRESH (outside air) Air flow—PANEL Air conditioning—OFF For best results, set controls to: Fan speed—Any setting except ”OFF” Temperature—Towards WARM (red zone) to heat; COLD (blue zone) to cool Air intake—FRESH (outside air) Air flow—WINDSHIELD Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Press the ”A/C” button for dehumidified heating or cooling. This setting clears the front view more quickly.  On humid days, do not blow cold air on the windshield—the difference between the outside and inside temperatures could make the fogging worse. ’99camry U —Side vents Defrosting The outside of the windshield For best results, set controls to: Fan speed—Any setting except ”OFF” Temperature—Towards WARM (red zone) Air intake—FRESH (outside air) Air flow—WINDSHIELD Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Press the ”A/C” button for dehumidified heating. This setting clears the front view more quickly.  To heat the vehicle interior while defrosting the windshield, floor/windshield air flow. If air flow control is not satisfactory, check the side vents. The side vents may be opened or closed as shown. choose 145 ’99camry U 146 ’99camry U Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Clock The digital clock indicates the time. The key must be in the ”ACC” or ”ON” position. To reset the hour: Push the ”H” button. To reset the minutes: Push the ”M” button. If the electrical power source has been disconnected from the clock, the time display will automatically be set to 1:00 (one o’clock). Chapter 1–8 Other equipment When the instrument panel lights are turned on, the brightness of the time indication will be reduced.
Clock
Cigarette lighter and ashtrays
Power outlet Type A Type B only— If quick adjustment to a full hour is desired, push the ”:00” button.
Glove box
Garage door opener box For example, if the ”:00” button is depressed when the time is between 1:01—1:29, the time will change to 1:00. If the time is between 1:30—1:59, the time will change to 2:00.
Miscellaneous box
Auxiliary box
Cup holder
Traction control system
Floor mat Type B 147 ’99camry U Cigarette lighter and ashtrays Power outlet CIGARETTE LIGHTER To use the cigarette lighter, press it in. When it becomes heated, it automatically pops out ready for use. If the engine is not running, the key must be in the ”ACC” position. Do not hold the cigarette lighter pressed in. Use a Toyota genuine cigarette lighter or equivalent for replacement. ASHTRAYS Cigarette lighter and front ashtray To use the ashtray, open out. When finished with your cigarette, thoroughly extinguish it in the ashtray to prevent other cigarette butts from catching fire. After using the ashtray, push it back in completely. To remove the ashtray, press down on the lock spring plate and pull out. CAUTION To reduce the chance of injury in case of an accident or sudden stop while driving, always push the ashtray back in completely after use. Rear ashtray (on some models ) 148 The power outlet is designed for power supply for car accessories. The key must be in the ”ACC” or ”ON” position for the power outlet to be used. NOTICE  To prevent the fuse from being blown, do not use the electricity over the total vehicle capacity of 12V/120W.  To prevent the battery from being discharged, do not use the power outlet longer than necessary when the engine is not running. ’99camry U Glove box Garage door opener box To use the glove box, do this. The box is designed to store a garage door opener transmitter.  Close the power outlet lid when the power outlet is not in use. Inserting a foreign object other than the appropriate plug that fits the outlet, or allowing any liquid into the outlet may cause electrical failure or short circuits. To open: Pull the lever. With the instrument panel lights on, the glove box light will come on when the glove box is open. Open the cover and remove the Velcro loop. To lock: Insert the master key and turn it clockwise. CAUTION To reduce the chance of injury in case of an accident or a sudden stop, always keep the glove box door closed while driving. 149 ’99camry U Remove the paper strip covering the adhesive on back side of loop and adhere loop to back side of the transmitter near center. 150 Please note if transmitter has wire clip for sun visor, this clip must be removed prior to adhesion of the Velcro. Place the transmitter with Velcro loop facing inside of box into the box. Make sure the transmitter button is located above button pins. ’99camry U Remove spacers from the center panel. Place the largest spacer on the pin that would be below transmitter button when the cover is closed. Close the cover. When the garage door opener transmitter is properly installed, you can operate the transmitter by pushing the center panel of the cover. If the center panel does not contact with your garage door opener transmitter:
Check to see if spacer is on correct pin.
Attach another spacer to the top of original spacer. Check operation. If required, continue add spacers until contact is achieved. If the transmitter is clattering during driving, fill in a piece of felt or pad to prevent the transmitter from clattering. 151 ’99camry U CAUTION
To reduce the chance of injury in case of an accident or a sudden stop, always keep the garage door opener box closed while driving.
Keep the remained spacers away from children. The miscellaneous box and garage door opener box (stored in the glove box) are interchangeable. Removing the cover— Half open the cover. Pinch each hinge and pull it out of its pivot one by one as shown above. Do not remove the cover forcibly. 152 Installing the cover— Align the hinges to the pivots, and press each hinge with a thumb until you hear a click. Make sure that closes smoothly. the cover opens and ’99camry U Miscellaneous box Auxiliary box To use the box, open it as shown above. To use the box, pull on the handle. Cup holder Front CAUTION CAUTION To reduce the chance of injury in case of an accident or a sudden stop, always keep the miscellaneous box closed while driving. To reduce the chance of injury in case of an accident or a sudden stop, always keep the auxiliary box closed while driving. NOTICE In hot weather, inside of the vehicle becomes very hot. Do not leave anything flammable or deformable such as a lighter, the glasses, etc. inside. Rear 153 ’99camry U Traction control system The cup holder is designed for holding cups or drink–cans securely in its holes. AUTOMATIC TRACTION CONTROL SYSTEM Front: To use the holder, open the lid. Rear: To use the holder, pull it out. CAUTION
Do not place anything else other than cups or drink–cans on the cup holder, as such item may be thrown about in the compartment and possibly injure people in the vehicle during sudden braking or an accident. Slip indicator light Leave the system on during ordinary driving so that it can operate when needed. When traction control is applied, the slip indicator light blinks.
To reduce the chance of injury in case of an accident or sudden stop while driving, keep the cup holder closed when it is not in use. ”TRAC OFF” indicator/warning light 154 The traction control system automatically helps control the spinning of the front wheels which may occur when accelerating on slippery road surfaces, thus assisting driver to control the driving power of the front wheels. When you turn the ignition switch on, the traction control system always turns on automatically, and the slip indicator light and ”TRAC OFF” indicator/warning light will come on. The indicator lights will go off after about 3 seconds. You may hear a sound in the engine compartment for a few seconds when the engine is started or just after the vehicle is started. This means that the traction control system is in the self–check mode, and does not indicate malfunction. When the traction control system is operating, you may feel vibration or noise of your vehicle, caused by operation of the brakes. This indicates the system is functioning properly. ’99camry U When getting the vehicle out of mud or new snow, etc. the traction control system will help operate to prevent the wheels from spinning. CAUTION MANUAL OPERATION You can turn off the traction control system by pushing the ”TRAC OFF” switch. The ”TRAC OFF” indicator/warning light will come on. Pushing the ”TRAC OFF” switch a second time turns on the traction control system and the ”TRAC OFF” indicator/warning light will go off. Under certain slippery road conditions, full traction of the vehicles and power to the front wheels may not be maintained, even though the traction control system is in operation. Do not drive the vehicle at any speed or conduct any during maneuver which will cause the vehicle to lose traction. In situations where the road surface is covered with ice or snow, your vehicle should be fitted with snow tires or tire chains. Always drive at an appropriate and cautious speed for the road conditions present. 155 ’99camry U Floor mat Use a floor mat of the correct size. If the floor carpet and floor hole, then it is designed for locking clip. Fix the floor mat clip into the hole in the floor 156 mat have a use with a with locking carpet. CAUTION Make sure the floor mat is properly placed on the floor carpet. If the floor mat slips and interferes with the movement of the pedals during driving, it may cause an accident. ’99camry U Part 7 DO–IT–YOURSELF MAINTENANCE— Chapter 7–1 Introduction  Engine compartment overview  Fuse locations  Do–it–yourself service precautions  Parts and tools 209 ’99camry U Engine compartment overview
5S–FE engine 1. Power steering fluid reservoir 2. Engine coolant reservoir 3. Engine oil filler cap 4. Engine oil level dipstick 5. Brake fluid reservoir 6. Fuse blocks 7. Battery 8. Electric cooling fans 9. Windshield washer fluid tank 210 ’99camry U
1MZ–FE engine 1. Power steering fluid reservoir 2. Engine coolant reservoir 3. Engine oil level dipstick 4. Engine oil filler cap 5. Brake fluid reservoir 6. Fuse blocks 7. Battery 8. Electric cooling fans 9. Windshield washer fluid tank 211 ’99camry U Fuse locations Spare fuses Type A With daytime running light system only 212 Type B ’99camry U Do–it–yourself service precautions If you perform maintenance by yourself, be sure to follow the correct procedure given in this part. You should be aware that improper or incomplete servicing may result in operating problems. Performing do–it–yourself maintenance during the warranty period may affect your warranty coverage. Read the separate Toyota Warranty statement for details and suggestions. CAUTION  When the engine is running, keep hands, clothing, and tools away from the moving fan and engine drive belts. (Removing rings, watches, and ties is advisable.)  Right after driving, the engine compartment—the engine, radiator, exhaust manifold and spark plug boots, etc.—will be hot. So be careful not to touch them. Oil, fluids and spark plugs may also be hot. This part gives instructions only for those items that are relatively easy for an owner to perform. As explained in Part 6, there are still a number of items that must be done by a qualified technician with special tools.  If the engine is hot, do not remove For information on tools and parts for do– it–yourself maintenance, see ”Parts and tools”. low open flames around fuel or the battery. Their fumes are flammable. Utmost care ing on your injury. Here you should serve: should be taken when workvehicle to prevent accidental are a few precautions that be especially careful to ob- the radiator cap or loosen the drain plugs to prevent burning yourself.  Do not smoke, cause sparks or al Be extremely cautious when working on the battery. It contains poisonous and corrosive sulfuric acid.  Do not get under your vehicle with just the body jack supporting it. Always use automotive jack stands or other solid supports. 213 ’99camry U  Be sure that the ignition is off if  Dispose of used oil and filter only you work near the electric cooling fans or radiator grille. With the ignition on, the electric cooling fans will automatically start to run if the engine coolant temperature is high and/or the air conditioning is on. in a safe and acceptable manner. Do not dispose of used oil and filter in household trash, in sewers or onto the ground. Call your dealer or a service station for information concerning recycling or disposal.  Use eye protection whenever you work on or under your vehicle where you may be exposed to flying or falling material, fluid spray, etc.  Used engine oil contains potentially harmful contaminants which may cause skin disorders such as inflammation or skin cancer, so care should be taken to avoid prolonged and repeated contact with it. To remove used engine oil from your skin, wash thoroughly with soap and water.  Do not leave used oil within the reach of children. NOTICE  Remember that battery and ignition cables carry high currents or voltages. Be careful of accidentally causing a short circuit.  Add only demineralized or distilled water to fill the radiator. And if you spill some of the coolant, be sure to wash off with water to prevent it from damaging the parts or paint.  Do not allow dirt or anything else to fall through the spark plugholes.  Use only spark plugs of the specified type. Using other types will cause engine damage, loss of performance or radio noise.  Do not reuse platinum–tipped spark plugs by cleaning or regapping. 214  Do not overfill automatic transmission fluid, or the transmission could be damaged.  Do not drive with the air cleaner filter removed, or excessive engine wear could result. Also backfiring could cause a fire in the engine compartment.  Be careful not to scratch the glass surface with the wiper frame.  When closing the engine hood, check to see that you have not forgotten any tools, rags, etc. ’99camry U Parts and tools Here is a list of parts and tools you will need on performing do–it–yourself maintenance. Remember all Toyota parts are designed in metric sizes, so your tools must be metric. Checking the engine oil level Parts (if level is low):  Engine oil API grade SJ, ”Energy–Conserving” or ILSAC multigrade having viscosity proper for your climate Tools:  Rag or paper towel  Funnel (only for adding oil) Checking the engine coolant level Parts (if level is low):  ”Toyota Long Life Coolant” or equivalent See Chapter 7–2 for details about coolant type selection.  Demineralized or distilled water Tools:  Funnel (only for adding coolant) Checking brake fluid Checking and replacing fuses Parts (if level is low):  SAE J1703 or FMVSS No.116 DOT 3 brake fluid Parts (if replacement is necessary):  Genuine Toyota fuse or equivalent with same amperage rating as original Tools:  Rag or paper towel  Funnel (only for adding fluid) Adding washer fluid Parts:  Water  Washer fluid containing antifreeze (for winter use) Checking power steering fluid Parts (if level is low):  Automatic transmission DEXRONII or III fluid Tools:  Rag or paper towel  Funnel (only for adding fluid) Replacing light bulbs Parts:  Bulb with same number and wattage rating as original (See charts in ”Replacing light bulbs” in Chapter 7–3.) Checking battery condition Tools:  Warm water  Baking soda  Grease  Conventional clamp bolts) Tools:  Funnel Tools:  Screwdriver wrench (for terminal  Flat–bladed screwdriver 215 ’99camry U 216 ’99camry U Part 7 DO–IT–YOURSELF MAINTENANCE— Checking the engine oil level Low level Full level CAUTION Type A Chapter 7–2 Engine and Chassis Type B
Checking the engine oil level
Checking the engine coolant level
Checking brake fluid
Checking power steering fluid
Checking tire pressure
Checking and replacing tires
Rotating tires
Installing snow tires and chains
Replacing wheels
Aluminum wheel precautions Add oil O.K. Too full With the engine at operating temperature and turned off, check the oil level on the dipstick. 1. To get a true reading, the vehicle should be on a level spot. After turning off the engine, wait a few minutes for the oil to drain back into the bottom of the engine. 2. Pull out the dipstick, and wipe it clean with a rag. Be careful not to touch the hot exhaust manifold. If the oil level is below or only slightly above the low level line, add engine oil of the same type as already in the engine. Remove the oil filler cap and add engine oil in small quantities at a time, checking the dipstick. The approximate quantity of oil needed to fill between the low level and the full level on the dipstick is indicated below for reference. When the level reaches within the correct range, install the filler cap hand–tight. Oil quantity, L (qt., lmp. qt.): 5S–FE engine 0.7 (0.7, 0.6) 1MZ–FE engine 1.5 (1.6, 1.3) NOTICE 3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be correct.  Avoid overfilling, or could be damaged. 4. Pull the dipstick out and look at the oil level on the end.  Check the oil level on the dipstick once again after adding the oil. the engine 217 ’99camry U Engine oil selection Oil identification marks Use API grade SJ, ”Energy–Conserving” or ILSAC multigrade engine oil. Either or both API registered marks are added to some oil containers to help you select the oil you should use. Recommended viscosity (SAE): The API Service Symbol is located anywhere on the outside of the container. API service symbol The ILSAC (International Lubricant Standardization and Approval Committee) Certification Mark is displayed on the front of the container. SAE 5W–30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. If you use SAE 10W–30 engine oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W–30engine oil is recommended. ILSAC certification mark 218 The top portion of the label shows the oil quality by API (American Petroleum Institute) designations such as SJ. The center portion of the label shows the SAE viscosity grade such as SAE 5W–30. ”Energy– Conserving” shown in the lower portion, indicates that the oil has fuel–saving capabilities. ’99camry U Checking the engine coolant level Look at the see–through coolant reservoir when the engine is cold. The coolant level is satisfactory if it is between the ”FULL” and ”LOW” lines on the reservoir. If the level is low, add ethylene–glycol type coolant for a proper corrosion protection of aluminum components. The coolant level in the reservoir will vary with engine temperature. However, if the level is on or below the ”LOW” line, add coolant. Bring the level up to the ”FULL” line. Always use ethylene–glycol type coolant for a proper corrosion protection of aluminum components. See information in the next column. If the coolant level drops within a short time after replenishing, there may be a leak in the system. Visually check the radiator, hoses, engine coolant filler cap, radiator cap and drain cock and water pump. If you can find no leak, have your Toyota dealer test the cap pressure and check for leaks in the cooling system. CAUTION To prevent burning yourself, do not remove the radiator cap when the engine is hot. Coolant type selection Use of improper coolants may damage your engine cooling system. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of your engine that contains aluminum components. Use ”Toyota Long Life Coolant” or equivalent. We recommend to use 50% solution for your Toyota, to provide protection down to about –35C (–31F). When it is extremely cold, to provide protection down to about –50°C (–58°F), 60% solution is recommended. Do not use more than 70% solution for better coolant performance. NOTICE Do not use alcohol type antifreeze or plain water alone. In addition to preventing freezing and subsequent damage to the engine, this type of coolant will also prevent corrosion. Further supplemental inhibitors or additives are neither needed nor recommended. Read the coolant container for information on freeze protection. Follow the manufacturer’s directions for how much to mix with plain water (preferably demineralized water or distilled water). The total capacity of the cooling system is given in Part 8. 219 ’99camry U Checking brake fluid Checking power steering fluid Use only newly opened brake fluid. Once opened, brake fluid absorbs moisture from the air, and excess moisture can cause a dangerous loss of braking. CAUTION Take care when filling the reservoir because brake fluid can harm your eyes and damage painted surfaces. If fluid gets in your eyes, flush your eyes with clean water. To check the fluid level, simply look at the see–through reservoir. The level should be between the ”MAX” and ”MIN” lines on the reservoir. It is normal for the brake fluid level to go down slightly as the brake pads wear. So be sure to keep the reservoir filled. If the reservoir needs frequent refilling, it may indicate a serious mechanical problem. If the level is low, add SAE J1703 or FMVSS No.116 DOT 3 brake fluid to the brake reservoir. Remove and replace the reservoir cover by hand. 220 NOTICE If you spill some of the fluid, be sure to wash it off with water to prevent it from damaging the parts or paint. Open If hot O.K. Close If cold O.K. If cold add If hot add Check the fluid level through the reservoir. If necessary, add automatic transmission fluid DEXRONII or III. If the vehicle has been driven around 80 km/h (50 mph) for 20 minutes (a little more in frigid temperatures), the fluid is hot (60C—80C or 140F—175F). You may also check the level when the fluid is cold (about room temperature, 10C—30C or 50F—85F) if the engine has not been run for about five hours. ’99camry U Checking tire pressure Clean all dirt from outside of the reservoir tank and look at the fluid level. If the fluid is cold, the level should be in the ”COLD” range. Similarly, if it is hot, the fluid level should be in the ”HOT” range. If the level is at the low side of either range, add automatic transmission fluid DEXRONII or III to bring the level within the range. Low tire pressure results in excessive wear, poor handling, reduced fuel economy, and the possibility of blowouts from overheated tires. Also, low tire pressure can cause poor sealing of the tire bead. If the tire pressure is excessively low, there is the possibility of wheel deformation and/or tire separation. To remove the filler cap, turn it counterclockwise and lift up. To reinstall it, turn it clockwise. After replacing the filler cap,visually check the steering box case, vane pump and hose connections for leaks or damage. High tire pressure produces a harsh ride, handling problems,excessive wear at the center of the tire tread, and a greater possibility of tire damage from road hazards. CAUTION The reservoir tank may be hot so be careful not to burn yourself. NOTICE Avoid overfilling, or the power steering could be damaged. Keep your tire pressures at the proper level. The recommended cold tire pressures, tire size and the vehicle capacity weight are given in Part 8. They are also on the tire pressure label as shown. You should check the tire pressures every two weeks, or at least once a month. And don’t forget the spare! Incorrect tire pressure can reduce tire life and make your vehicle less safe to drive. If a tire frequently needs refilling, have it checked by your Toyota dealer. The following instructions for checking tire pressure should be observed:
The pressure should be checked only when the tires are cold. If your vehicle has been parked for at least 3 hours and has not been driven for more than 1.5 km or 1 mile since, you will get an accurate cold tire pressure reading.
Always use a tire pressure gauge. The appearance of a tire can be misleading. Besides, tire pressures that are even just a few pounds off can degrade handling and ride. 221 ’99camry U Checking and replacing tires
Take special care when adding air to the compact spare tire. The smaller tire size can gain pressure very quickly. Add compressed air in small quantities and check the pressure often until it reaches the specified pressure. Tread wear indicator Even if the damage does not appear serious, a qualified technician should examine the damage. Objects which have penetrated the tire may have caused internal damage.
Do not bleed or reduce tire pressure after driving. It is normal for the tire pressure to be higher after driving.
Never exceed the vehicle capacity Any tires which are over six years old must be checked by a qualified technician even if damage is not obvious. weight. The passenger and luggage weight should be located so that the vehicle is balanced.
Be sure to reinstall the tire inflation valve caps. Without the valve caps, dirt or moisture could get into the valve core and cause air leakage. If the caps have been lost, have new ones put on as soon as possible. CHECKING YOUR TIRES Check the tires tread for the tread wear indicators. If the indicators show, replace the tires. The tires on your Toyota have built–in tread wear indicators to help you know when the tires need replacement. When the tread depth wears to 1.6 mm (0.06 in.) or less, the indicators will appear. If you can see the indicators in two or more adjacent grooves, the tire should be replaced. The lower the tread, the higher the risk of skidding. The effectiveness of snow tires is lost if the tread wears down below 4 mm (0.16 in.). 222 Check the tires regularly for damage such as cuts, splits and cracks. If any damage is found, consult with a technician and have the tire repaired or replaced. Tires deteriorate with age even if they have never or seldom been used. This applies also to the spare tire and tires stored for future use. REPLACING YOUR TIRES When replacing a tire, use only the same size and construction as originally installed and with the same or greater load capacity. Using any other size or type of tire may seriously affect handling, ride, speedometer/odometer calibration, ground clearance, and clearance between the body and tires or snow chains. ’99camry U Rotating tires WHEN TO CHAINS CAUTION bias–ply tires on your vehicle. It can cause dangerous handling characteristics, resulting in loss of control. When a tire is replaced, the wheel should always be balanced. An unbalanced wheel may affect vehicle handling and tire life. Wheels can get out of balance with regular use and should therefore be balanced occasionally. When replacing a tubeless tire, the air valve should also be replaced with a new one. TIRES OR SNOW TIRE SELECTION If you need snow tires, select the same size, construction and load capacity as the original tires on your Toyota. recom- See ”If you have a flat tire” in Part 4 for tire change procedure. SNOW On wet or dry roads, conventional tires provide better traction than snow tires.
Do not use tires or wheels other Toyota recommends all four tires, or at least both of the front or rear tires be replaced at a time as a set. USE Snow tires or chains are recommended when driving on snow or ice.
Do not mix radial, bias belted, or than the manufacturer’s mended size. Installing snow tires and chains To equalize the wear and help extend tire life, Toyota recommends that you rotate your tires approximately every 12000 km (7500 miles). However, the most appropriate timing for tire rotation may vary according to your driving habits and road surface conditions. See ”If you have a flat tire” in Part 4 for tire change procedure. When rotating tires, check for uneven wear and damage. Abnormal wear is usually caused by incorrect tire pressure, improper wheel alignment, out–of–balance wheels, or severe braking. Do not use tires other than those mentioned above. Do not install studded tires without first checking local regulations for possible restrictions. SNOW TIRE INSTALLATION Snow tires should be installed on all wheels. Installing snow tires on the front wheels only can lead to an excessive difference in road grip capability between the front and rear tires which could cause loss of vehicle control. When storing removed tires you should store them in a cool dry place. Mark the direction of rotation and be sure to install them in the same direction when replacing. 223 ’99camry U Replacing wheels CAUTION
Do not drive with the snow tires If wheel covers are used, they will be scratched by the chain band,so remove the covers before putting on the chains. incorrectly inflated.
Never drive over 120 km/h (75 mph) with any type of snow tires. TIRE CHAIN SELECTION CAUTION
Do not exceed 50 km/h (30 mph) or the chain manufacturer’s recommended speed limit, whichever is lower. Use the tire chains of correct size and type.
Drive Use SAE Class ”S” type radial tire chains except radial cable chains or V–bar type chains.
Avoid sharp turns or locked–wheel Regulations regarding the use of tire chains vary according to location or type of road, so always check them before installing chains. CHAIN INSTALLATION Install the chains on the front tires as tightly as possible. Do not use tire chains on the rear tires. Retighten chains after driving 0.5—1.0 km (1/4—1/2 mile). When installing chains on your tires, carefully follow the instructions of the chain manufacturer. 224 carefully avoiding bumps, holes, and sharp turns, which may cause the vehicle to bounce. braking, as use of chains may adversely affect vehicle handling. WHEN TO REPLACE YOUR WHEELS If you have wheel damage such as bending, cracks or heavy corrosion, the wheel should be replaced. If you fail to replace damaged wheels, the tire may slip off the wheel or they may cause loss of handling control. WHEEL SELECTION When replacing wheels, care should be taken to ensure that the wheels are replaced by ones with the same load capacity, diameter, rim width, and offset. This must be observed on compact spare tires, too. Correct replacement wheels are available at your Toyota dealer. A wheel of a different size or type may adversely affect handling, wheel and bearing life, brake cooling, speedometer/odometer calibration, stopping ability, headlight aim, bumper height, vehicle ground clearance, and tire or snow chain clearance to the body and chassis. ’99camry U Replacement with used wheels is not recommended as they may have been subjected to rough treatment or high mileage and could fail without warning. Also, bent wheels which have been straightened may have structural damage and therefore should not be used. Never use an inner tube in a leaking wheel which is designed for a tubeless tire. Aluminum wheel precautions
After driving your vehicle the first 1600 km (1000 miles), check that the wheel nuts are tight.
If you have changed your wheel nuts are 1600 km (1000 rotated, repaired, or tires, check that the still tight after driving miles).
When using tire chains, be careful not to damage the aluminum wheels.
Use only the Toyota wheel nuts and wrench designed for wheels. your aluminum
When balancing your wheels, use only Toyota balance weights or equivalent and a plastic or rubber hammer.
As with any wheel, periodically check your aluminum wheels for damage. If damaged, replace immediately. 225 ’99camry U 226 ’99camry U Part 7 DO–IT–YOURSELF MAINTENANCE— Chapter 7–3 Electrical components
Checking battery condition
Battery recharging precautions Checking battery condition— —Precautions CAUTION
If electrolyte gets on your skin, BATTERY PRECAUTIONS thoroughly wash the contact area. If you feel pain or burning, get medical attention immediately. The battery produces flammable and explosive hydrogen gas.
Do not cause a spark from the battery with tools.
Do not smoke or light a match near the battery.
Checking and replacing fuses The electrolyte contains poisonous and corrosive sulfuric acid.
Adding washer fluid
Avoid contact with eyes, skin or
Replacing light bulbs clothes.
Never ingest electrolyte.
Wear protective safety glasses when
If electrolyte gets on your clothes, there is a through to ly take off follow the essary. possibility of its soaking your skin, so immediatethe exposed clothing and procedure above, if nec-
If you happen to swallow electrolyte, drink a large quantity of water or milk. Follow with milk of magnesia, beaten raw egg or vegetable oil. Then go immediately for emergency help. working near the battery.
Keep children away from the battery. EMERGENCY MEASURES
If electrolyte gets in your eyes, flush your eyes with clean water immediately and get immediate medical attention. If possible, continue to apply water with a sponge or cloth while en route to the medical office. 227 ’99camry U —Checking battery exterior Terminals Ground cable —Checking battery fluid NOTICE  Be sure the engine and all accessories are off before performing maintenance.  When checking the battery, remove the ground cable from the negative terminal (”–” mark) first and reinstall it last. Type A Green Dark Type B Blue White Clear or light yellow Red  Be careful not to cause a short circuit with tools. Hold–down clamp Check the battery for corroded or loose terminal connections, cracks, or loose hold–down clamp. a. If the battery is corroded, wash it off with a solution of warm water and baking soda. Coat the outside of the terminals with grease to prevent further corrosion. b. If the terminal connections are loose, tighten their clamp nuts—but do not overtighten. c. Tighten the hold–down clamp only enough to keep the battery firmly in place. Overtightening may damage the battery case. 228  Take care no solution gets into the battery when washing it. CHECKING BY THE HYDROMETER Check the battery hydrometer color. Hydrometer color condition by the Condition Type A Type B GREEN BLUE Good DARK WHITE Charging necessary. Have battery checked by your Toyota dealer. CLEAR or LIGHT YELLOW RED Have battery checked by your Toyota dealer. ’99camry U Battery recharging precautions Checking and replacing fuses During recharging, the battery is producing hydrogen gas. Therefore, before recharging: Type A 1. If recharging with the battery installed on the vehicle, be sure to disconnect the ground cable. 2. Be sure the power switch on the recharger is off when connecting the charger cables to the battery and when disconnecting them. CAUTION Good Blown Type B
Always charge the battery in an unconfined area. Do not charge the battery in a garage or closed room where there is not sufficient ventilation.
Only do a slow charge (5 A or less). Charging at a quicker rate is dangerous. The battery may explode, causing personal injuries. If the headlights or other electrical components do not work, check the fuses. If any of the fuses are blown, they must be replaced. Good Blown Type C Turn the ignition switch and inoperative component off. Pull a suspected fuse straight out and check it. NOTICE Never recharge the battery while the engine is running. Also, be sure all accessories are turned off. Good See ”Fuse locations” in Chapter 7–1 for locations of the fuses. Blown Determine which fuse may be causing the problem. The lid of the fuse box shows the name of the circuit for each fuse. See Part 8 of this manual for the functions controlled by each circuit. 229 ’99camry U Adding washer fluid Type A fuses can be pulled out by the pull–out tool. The location of the pull–out tool is shown in the illustration. If you are not sure whether the fuse has blown, try replacing the suspected fuse with one that you know is good. If the fuse has blown, push a new fuse into the clip. Only install a fuse with the amperage rating designated on the fuse box lid. If you do not have a spare fuse, in an emergency you can pull out the ”MIRROR–HEATER”, ”DOME” or ”A/C” fuse, which may be dispensable for normal driving, and use it if its amperage rating is the same. If you cannot use one of the same amperage, use one that is lower,but as close as possible to, the rating. If the amperage is lower than that specified, the fuse might blow out again but this does not indicate anything wrong. Be sure to get the correct fuse as soon as possible and return the substitute to its original clip. It is a good idea to purchase a set of spare fuses and keep them in your vehicle for emergencies. 230 If the new fuse immediately blows out, there is a problem with the electrical system. Have your Toyota dealer correct it as soon as possible. CAUTION Never use a fuse with a higher amperage rating, or any other object, in place of a fuse. This may cause extensive damage and possibly a fire. If any washer does not work or low windshield washer fluid level warning light comes on, the washer tank may be empty. Add washer fluid. You may use plain water as washer fluid. However, in cold areas where temperatures range below freezing point, use washer fluid containing antifreeze. This product is available at your Toyota dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water. NOTICE Do not use engine antifreeze or any other substitute because it may damage your vehicle’s paint. ’99camry U Replacing light bulbs— The following illustrations show how to gain access to the bulbs. When replacing a bulb, make sure the ignition switch and light switch are off. Use bulbs with the wattage ratings given in the table. CAUTION Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped. Hold a bulb only by its plastic or metal case. Do not touch the glass part of a bulb with bare hands. NOTICE Only use a bulb of the listed type. Light bulbs Headlights Bulb No. W Type HB2 60/55 A Parking, front side marker and front turn signal lights — 27/8 B Rear side marker lights 194 3.8 C Rear turn signal lights 3156 27 C Stop and tail lights 3157 27/8 C Tail light 904 9.3 C Back–up lights 921 18 C — 5 C High mounted stoplight 21CP 18 C Personal light — 10 B Interior light — 10 D Vanity lights — 3 D Glove box light — 1.2 C Trunk light — 3.8 C License plate lights A: B: C: D: HB2 halogen bulbs Single end bulbs Wedge base bulbs Double end bulbs 231 ’99camry U —Headlights 1. Open the hood. Unplug the connector. Remove the rubber cover. If the connector is tight, wiggle it. 2. Release the bulb retaining spring and remove the bulb. Install a new bulb and the bulb retaining spring. To install a bulb, align the tabs of the bulb with the cutouts of the mounting hole. 3. Install the rubber cover with the ”TOP” mark upward, and snuggle on the boss. Insert the connector. Then install the plastic cover. Make sure the rubber cover fits snugly on the connector and the headlight body. Aiming is not necessary after replacing the bulb. When aiming adjustment is necessary, contact your Toyota dealer. 232 ’99camry U —Parking, front side marker and front turn signal lights Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. Removing cover clips Use a flat–bladed screw driver. To protect the surface, place several sheets of paper over the surface. Installing cover clips 233 ’99camry U —Rear side maker, rear turn signal, stop and tail lights a: Rear side marker light b: Rear turn signal light c: Stop and tail light 234 ’99camry U —Back–up (type A) and tail lights —Back–up (type B) a: Back–up light b: Tail light and tail lights Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. 235 ’99camry U —License plate lights Removing the cover clips Installing the cover clips 236 Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. a: Back–up light b: Tail light ’99camry U —High mounted stoplight Removing cover clips Installing cover clips 237 ’99camry U 238 ’99camry U Part 2 INFORMATION BEFORE DRIVING YOUR TOYOTA Break–in period Fuel Drive gently and avoid high speeds. FUEL TYPE Your vehicle does not need an elaborate break–in. But following a few simple tips for the first 1600 km (1000 miles) can add to the future economy and long life of your vehicle: Your new vehicle must use only unleaded gasoline.
Break–in period
Do not drive over 88 km/h (55 mph).
Run the engine at moderate speed be-
Fuel
Operation in foreign countries
Three–way catalytic converters
Engine exhaust cautions
Facts about engine oil consumption
Twin ground electrode platinum–tipped spark plugs
Brake system
Brake pad wear limit indicators tween 2000 and 4000 rpm.
Avoid full–throttle starts.
Try to avoid hard stops during the first 300 km (200 miles).
Do not drive slowly with the manual transmission in a high gear.
Do not drive for a long time at any single speed, either fast or slow.
Do not tow a trailer during the first 800 km (500 miles). To help prevent gas station mix–ups, your Toyota has a new smaller fuel tank opening. The special nozzle on pumps with unleaded fuel will fit it, but the larger standard nozzle on pumps with leaded gas will not. At a minimum, the gasoline you use should meet the specifications of ASTM D4814 in the U.S.A. and CGSB 3.5–M93 in Canada. NOTICE Do not use leaded gasoline. Use of leaded gasoline will cause the three– way catalytic converter to lose its effectiveness and the emission control system to function improperly. Also, this can increase maintenance costs.
Luggage stowage precautions
Your Toyota’s identification
Theft prevention labels
Suspension and chassis
Types of tires 157 ’99camry U OCTANE RATING 5S–FE engine: Select Octane Rating 87 (Research Octane Number 91) or higher. 1MZ–FE engine: Select Octane Rating 87 (Research Octane Number 91) or higher. For improved vehicle performance, the use of premium unleaded gasoline with an Octane Rating 91 (Research Octane Number of 96) or higher is recommended. Use of unleaded gasoline with an octane rating or research octane number lower than stated above will cause persistent heavy knocking. If it is severe, this will lead to engine damage. If your engine knocks... If you detect heavy knocking even when using the recommended fuel, or if you hear steady knocking while holding a steady speed on level roads, consult your Toyota dealer. However, now and then, you may notice light knocking for a short time while accelerating or driving up hills. This is no cause for concern. 158 GASOLINES ADDITIVES CONTAINING DETERGENT Toyota recommends use of gasolines that contain detergent additives to avoid build–up of engine deposits. For further details, ask your Toyota dealer or a local gasoline retailer. IMPROVED GASOLINES The American Automobile Manufacturers Association (AAMA) has developed a specification of improved gasolines. The AAMA specification offers optimal fuel information for better vehicle performance and better protection of your engine. Toyota recommends the use of gasolines that meet the AAMA specification, if available, for improved driveability and emission control system. GASOLINES CONTAINING MTBE Gasolines that contain MTBE (Methyl Tertiary–Butyl Ether) are available in the market. If you use a gasoline mixed with MTBE, make certain that it does not contain more than 15% of MTBE. GASOLINES CONTAINING MMT Some gasolines contain an octane–enhancing additive called MMT (methylcyclopentadienyl manganese tricarbonyl). Toyota does not recommend the use of gasolines that contain MMT. If fuels containing MMT are used, your emission control system may be adversely affected. The Malfunction Indicator Lamp on the instrument cluster may come on. If this happens, contact your Toyota dealer for service. GASOLINES CONTAINING ALCOHOL If you use gasohol in your Toyota, be sure that it is unleaded, has an octane rating no lower than 87 and does not contain more than 10% ethanol. Gasohol is a mixture of gasoline and ethanol. Toyota does not recommend the use of gasolines containing methanol. If you use gasoline containing methanol, use only gasoline meeting the requirements above and also containing less than 5% methanol with cosolvents and corrosion inhibitors for methanol. ’99camry U Operation in foreign countries GASOLINES QUALITY In a very few cases, you may experience driveability problems caused by the particular gasoline that you are using. If you continue to have unacceptable driveability, try changing gasoline brands. If that does not rectify your problem, then consult your Toyota dealer. Three–way catalytic converters If you plan to drive your Toyota in another country... First, comply with the vehicle registration laws. Second, confirm the availability of the correct fuel (unleaded and minimum octane number). NOTICE  Do not use gasohol other than stated above. It will cause fuel system damage or vehicle performance problems. Type A  If driveability problems are encountered (poor hot starting, vaporizing, engine knock, etc.), discontinue the use.  Take care not to spill gasohol during refueling. Gasohol may cause paint damage. FUEL TANK CAPACITY 70 L (18.5 gal., 15.4 lmp. gal.) Type B 159 ’99camry U CAUTION NOTICE
Keep people and combustible mate- A large amount of unburned gases flowing into the three–way catalytic converter may cause it to overheat and create a fire hazard. To prevent this and other damage, observe the following precautions: rials away from the exhaust pipe while the engine is running. The exhaust gas is very hot.
Do not drive, idle or park your vehicle over anything that might burn easily such as grass, leaves, paper or rags. Type C The three–way catalytic converter is an emission control device installed in the exhaust system. The purpose is to reduce pollutants in the exhaust gas.  Use only unleaded gasoline.  Do not drive with an extremely low fuel level; running out of fuel could cause the engine to misfire, creating an excessive load on the three– way catalytic converter.  Do not allow the engine to run at idle speed for more than 20 minutes.  Avoid racing the engine.  Do not push–start or pull–start your vehicle.  Do not turn off the ignition while the vehicle is moving. 160 ’99camry U Engine exhaust cautions  Keep your engine in good running order. Malfunctions in the engine electrical system, electronic ignition system/distributor ignition system or fuel system could cause an extremely high three–way catalytic converter temperature. CAUTION
Avoid inhaling the engine exhaust. It contains carbon monoxide, which is a colorless and odorless gas. It can cause unconsciousness or even death.  If the engine becomes difficult to start or stalls frequently, take your vehicle in for a check–up as soon as possible. Remember, your Toyota dealer knows your vehicle and its three–way catalytic converter system best.
Make sure the exhaust system has  To ensure that the three–way catalytic converter and the entire emission control system operate properly, your vehicle must receive the periodic inspections required by the Toyota Maintenance Schedule. For scheduled maintenance information, refer to the separate ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement”.
Do not run the engine in a garage no holes or loose connections. The system should be checked from time to time. If you hit something, or notice a change in the sound of the exhaust, have the system checked immediately.
Keep the trunk lid closed while driving. An open or unsealed trunk lid may cause exhaust gases to be drawn into the vehicle.
To allow proper operation of your vehicle’s ventilation system, keep the inlet grilles in front of the windshield clear of snow, leaves, or other obstructions.
If you smell exhaust fumes in the vehicle, drive with the windows open and the trunk lid closed. Have the cause immediately located and corrected. or enclosed area except for the time needed to drive the vehicle in or out. The exhaust gases cannot escape, making this a particularly dangerous situation.
Do not remain for a long time in a parked vehicle with the engine running. If it is unavoidable, however, do so only in an unconfined area and adjust the heating or cooling system to force outside air into the vehicle. 161 ’99camry U Facts about engine oil consumption FUNCTIONS OF ENGINE OIL Engine oil has the primary functions of lubricating and cooling the inside of the engine, and plays a major role in maintaining the engine in proper working order. ENGINE OIL CONSUMPTION It is normal that an engine should consume some engine oil during normal engine operation. The causes of oil consumption in a normal engine are as follows.
Oil is used to lubricate pistons, piston rings and cylinders. A thin film of oil is left on the cylinder wall when a piston moves downwards in the cylinder. High negative pressure generated when the vehicle is decelerating sucks some of this oil into the combustion chamber. This oil as well as some part of the oil film left on the cylinder wall is burned by the high temperature combustion gases during the combustion process.
Oil is also used to lubricate the stems of the intake valves. Some of this oil is sucked into the combustion chamber together with the intake air and is burned along with the fuel. High temperature exhaust gases also burn the oil used to lubricate the exhaust valve stems. The amount of engine oil consumed depends on the viscosity of the oil, the quality of the oil and the conditions the vehicle is driven under. More oil is consumed by high–speed driving and frequent acceleration and deceleration. A new engine consumes more oil, since its pistons, piston rings and cylinder walls have not become conditioned. When judging the amount of oil consumption, note that the oil may become diluted and make it difficult to judge the true level accurately. As an example, if a vehicle is used for repeated short trips, and consumes a normal amount of oil, the dipstick may not show any drop in the oil level at all, even after 1000 km (600 miles) or more. This is because the oil is gradually becoming diluted with fuel or moisture, making it appear that the oil level has not changed. 162 The diluting ingredients evaporate out when the vehicle is then driven at high speeds, as on an express way, making it appear that oil is excessively consumed after driving at high speeds. IMPORTANCE OF ENGINE OIL LEVEL CHECK One of the most important points in proper vehicle maintenance is to keep the engine oil at the optimum level so that oil function will not be impaired. Therefore, it is essential that the oil level be checked regularly. Toyota recommends that the oil level be checked every time you refuel the vehicle. NOTICE Failure to check the oil level regularly could lead to serious engine trouble due to insufficient oil. For detailed information on oil level check, see ”Checking the engine oil level” in Chapter 7–2. ’99camry U Twin ground electrode platinum–tipped spark plugs Brake system TANDEM SYSTEM MASTER CYLINDER BRAKE The tandem master cylinder brake system is a hydraulic system with two separate sub–systems. If either sub–system should fail, the other will still work. However, the pedal will be harder to press, and your stopping distance will be longer. Also, the brake system warning light may come on. CAUTION Your engine is fitted with twin ground electrode platinum–tipped spark plugs. NOTICE Use only twin ground electrode platinum–tipped spark plugs for your engine performance. Do not drive your vehicle with only a single brake system. Have your brakes fixed immediately. BRAKE BOOSTER The brake booster uses engine vacuum to power–assist the brakes. If the engine should quit while you are driving, you can bring the vehicle to a stop with normal pedal pressure. There is enough reserve vacuum for one or two stops—but no more! CAUTION
Do not pump the brake pedal if the engine stalls. Each push on the pedal uses up your vacuum reserve.
Even if the power assist is completely lost, the brakes will still work. But you will have to push the pedal hard—much harder than normal. And your braking distance will be longer. ANTI–LOCK BRAKE ”ABS” warning light) SYSTEM (with The anti–lock brake system is designed to automatically help prevent lock–up of the wheels during sudden braking or braking on slippery road surfaces. This assists in providing directional stability and steering performance of the vehicle under these circumstances. The anti–lock brake system becomes operative after the vehicle has accelerated to a speed in excess of approximately 10 km/h (6 mph). It stops operating when the vehicle decelerate to a speed below approximately 5 km/h (3 mph). 163 ’99camry U You may hear a sound in the engine compartment for a few seconds when the engine is started or just after the vehicle is started. This means that the anti–lock brake system is in the self check mode, and does not indicate a malfunction. Effective way to press the ”ABS” brake pedal: When the anti–lock brake system function is in action, you may feel the brake pedal pulsating and hear a noise. In this situation, to let the anti–lock brake system work for you, just hold the brake pedal down more firmly. Do not pump the brake in a panic stop. Pumping the brake pedal makes the stopping distance longer. The brake pedal pulsation caused by the anti–lock brake system may indicate hazardous road surface conditions. Although the anti–lock brake system assists in providing vehicle control, it is still important to drive with all due care, because the anti–lock brake system cannot overcome the laws of physics that act on your vehicle:
Braking capability is dependent on tire friction with the road surface. 164
Even though the anti–lock brake system is operating, a driver cannot maintain full control on certain slippery road surfaces, when cornering at high speeds, or in violent maneuvers.
Avoid high speeds on wet roads. The anti–lock brake system cannot eliminate the risk of hydroplaning and loss of tire friction. Always maintain a safe distance from the vehicle in front of you. Compared with vehicles not fitted with an anti–lock brake system, your vehicle may require a longer stopping distance in the following cases:
Driving on rough, gravel or snow–covered roads.
Driving with tire chains installed.
Driving on roads where the road surface is pitted or has other differences in surface height. ”ABS” warning light The light comes on when the ignition key is turned to the ”ON” position. After a few seconds, the light will go off. If either of the following conditions occurs, this indicates a malfunction somewhere in the parts monitored by the warning light system. Contact your Toyota dealer as soon as possible to service the vehicle.
The light does not come on as described above, or remains on.
The light comes on while driving. ’99camry U Brake pad wear limit indicators Even if the anti–lock brake system should fail, the brake system will still operate conventionally. However, when the ”ABS” warning light is on (and the brake system warning light is off), the anti–lock brake system is not assisting brake performance so that the wheels can lock–up during sudden braking or braking on slippery road surfaces. Have your vehicle checked by your Toyota dealer as soon as possible. When stowing luggage or cargo in the vehicle, observe the following:
Put luggage or cargo in the trunk when at all possible. Be sure all items are secured in place.
Be careful to keep the vehicle balanced. Locating the weight as far forward as possible helps maintain balance.
For better fuel economy, do not carry unneeded weight. DRUM–IN–DISC TYPE PARKING BRAKE SYSTEM (1MZ–FE engine) Your vehicle has a drum–in–disc type parking brake system. This type of brake system needs bedding–down of the brake shoes periodically or whenever the parking brake shoes and/or drums are replaced. Have your Toyota dealer perform the bedding–down. Luggage stowage precautions CAUTION The brake pad wear limit indicators on your disc brakes give a warning noise when the brake pads are worn to where replacement is required. If you hear a squealing or scraping noise while driving, have the brake pads checked and replaced by your Toyota dealer as soon as possible. Expensive rotor damage can result if the pads are not replaced when necessary.
To prevent luggage or packages from sliding forward during do not stack anything in larged trunk. Keep luggage ages low, as close to the possible. braking, the enor packfloor as 165 ’99camry U Your Toyota’s identification— —Vehicle identification number
Never allow anyone to ride in the enlarged trunk. It is not designed for passengers. They should ride in their seats with their seat belts properly fastened. Otherwise, they are much more likely to suffer serious bodily injury, in the event of sudden braking or a collision.
Do not place anything on the filler panel behind the rear seatback. Such items may be thrown about and possibly injure people in the vehicle during sudden braking or an accident.
Do not drive with objects left on top of the instrument panel. They may interfere with the driver’s field of view. Or they may move during sharp vehicle acceleration or turning, and impair the driver’s control of the vehicle. In an accident they may injure the vehicle occupants. NOTICE Do not load the vehicle beyond the vehicle capacity weight specified in Part 8. 166 The vehicle identification number (VIN) is the legal identifier for your vehicle. This number is on the left top of the instrument panel, and can be seen through the windshield from outside. This is the primary identification number for your Toyota. It is used in registering the ownership of your vehicle. The vehicle identification number (VIN) is also on the Certification Label. ’99camry U —Engine number Theft prevention labels The engine number is stamped on the engine block as shown. Your new vehicle carries theft prevention labels which are approximately 56 mm (2.20 in.) by 16 mm (0.63 in.). The purpose of these labels is to reduce the incidence of vehicle thefts by facilitating the tracing and recovery of parts from stolen vehicles. The label is designed so that once it is applied to a surface, any attempt to remove it will result in destroying the integrity of the label. Transferring these labels intact from one part to another, will be impossible. 5S–FE engine NOTICE You should not attempt to remove the theft prevention labels as it may violate certain state or federal laws. 1MZ–FE engine 167 ’99camry U Suspension and chassis Types of tires CAUTION Determine what kind of tires your vehicle is originally equipped with. Do not modify the suspension/chassis with lift kits, spacers, springs, etc. It can cause dangerous vehicle handling characteristics, resulting in loss of control. Summer tires are high–speed capability tires best suited to highway driving under dry conditions. 1. Summer tires Since summer tires do not have the same traction performance as snow tires, summer tires are inadequate for driving on snow–covered or icy roads. For driving on snow–covered or icy roads, we recommend using snow tires. If installing snow tires, be sure to replace all four tires. 2. All season tires All season tires are designed to provide better traction in snow and to be adequate for driving in most winter conditions, as well as for use all year round. All season tires, however, do not have adequate traction performance compared with snow tires in heavy or loose snow. Also, all season tires fall short in acceleration and handling performance compared with summer tires in highway driving. 168 CAUTION
Do not mix summer and all season tires on your vehicle as this can cause dangerous handling characteristics, resulting in loss of control.
Do not use tires other than the manufacturer’s designated tires, and never mix tires or wheels of the sizes different from the originally equipped tires and wheels. ’99camry U Part 3 STARTING AND DRIVING
Before starting the engine
How to start the engine
Tips for driving in various conditions
Winter driving tips
Trailer towing
How to save fuel and make your vehicle last longer, too Before starting the engine 1. Check the area around the vehicle before entering it. 2. Adjust seat position, seatback angle, head restraint height and steering wheel angle. 3. Adjust inside and outside rear view mirrors. 4. Lock all doors. 5. Fasten seat belts. How to start the engine— (a) Before cranking 1. Apply the parking brake firmly. 2. Turn off unnecessary lights and accessories. 3. Manual transmission: Press the clutch pedal to the floor and shift the transmission into neutral. Hold the clutch pedal to the floor until the engine is started. A starter safety device will prevent the starter from operating if the clutch pedal is not fully depressed. Automatic transmission: Put the selector lever in ”P”. If you need to restart the engine while the vehicle is moving, put the selector lever in ”N”. A starter safety device will prevent the starter from operating if the selector lever is in any drive position. 4. Automatic transmission only: Depress the brake pedal and hold it to the floor until driving off. 169 ’99camry U (b) Starting the engine Before starting the engine, be sure to follow the instructions in ”(a) Before cranking”. Normal starting procedure The multiport fuel injection system/sequential multiport fuel injection system in your engine automatically controls the proper air–fuel mixture for starting. You can start a cold or hot engine as follows: 1. With your foot off the accelerator pedal, crank the engine by turning the key to ”START”. Release it when the engine starts. 2. After the engine runs for about 10 seconds, you are ready to drive. If the weather is below freezing, let the engine warm up for a few minutes before driving. If the engine stalls... Simply restart it, using the correct procedure given in normal starting. If the engine will not start... See ”If your vehicle will not start” in Part 4. 170 NOTICE  Do not crank for more than 30 seconds at a time. This may overheat the starter and wiring systems.  Do not race a cold engine.  If the engine becomes difficult to start or stalls frequently, have the engine checked immediately. Tips for driving in various conditions
Always slow down in gusty crosswinds. This will allow you much better control.
Drive slowly onto curbs and, if possible, at a right angle. Avoid driving onto high, sharp–edged objects and other road hazards. Failure to do so can lead to severe tire damage resulting in tire bursts.
When parking on a hill, turn the front wheels until they touch the curb so that the vehicle will not roll. Apply the parking brake, and place the transmission in ”P” (automatic) or in first or reverse (manual). If necessary, block the wheels.
Washing your vehicle or driving through deep water may get the brakes wet. To see whether they are wet, check that there is no traffic near you, and then press the pedal lightly. If you do not feel a normal braking force, the brakes are probably wet. To dry them, drive the vehicle cautiously while lightly pressing the brake pedal with the parking brake pulled. If they still do not work safely, pull to the side of the road and call a Toyota dealer for assistance. ’99camry U Winter driving tips CAUTION
Before driving off, make sure that the parking brake is fully released and the parking brake reminder light is off.
Do not leave your vehicle unattended while the engine is running.
Do not rest your foot on the brake pedal while driving. It can cause dangerous overheating, needless wear, and poor fuel economy.
To drive down a long or steep hill, reduce your speed and downshift. Remember, if you ride the brakes excessively, they may overheat and not work properly.
Be careful when accelerating, upshifting, downshifting or braking on a slippery surface. Sudden acceleration or engine braking could cause the vehicle to spin or skid.
Do not drive in excess of the speed limit. Even if the legal speed limit permits it, do not drive over 140 km/h (85 mph) unless your vehicle has high–speed capability tires. Driving over 140 km/h (85 mph) may result in tire failure, loss of control and possible injury. Be sure to consult a tire dealer to determine whether the tires on your vehicle are high–speed capability tires or not before driving at such speeds.
Do not continue normal driving when the brakes are wet. If they are wet, your vehicle will require a longer stopping distance, and it may pull to one side when the brakes are applied. Also, the parking brake will not hold the vehicle securely. Make sure you have a proper freeze protection of engine coolant. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of aluminum components. Use ”Toyota Long Life Coolant” or equivalent. See Chapter 7–2 for details about coolant type selection. NOTICE Do not use alcohol type antifreeze or plain water alone. When it is extremely cold, we recommend to use 60% solution for your Toyota, to provide protection down to about –50°C (–58°F). Do not use more than 70% solution for better coolant performance. Check the condition of the battery and cables. Cold temperatures reduce the capacity of any battery, so it must be in top shape to provide enough power for winter starting. Chapter 7–3 tells you how to visually inspect the battery. Your Toyota dealer and most service stations will be pleased to check the level of charge. 171 ’99camry U Trailer towing Make sure the engine oil viscosity is suitable for the cold weather. Do not use your parking brake when there is a possibility it could freeze. See Chapter 7–2 for recommended viscosity. Leaving a heavy summer oil in your vehicle during winter months may cause harder starting. If you are not sure about which oil to use, call your Toyota dealer—he will be pleased to help. Keep the door locks from freezing. When parking, put the transmission into ”P” (automatic) or into first or reverse (manual) and block the rear wheels. Do not use the parking brake, or snow or water accumulated in and around the parking brake mechanism may freeze, making it hard to release. Squirt lock de–icer or glycerine into the locks to keep them from freezing. Keep ice and snow from accumulating under the fenders. Use a washer fluid containing an antifreeze solution. Ice and snow built up under your fenders can make steering difficult. During bad winter driving, stop and check under the fenders occasionally. This product is available at your Toyota dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water. NOTICE Do not use engine antifreeze or any other substitute because it may damage your vehicle’s paint. 172 Depending on where you are driving, we recommend you carry some emergency equipment. Some of the things you might put in the vehicle are tire chains, window scraper, bag of sand or salt, flares, small shovel, jumper cables, etc. Your vehicle is designed primarily as a passenger–carrying vehicle. Towing a trailer will have an adverse effect on handling, performance, braking, durability and driving economy (fuel consumption, etc.). Your safety and satisfaction depend on the proper use of correct equipment and cautious driving habits. For your safety and the safety of others, you must not overload your vehicle or trailer. Toyota warranties do not apply to damage or malfunction caused by towing a trailer for commercial purposes. Ask your local Toyota dealer for further details before towing. NOTICE When towing a trailer, be sure to consult your Toyota dealer for further information on additional requirements such as a towing kit, etc. ’99camry U WEIGHT LIMITS
Trailer hitch assemblies have differ- Before towing, make sure the total trailer weight, gross vehicle weight, gross axle weight and trailer tongue load are all within the limits. ent weight capacities established by the hitch manufacturer. Even though the vehicle may be physically capable of towing a higher weight, the operator must determine the maximum weight rating of the particular hitch assembly and never exceed the maximum weight rating specified for the trailer–hitch. Exceeding the maximum weight rating set by the trailer hitch manufacturer can cause an accident resulting in serious personal injuries. The total trailer weight and tongue load can be measured with platform scales found at a highway weighing station, building supply company, trucking company, junk yard, etc. CAUTION
The total trailer weight (trailer weight plus its cargo load) must not exceed 907 kg (2000 lb.). Exceeding this weight is dangerous.
The gross vehicle weight must not exceed the Gross Vehicle Weight Rating (GVWR) indicated on the Certification Label. The gross vehicle weight is the sum of weights of the unloaded vehicle, driver, passengers, luggage, hitch and trailer tongue load. It also includes the weight of any special equipment installed on your vehicle. 173 ’99camry U
The load on either the front or rear axle resulting from distribution of the gross vehicle weight on both axles must not exceed the Gross Axle Weight Rating (GAWR) listed on the Certification Label. HITCHES Total trailer weight Tongue load
Use only a hitch which is recommended by the hitch manufacturer and conforms to the total trailer weight requirement.
Follow the directions supplied by the hitch manufacturer. Lubricate the hitch ball with a light coat of grease.
Toyota recommends removing the trailTongue load Total trailer weight
100 = 9 to 11% er hitch whenever you are not towing a trailer to reduce the possibility of additional damage caused by the hitch if your vehicle is struck from behind.
The trailer cargo load should be distributed so that the tongue load is 9 to 11% of the total trailer weight, not exceeding the maximum of 90 kg (200 lb.). Never load the trailer with more weight in the back than in the front. About 60% of the trailer load should be in the front half of the trailer and the remaining 40% in the rear. NOTICE Do not use axle–mounted hitches as they can cause damage to the axle housing, wheel bearings, wheels or tires. Also, never install a hitch which may interfere with the normal function of an Energy Absorbing Bumper, if so equipped. BRAKES AND SAFETY CHAINS
Toyota recommends trailers with brakes that conform to any applicable federal and state/provincial regulations. 174 ’99camry U
A safety chain must always be used between the towing vehicle and the trailer. Leave sufficient slack in the chain for turns. The chain should cross under the trailer tongue to prevent the tongue from dropping to the ground in case it becomes damaged or separated. For correct safety chain procedures, follow the hitch or trailer manufacturer’s recommendations. CAUTION
If the total trailer weight exceeds 453 kg (1000 lb.), trailer brakes are required.
Never tap into your vehicle’s hydraulic system as it would lower its braking effectiveness.
Never tow a trailer without using a safety chain securely attached to both the trailer and the vehicle. If damage occurs to the coupling unit or hitch ball, there is danger of the trailer wandering over into another lane. TIRES TRAILER LIGHTS
Ensure that your vehicle’s tires are
Trailer lights must comply with federal, properly inflated. Adjust the tire pressure to the recommended cold tire pressure indicated below (see Chapter 7–2 for instructions.): state/provincial and local regulations. See your local recreational vehicle dealer or rental agency for the correct type of wiring and relays for your trailer. Check for correct operation of the turn signals and stop lights each time you hitch up. Direct splicing may damage your vehicle’s electrical system and cause a malfunction of your lights. Tire pressure, kPa (kgf/cm2 or bar, psi) 5S–FE engine Front 210 (2.1, 30) Rear 210 (2.1, 30) 1MZ–FE engine Front 220 (2.2, 32) Rear 220 (2.2, 32)
The trailer tires should be inflated to the pressure recommended by the trailer manufacturer in respect to the total trailer weight. BREAK–IN SCHEDULE
Toyota recommends that you do not tow a trailer with a new vehicle or a vehicle with any new power train component (engine, transmission, differential, wheel bearing, etc.) for the first 800 km (500 miles) of driving. MAINTENANCE
If you tow a trailer, your vehicle will require more frequent maintenance due to the additional load. For this information, please refer to the scheduled maintenance information in the ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement”.
Retighten all fixing bolts of the towing ball and bracket after approximately 1000 km (600 miles) of trailer driving. 175 ’99camry U PRE–TOWING SAFETY CHECK
Check that your vehicle remains level when a loaded or unloaded trailer is hitched. Do not drive if the vehicle has an abnormal nose–up or nose–down condition, and check for improper tongue load, overload,worn suspension or other possible causes.
Make sure the trailer cargo is securely loaded so that it can not shift.
Check that your rear view mirrors conform to any applicable federal, state/ provincial or local regulation. If not, install the rear view mirrors required for towing purpose. TRAILER TOWING TIPS When towing a trailer, your vehicle will handle differently than when not towing. The three main causes of vehicle– trailer accidents are driver error, excessive speed and improper trailer loading. Keep these in mind when towing:
Before starting out, check operation of the lights and all vehicle–trailer connections. After driving a short distance, stop and recheck the lights and connections. Before actually towing a trailer, practice turning, stopping and backing with a trailer in an area away from traffic until you learn the feel. 176
Backing with a trailer is difficult and
Avoid jerky steering and sharp turns. requires practice. Grip the bottom of the steering wheel and move your hand to the left to move the trailer to the left. Move your hand to the right to move the trailer to the right. (This procedure is generally opposite to that when backing without a trailer). Also, just turn the steering wheel a little at a time, avoiding sharp or prolonged turning. Have someone guide you when backing to reduce the risk of an accident. The trailer could hit your vehicle in a tight turn. Slow down before making a turn to avoid the necessity of sudden braking.
Because stopping distance may be increased, vehicle–to–vehicle distance should be increased when towing a trailer. For each 16 km/h (10 mph) of speed, allow at least one vehicle and trailer length between you and the vehicle ahead. Avoid sudden braking as you may skid, resulting in jackknifing and loss of control. This is especially true on wet or slippery surfaces.
Avoid jerky starts or sudden acceleration. If your vehicle has a manual transmission, prevent excessive clutch slippage by keeping engine rpm low and not racing the engine. Always start out in first gear.
Remember that when making a turn, the trailer wheels will be closer than the vehicle wheels to the inside of the turn. Therefore, compensate for this by making a larger than normal turning radius with your vehicle.
Crosswinds and rough roads will adversely affect handling of your vehicle and trailer, causing sway. Pay attention to the rear from time to time to prepare yourself for being passed by large trucks or buses, which may cause your vehicle and trailer to sway. If swaying happens, firmly grip the steering wheel and reduce speed immediately but gradually. Never increase speed. Steer straight ahead. If you make no extreme correction with the steering or brakes, the vehicle and trailer will stabilize.
Be careful when passing other vehicles. Passing requires considerable distance. After passing a vehicle, do not forget the length of your trailer and be sure you have plenty of room before changing lanes. ’99camry U
In order to maintain engine braking efficiency do not use fifth gear (manual transmission) or overdrive (automatic transmission).
Because of the added load of the trailer, your vehicle’s engine may overheat on hot days (at temperatures over 30C [85F]) when going up a long or steep grade with a trailer. If the engine coolant temperature gauge indicates overheating, immediately turn off the air conditioning (if in use), pull off the road and stop in a safe spot. Refer to ”If your vehicle overheats” in Part 4 of this manual.
Always place wheel blocks under both the vehicle and trailer wheels when parking. Apply the parking brake firmly. Put the transmission in ”P” (automatic) or in first or reverse (manual). Avoid parking on a slope with a trailer, but if it cannot be avoided, do so only after performing the following: 1. Apply the brakes and hold. 2. Have someone place wheel blocks under both the vehicle and trailer wheels. 3. When the wheel blocks are in place, release your brakes slowly until the blocks absorb the load. 4. Apply the parking brake firmly. 5. Shift into first or reverse (manual) or ”P” (automatic) and turn off the engine. CAUTION
Do not exceed 72 km/h (45 mph) or the posted towing speed limit,whichever is lower. Because instability (swaying) of a towing vehicle– trailer combination usually increases as the speed increases,exceeding 72 km/h (45 mph) may cause loss of control. When restarting out after parking on a slope:
Slow down and downshift before 1. With the transmission in ”P” position (automatic) or the clutch pedal depressed (manual), start the engine. (With an automatic transmission, be sure to keep the brake pedal depressed.)
Avoid holding the brake pedal down 2. Shift into gear. descending steep or long downhill grades. Do not make sudden downshifts. too long or too frequently. This could cause the brakes to overheat and result in reduced braking efficiency. 3. Release the parking brake (also foot brake on automatic transmission vehicles) and slowly pull or back away from the wheel blocks. Stop and apply your brakes. 4. Have someone retrieve the blocks. 177 ’99camry U How to save fuel and make your vehicle last longer, too Getting more kilometers/mileage from a liter/gallon of fuel is easy—just take it easy. It will help make your vehicle last longer, too. Here are some specific tips on how to save money on both fuel and repairs:
Avoid engine lug or overrevving. Use
Keep the front wheels in proper a gear position suitable for the road on which you are travelling. alignment. Avoid hitting the curb and slow down on rough roads. Improper alignment not only causes faster tire wear but also puts an extra load on the engine, which, in turn, wastes fuel.
Keep your tires inflated at the cor-
Avoid rect pressure. Underinflation causes tire wear and wastes fuel. See Chapter 7–2 for instructions.
Do not carry unneeded weight in your vehicle. Excess weight puts a heavier load on the engine, causing greater fuel consumption.
Avoid lengthy warm–up idling. Once the engine is running smoothly, begin driving—but gently. Remember, however, that on cold winter days this may take a little longer.
Accelerate slowly and smoothly. Avoid jackrabbit starts. Get into high gear as quickly as possible.
Avoid long engine idling. If you have a long wait and you are not in traffic, it is better to turn off the engine and start again later. 178
Avoid continuous speeding up and slowing down. wastes fuel. Stop–and–go driving unnecessary stopping and braking. Maintain a steady pace. Try to time the traffic signals so you only need to stop as little as possible or take advantage of through streets to avoid traffic lights. Keep a proper distance from other vehicles to avoid sudden braking. This will also reduce wear on your brakes.
Avoid heavy traffic or traffic jams whenever possible.
Do not rest your foot on the clutch or brake pedal. This causes needless wear, overheating and poor fuel economy.
Maintain a moderate speed on highways. The faster you drive,the greater the fuel consumption. By reducing your speed, you will cut down on fuel consumption.
Keep the bottom of your vehicle free from mud, etc. This not only lessens weight but also helps prevent corrosion.
Keep your vehicle tuned–up and in top shape. A dirty air cleaner, improper valve clearance, dirty plugs, dirty oil and grease,brakes not adjusted, etc. all lower engine performance and contribute to poor fuel economy. For longer life of all parts and lower operating costs, keep all maintenance work on schedule, and if you often drive under severe conditions, see that your vehicle receives more frequent maintenance (For scheduled maintenance information, please refer to the separate ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement”). ’99camry U CAUTION Never turn off the engine to coast down hills. Your power steering and brake booster will not function without the engine running. Also, the emission control system operates properly only when the engine is running. 179 ’99camry U 180 ’99camry U Part 4 IN CASE OF AN EMERGENCY
If your vehicle will not start
If your engine stalls while driving
If your vehicle overheats
If you have a flat tire
If your vehicle needs to be towed
If you cannot shift automatic transmission selector lever
If you lose your keys
If you lose your wireless remote control transmitter If your vehicle will not start— (a) Simple checks Before making these checks, make sure you have followed the correct starting procedure given in ”How to start the engine” in Part 3 and that you have sufficient fuel. If your vehicle is equipped with the engine immobiliser system, also check whether the other keys will start the engine. If they work, your key may be broken. Have the key checked at your Toyota dealer. If none of your keys work, the system is possibly broken. Call your Toyota dealer. (See ”Keys (with engine immobiliser system)” in Chapter 1–2.) If the engine is not turning over or is turning over too slowly— 1. Check that the battery terminals are tight and clean. 2. If the battery terminals are O.K., switch on the interior light. NOTICE Do not pull– or push–start the vehicle. It may damage the vehicle or cause a collision when the engine starts. Also the three–way catalytic converter may overheat and become a fire hazard. If the engine turns over at its normal speed but will not start— 1. Check that all the push–on connectors are tight. (For example, connectors at the spark plugs, ignition coil and/or distributor) 2. If the connectors are O.K., the engine may be flooded because of repeated cranking. See ”(b) Starting a flooded engine” for further instructions. 3. If the light is out, dim or goes out when the starter is cranked, the battery is discharged. You may try jump starting. See ”(c) Jump starting” for further instructions. If the light is O.K., but the engine still will not start, it needs adjustment or repair. Call a Toyota dealer or qualified repair shop. 181 ’99camry U (b) Starting a flooded engine (c) Jump starting If the engine will not start, your engine may be flooded because of repeated cranking. To avoid serious personal injury and damage to your vehicle which might result from battery explosion, acid burns, electrical burns, or damaged electronic components, these instructions must be followed precisely. If this happens, turn the key to ”START” with the accelerator pedal held down. Keep the key and accelerator pedal so for 15 seconds and release them. Then try starting the engine with your foot off the accelerator pedal. If the engine does not start after 30 seconds of cranking, release the key, wait a few minutes and try again. If the engine still will not start, it needs adjustment or repair. Call a Toyota dealer or qualified repair shop for assistance. NOTICE Do not crank for more than 30 seconds at a time. This may overheat the starter and wiring systems. 182 If you are unsure about how to follow this procedure, we strongly recommend that you seek the help of a competent mechanic or towing service. CAUTION
Batteries contain sulfuric acid which is poisonous and corrosive. Wear protective safety glasses when jump starting, and avoid spilling acid on your skin, clothing, or vehicle.
If you should accidentally get acid on yourself or in your eyes, remove any contaminated clothing and flush the affected area with water immediately. Then get immediate medical attention. If possible, continue to apply water with a sponge or cloth while enroute to the medical office.
The gas normally produced by a battery will explode if a flame or spark is brought near. Use only standardised jumper cables and do not smoke or light a match while jump starting. NOTICE The battery used for boosting must be 12 V. Do not jump start unless you are sure that the booster battery is correct. ’99camry U JUMP STARTING PROCEDURE Discharged battery 1. If the booster battery is installed in another vehicle, make sure the vehicles are not touching. Turn off all unnecessary lights and accessories. 2. If required, remove all the vent plugs from the booster and discharged batteries. Lay a cloth over the open vents on the batteries. (This helps reduce the explosion hazard, personal injuries and burns.) 3. If the engine in the vehicle with the booster battery is not running, start it and let it run for a few minutes. During jump starting run the engine at about 2000 rpm with the accelerator pedal lightly depressed. Jumper cable Booster battery Positive Jumper terminal (”+” mark) cable Positive terminal (”+” mark) 4. Make the cable connections in the order a, b, c, d. a. Connect the clamp of the positive (red) jumper cable to the positive ( ) terminal on the discharged battery. b. Connect the clamp at the other end of the positive (red) jumper cable to the positive ( ) terminal on the booster battery. Discharged battery Negative terminal (”–” mark) Booster battery c. Connect the clamp of the negative (black) jumper cable to the negative ( ) terminal on the booster battery. d. Connect the clamp at the other end of the negative (black) jumper cable to a solid, stationary, unpainted, metallic point of the vehicle with the discharged battery. The recommended connecting points are shown in the following illustrations: 183 ’99camry U If your engine stalls while driving Do not connect it to or near any part that moves when the engine is cranked. CAUTION When making the connections, to avoid serious injury, do not lean over the battery or accidentally let the jumper cables or clamps touch anything except the correct battery terminals or the ground. Connecting point for 5S–FE engine 5. Start your engine in the normal way. After starting, run it at about 2000 rpm for several minutes with the accelerator pedal lightly depressed. 6. Carefully disconnect the cables in the exact reverse order: the negative cable and then the positive cable. 7. Carefully dispose of the battery cover cloths—they may now contain sulfuric acid. 8. If removed, replace all the battery vent plugs. Connecting point for 1MZ–FE engine 184 If the cause of your battery discharging is not apparent (for example, lights left on), you should have it checked. If your engine stalls while driving... 1. Reduce your speed gradually, keeping a straight line. Move cautiously off the road to a safe place. 2. Turn on your emergency flashers. 3. Try starting the engine again. If the engine will not start, see ”If your vehicle will not start”. CAUTION If the engine is not running, the power assist for the brakes and steering will not work so steering and braking will be much harder than usual. ’99camry U If your vehicle overheats If your engine coolant temperature gauge indicates overheating, if you experience a loss of power, or if you hear a loud knocking or pinging noise, the engine has probably overheated. You should follow this procedure... 3. Look for obvious coolant leaks from the radiator, hoses,and under the vehicle. However, note that water draining from the air conditioning is normal if it has been used. 1. Pull safely off the road, stop the vehicle and turn on your emergency flashers. Put the transmission in ”P” (automatic) or neutral (manual) and apply the parking brake. Turn off the air conditioning if it is being used. CAUTION 2. If coolant or steam is boiling out of the radiator or reservoir,stop the engine. Wait until the steam subsides before opening the hood. If there is no coolant boiling over or steam, leave the engine running and make sure the electric cooling fan is operating. If it is not, turn the ignition off. 6. After the engine coolant temperature has cooled to normal, again check the coolant level in the reservoir. If necessary, bring it up to half full again. Serious coolant loss indicates a leak in the system. You should have it checked as soon as possible at your Toyota dealer. When the engine is running, keep hands and clothing away from the moving fan and engine drive belts. 4. If the coolant is leaking, stop the engine immediately. Call a Toyota dealer for assistance. 5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add coolant to the reservoir while the engine is running. Fill it about half full. CAUTION CAUTION To help avoid personal injury, keep the hood closed until there is no steam. Escaping steam or coolant is a sign of very high pressure. Do not attempt to remove the radiator cap when the engine and radiator are hot. Serious injury could result from scalding hot fluid and steam blown out under pressure. 185 ’99camry U If you have a flat tire— 1. Reduce your speed gradually, keeping a straight line. Move cautiously off the road to a safe place well away from the traffic. Avoid stopping on the center divider of a highway. Park on a level spot with firm ground. 2. Stop the engine and emergency flashers. turn on your 3. Firmly set the parking brake and put the transmission in ”P” (automatic) or reverse (manual). 4. Have everyone get out of the vehicle on the side away from traffic.
Stop the vehicle on a level firm ground, firmly set the parking brake and put the transmission in ”P” (automatic) or reverse (manual). Block the wheel diagonally opposite to the one being changed if necessary.
Make sure to set the jack properly in the jack point. Raising the vehicle with jack improperly positioned will damage the vehicle or may allow the vehicle to fall off the jack and cause personal injury. 5. Read the following instructions thoroughly.
Never get under the vehicle when CAUTION
Use the jack only for lifting your When jacking, be sure to observe the following to reduce the possibility of personal injury:
Follow jacking instructions.
Do not start or run the engine while your vehicle is supported by the jack. 186 the vehicle is supported by the jack alone. vehicle during wheel changing.
Do not raise the vehicle with someone in the vehicle.
When raising the vehicle, do not put an object on or under the jack.
Raise the vehicle only high enough to remove and change the tire. NOTICE Do not continue driving with a deflated tire. Driving even a short distance can damage a tire beyond repair. ’99camry U —Required tools and spare tire 1. Get the required tools and spare tire. 1. 2. 3. 4. Wheel nut wrench Jack Jack handle Spare tire To prepare yourself for an emergency, you should familiarize yourself with the use of the jack, each of the tools and their storage locations. Turn the jack joint by hand. To remove the spare tire: To remove: Turn the joint in direction 1 until the jack is free. To store: Turn the joint in direction 2 until the jack is firmly secured to prevent it flying forward during a collision or sudden braking. 1. Loosen the nut and remove it. 2. Remove the spare tire cover. 3. Loosen the bolt and remove it. 4. Remove the spacer. Then take the spare tire out of the vehicle. When storing the spare tire, put it in place with the outer side of the wheel facing up. Then secure the tire by repeating the above removal steps in reverse order to prevent it from flying forward during a collision or sudden braking. 187 ’99camry U —Blocking the wheel —Removing wheel ornament 3. Remove the wheel ornament. Pry off the wheel ornament, using the beveled end of the wheel nut wrench as shown. CAUTION Do not try to pull off the ornament by hand. Take due care in handling the ornament to avoid unexpected personal injury. 2. Block the wheel diagonally opposite the flat tire to keep the vehicle from rolling when it is jacked up. Steel wheels When blocking the wheel, place a wheel block from the front for the front wheels or from the rear for the rear wheels. Aluminium wheels 188 ’99camry U —Loosening wheel nuts —Positioning the jack —Raising your vehicle 4. Loosen all the wheel nuts. 5. Position the jack at the correct jack point as shown. 6. After making sure that no one is in the vehicle, raise it high enough so that the spare tire can be installed. Always loosen the wheel nuts before raising the vehicle. The nuts turn counterclockwise to loosen. To get maximum leverage, fit the wrench to the nut so that the handle is on the right side, as shown above. Grab the wrench near the end of the handle and pull up on the handle. Be careful that the wrench does not slip off the nut. Do not remove the nuts yet—just unscrew them about one–half turn. Make sure the jack is positioned on a level and solid place. Remember you will need more ground clearance when putting on the spare tire than when removing the flat tire. To raise the vehicle, insert the jack handle into the jack (it is a loose fit) and turn it clockwise. As the jack touches the vehicle and begins to lift, double–check that it is properly positioned. 189 ’99camry U —Changing wheels CAUTION Never get under the vehicle when the vehicle is supported by the jack alone. 7. Remove the wheel nuts and change tires. Lift the flat tire straight off and put it aside. Roll the spare wheel into position and align the holes in the wheel with the bolts. Then lift up the wheel and get at least the top bolt started through its hole. Wiggle the tire and press it back over the other bolts. 190 Before putting on wheels, remove any corrosion on the mounting surfaces with a wire brush or such. Installation of wheels without good metal–to–metal contact at the mounting surface can cause wheel nuts to loosen and eventually cause a wheel to come off while driving. Therefore after the first 1600 km (1000 miles), check to see that the wheel nuts are tight. ’99camry U —Reinstalling wheel nuts —Lowering your vehicle CAUTION When lowering the vehicle, make sure all portions of your body and all other persons around will not be injured as the vehicle is lowered to the ground. 8. Reinstall all the wheel nuts finger tight. 9. Lower the vehicle completely and tighten the wheel nuts. Reinstall the wheel nuts (tapered end inward) and tighten them as much as you can by hand. Press back on the tire and see if you can tighten them more. Turn the jack handle counterclockwise to lower the vehicle. Use only the wheel nut wrench to tighten the nuts. Do not use other tools or any additional leverage other than your hands, such as a hammer, pipe or your foot. Make sure the wrench is securely engaged over the nut. Tighten each nut a little at a time in the order shown. Repeat the process until all the nuts are tight. 191 ’99camry U —Reinstalling wheel ornament —After changing wheels 10. Reinstall the wheel ornament. 1. Put the wheel ornament into position. On some models, align the cutout of the wheel ornament with the valve stem as shown. 2. Then tap it firmly with the side or heel of your hand to snap it into place. CAUTION Steel wheels Take due care in handling the ornament to avoid unexpected personal injury. 11. Check the air pressure of the replaced tire. Adjust the air pressure to the specification designed in Part 8. If the pressure is lower, drive slowly to the nearest service station and fill to the correct pressure. Do not forget to reinstall the tire inflation valve cap as dirt and moisture could get into the valve core and possibly cause air leakage. If the cap is missing, have a new one put on as soon as possible. 12. Restow all the tools, jack and flat tire securely. As soon after changing wheels as possible, tighten the wheel nuts to the torque specified in Part 8 with a torque wrench and have a technician repair the flat tire. CAUTION Before driving, make sure all the tools, jack and flat tire are securely in place in their storage location to reduce the possibility of personal injury during a collision or sudden braking. Aluminum wheels 192 ’99camry U If your vehicle needs to be towed— (a) Towing with wheel lift type truck— —From front —From rear If towing is necessary, we recommend you to have it done by your Toyota dealer or a commercial tow truck service. In consultation with them, have your vehicle towed using either (a) or (b). Only when you cannot receive a towing service from a Toyota dealer or commercial tow truck service, tow your vehicle carefully in accordance with the instructions given in ”—Emergency towing” in this part. Proper equipment will help ensure that your vehicle is not damaged while being towed. Commercial operators are generally aware of the state/provincial and local laws pertaining to towing. (b) Using flat bed truck Your vehicle can be damaged if it is towed incorrectly. Although most operators know the correct procedure, it is possible to make a mistake. To avoid damage to your vehicle, make sure the following few precautions are observed. If necessary, show this page to the tow truck driver. TOWING PRECAUTIONS: Use a safety chain system for all towing, and abide by the state/provincial and local laws. The wheels and axle on the ground must be in good condition. If they are damaged, use a towing dolly. (a) Towing with wheel lift type truck From front—Release the parking brake. NOTICE When lifting wheels, take care to ensure adequate ground clearance for towing at the opposite end of the raised vehicle. Otherwise, the bumper and/or underbody of the towed vehicle will be damaged during towing. From rear—
Manual transmission: We recommend using a towing dolly under the front wheels. If you do not use a towing dolly, place the ignition key in the ”ACC” position and put the transmission in neutral. NOTICE Do not tow with the key removed or in the ”LOCK” position when towing from the rear without a towing dolly. The steering lock mechanism is not strong enough to hold the front wheels straight. 193 ’99camry U —Emergency towing
Automatic transmission: Use a towing dolly under the front wheels. (c) Towing with sling type truck NOTICE Never tow a vehicle with an automatic transmission from the rear with the front wheels on the ground, as this may cause serious damage to the transmission. (b) Using flat bed truck (c) Towing with sling type truck NOTICE Do not tow with sling type truck, either from the front or rear. This may cause body damage. If towing is necessary, we recommend you to have it done by your Toyota dealer or a commercial tow truck service. If towing service is not available in an emergency, your vehicle may be temporarily towed by a cable or chain secured to one of the emergency towing eyelets under the vehicle. Use extreme caution when towing vehicles. A driver must be in the vehicle to steer it and operate the brakes. Towing in this manner may be done only on hard–surfaced roads for a short distance and at low speeds. Also, the wheels, axles, drive train,steering and brakes must all be in good condition. 194 ’99camry U If you cannot shift automatic transmission selector lever CAUTION CAUTION Use extreme caution when towing vehicles. Avoid sudden starts or erratic driving maneuvers which would place excessive stress on the emergency towing eyelets and towing cable or chain. The eyelets and towing cable or chain may break and cause serious injury or damage. If the engine is not running, the power assist for the brakes and steering will not work so steering and braking will be much harder than usual. NOTICE Use only a cable or chain specifically intended for use in towing vehicles. Securely fasten the cable or chain to the towing eyelets provided. Before towing, release the parking brake and put the transmission in neutral (manual) or ”N” (automatic). The key must be in ”ACC” (engine off) or ”ON” (engine running). If you cannot shift the selector lever out of ”P” position to other positions even though the brake pedal is depressed, use the shift lock override button as follows: 1. Turn the ignition key to position. Make sure the brake is on. ”LOCK” parking 2. Pry up the cover with a flat–bladed screwdriver or equivalent. 195 ’99camry U If you lose your keys Please contact your nearest Toyota dealer and ask for duplicating key. You must inform of the key number and, in case of making the immobiliser key, one of the master keys must be presented. See the suggestion given in ”Keys” in Chapter 1–2. 3. Insert your finger into the push down the shift lock button. You can shift out position only while pushing ton. hole to override of ”P” the but- 4. Shift into ”N” position. 5. Insert the cover. 6. Start the engine. For your safety, keep the brake pedal depressed. Be sure to have the system checked by your Toyota dealer as soon as possible. 196 If your keys are locked in the vehicle and you cannot get a duplicate, many Toyota dealers can still open the door for you, using their special tools. If you must break a window to get in, we suggest breaking the smallest side window because it is the least expensive to replace. Be extremely cautious to avoid cuts from the glass. Vehicles with engine immobiliser system— Even if you lose only one key, contact your Toyota dealer to make a new key. However, if you loose all your master keys, the dealer cannot duplicate key but only replace the whole system. If you lose your wireless remote control transmitter If you lose your transmitter, you can purchase a new one at your Toyota dealer. You can use the wireless remote control system with the new transmitter. Contact your Toyota dealer for detailed information. ’99camry U Part 5 CORROSION PREVENTION AND APPEARANCE CARE
Protecting your Toyota from corrosion
Washing and waxing your Toyota
Cleaning the interior Protecting your Toyota from corrosion Toyota, through its diligent research, design and use of the most advanced technology available, has done its part to help prevent corrosion and has provided you with the finest quality vehicle construction. Now, it is up to you. Proper care of your Toyota can help ensure long– term corrosion prevention. The most common causes of corrosion to your vehicle are:
The accumulation of road salt, dirt and moisture in hard–to–reach areas under the vehicle.
Chipping of paint, or undercoating caused by minor accidents or by stones and gravel. Care is especially important if you live in particular areas or operate your vehicle under certain environmental conditions:
Road salt or dust control chemicals will accelerate corrosion, as will the presence of salt in the air near the sea– coast or in areas of industrial pollution.
High humidity accelerates corrosion especially when temperatures range just above the freezing point.
Wetness or dampness to certain parts of your vehicle for an extended period of time, may cause corrosion even though other parts of the vehicle may be dry.
High temperatures will cause corrosion to those components of the vehicle which are prevented from quick–drying due to lack of proper ventilation. The above signifies the necessity to keep your vehicle, particularly the underside, as clean as possible and to repair any damage to paint or protective coatings as soon as possible. To help prevent corrosion on Toyota, follow these guidelines: your Wash your vehicle frequently. It is, of course, necessary to keep your vehicle clean by regular washing, but to prevent corrosion, the following points should be observed:
If you drive on salted roads in the winter or if you live near the ocean, you should hose off the undercarriage at least once a month to minimize corrosion. 197 ’99camry U Washing and waxing your Toyota
High pressure water or steam is effective for cleaning the vehicle’s underside and wheel housings. Pay particular attention to these areas as it is difficult to see all the mud and dirt. It will do more harm than good to simply wet the mud and debris without removing them. The lower edge of doors, rocker panels and frame members have drain holes which should not be allowed to clog with dirt as trapped water in these areas can cause corrosion.
Wash the underside of the vehicle thoroughly when winter is over. See ”Washing and waxing your Toyota” for more tips. Check the condition of your vehicle’s paint and trim. If you find any chips or scratches in the paint, touch them up immediately to prevent corrosion from starting. If the chips or scratches have gone through the bare metal, have a qualified body shop make the repair. 198 Check the interior of your vehicle. Water and dirt can accumulate under the floor mats and could cause corrosion. Occasionally check under the mats to make sure the area is dry. Be particularly careful when transporting chemicals, cleansers, fertilizers, salt, etc.; these should be transported in proper containers. If a spill or leak should occur, immediately clean and dry the area. Use mud shields on your wheels. If you drive on salted or gravel roads, mud shields help protect your vehicle. Full–size shields, which come as near to the ground as possible, are the best. We recommend that the fittings and the area where the shields are installed be treated to resist corrosion. Your Toyota dealer will be happy to assist in supplying and installing the shields if they are recommended for your area. Keep your vehicle in a well ventilated garage or a roofed place. Do not park your vehicle in a damp, poorly ventilated garage. If you wash your vehicle in the garage, or if you drive it in covered with water or snow, your garage may be so damp it will cause corrosion. Even if your garage is heated, a wet vehicle can corrode if the ventilation is poor. Washing your Toyota Keep your washing. vehicle clean by regular The following cases may cause weakness to the paint or corrosion to the body and parts. Wash your vehicle as soon as possible.
When driving in a coastal area
When driving on a road sprinkled with antifreeze
When having stuck of coal tar, tree sap, bird droppings and carcass of an insect
When driving in the areas where there is a lot of smoke, soot, dust, iron dust and chemical substance
When the vehicle becomes remarkably dirty with dust and mud Hand–washing your Toyota Work in the shade and wait until the vehicle body is not hot to the touch. CAUTION When cleaning under floor or chassis, be careful not to injure your hands. ’99camry U 1. Rinse off loose dirt with a hose. Remove any mud or road salt from the underside of the vehicle or in the wheel wells. 4. To prevent water spots, dry the vehicle using a clean soft cotton towel. Do not rub or press hard—you might scratch the paint. 2. Wash with a mild car–wash soap, mixed according to the manufacturer’s instructions. Use a soft cotton mitt and keep it wet by dipping it frequently into the wash water. Do not rub hard—let the soap and water remove the dirt. Automatic car wash Aluminum wheels: Use only a mild soap or neutral detergent. Plastic bumpers: Wash carefully. Do not scrub with abrasive cleaners. The bumper faces are soft. Road tar: Remove with turpentine or cleaners that are marked safe for painted surfaces. NOTICE Do not use gasoline or strong solvents, which may be toxic or cause damage. Your vehicle may be washed in an automatic car wash, but remember that the paint can be scratched by some type of brushes, unfiltered washing water, or the washing process itself. Scratching reduces paint durability and gloss, especially on darker colors. The manager of the car wash should be able to advise you whether the process is safe for the paint on your vehicle. Waxing your Toyota Polishing and waxing is recommended to maintain the original beauty of your Toyota’s finish. Once a month or if the vehicle does not repel water well, apply wax. 1. Always wash and dry the vehicle before you begin waxing, even if you are using a combined cleaner and wax. 2. Use a good quality polish and wax. If the finish has become extremely weathered, use a car–cleaning polish, followed by a separate wax. Carefully follow the manufacturer’s instructions and precautions. Be sure to polish and wax the chrome trim as well as the paint. 3. Wax the vehicle again when water does not bead but remains on the surface in large patches. NOTICE Always remove the plastic bumpers if your vehicle is re–painted and placed in a high heat paint waxing booth. High temperatures could damage the bumpers. 3. Rinse thoroughly—dried soap can cause streaking. In hot weather you may need to rinse each section right after you wash it. 199 ’99camry U Cleaning the interior CAUTION
Vehicles with side airbags: Be careful not to splash water or spill liquid on the floor. This may prevent the side airbags from activating correctly, resulting in serious injury
Do not wash the vehicle floor with water, or allow water to get onto the floor when cleaning the vehicle interior or exterior. Water may get into audio components or other electrical components above or under the floor carpet (or mat) and cause a malfunction; and it may cause body corrosion. Vinyl interior The vinyl upholstery may be easily cleaned with a mild soap or detergent and water. 200 First vacuum over the upholstery to remove loose dirt. Then, using a sponge or soft cloth, apply the soap solution to the vinyl. After allowing it to soak in for a few minutes to loosen the dirt, remove the dirt and wipe off the soap with a clean damp cloth. If all the dirt do not come off, repeat the procedure. Commercial foaming– type vinyl cleaners are also available which work well. Follow the manufacturer’s instructions. Do not apply water—the best results are obtained by keeping the carpet as dry as possible. Read the shampoo instructions and follow them closely. Seat belts The seat belts may be cleaned with mild soap and water or with lukewarm water. Use a cloth or sponge. As you are cleaning, check the belts for excessive wear, fraying, or cuts. NOTICE Do not use solvent, thinner, gasoline or window cleaner on the interior. Carpets Use a good foam–type clean the carpets. shampoo to Begin by vacuuming thoroughly to remove as much dirt as possible. Several types of foam cleaners are available; some are in aerosol can sand others are powders or liquids which you mix with water to produce a foam. To shampoo the carpets, use a sponge or brush to apply the foam. Rub in overlapping circles. NOTICE  Do not use dye or bleach on the belts—it may weaken them.  Do not use the belts until they become dry. Windows The windows may be cleaned with any household window cleaner. NOTICE When cleaning the inside of the windows, be careful not to scratch or damage the heater wires on the rear window. ’99camry U Air conditioning control panel, car audio, instrument panel, console panel, and switches Leather Interior Use a soft damp cloth for cleaning. Remove dirt using a soft cloth dampened with 5% solution of neutral detergent for wool. Then thoroughly wipe off all traces of detergent with a clean damp cloth. Soak a clean soft cloth in water or lukewarm water then lightly wipe off dirt. NOTICE  Do not use organic substances (solvents, kerosene, alcohol, gasoline, etc.) or alkaline or acidic solutions. These chemicals can cause discoloring, staining or peeling of the surface.  If you use cleaners or polishing agents, make sure their ingredients do not include the substances mentioned above.  If you use a liquid car freshener, do not spill the liquid onto the vehicle’s interior surfaces. It may contain the ingredients mentioned above. Immediately clean any spill using the method mentioned above. The leather upholstery may be cleaned with neutral detergent for wool. After cleaning or whenever any part of the leather gets wet, dry with a soft clean cloth. Allow the leather to dry in a ventilated shaded area. NOTICE  If a stain should fail to come out with a neutral detergent, apply a cleaner that does not contain an organic solvent.  Never use organic substances such as benzine, alcohol or gasoline, or alkaline or acid solutions for cleaning the leather as these could cause discoloring.  Use of a nylon brush or synthetic fiber cloth, etc. may scratch the fine grained surface of the leather.  Mildew may develop on soiled leather upholstery. Be especially careful to avoid oil spots. Try to keep your upholstery always clean.  Long exposure to direct sunlight may cause the leather surface to harden and shrink. Keep your vehicle in a shaded area, especially in the summer.  The interior of your vehicle is apt to heat up on hot summer days, so avoid placing on the upholstery items made of vinyl or plastic or containing wax as these tend to stick to leather when warm.  Improper cleaning of the leather upholstery could result in discoloration or staining. If you have any questions about the cleaning of your Toyota, your local Toyota dealer will be pleased to answer them. 201 ’99camry U 202 ’99camry U Part 6 VEHICLE MAINTENANCE AND CARE
Maintenance requirements
General maintenance
Does your vehicle need repairing? Maintenance requirements Your Toyota vehicle has been designed to for fewer maintenance requirements with longer service intervals to save both your time and money. However, each regular maintenance, as well as day–to–day care, is more important than ever before to ensure smooth, trouble–free, safe, and economical drivings. It is the owner’s responsibility to make sure the specified maintenance, including general maintenance service, is performed. Note that both the new vehicle and emission control system warranties specify that proper maintenance and care must be performed. See ”Owner’s Warranty Information Booklet” or ”Owner’s Manual Supplement”. General maintenance For scheduled maintenance information, please refer to the separate ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement”. General maintenance items are those day– to–day care practices that are important to your vehicle for proper operation. It is the owner’s responsibility to insure that the general maintenance items are performed regularly. These checks or inspections can be done either by yourself or a qualified technician, or if you prefer, your Toyota dealer will be pleased to do them at a nominal cost. Scheduled maintenance The scheduled maintenance items listed in the ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement” are those required to be serviced at regular intervals. For details of your maintenance schedule, read the separate ”Scheduled Maintenance Guide” or ”Owner’s Manual Supplement”. It is recommended that any replacement parts used for maintenance or for the repair of the emission control system be Toyota supplied. The owner may elect to use non–Toyota supplied parts for replacement purposes without invalidating the emission control system warranty. However, use of replacement parts which are not of equivalent quality may impair the effectiveness of the emission control systems. You may also elect to have maintenance, replacement, or repair of the emission control devices and system performed by any automotive repair establishment or individual without invalidating this warranty. See ”Owner’s Warranty Information Booklet” or ”Owner’s Manual Supplement” for complete warranty information. 203 ’99camry U General maintenance Where to go for service? Toyota technicians are well–trained specialists and are kept up to date with the latest service information through technical bulletins, service tips, and in–dealership training programs. They learn to work on Toyotas before they work on your vehicle, rather than while they are working on it. You can be confident that your Toyota dealer’s service department performs the best job to meet the maintenance requirements on your vehicle—reliably and economically. Your copy of the repair order is proof that all required maintenance has been performed for warranty coverage. And if any problems should arise with your vehicle while under warranty, your Toyota dealer will promptly take care of it. Again, be sure to keep a copy of the repair order for any service performed on your Toyota. What about do–it–yourself maintenance? Many of the maintenance items are easy to do yourself if you have a little mechanical ability and a few basic automotive tools. Simple instructions for how to perform them are presented in Part 7. 204 If you are a skilled do–it–yourself mechanic, the Toyota service manuals are recommended. Please be aware that do–it–yourself maintenance can affect your warranty coverage. See ”Owner’s Warranty Information Booklet” or ”Owner’s Manual Supplement” for the details. Listed below are the general maintenance items that should be performed as frequently as specified. In addition to checking the items listed, if you notice any unusual noise, smell or vibration, you should investigate the cause or take your vehicle to your Toyota dealer or a qualified service shop immediately. It is recommended that any problem you notice be brought to the attention of your dealer or the qualified service shop for their advice. CAUTION Make these checks only where adequate ventilation can be obtained if you run the engine. OUTSIDE THE VEHICLE Items listed below should be performed from time to time, unless otherwise specified. Tire pressure Check the pressure with a gauge every two weeks, or at least once a month. See Chapter 7–2 for additional information. ’99camry U Tire surface and wheel nuts Check the tires carefully for cuts, damage or excessive wear. See Chapter 7–2 for additional information. When checking the tires, make sure no nuts are missing, and check the nuts for looseness. Tighten them if necessary. Tire rotation Rotate the tires every 12000 km (7500 miles). See Chapter 7–2 for additional information. Fluid leaks Check underneath for leaking fuel, oil, water or other fluid after the vehicle has been parked for a while. If you smell fuel fumes or notice any leak, have the cause found and corrected immediately. Doors and engine hood Check that all doors including trunk lid operate smoothly and all latches lock securely. Make sure the engine hood secondary latch secures the hood from opening when the primary latch is released. INSIDE THE VEHICLE Items listed below should be checked regularly, e.g. while performing periodic services, cleaning the vehicle, etc. Lights Make sure the headlights, stop lights, tail lights, turn signal lights, and other lights are all working. Check headlight aim. Service reminder indicators and warning buzzers Check that all service reminder indicators and warning buzzers function properly. Steering wheel Be alert for changes in steering condition, such as hard steering or strange noise. Seats Check that all front seat controls such as seat adjusters, seatback recliner, etc. operate smoothly and that all latches lock securely in any position. Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. For folding–down rear seatbacks, check that the latches lock securely. Seat belts Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. Make sure that the belt webbings not cut, frayed, worn or damaged. Accelerator pedal Check the pedal for smooth operation and uneven pedal effort or catching. Clutch pedal Check the pedal for smooth operation. Brake pedal Check the pedal for smooth operation and that the pedal has the proper clearance. Check the brake booster function. Brakes At a safe place, check that the brakes do not pull to one side when applied. Parking brake Check that the lever has the proper travel and that, on a safe incline, your vehicle is held securely with only the parking brake applied. Automatic transmission ”Park” mechanism Check the lock release button of the selector lever for proper and smooth operation. On a safe incline, check that your vehicle is held securely with the selector lever in ”P” position and all brakes released. 205 ’99camry U Does your vehicle need repairing? IN THE ENGINE COMPARTMENT Items listed below should be checked from time to time, e.g. each time when refueling. Washer fluid Make sure there is sufficient fluid in the tank. See Chapter 7–3 for additional information. Engine coolant level Make sure the coolant level is between the ”FULL” and ”LOW” lines on the see– through reservoir when the engine is cold. See Chapter 7–2 for additional information. Battery electrolyte level Make sure the electrolyte level of all battery cells is between upper and lower level lines on the case. Add only distilled water when replenishing. See Chapter 7–3 for additional information. Brake fluid level Make sure the brake fluid level is correct. See Chapter 7–2 for additional information. Engine oil level Check the level on the dipstick with the engine turned off and the vehicle parked on a level spot. See Chapter 7–2 for additional information. Power steering fluid level Check the level through the reservoir. The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature. See Chapter 7–2 for additional information. Exhaust system If you notice any change in the sound of the exhaust or smell exhaust fumes, have the cause located and corrected immediately. (See engine exhaust cautions in Part 2.) Be on the alert for changes in performance, sounds, and visual tip–offs that indicate service is needed. Some important clues are as follows:



Engine missing, stumbling, or pinging Appreciable loss of power Strange engine noises A leak under the vehicle (however, water dripping from the air conditioning after use is normal.)
Change in exhaust sound (This may indicate a dangerous carbon monoxide leak. Drive with the windows open and have the exhaust system checked immediately.)
Flat–looking tire; excessive tire squeal when cornering; uneven tire wear
Vehicle pulls to one side when driving straight on a level road
Strange noises related to suspension movement
Loss of brake effectiveness; spongy feeling brake or clutch pedal;pedal almost touches floor; vehicle pulls to one side when braking
Engine coolant temperature continually higher than normal 206 ’99camry U If you notice any of these clues, take your vehicle to your Toyota dealer as soon as possible. It probably needs adjustment or repair. CAUTION Do not continue driving with the vehicle unchecked. It could result in serious vehicle damage and possibly personal injury. 207 ’99camry U 208 ’99camry U Part 8 SPECIFICATIONS Dimensions and weight P195/70R14 tire P205/65R15 tire Overall length mm (in.) 4783 (188.3) 4783 (188.3) Overall width mm (in.) 1780 (70.1) 1780 (70.1) Overall height mm (in.) 1416 (55.7)∗ 1419 (55.9)∗
Service specifications Wheelbase mm (in.) 2670 (105.1) 2670 (105.1)
Tires Front tread mm (in.) 1547 (61.0) 1547 (61.0)
Fuses Rear tread mm (in.) 1520 (59.8) 1520 (59.8) 410 (900) 410 (900)
Dimensions and weight
Engine
Fuel Vehicle capacity weight (occupants + luggage) kg (lb) ∗: Unladen vehicle 239 ’99camry U Engine Fuel Service specifications Model: 5S–FE and 1MZ–FE Fuel type: 5S–FE engine Unleaded gasoline, Octane Rating 87 (Research Octane Number 91) or higher ENGINE Type: 5S–FE engine 4 cylinder in line, 4 cycle, gasoline 1MZ–FE engine 6 cylinder V type 4 cycle, gasoline Bore and stroke, mm (in.): 5S–FE engine 87.0
91.0 (3.43
3.58) 1MZ–FE engine 87.5
83.0 (3.44
3.27) Displacement, cm3 (cu. in.): 5S–FE engine 2164 (132.0) 1MZ–FE engine 2995 (182.8) 1MZ–FE engine Unleaded gasoline, Octane Rating 87 (Research Octane Number 91) or higher. For improved vehicle performance, the use of premium unleaded gasoline with an Octane Rating of 91 (Research Octane Number 96) or higher is recommended. Fuel tank capacity, L (gal., Imp. gal.): 70 (18.5, 15.4) Valve clearance (engine cold), mm (in.): 5S–FE engine Intake 0.19—0.29 (0.007—0.011) Exhaust 0.28—0.38 (0.011—0.015) 1MZ–FE engine Intake 0.15—0.25 (0.006—0.010) Exhaust 0.25—0.35 (0.010—0.014) Spark plug type: DENSO NGK Spark plug gap, mm(in.): 1.1 (0.043) Drive belt tension measured with Borroughs drive belt tension gauge No.BT–33–73F (used belt), Ibf: 5S–FE engine With air conditioning Generator belt Power steering pump belt Without air conditioning Generator belt Power steering pump belt 1MZ–FE engine 240 PK20TR11 BKR6EKPB11 13010 8020 6520 8020 11520 ’99camry U ENGINE LUBRICATION COOLING SYSTEM CLUTCH Oil capacity (drain and refill), L (qt., Imp. qt.): Total capacity, L (qt., Imp. qt.): 5S–FE engine 6.9 (7.3, 6.1) 1MZ–FE engine 9.1 (9.6, 8.4) Pedal freeplay, mm (in.): 5—15 (0.2—0.6) 5S–FE engine With filter Without filter 1MZ–FE engine With filter Without filter 3.6 (3.8, 3.2) 3.4 (3.6, 3.0) Coolant type: 4.7 (5.0, 4.1) 4.5 (4.8, 4.0) Oil grade: API grade SJ, ”Energy–Conserving” or ILSAC multigrade engine oil is recommended. Recommended oil viscosity (SAE): ”Toyota Long Life Coolant” or equivalent MANUAL TRANSAXLE With ethylene–glycol type coolant for a proper corrosion protection of aluminum components Oil capacity, L (qt., Imp. qt.): 5S–FE engine 2.2 (2.3, 1.9) 1MZ–FE engine 4.2 (4.4, 3.7) Do not use alcohol type antifreeze or plain water alone. Oil type: Gear oil API GL–4 or GL–5 BATTERY Open voltage∗ at 20C (68F): 12.6—12.8V Fully charged 12.2—12.4V Half charged 11.8—12.0V Discharged ∗: Fluid type: SAE J1703 or FMVSS No.116 DOT 3 Voltage that is checked 20 minutes after the key is removed with all the lights turned off Charging rates: 5 A max. Recommended oil viscosity: SAE 75W–90 AUTOMATIC TRANSAXLE 1MZ–FE engine Fluid capacity (drain and refill), L (qt., Imp. qt.): Up to 4.75 (5.0, 4.2) Fluid type: Automatic transmission fluid D–ll or DEXRONIIl (DEXRONII) 241 ’99camry U 5S–FE engine Automatic transmission Fluid capacity (drain and refill), L (qt., Imp. qt.): Up to 2.5 (2.6, 2.2) Fluid type: Automatic transmission fluid D–ll or DEXRONIIl (DEXRONII) Differential Fluid capacity L (qt., Imp. qt.): 1.6 (1.7, 1.4) Fluid type: Automatic transmission fluid D–II or DEXRONIII (DEXRONII) BRAKES Minimum pedal clearance when depressed with the pressure of 490 N (50 kgf, 110 lbf) with the engine running, mm (in.): 70 (2.8) Pedal freeplay, mm (in.): 1—6 (0.04—0.24) Pad wear limit, mm (in.): 1.0 (0.04) Lining wear limit, mm (in.): 1.0 (0.04) Parking brake adjustment when pulled with the force of 196 N (20 kgf, 44 lbf): 5—8 clicks 242 Fluid type: SAE J1703 or FMVSS No.116 DOT 3 STEERING Wheel freeplay: Less than 30 mm (1.2 in.) Power steering fluid type: Automatic transmission fluid DEXRONII or III ’99camry U Tires Normal driving kPa (kgf/cm2 or bar, psi) For all loads including full rated loads Tire size For reduced loads (1 to 4 passengers) Wheel size Front Rear Front Rear P195/70R14 90S 210 (2.1, 30) 210 (2.1, 30) 210 (2.1, 30) 210 (2.1, 30) 14
5.5JJ P205/65R15 92H 220 (2.2, 32) 220 (2.2, 32) 200 (2.0, 29) 200 (2.0, 29) 15
6JJ Trailer driving kPa (kgf/cm2 or bar, psi) Tire size Front Rear P195/70R14 90S 210 (2.1, 30) 210 (2.1, 30) P205/65R15 92H 220 (2.2, 32) 220 (2.2, 32) When driving under the above vehicle load conditions at sustained high speeds above 160 km/h (100 mph), in countries where such speeds are permitted by–law, inflate the front and rear tires to 240 kPa (2.4 kgf/cm2 or bar, 35 psi) provided that it dose not exceed the maximum cold tire pressure molded on the tire sidewall. Wheel nut torque, N·m (kgf·m, ft·lbf): 104 (10.5, 77) 243 ’99camry U Fuses Engine compartment Engine compartment (type A) Fuses (type A) 8. HORN 10 A: Horn, theft deterrent system 1. A/C 10 A: Air conditioning system 2. SPARE 10 A: Spare fuse 3. SPARE 15 A: Spare fuse 4. SPARE 30 A: Spare fuse 5. ALT–S 5 A: Charging system 6. HEAD RH(UPR) (with daytime running light system) or HEAD (RH) (without daytime running light system) 15 A: Right–hand headlight Engine compartment 244 7. EFI 15 A: Multiport fuel injection system/sequential multiport fuel injection system 9. HAZARD 10 A: Emergency flasher 10. AM2 30 A: Gauge and meter, SRS airbag system, seat belt pretensioners, Multiport fuel injection system/sequential multiport fuel injection system, ”IGN” and ”ST” fuses 11. TEL 5 A: No circuit 12. HEAD LH(UPR) (with daytime running light system) or HEAD (LH) (without daytime running light system) 15 A: Left–hand headlight 13. RADIO NO.1 20 A: Audio system ’99camry U 22. GAUGE 10 A: Gauges and meters, back–up lights, cruise control system, charging system, traction control system, daytime running light system, power windows, service reminder indicators and warning buzzers 23. WIPER 25 A: Windshield wipers and washer 24. MIRROR–HEATER 10 A: Outside rear view mirror defogger Engine compartment (type B) 14. DOME 7.5 A: Theft deterrent system, daytime running light system, clock, locking with wireless remote control system, ignition switch light, personal light, trunk light, electric moon roof lamp, interior light, vanity mirror light, door courtesy light, power door lock system 15. ECU–B 10 A: Cruise control system, anti–lock brake system, SRS airbag system, seat belt pretensioners Instrument panel 17. H–LP LH(LWR) 10 A: Left–hand headlight 18. H–LP RH(LWR) headlight 10 A: Right–hand 19. A/F HTR 25 A: A/F sensor 20. SEAT–HEATER 20 A: No circuit 21. HEATER 10 A: Air conditioning system, rear window defogger, starting system 25. ECU–IG 15 A: Cruise control system, anti–lock brake system, power antenna, SRS airbag system, seat belt pretensioners, theft deterrent system, shift lock control system, traction control system, daytime running light system, locking with wireless remote control system, multiport fuel injection system/ sequential multiport fuel injection system 26. IGN 5 A: Gauges and meters, charging system, SRS airbag system, seat belt pretensioners, multiport fuel injection system/sequential multiport fuel injection system 16. DRL NO.2 5 A: Daytime running light system 245 ’99camry U 27. STOP 15 A: Stop lights, cruise control system, high–mounted stoplight, anti– lock brake system, shift lock control system, multiport fuel injection system/ sequential multiport fuel injection system 28. TAIL 10 A: Parking lights, license plate lights, tail lights, front side marker lights, daytime running light system, multiport fuel injection system/sequential multiport fuel injection system 29. POWER–OUTLET 15 A: Power outlet 30. OBD 7.5 A: On–board diagnosis system 31. FOG 15 A: No circuit 32. STARTER 5 A: Gauges and meters, Multiport fuel injection system/sequential multiport fuel injection system 33. DOOR 25 A: Power door lock system, theft deterrent system, fuel filler door control system 34. PANEL 7.5 A: Gauge and meter, audio system, cigarette lighter, glove box light, clock, instrument panel light control, service reminder indicators, air conditioning control panel lights, ashtray light, emergency flasher, seat heater control system, daytime running light system, rear window defogger, electronically controlled automatic transmission system 35. TURN 7.5 A: Emergency flasher 36. RAD–NO.2 7.5 A: Audio system, power antenna 37. CIG 15 A: Cigarette lighter, shift lock control system, power rear view mirror controls, theft deterrent system, power door lock system, SRS airbag system, seat belt pretensioners, outside rear view mirror defogger, air conditioning system Fuses (type B) 38. CDS 30 A: Electric cooling fans 39. RDI 30 A: Electric cooling fans 40. MAIN 40 A: ”HEAD RH(UPR)”, ”HEAD RH”, ”H–LP RH(LWR)” fuses 41. HTR 50 A: ”AM1”, ”A/C” fuses 42. DEF 40 A: Rear window defogger 246 43. PWR 30 A: Power window control system, power seat, electric moon roof 44. AM1 40 A: Head lamp cleaner 45. T–STK 40 A or CDS NO.2 30 A: No Circuit Fuses (type C) 46. ALT 100 A: ”RDI”, ”CDS” fuses 47. ABS 60 A: Anti–lock brake system ’99camry U Part 9 REPORTING SAFETY DEFECTS FOR U.S. OWNERS AND UNIFORM TIRE QUALITY GRADING
Reporting safety defects for U.S. owners
Uniform tire quality grading Reporting safety defects for U.S. owners If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Toyota Motor Sales, U.S.A., Inc. (Toll–free: 1–800–331–4331). To contact NHTSA, you may either call the Auto Safety Hotline toll–free at 1–800–424–9393 (or 366–0123 in Washington,D.C. area) or write to: NHTSA. U.S.Department of Transportation. Washington,D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Toyota Motor Sales, U.S.A., Inc. 247 ’99camry U Uniform tire quality grading This information has been prepared in accordance with regulations issued by the National Highway Traffic Safety Administration of the U.S. Department of Transportation. It provides the purchasers and/ or prospective purchasers of Toyota vehicles with information on uniform tire quality grading. Traction AA, A, B, C—The traction grades, from highest to lowest, are AA, A, B, and C, and they represent the tire’s ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Your Toyota dealer will help answer any questions you may have as you read this information. Warning: The traction grade assigned to this tire is based on braking (straight ahead) traction tests and does not include cornering (turning) traction. DOT quality grades—All passenger vehicle tires must conform to Federal Safety Requirements in addition to these grades. These quality grades are molded on the sidewall. Treadwear—The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire graded 150 would wear one and a half (1–1/2) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate. 248 Temperature A, B, C—The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. Warning: The temperature grades for this tire are established for a tire that is properly inflated and not overloaded. Excessive speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure. ’99camry U Part 10 INDEX 249 ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–1 Overview of instruments and controls
Instrument panel overview
Instrument cluster overview
Indicator symbols on the instrument panel Instrument panel overview 1. Side defroster outlets 2. Side vents 3. Instrument cluster 4. Center vents i ’99camry CNG 5. Glove box 6. Garage door opener box or miscellaneous box 7. Power door lock switches 8. Power window switches 9. Cup holders 10. Cup holder or rear ashtray 11. Parking brake lever 12. Automatic transmission selector lever 13. Auxiliary box 14. Hood lock release lever 15. Window lock switch 1. Power rear view mirror control switch 2. Headlight and turn signal switch 3. Wiper and washer switches 4. Clock 5. Emergency flasher switch 6. Car audio 7. Rear window and outside rear view mirror defoggers switch 8. Air conditioning controls ii ’99camry CNG 9. Front ashtray 10. Power outlet 11. Cigarette lighter 12. Ignition switch 13. Cruise control switch 14. Tilt steering lock release lever 15. Instrument panel light control knob iii ’99camry CNG Instrument cluster overview 1. Engine coolant temperature gauge 2. Service reminder indicators and indicator lights 3. Fuel gauge 4. Speedometer 5. Odometer and two trip meters 6. Tachometer 7. Trip meter reset knob iv ’99camry CNG 8. Low fuel level warning light v ’99camry CNG Indicator symbols on the instrument panel Brake system warning light∗1 Low windshield washer fluid level warning light∗1 Seat belt reminder light∗1 Turn signal indicator lights Discharge warning light∗1 Headlight high beam indicator light Malfunction indicator lamp∗1 Overdrive–off indicator light Low oil pressure warning light∗1 Cruise control indicator light∗2 Anti–lock brake system warning light∗1 Automatic transmission indicator lights Open door warning light∗1 ∗1 : ∗2 : For details, see “Service reminder indicators and warning buzzers” in Chapter 1–5. If this light flashes, see “Cruise control” in Chapter 1–6. Rear light failure warning light∗1 SRS warning light∗1 vi ’99camry CNG vii ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–2 Keys and Doors
Keys
Side doors
Power windows
Trunk lid
Hood
Refueling Keys viii ’99camry CNG Your vehicle is supplied with two kinds of key. 1. Master key—This key works in every lock. 2. Sub key—This key will not work in the glove box and trunk. To protect things locked in the glove box or trunk when you have your vehicle parked, leave the sub key with the attendant. Since the doors and trunk lid can be locked without a key, you should always carry a spare master key in case you accidentally lock your keys inside the vehicle. ix ’99camry CNG KEY NUMBER PLATE Your key number is shown on the plate. Keep the plate in a safe place such as your wallet, not in the vehicle. If you should lose your keys or if you need additional keys, duplicates can be made by your authorized Toyota CNG dealer using the key number. We recommend you to write down the key number and keep it in safe place. Side doors x ’99camry CNG LOCKING AND UNLOCKING WITH KEY Insert the key into the keyhole and turn it. To lock: Turn the key forward. To unlock: Turn the key backward. All the doors lock and unlock simultaneously with either front door. In the driver’s door lock, turning the key once will unlock the driver’s door and twice in succession will unlock all the doors simultaneously. xi ’99camry CNG LOCKING AND UNLOCKING WITH INSIDE LOCK BUTTON Move the lock button. To lock: Push the knob forward. To unlock: Pull the knob backward. Closing the door with the lock knob in the lock position will also lock the door. Be careful not to lock your keys in the vehicle. The door cannot be locked if you leave the key in the ignition switch. xii ’99camry CNG Driver’s side Passenger’s side xiii ’99camry CNG LOCKING AND UNLOCKING WITH POWER DOOR LOCK SWITCH Push the switch. To lock: Push the switch on the front side. To unlock: Push the switch on the rear side. All the doors lock or unlock simultaneously. REAR DOOR CHILD–PROTECTORS Move the lock lever to the “LOCK” position as shown on the label. This feature allows you to lock a rear door so it can be opened from the outside only, not from inside. We recommend using this feature whenever small children are in the vehicle. xiv ’99camry CNG CAUTION Before driving, be sure that the doors are closed and locked, especially when small children are in the vehicle. Along with the proper use of seat belts, locking the doors helps prevent the driver and passengers from being thrown out from the vehicle during an accident. It also helps prevent the doors from being opened unintentionally. Power windows The windows can be operated with the switch on each door. The power windows work when the ignition switch is in the “ON” position. Key off operation: If both front doors are closed, they work for 45 seconds even after the ignition switch is turned off. They stop working when either front door is opened. OPERATING THE DRIVER’S WINDOW xv ’99camry CNG Use the switch on the driver’s door. Normal operation: The window moves as long as you hold the switch. To open: Lightly push down the switch. To close: Pull up the switch. Automatic operation (to open only): Push the switch completely down and then release it. The window will fully open. To stop the window partway, lightly pull the switch up and then release it. xvi ’99camry CNG Window lock switch OPERATING THE PASSENGERS’ WINDOWS Use the switches on the passengers’ doors. The driver’s door also has switches that control the passengers’ windows. The window moves as long as you hold the switch. To open: Push down the switch. To close: Pull up the switch. If you push in the window lock switch on the driver’s door, the passengers’ windows cannot be operated. xvii ’99camry CNG xviii ’99camry CNG CAUTION To avoid serious personal injury, you must do the following.
Always make sure the head, hands and other parts of the body of all occupants are kept completely inside the vehicle before you close the power windows. If someone’s neck, head or hands gets caught in a closing window, it could result in a serious injury. When anyone closes the power windows, be sure that they operate the windows safely.
When small children are in the vehicle, never let them use the power window switches without supervision. Use the window lock switch to prevent them from making unexpected use of the switches.
Never leave small children alone in the vehicle, especially with the ignition key still inserted. They could use the power window switches and get trapped in a window. Unattended children can become involved in serious accidents. Trunk lid— xix ’99camry CNG To open the trunk lid from the outside, insert the master key and turn it clockwise. See “Luggage stowage precautions” in Part 2 for precautions to observe for loading luggage. To close the trunk lid, lower it and press down on it. After closing the trunk lid, try pulling it up to make sure it is securely closed. CAUTION Keep the trunk lid closed while driving. This not only keeps the luggage from being thrown out but also prevents exhaust gases from entering the vehicle. —Lock release lever xx ’99camry CNG To open the trunk lid from the driver’s seat, pull up on the lock release lever. —Luggage security system xxi ’99camry CNG This system deactivates the lock release lever so that things locked in the trunk can be protected. After closing the trunk lid, insert the master key and turn it counterclockwise to deactivate the lock release lever. After closing the trunk lid, try pulling it up to make sure it is securely locked. Hood To open the hood: 1. Pull the hood lock release lever. The hood will spring up slightly. CAUTION Before driving, be sure that the hood is closed and securely locked. Otherwise, the hood may open unexpectedly while driving and an accident may occur. xxii ’99camry CNG 2. In front of the vehicle, pull up the auxiliary catch lever and lift the hood. xxiii ’99camry CNG Refueling— 3. Hold the hood open by inserting the support rod into the slot. —Refueling precaution Before closing the hood, check to see that you have not forgotten any tools, rags, etc. and return the support rod to its clip—this prevents rattles. Then lower the hood make sure it locks into place. If necessary, press down gently on the front edge to lock it. CAUTION After inserting the support rod into the slot, make sure the rod supports the hood securely from falling down on to your head or body. When refueling, you must NGV–1–1994 standards. use a special nozzle that meets ANSI/AGA There are three types of nozzles. Use a P36 type nozzle for this vehicle. If a P36 nozzle is not available at a nearby CNG station, you may use another type of nozzle, but you cannot expect to get a completely full tank with it. For your safety, ask and follow the instructions at the refueling station when refueling. Before starting to refuel, wipe off mud or dirt that may be deposited around the fuel receptacle. You will hear a chattering noise from the tank when it is being filled, but this is quite normal. If you hear fuel leaking from the fuel receptacle, stop refueling immediately and have your authorized Toyota CNG dealer check the fuel receptacle. For information on CNG stations, refer to the station “Refueling station information” on page iii in the beginning of this manual. xxiv ’99camry CNG —Refueling method (high speed refueling) CAUTION
In order to safety refuel and avoid serious personal injury, ask the CNG station staff to refuel the vehicle with CNG for you.
Do not start the engine while refueling. As the natural gas is flammable, an explosion or a fire could occur. Also, do not smoke or allow open flames when refueling.
If you smell or hear fuel leaking while refueling, immediately stop refueling. Do not refuel it until after the leak has been repaired. There are two ways of natural gas refueling: high and low speed. This manual explains typical high speed refueling. As for the low speed refueling method, follow the instructions provided by the manufacturer for the refueling equipments. xxv ’99camry CNG 1. To open the refueling plug door, pull the lever up. When refueling, turn off the engine. 2. Remove the rubber cap. Check there is no mud or dirt around the fuel receptacle. xxvi ’99camry CNG 3. Fit the filling nozzle securely on the fuel receptacle. There are various types of filling nozzles so follow the instructions at each CNG station. xxvii ’99camry CNG 4. Turn the valve lever to fasten the nozzle to the fuel receptacle and to start filling the tank. 5. Refueling will stop automatically when the tank is full. When disconnecting the filling nozzle, follow the instructions of the refueling station. Reverse the procedure to disconnect the nozzle after filling the tank. When disconnecting the filling nozzle, you may hear a brief hissing sound as a small amount of fuel escapes, but this is normal. xxviii ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–3 Seats, Seat belts, Steering wheel and Mirrors
Seats
Front seats
Head restraints
Seat belts
SRS driver and front passenger airbags
Child restraint
Tilt steering wheel
Outside rear view mirrors
Anti–glare inside rear view mirror xxix ’99camry CNG Front seats— —Seat adjustment
precautions Sun visors Seats While the vehicle is being driven, all vehicle occupants should have the seatback upright, sit well back in the seat and properly wear the seat belts provided. CAUTION
Do not drive the vehicle unless the occupants are properly seated. Do not allow sitting on top of a folded–down seatback, or in the luggage compartment. Persons not properly seated and not properly restrained by seat belts can be severely injured in the event of emergency braking or a collision.
During driving, do not allow passengers to stand up or move around between seats. Severe injuries can occur in the event of emergency braking or a collision. Adjust the driver’s seat so that the foot pedals, steering wheel and instrument panel controls are within easy reach of the driver. xxx ’99camry CNG CAUTION
Adjustments should not be made while the vehicle is moving, as the seat may unexpectedly move and cause the driver to lose control of the vehicle.
When adjusting the seat, be careful not to hit the seat against a passenger or luggage.
After adjusting the seat position, try sliding it forward and backward to make sure it is locked in position.
After adjusting the seatback, exert body pressure to make sure it is locked in position.
Do not put objects under the seats. The objects may interfere with the seat–lock mechanism or unexpectedly push up the seat position adjusting lever; the seat may suddenly move, causing the driver to lose control of the vehicle.
While adjusting the seat, do not put your hands under the seat or near the moving parts. You may catch and injure your hands or fingers. —Adjusting front seats xxxi ’99camry CNG 1. SEAT POSITION ADJUSTING LEVER xxxii ’99camry CNG Pull the lever up. Then slide the seat to the desired position with slight body pressure and release the lever. 2. SEATBACK ANGLE ADJUSTING LEVER Lean forward and pull the lever up. Then lean back to the desired angle and release the lever. CAUTION To reduce the risk of sliding under the lap belt during a collision, avoid reclining the seatback any more than needed. The seat belts provide maximum protection in a frontal or rear collision when the driver and the passenger are sitting up straight and well back in the seats. If you are reclined, the lap belt may slide past your hips and apply restraint forces directly to the abdomen. Therefore, in the event of a frontal collision, the risk of personal injury may increase with increasing recline of the seatback. 3. SEAT CUSHION HEIGHT ADJUSTING KNOB Turn the knob either way. Head restraints xxxiii ’99camry CNG Front Rear xxxiv ’99camry CNG Seat belts— —Seat belt precautions For your safety and comfort, adjust the head restraint before driving. To raise: Pull it up. To lower: Push it down while pressing the lock release button. Front head restraint only—You can also move the head restraint forward or backward. If such adjustment is desired, pull or push on the top of the head restraint. The head restraint is most effective when it is close to your head. Therefore, using a cushion on the seatback is not recommended. CAUTION
Adjust the center of the head restraint so that it is closest to the top of your ears.
After adjusting the head restraint, make sure it is locked in position.
Do not drive with the head restraints removed. Toyota strongly urges that the driver and passengers in the vehicle be properly restrained at all times with the seat belts provided. Failure to do so could increase the chance of injury and/or the severity of injury in accidents. Child. Use a child restraint system appropriate for the child until the child becomes large enough to properly wear the vehicle’s seat belts. See “Child restraint” for details. If a child is too large for a child restraint system, the child should sit in the rear seat and must be restrained using the vehicle’s seat belt. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat. xxxv ’99camry CNG If a child must sit in the front seat, the seat belts should be worn properly. If an accident occurs and the seat belts are not worn properly, the force of the rapid inflation of the airbag may cause death or serious injury to the child. Do not allow the child to stand up or kneel on either rear or front seats. An unrestrained child could suffer serious injury or death during emergency braking or a collision. Also, do not let the child sit on your lap. It does not provide sufficient restraint. Pregnant woman. Toyota recommends the use of a seat belt. Ask your doctor for specific recommendations. The lap belt should be worn securely and as low as possible over the hips and not on the waist. Injured person. Toyota recommends the use of a seat belt. Depending on the injury, first check with your doctor for specific recommendations. xxxvi ’99camry CNG —Front seat belts and rear outside seat belts CAUTION Persons should ride in their seats properly wearing their seat belts whenever the vehicle is moving. Otherwise, they are much more likely to suffer serious bodily injury or death in the event of sudden braking or a collision. When using the seat belts, observe the following:
Use the belt for only one person at a time. Do not use a single belt for two or more people—even children.
Avoid reclining the seatbacks too much. The seat belts provide maximum protection when the seatbacks are in the upright position. (Refer to the seat adjustment instructions.)
Be careful not to damage the belt webbing or hardware. Take care that they do not get caught or pinched in the seat or doors.
Inspect the belt system periodically. Check for cuts, fraying, and loose parts. Damaged parts should be replaced. Do not disassemble or modify the system.
Keep the belts clean and dry. If they need cleaning, use a mild soap solution or lukewarm water. Never use bleach, dye, or abrasive cleaners—they may severely weaken the belts. (See “Cleaning the interior” in Part 5.)
Replace the belt assembly (including bolts) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. xxxvii ’99camry CNG Adjust the seat as needed (front seats only) and sit up straight and well back in the seat. To fasten your belt, pull it out of the retractor and insert the tab into the buckle. You will hear a click when the tab locks into the buckle. The seat belt length automatically adjusts to your size and the seat position. The retractor will lock the belt during a sudden stop or on impact. It also may lock if you lean forward too quickly. A slow, easy motion will allow the belt to extend, and you can move around freely. If the seat belt cannot be pulled out of the retractor, firmly pull the belt and release it. You will then be able to smoothly pull the belt out of the retractor. When a passenger’s shoulder belt is completely extended and is then retracted even slightly, the belt is locked in that position and cannot be extended. This feature is used to hold the child restraint system securely. (For details, see “Child restraint” in this chapter.) To free the belt again, fully retract the belt and then pull the belt out once more. xxxviii ’99camry CNG CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the belt is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, immediately contact your authorized Toyota CNG dealer. Do not use the seat until the seat belt is fixed. It cannot protect an adult occupant or your child from injury. Seat belts with an adjustable shoulder anchor— Adjust the shoulder anchor position to your size. To raise: Slide the anchor up. To lower: Push in the lock release button and slide the anchor down. xxxix ’99camry CNG After adjustment make sure the anchor is locked in position. CAUTION Always make sure the shoulder belt is positioned across the center of your shoulder. The belt should be kept away from your neck, but not falling off your shoulder. Failure to do so could reduce the amount of protection in an accident and cause serious injures in a collision. Take up slack Too high Keep as low on hips as possible Adjust the position of the lap and shoulder belts. Position the lap belt as low as possible on your hips—not on your waist, then adjust it to a snug fit by pulling the shoulder portion upward through the latch plate. xl ’99camry CNG CAUTION
High–positioned lap belts and loose–fitting belts both could cause serious injuries due to sliding under the lap belt during a collision or other unintended result. Keep the lap belt positioned as low on hips as possible.
For your safety, do not place the shoulder belt under your arm. To release the belt, press the buckle–release button and allow the belt to retract. If the belt does not retract smoothly, pull it out and check for kinks or twists. Then make sure it remains untwisted as it retracts. —Rear center seat belt xli ’99camry CNG Lengthen Sit up straight and well back in the seat. To fasten your belt, insert the tab into the buckle. You will hear a click when the tab locks into the buckle. If the belt is not long enough for you, hold the tab at a right angle to the belt and pull on the tab. xlii ’99camry CNG CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the belt is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, immediately contact your authorized Toyota CNG dealer. Do not use the seat until the seat belt is fixed. It cannot protect an adult occupant or your child from injury. Too high Adjust to a snug fit Keep as low on hips as possible Remove excess length of the belt and adjust the belt position. To shorten the belt, pull the free end of the belt. Position the lap belt as low as possible on your hips—not on your waist, then adjust it to a snug fit. xliii ’99camry CNG CAUTION High–positioned and loose–fitting lap belts could cause serious injuries due to sliding under the lap belt during a collision or other unintended result. Keep the lap belt positioned as low on hips as possible. To release the belt, press the buckle–release button. —Seat belt extender If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available from your authorized Toyota CNG dealer free of charge. Please contact your authorized Toyota CNG dealer so that he/she can order the proper required length for the extender. Bring the heaviest coat you expect to wear xliv ’99camry CNG for proper measurement and selection of length. Additional ordering information is available at your authorized Toyota CNG dealer. CAUTION When using the seat belt extender, observe the following. Failure to follow these instructions could result in less effectiveness of the seat belt restraint system in case of vehicle accident, increasing the chance of personal injury.
Never use the seat belt extender if you can fasten the seat belt without it.
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another person or at a different seating position than the one originally intended for. xlv ’99camry CNG To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the “PRESS” signs on the buckle–release buttons of the extender and the seat belt are both facing outward as shown. You will hear a click when the tab locks into the buckle. When releasing the seat belt, press on the buckle–release button on the extender, not on the seat belt. This helps prevent damage to the vehicle interior and extender itself. When not in use, remove the extender and store in the vehicle for future use. xlvi ’99camry CNG CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the seat belt extender is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, immediately contact your authorized Toyota CNG dealer. Do not use the seat until the seat belt is fixed. It cannot protect an adult occupant or your child from injury. —Front seat belt pretensioners The driver and front passenger’s seat belt pretensioners are designed to be activated in response to a severe frontal impact. xlvii ’99camry CNG When the airbag sensor detects the shock of a severe frontal impact, the front seat belt is quickly drawn back in by the retractor so that the belt snugly restrains the front seat occupants. The seat belt pretensioners are activated even with no passenger in the front seat. This indicator comes on when the ignition key is turned to the “ACC” or “ON” position. It goes off after about 6 seconds. This means the front seat belt pretensioners are operating properly. This warning light system monitors the airbag sensor assembly, front airbag sensors, seat belt pretensioner assemblies, warning light, interconnecting wiring and power sources. (For details, see “Service reminder indicators and warning buzzers” in Chapter 1–5.) xlviii ’99camry CNG The seat belt pretensioner system mainly consists of the following components and their locations are shown in the illustration. 1. Front airbag sensors 2. SRS warning light 3. Seat belt pretensioner assemblies 4. Airbag sensor assembly The seat belt pretensioner is controlled by the airbag sensor assembly. The airbag sensor assembly consists of a safing sensor and airbag sensor. When a seat belt pretensioner is activated, an operating noise may be heard and a small amount of smoke–like gas may be released. This gas is harmless and does not indicate that a fire is occurring. Once the seat belt pretensioner has been activated, the seat belt retractor remains locked. xlix ’99camry CNG CAUTION Do not modify, remove, strike or open the front seat belt pretensioner assemblies, airbag sensor or surrounding area or wiring. Doing any of these may cause sudden operation of the front seat belt pretensioners or disable the system, which could result in serious injury. Failure to follow these instructions can result in serious injuries. NOTICE Do not perform any of the following changes without consulting your authorized Toyota CNG dealer. Such changes can interfere with proper operation of the seat belt pretensioners in some cases.  Installation of electronic items such as a mobile two–way radio, cassette tape player or compact disc player  Repairs on or near the front seat belt retractor assemblies  Modification of the suspension system  Modification of the front end structure  Attachment of a grille guard (bull bar, kangaroo bar, etc.), snowplow, winches or any other equipment to the front end  Repairs made on or near the front fenders, front end structure or console l ’99camry CNG This front seat belt pretensioner system has a service reminder indicator to inform the driver of operating problems. If either of the following conditions occurs, this indicates a malfunction of the airbags or pretensioners. Contact your authorized Toyota CNG dealer as soon as possible to service the vehicle.
The light does not come on when the ignition key is turned to the “ACC” or “ON” position, or remains on.
The light comes on or flashes while driving.
If either front seat belt does not retract or can not be pulled out due to a malfunction or activation of the pretensioner.
The front seat belt pretensioner assembly or surrounding area has been damaged.
The front part of the vehicle (shaded in the illustration) was involved in an accident that did not cause the seat belt pretensioners to operate.
The front seat belt pretensioner assembly is scratched, cracked, or otherwise damaged. li ’99camry CNG SRS driver and front passenger airbags The SRS (Supplemental Restraint System) airbags are designed to provide further protection for the driver and front passenger when added to the primary protection provided by the seat belts. In response to a severe frontal impact, the SRS airbags work together with the seat belts to help prevent or reduce injury by inflating, in order to decrease the likelihood of the driver’s or front passenger’s head or chest directly hitting the steering wheel or dashboard. The passenger airbag is activated even with no passenger in the front seat. Be sure to wear your seat belt. lii ’99camry CNG CAUTION A driver or front passenger too close to the steering wheel or dashboard during airbag deployment can be killed or seriously injured. Toyota strongly recommends that:
The driver sit as far back as possible from the steering wheel while still maintaining control of the vehicle.
The front passenger sit as far back as possible from the dashboard.
All vehicle occupants be properly restrained using the available seat belts. This indicator comes on when the ignition key is turned to the “ACC” or “ON” position. It goes off after about 6 seconds. This means the SRS airbags are operating properly. liii ’99camry CNG This warning light system monitors the airbag sensor assembly, front airbag sensors, inflators, warning light, interconnecting wiring and power sources. (For details, see “Service reminder indicators and warning buzzers” in Chapter 1–5.) The SRS airbag system is designed to activate in response to a severe frontal impact within the shaded area between the arrows in the illustration. There may be the case that the SRS airbag will not activate with such an impact in which the occupant wearing the seat belt correctly would not get serious injury. The SRS airbags will deploy if the severity of the impact is above the designed threshold level, comparable to an approximate 25 km/h (15 mph) collision when impacting straight into a fixed barrier that does not move or deform. If the severity of the impact is below the above threshold level, the SRS airbags may not deploy. liv ’99camry CNG However, this threshold velocity will be considerably higher if the vehicle strikes an object, such as a parked vehicle or sign pole, which can move or deform on impact, or if it is involved in an underride collision (e.g. a collision in which the nose of the vehicle “underrides”, or goes under, the bed of a truck, etc.). It is possible with collision severity at the marginal level of airbag sensor detection and activation that only one of your vehicle’s two airbags will deploy. For the safety of all occupants, be sure to always wear seat belts. Collision from the rear Collision from the side Vehicle rollover The SRS airbags are not designed to inflate if the vehicle is subjected to a side or rear impact, if it rolls over, or if it is involved in a low–speed frontal collision. lv ’99camry CNG Hitting a curb, edge of pavement or hard material Falling into or jumping over a deep hole Landing hard or vehicle falling The SRS airbags may deploy if a serious impact occurs to the underside of your vehicle. Some examples are shown in the illustration. lvi ’99camry CNG The SRS airbag system mainly consists of the following components and their locations are shown in the illustration. 1. Front airbag sensors 2. SRS warning light 3. Airbag module for passenger (airbag and inflator) 4. Airbag sensor assembly 5. Airbag module for driver (airbag and inflator) The airbag sensor assembly consists of a safing sensor and airbag sensor. In a severe frontal impact, sensors detect deceleration and the system triggers the airbag inflators. Then a chemical reaction in the inflators momentarily fills the airbags with non–toxic gas to help restrain the forward motion of the occupants. When the airbags inflate, they produce a fairly loud noise and release some smoke and residue along with non–toxic gas. This does not indicate a fire. This gas is normally harmless, however, for those who have delicate skin, it may cause minor skin irritation. Be sure to wash off any residue as soon as possible to prevent minor skin irritation. Deployment of the airbags happens in a fraction of a second, so the airbags must inflate with considerable force. While the system is designed to reduce serious injuries, it may also cause minor burns or abrasions and swellings. Parts of the airbag module (steering wheel hub, dashboard) may be hot for several minutes, but the airbags themselves will not be hot. The airbags are designed to inflate only once. A crash severe enough to inflate the airbags may break the windshield as the vehicle buckles. In vehicles with a passenger airbag the windshield may also be damaged by absorbing some of the force of the inflating airbag. lvii ’99camry CNG CAUTION
The SRS airbag system is designed only as a supplement to the primary protection of the driver side and front passenger side seat belt systems. The front seat occupants can be killed or seriously injured by an inflating airbag if they do not wear the available seat belts. During sudden braking just before a collision, an unrestrained driver or front passenger can move forward into direct contact with or close proximity to the airbag which may then deploy during the collision. To obtain maximum protection in an accident, the driver and all passengers in the vehicle must wear their seat belts. Wearing a seat belt during an accident reduces the chances of death or serious injuries or being thrown out of the vehicle. For instructions and precautions concerning the seat belt system, see “Seat belts” in this chapter.
Improperly seated and/or restrained infants and children can be killed or seriously injured by a deploying airbag. An infant or child who is too small to use a seat belt should be properly secured using a child restraint system. Toyota strongly recommends that all infants and children be placed in the rear seat of the vehicle and properly restrained. The rear seat is the safest for infants and children. For instructions concerning the installation of a child restraint system, see “Child restraint” in this chapter. lviii ’99camry CNG
Never put a rear–facing child restraint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child. lix ’99camry CNG Move seat fully back
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child.
For instructions concerning the installation of a child restraint system, see “Child restraint” in this chapter. lx ’99camry CNG
Do not sit on the edge of the seat or lean over the dashboard when the vehicle is in use. The airbags inflate with considerable speed and force; you may be killed or seriously injured. Sit up straight and well back in the seat, and always use your seat belt. lxi ’99camry CNG
Do not allow a child to stand up, or to kneel on the front passenger seat. The airbag inflates with considerable speed and force; the child may be killed or seriously injured.
Do not hold a child on your lap or in your arms. Use a child restraint system in the rear seat. For instructions concerning the installation of a child restraint system, see “Child restraint” in this chapter. lxii ’99camry CNG
Do not put objects or your pets on or in front of the dashboard or steering wheel pad that houses the airbag system. They might restrict inflation or cause death or serious injury as they are projected rearward by the force of deploying airbags. Likewise, the driver and front passenger should not hold things in their arms or on their knees.
Do not modify or remove any wiring. Do not modify, remove, strike or open any components such as the steering wheel pad, steering wheel, column cover, front passenger airbag cover, front passenger airbag or airbag sensor assembly. Doing any of these may cause sudden SRS airbag inflation or disable the system, which could result in death or serious injury. Failure to follow these instructions can result in death or serious injuries. lxiii ’99camry CNG NOTICE Do not perform any of the following changes without consulting your authorized Toyota CNG dealer. Such changes can interfere with proper operation of the SRS airbag system in some cases.  Installation of electronic items such as a mobile two–way radio, cassette tape player or compact disc player  Modification of the suspension system  Modification of the front end structure  Attachment of a grille guard (bull bar, kangaroo bar, etc.), snowplow, winches or any other equipment to the front end  Repairs made on or near the front fenders, front end structure, console, steering column, steering wheel or dashboard near the front passenger airbag lxiv ’99camry CNG This SRS airbag system has a service reminder indicator to inform the driver of operating problems. If either of the following conditions occurs, this indicates a malfunction of the airbags. Contact your authorized Toyota CNG dealer as soon as possible to service the vehicle.
The light does not come on when the ignition key is turned to the “ACC” or “ON” position, or remains on.
The light comes on while driving. lxv ’99camry CNG Child restraint— —Child restraint precautions In the following cases, contact your authorized Toyota CNG dealer as soon as possible:
The SRS airbags have been inflated.
The front part of the vehicle (shaded in the illustration) was involved in an accident that did not cause the SRS airbags to inflate.
The pad section of the steering wheel or front passenger airbag cover (shaded in the illustration) is scratched, cracked, or otherwise damaged. NOTICE Do not disconnect the battery cables before contacting your authorized Toyota CNG dealer. lxvi ’99camry CNG Toyota strongly urges the use of child restraint systems for children small enough to use them. The laws of all fifty states in the U.S.A. and Canada now require the use of a child restraint system. Your vehicle conforms to SAEJ1819. If a child is too large for a child restraint system, the child should sit in the rear seat and must be restrained using the vehicle’s seat belt. See “Seat belts” for details. CAUTION
For effective protection in automobile accidents and sudden stops, children must be properly restrained using a seat belt or child restraint system depending on the age and size of the child. Holding a child in your arms is not a substitute for a child restraint system. In an accident, the child can be crushed against the windshield, or between you and the vehicle’s interior. lxvii ’99camry CNG
Toyota strongly urges use of a proper child restraint system which conforms to the size of the child, and is put on the rear seat. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat.
Never put a rear–facing child restraint system on the front seat. In the event of an accident, the force of the rapid inflation of the airbag can cause death or serious injury if a rear–facing child restraint system is put on the front seat.
Unless it is unavoidable, do not put a child restraint system on the front seat.
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child.
Make sure that you have complied with all installation instructions provided by the child restraint manufacturer and that the system is properly secured. —Child restraint system A child restraint system for a small child or baby must itself be properly restrained on the seat with either the lap belt or the lap portion of the lap/shoulder belt. You must carefully consult the manufacturer’s instructions which accompany your child restraint system. To provide proper restraint, use a child restraint system following the manufacturer’s instructions about the appropriate age and size of the child for the restraint system. lxviii ’99camry CNG Install the child restraint system correctly following the instructions provided by its manufacturer of the system. General directions are also provided under the following illustrations. The child restraint system should be installed on the rear seat. According to accident statistics, the child is safer when properly restrained in the rear seat than in the front seat. CAUTION
Never put a rear–facing child restraint system on the front seat. In the event of an accident, the force of the rapid inflation of the airbag can cause death or serious injury if a rear–facing child restraint system is put on the front seat.
Unless it is unavoidable, do not put a child restraint system on the front seat.
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child.
After installing the child restraint system, make sure it is secured in place following the manufacturer’s instructions. If it is not restrained securely, it may cause death or serious injury to the child in the event of a sudden stop or accident. When not using the child restraint system, keep it secured with the seat belt or place it in the trunk or somewhere other than the passenger compartment. This will prevent it from injuring passengers in the event of a sudden stop or accident. lxix ’99camry CNG —Types of child restraint system Child restraint systems are classified into the following 3 types depending on the child’s age and size. (A) Infant seat (B) Convertible seat (C) Booster seat Install the child restraint system following the instructions provided by its manufacturer. (A) Infant seat lxx ’99camry CNG (B) Convertible seat (C) Booster seat lxxi ’99camry CNG —Installation with 2–point type seat belt (A) INFANT SEAT INSTALLATION An infant seat is used in rear–facing position only. lxxii ’99camry CNG CAUTION Do not put a rear–facing child restraint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. lxxiii ’99camry CNG 1. Run the center lap belt through or around the infant seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the lap belt. CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap belt is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your authorized Toyota CNG dealer immediately. Do not use the seat until the seat belt is fixed. lxxiv ’99camry CNG 2. While pressing the infant seat firmly against the seat cushion and seatback, tighten the lap belt by pulling its free end to hold the infant seat securely. lxxv ’99camry CNG CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 3. To remove the infant seat, press the buckle–release button. lxxvi ’99camry CNG (B) CONVERTIBLE SEAT INSTALLATION A convertible seat is used in forward–facing and rear–facing position depending on the child’s age and size. When installing, follow the manufacturer’s instructions about the applicable child’s age and size as well as directions for installing a child restraint system. lxxvii ’99camry CNG CAUTION Do not put a rear–facing child restraint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. lxxviii ’99camry CNG 1. Run the center lap belt through or around the convertible seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the lap belt. CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap belt is not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your authorized Toyota CNG dealer immediately. Do not use the seat until the seat belt is fixed. lxxix ’99camry CNG 2. While pressing the convertible seat firmly against the seat cushion and seatback, tighten the lap belt by pulling its free end to hold the convertible seat securely. lxxx ’99camry CNG —Installation with 3–point type seat belt CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 3. To remove the convertible seat, press the buckle–release button. lxxxi ’99camry CNG (A) INFANT SEAT INSTALLATION An infant seat is used in rear–facing position only. lxxxii ’99camry CNG CAUTION
Never put a rear–facing child restraint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child.
Do not put a rear–facing child restraint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. lxxxiii ’99camry CNG 1. Run the lap and shoulder belt through or around the infant seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Keep the lap portion of the belt tight. CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your authorized Toyota CNG dealer immediately. Do not use the seat until the seat belt is fixed. lxxxiv ’99camry CNG 2. Fully extend the shoulder belt to put it in the lock mode. When the belt is then retracted even slightly, it cannot be extended. To hold the infant seat securely, make sure the belt is in the lock mode before letting the belt retract. lxxxv ’99camry CNG 3. While pressing the infant seat firmly against the seat cushion and seatback, let the shoulder belt retract as far as it will go to hold the infant seat securely. lxxxvi ’99camry CNG CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 4. To remove the infant seat, press the buckle–release button and allow the belt to retract completely. The belt will move freely again and be ready to work for an adult or older child passenger. lxxxvii ’99camry CNG (B) CONVERTIBLE SEAT INSTALLATION A convertible seat is used in forward–facing and rear–facing position depending on the child’s age and size. When installing, follow the manufacturer’s instructions about the applicable child’s age and size as well as directions for installing a child restraint system. lxxxviii ’99camry CNG CAUTION
Never put a rear–facing child restraint system on the front seat because the force of the rapid inflation of the passenger airbag can cause death or serious injury to the child. lxxxix ’99camry CNG Move seat fully back
A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. xc ’99camry CNG
Do not put a rear–facing child restraint system on the rear seat if it interferes with the lock mechanism of the front seats. This can cause severe injury to the child and front passenger in case of sudden braking or a collision. xci ’99camry CNG 1. Run the lap and shoulder belt through or around the convertible seat following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Keep the lap portion of the belt tight. CAUTION
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your authorized Toyota CNG dealer immediately. Do not use the seat until the seat belt is fixed. xcii ’99camry CNG 2. Fully extend the shoulder belt to put it in the lock mode. When the belt is then retracted even slightly, it cannot be extended. To hold the convertible seat securely, make sure the belt is in the lock mode before letting the belt retract. xciii ’99camry CNG 3. While pressing the convertible seat firmly against the seat cushion and seatback, let the shoulder belt retract as far as it will go to hold the convertible seat securely. xciv ’99camry CNG CAUTION Push and pull the child restraint system in different directions to be sure it is secure. Follow all the installation instructions provided by its manufacturer. 4. To remove the convertible seat, press the buckle–release button and allow the belt to retract completely. The belt will move freely again and be ready to work for an adult or older child passenger. xcv ’99camry CNG (C) BOOSTER SEAT INSTALLATION A booster seat is used in forward–facing position only. Move seat fully back xcvi ’99camry CNG CAUTION A forward–facing child restraint system should be allowed to put on the front seat only when it is unavoidable. Always move the seat as far back as possible, because the force of a deploying airbag could cause death or serious injury to the child. 1. Sit the child on a booster seat. Run the lap and shoulder belt through or around the booster seat and child following the instructions provided by its manufacturer and insert the tab into the buckle taking care not to twist the belt. Make sure the shoulder belt is correctly across the child’s shoulder and that the lap belt is positioned as low as possible on child’s hips. See “Seat belts” for details. xcvii ’99camry CNG CAUTION
Always make sure the shoulder belt is positioned across the center of child’s shoulder. The belt should be kept away from child’s neck, but not falling off child’s shoulder. Failure to do so could reduce the amount of protection in an accident and cause serious injuries in a collision.
High–positioned lap belts and loose–fitting belts both could cause serious injuries due to sliding under the lap belt during a collision or other unintended result. Keep the lap belt positioned as low on hips as possible.
For child’s safety, do not place the shoulder belt under child’s arm.
After inserting the tab, make sure the tab and buckle are locked and that the lap and shoulder portions of the belt are not twisted.
Do not insert coins, clips, etc. in the buckle as this may prevent you from properly latching the tab and buckle.
If the seat belt does not function normally, it cannot protect your child from injury. Contact your authorized Toyota CNG dealer immediately. Do not use the seat until the seat belt is fixed. xcviii ’99camry CNG 2. To remove the child restraint system, press the buckle–release button and allow the belt to retract. Tilt steering wheel xcix ’99camry CNG To change the steering wheel angle, hold the steering wheel, pull up the lock release lever, tilt the steering wheel to the desired angle and release the lever. When the steering wheel is in a low position, it will spring up as you release the lock release lever. CAUTION
Do not adjust the steering wheel while the vehicle is moving.
After adjusting the steering wheel, try moving it up and down to make sure it is locked in position. Outside rear view mirrors— Adjust the mirror so that you can just see the side of your vehicle in the mirror. c ’99camry CNG —Power rear view mirror Be careful when judging the size or distance of any object seen in the outside rear control view mirror on the passenger’s side. It is a convex mirror with a curved surface. Any object seen in a convex mirror will look smaller and farther away than when seen in a flat mirror. On some models, when you push the rear window defogger switch, the heater panels in the outside rear view mirrors will quickly clear the mirror surface. CAUTION
Do not adjust the mirror while the vehicle is moving. It may cause the driver to mishandle the vehicle and an accident may occur resulting in personal injuries.
Since the mirror surfaces can get hot, keep your hands off them when the defogger switch is on. ci ’99camry CNG Anti–glare inside rear view mirror To adjust a mirror, use the switches. 1. Master switch—To select the mirror to be adjusted Place the switch at “L” (left) or “R” (right). 2. Control switch—To move the mirror Push the switch in the desired direction. Mirror can be adjusted when key is in the “ACC” or “ON” position. NOTICE If ice should jam the mirror, do not operate the control or scrape the mirror face. Use a spray de–icer to free the mirror. cii ’99camry CNG Adjust the mirror so that you can just see the rear of your vehicle in the mirror. To reduce glare from the headlights of the vehicle behind you during night driving, operate the lever on the lower edge of the mirror. Daylight driving—Lever at position 1 The reflection in the mirror has greater clarity at this position. Night driving—Lever at position 2 Remember that by reducing glare you also lose some rear view clarity. CAUTION Do not adjust the mirror while the vehicle is moving. It may cause the driver to mishandle the vehicle and an accident may occur resulting in personal injuries. ciii ’99camry CNG Sun visors— To block out glare, move the sun visor. To block out glare from the front—Swing down the sun visor (position 1). To block out glare from the side—Swing down the sun visor, remove it from the hook and swing it to the lateral side (position 2). If glare comes from obliquely behind you, extend the plate at the end of the visor (to position 3 or 4). CAUTION Do not extend the plate at the end of the sun visor when the visor is in the position 1. It can cover the anti–glare inside rear view mirror and obstruct the rear view. civ ’99camry CNG —Vanity mirrors To use the vanity mirrors, swing down the sun visor and open the cover. cv ’99camry CNG cvi ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–4 Lights, Wipers and Defogger
Headlights and turn signals
Emergency flashers
Instrument panel light control
Interior light
Ignition switch light
Windshield wipers and washer
Rear window and outside rear view mirror defoggers Headlights and turn signals cvii ’99camry CNG HEADLIGHTS To turn on the following lights: Twist the headlight/turn signal lever knob. Position 1—Parking, tail, license plate, side marker and instrument panel lights Position 2—Headlights and all of the above The lights automatically turn off when the driver’s door is opened with the ignition turned off. To turn them on again, turn the key to the “ON” position or actuate the headlight switch. If you are going to park for over one week, make sure the headlight switch is off. NOTICE To prevent the battery from being discharged, do not leave the lights on for a long period when the engine is not running. cviii ’99camry CNG High–Low beams—For high beams, turn the headlights on and push the lever away from you (position 1). Pull the lever toward you (position 2) for low beams. The headlight high beam indicator light (blue light) on the instrument panel will tell you that the high beams are on. Flashing the high beam headlights (position 3)—Pull the lever all the way back. The high beam headlights turn off when you release the lever. You can flash the high beam headlights with the knob turned to “OFF”. cix ’99camry CNG TURN SIGNALS To signal a turn, push the headlight/turn signal lever up or down to position 1. The key must be in the “ON” position. The lever automatically returns after you make a turn, but you may have to return it by hand after you change lanes. To signal a lane change, move the lever up or down to the pressure point (position 2) and hold it. If the turn signal indicator lights (green lights) on the instrument panel flash faster than normal, a front or rear turn signal bulb is burned out. Emergency flashers cx ’99camry CNG To turn on the emergency flashers, push the switch. All the turn signal lights will flash. To turn them off, push the switch once again. Turn on the emergency flashers to warn other drivers if your vehicle must be stopped where it might be a traffic hazard. Always pull as far off the road as possible. The turn signal light switch will not work when the emergency flashers are operating. NOTICE To prevent the battery from being discharged, do not leave the switch on longer than necessary when the engine is not running. Instrument panel light control cxi ’99camry CNG To adjust the brightness of the instrument panel lights, turn the knob. Interior light To turn on the interior light, slide the switch. cxii ’99camry CNG Windshield wipers and The interior light switch has the following positions: washer “ON”—Keeps the light on all the time. “OFF”—Turns the light off. “DOOR”—Turns the light on when any of the door is opened. The light goes off when all the doors are closed. Ignition switch light For easy access to the ignition switch, the ignition switch light comes on when any of the doors are opened. The light remains on for a certain time after all the doors are closed. When all the doors are locked or the ignition switch is turned to “ACC”, “ON” after all the doors are closed, the light fades out. cxiii ’99camry CNG To turn on the windshield wipers, move the lever to the desired setting. The key must be in the “ON” position. Lever position Speed setting Position 1 Intermittent Position 2 Slow Position 3 Fast With interval adjuster: The “INT TIME” band lets you adjust the wiping time interval when the wiper lever is in the intermittent position (position 1). Twist the band upward to increase the time between sweeps, and downward to decrease it. To squirt washer fluid, pull the lever toward you. If the windshield wipers are off, they will operate a couple of times after the washer squirts. cxiv ’99camry CNG Rear window and outside For instructions on adding washer fluid, see “Adding washer fluid” in Chapter 7–3. rear view mirror defoggers In freezing weather, warm the windshield with the defroster before using the washer. This will help prevent the washer fluid from freezing on your windshield, which can block your vision. NOTICE Do not operate the wipers if the windshield is dry. It may scratch the glass. To defog or defrost the rear window, push the switch. The key must be in the “ON” position. The thin heater wires on the inside of the rear window will quickly clear the surfaces. An indicator light will illuminate to indicate the defogger is operating. On some models, heater panels in the outside rear view mirrors will also quickly clear the surfaces. cxv ’99camry CNG Push the switch once again to turn the defogger off. The system will automatically shut off after the defogger has operated about 15 minutes. CAUTION Since the mirror surfaces can get hot keep your hands off them when the defogger switch is on. Make sure you turn the defoggers off when the surfaces are clear. Leaving the defoggers on for a long time could cause the battery to discharge, especially during stop–and–go driving. The defoggers are not designed for drying rain water or for melting snow. If the outside rear view mirrors are heavily coated with ice, use a spray de–icer before operating the switch. NOTICE When cleaning the inside of the rear window, be careful not to scratch or damage the heater wires. cxvi ’99camry CNG cxvii ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–5 Gauges, Meters and Service reminder indicators
Fuel gauge
Engine coolant temperature gauge
Tachometer
Odometer and two trip meters
Service reminder indicators and warning buzzers Fuel gauge cxviii ’99camry CNG Low fuel level warning light The gauge works when the ignition switch is on and indicates the approximate quantity of fuel remaining in the tank. Nearly full—Needle at “F” Nearly empty—Needle at around 1/5 position It is a good idea to keep the tank over 1/4 full. This fuel gauge has a non–return type needle which remains at the last indicated position when the ignition switch is turned off. This gauge indicates the amount of fuel remaining in the tank is calculated from the pressure of the natural gas and the temperature inside the tank. The actual amount may be slightly above or below that indicated, depending on the outside temperature and environment. If the low fuel level warning light comes on, fill the fuel tank as soon as possible. If you continue to drive the vehicle after the low fuel level warning light comes on, the light will begin to blink, and at the same time you will not be able to drive at speeds over 80 km/h (50 mph). cxix ’99camry CNG Engine coolant temperature gauge NOTICE If the low fuel warning light begins to blink, the fuel tank will soon be empty. Move to a safe place as soon as possible. The gauge indicates the engine coolant temperature when the ignition switch is on. The engine operating temperature will vary with changes in weather and engine load. If the needle moves into the red zone, your engine is too hot. If your vehicle overheats, stop your vehicle and allow the engine to cool. Your vehicle may overheat during severe operating conditions, such as:
Driving up a long hill on a hot day.
Reducing speed or stopping after high speed driving. cxx ’99camry CNG
Idling for a long period with the air conditioning on in stop–and–go traffic.
Towing a trailer. NOTICE  Do not remove the thermostat in the engine cooling system as this may cause the engine to overheat. The thermostat is designed to control the flow of coolant to keep the temperature of the engine within the specified operating range.  Do not continue driving with an overheated engine. See “If your vehicle overheats” in Part 4. Tachometer The tachometer indicates engine speed in thousands of rpm (revolutions per minute). Use it while driving to select correct shift points and to prevent engine lugging and overrevving. cxxi ’99camry CNG Driving with the engine running too fast causes excessive engine wear and poor fuel economy. Remember, in most cases the slower the engine speed, the greater the fuel economy. NOTICE Do not let the indicator needle get into the red zone. This may cause severe engine damage. Odometer and two trip meters This meter displays the odometer and two trip meters. 1. Odometer—It shows the total distance the vehicle has been driven. 2. Two trip meters—They show two different distances independently driven since the last time each trip meter was set to zero. You can use one trip meter to calculate the fuel economy and the other to measure the distance on each trip. All trip meter data is cancelled if the electrical power source is disconnected. cxxii ’99camry CNG Service reminder indicators and warning buzzers 3. Trip meter reset knob—It can reset the two trip meters to zero, and also change the meter display. To change the meter display, quickly push and release the knob. The meter display changes in the order from the odometer to trip meter A to trip meter B, then back to the odometer each time you push. To reset the trip meter A to zero, display the meter A reading, then push and hold the knob until the meter is set to zero. The same process can be applied for resetting the trip meter B. cxxiii ’99camry CNG If the indicator or buzzer below comes on... Do this . ( a) If parking brake is off, stop and check. (b) Fasten seat belt. (Indicator and buzzer) (c) Stop and check. (d) Take vehicle to authorized Toyota CNG dealer. (e) (f) Low fuel level warning light Fill the tank up. Stop and check . cxxiv ’99camry CNG If the indicator or buzzer below comes on... Do this. (g) Take vehicle to authorized Toyota CNG dealer. (h) Close all doors. (i) Replace bulb. (j) Take vehicle to authorized Toyota CNG dealer immediately. (k) Add washer fluid. (l) Key reminder buzzer Remove key. (a) Brake System Warning Light cxxv ’99camry CNG This light has the following functions: Parking brake reminder If this light is on, make sure the parking brake is fully released. The light should go off. Low brake fluid level warning If this light comes on and stays on while you are driving, slow down and pull off the road. Then stop the vehicle carefully. Remember that stopping distance and pedal effort may be increased. There may be a problem somewhere in the brake system. Check the fluid level of the see–through reservoir. To make sure the parking brake has not caused the warning light to come on, check to see that the parking brake is fully released. If the brake fluid level is low... At a safe place, test your brakes by starting and stopping.
If you judge that the brakes still work adequately, drive cautiously to the nearest authorized Toyota CNG dealer or shop for repairs.
If the brakes are not working, have the vehicle towed in for repairs. (For towing information, see Part 4.) CAUTION It is dangerous to continue driving normally when the brake fluid level is low. If the brake fluid level is correct... Have the warning system checked by your authorized Toyota CNG dealer. (b) Seat Belt Reminder Light and Buzzer cxxvi ’99camry CNG This light and buzzer remind you to buckle up the driver’s seat belt. Once the ignition key is turned to “ON” or “START”, the reminder light and buzzer come on if the driver’s seat belt is not fastened. Unless the driver fastens the belt, the light stays on and the buzzer stops after about 4 to 8 seconds. (c) Discharge Warning Light This light warns that the battery is being discharged. If it comes on while you are driving, there is a problem somewhere in the charging system. The engine ignition will continue to operate, however, until the battery is discharged. Turn off the air conditioning, blower, radio, etc., and drive directly to the nearest authorized Toyota CNG dealer or repair shop. NOTICE Do not continue driving if the engine drive belt is broken or loose. (d) Malfunction Indicator Lamp This lamp warns that there is a problem somewhere in your engine or automatic transmission electrical system. If it comes on while you are driving, have your vehicle checked/repaired by your authorized Toyota CNG dealer as soon as possible. (e) Low Fuel Level Warning Light This light comes on when the amount of natural gas remaining in the tank drops to about 1/5. If you continue to drive the vehicle after the low fuel level warning light comes on, the light will begin to blink, and at the same time you will not be able to drive at speeds over 80 km/h (50 mph). cxxvii ’99camry CNG When the outside temperature is below –30°C (–22°F), the fuel gauge may indicate an amount less than actual amount and the indicator may come on. NOTICE If the low fuel warning light begins to blink, the fuel tank will soon be empty. Move to a safe place as soon as possible. (f) Low Oil Pressure Warning Light This light warns that the engine oil pressure is too low. If it flickers or stays on while you are driving, pull off the road to a safe place and stop the engine immediately. Call your authorized Toyota CNG dealer or qualified repair shop for assistance. The light may occasionally flicker when the engine is idling or it may come on briefly after a hard stop. There is no cause for concern if it then goes out when the engine is accelerated slightly. The light may come on when the oil level is extremely low. It is not designed to indicate low oil level, and the oil level must be checked using the level dipstick. NOTICE Do not drive the vehicle with the warning light on—even for one block. It may ruin the engine. (g) “ABS” Warning Light This light warns that there is a problem somewhere in your anti–lock brake system. cxxviii ’99camry CNG If the light comes on while you are driving, have your vehicle checked by your authorized Toyota CNG dealer as soon as possible. The light will come on when the ignition key is turned to the “ON” position. After a few seconds, the light will go off. When the “ABS” warning light is on (and the brake system warning light is off), the brake system operates conventionally but anti–lock brake system is not assisting brake performance so that the wheels can lock–up during sudden braking or braking on slippery road surfaces. (h) Open Door Warning Light This light remains on until all the doors and back door are completely closed. (i) Rear Light Failure Warning Light If this light comes on when the headlight switch is turned on (at the first or second clickstop), it indicates that one or more of the tail lights are burned out. If it comes on when the brake pedal is depressed, one or more stop lights are burned out. Have defective bulbs replaced as soon as possible. (j) SRS Warning Light This light will come on when the ignition key is turned to the “ACC” or “ON” position. After about 6 seconds, the light will go off. This means the systems of the airbag and front seat belt pretensioner are operating properly. The warning light system monitors the airbag sensor assembly, front airbag sensors, seat belt pretensioner assemblies, inflators, warning light, interconnecting wiring and power sources. If either of the following conditions occurs, this indicates a malfunction somewhere in the parts monitored by the warning light system. Contact your authorized Toyota CNG dealer as soon as possible to service the vehicle. cxxix ’99camry CNG
The light does not come on when the ignition key is turned to the “ACC” or “ON” position or remains on.
The light comes on or flashes while driving. (k) Low Windshield Washer Fluid Level Warning Light The light warns that the windshield washer fluid level is too low. Add washer fluid at your earliest opportunity. (For instructions, see “Adding washer fluid” in Chapter 7–3.) (l) Key Reminder Buzzer This buzzer reminds you to remove the key when you open the driver’s door with the ignition key in the “ACC” or “LOCK” position. CHECKING SERVICE REMINDER INDICATORS (except the low fuel level warning light and low windshield washer fluid level warning light) 1. Apply the parking brake. 2. Open one of the doors. The open door warning light should come on. 3. Close the door. The open door warning light should go off. 4. Turn the ignition key to “ACC”. The SRS warning light should come on. It goes off after about 6 seconds. 5. Turn the ignition key to “ON”, but do not start the engine. All the service reminder indicators except the open door warning light, SRS warning light and low windshield washer fluid level warning light should come on. The “ABS” warning light goes off after a few seconds. cxxx ’99camry CNG If any service reminder indicator or warning buzzer does not function as described above, either the bulb is burned out or the circuit is in need of repair. Have it checked by your authorized Toyota CNG dealer as soon as possible. cxxxi ’99camry CNG Ignition switch with steering lock 1 Part OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–6 Ignition switch, Transmission and Parking brake
Ignition switch with steering lock
Automatic transmission
Parking brake
Cruise control cxxxii ’99camry CNG “START”—Starter motor on. The key will return to the “ON” position when released. For starting tips, see Part 3. “ON”—Engine on and all accessories on. This is the normal driving position. “ACC”—Accessories such as the radio operate, but the engine is off. If you leave the key in the “ACC” or “LOCK” position and open the driver’s door, a buzzer will remind you to remove the key. “LOCK”—Engine is off and the steering wheel is locked. The key can be removed only at this position. You must push in the key to turn the key from “ACC” to the “LOCK” position. The selector lever must be put in the “P” position before pushing the key. cxxxiii ’99camry CNG When starting the engine, the key may seem stuck at the “LOCK” position. To free it, first be sure the key is pushed all the way in, and then rock the steering wheel slightly while turning the key gently. NOTICE Do not leave the key in the “ON” position if the engine is not running. The battery will discharge and the ignition could be damaged. cxxxiv ’99camry CNG Automatic transmission Lock release button To prevent misshifting Parking, engine starting and key removal position Reverse position Overdrive switch For selecting either a three–speed or four–speed transmission ON position (Shifting into overdrive possible) Neutral position Normal driving position Position for engine braking Position for stronger engine braking than that in “2” position With the brake pedal depressed, shift while holding the lock release button in. (The ignition switch must be in “ON” position.) Shift while holding the lock release button in OFF position (Shifting into overdrive not possible) “O/D OFF” indicator light shows the overdrive switch is in OFF position Shift normally Vehicles with cruise controlWhen the cruise control is being used, even if you downshift the transmission by turning off the overdrive switch, engine braking will cxxxv ’99camry CNG not be applied because the cruise control is not cancelled. For ways to decrease the vehicle speed, see “Cruise control” in this chapter. Your automatic transmission has a shift lock system to minimize the possibility of incorrect operation. This means you can only shift out of “P” position when the brake pedal is depressed (with the ignition switch in “ON” position and the lock release button depressed). (a) Normal driving 1. Start the engine as instructed in “How to start the engine” in Part 3. The transmission must be in “P” or “N”. 2. With your foot holding down the brake pedal, shift the selector lever to “D”. When the lever is in the “D” position, the automatic transmission system will select the most suitable gear for the running conditions such as normal cruising, hill climbing, hard towing, etc. Always turn the overdrive switch on for better fuel economy and quieter driving. If the engine coolant temperature is low, the transmission will not shift into overdrive gear even with the overdrive switch on. CAUTION Never put your foot on the accelerator pedal while shifting. 3. Release the parking brake and brake pedal. Depress the accelerator pedal slowly for smooth starting. (b) Using engine braking To use engine braking, you can downshift the transmission as follows: cxxxvi ’99camry CNG
Turn off the overdrive switch. The “O/D OFF” indicator light will come on and the transmission will downshift to the third gear.
Shift into the “2” position. The transmission will downshift to the second gear when the vehicle speed drops down to or lower than 106 km/h (66 mph), and more powerful engine braking will be obtained.
Shift into the “L” position. The transmission will downshift to the first gear When the vehicle speed drops down to or lower than 47 km/h (29 mph), and maximum engine braking will be applied. Vehicles with cruise controlWhen the cruise control is being used, even if you downshift the transmission by turning off the overdrive switch, engine braking is not applied because the cruise control is not cancelled. For ways to decrease the vehicle speed, see “Cruise control” in this chapter. CAUTION Be careful when downshifting on a slippery surface. Abrupt shifting could cause the vehicle to spin or skid. (c) Using “2” and “L” positions The “2” and “L” positions are used for strong engine braking as described previously. With the selector lever in “2” or “L”, you can start the vehicle in motion as with the lever in “D”. With the selector lever in “2”, the vehicle will start in the first gear and automatically shift to the second gear. With the selector lever in “L”, the transmission is engaged in the first gear. cxxxvii ’99camry CNG NOTICE  Be careful not to overrev the engine. Watch the tachometer to keep engine rpm from going into the red zone. The approximate maximum allowable speed for each position is given below for your reference: “2” . . . . . . . . . . 119 km/h (74 mph) “L” . . . . . . . . . . 66 km/h (41 mph)  Do not continue hill climbing or hard towing for a long time in the “2” or “L” position. This may cause severe automatic transmission damage from overheating. To prevent such damage, “D” position should be used in hill climbing or hard towing. (d) Backing up 1. Bring the vehicle to a complete stop. 2. With the brake pedal held down with your foot, shift the selector lever to the “R” position. NOTICE Never shift into reverse while the vehicle is moving. (e) Parking 1. Bring the vehicle to a complete stop. 2. Pull the parking brake lever up fully to securely apply the parking brake. 3. With the brake pedal pressed down, shift the selector lever to the “P” position. cxxxviii ’99camry CNG CAUTION While the vehicle is moving, never attempt to move the selector lever into “P” position under any circumstances. Serious mechanical damage and loss of vehicle control may result. (f) Good driving practice
If the transmission repeatedly shifts up and down between the third gear and overdrive when climbing a gentle slope, the overdrive switch should be turned off. Be sure to turn the switch on immediately afterward.
When towing a trailer, in order to maintain engine braking efficiency, do not use overdrive. CAUTION Always keep your foot on the brake pedal while stopped with the engine running. This prevents the vehicle from creeping. NOTICE Do not hold the vehicle on an upgrade with the accelerator pedal. It can cause the transmission to overheat. Always use the brake pedal or parking brake. (g) Rocking your vehicle if stuck cxxxix ’99camry CNG CAUTION If your vehicle becomes stuck in snow, mud, sand, etc., then you may attempt to rock your vehicle free by moving it forward and backward. Do not attempt this procedure if people or objects are anywhere near the vehicle. During the rocking operation the vehicle may suddenly move forward or backward as it becomes unstuck, causing injury or damage to nearby people or objects. NOTICE If you rock your vehicle, observe the following precautions to prevent damage to the transmission and other parts.  Do not depress the accelerator pedal while shifting the selector lever or before the transmission is completely shifted to forward or reverse gear.  Do not race the engine and avoid spinning the wheels.  If your vehicle remains stuck after rocking the vehicle several times, consider other ways such as towing. (h) If you cannot shift the selector lever out of “P” position If you cannot shift the selector lever from “P” position even though the brake pedal is depressed, use the shift lock override button. For instructions, see “If you cannot shift automatic transmission selector lever” in Part 4. Parking brake cxl ’99camry CNG When parking, firmly apply the parking brake to avoid inadvertent creeping. To set: Pull up the lever. For better holding power, first depress the brake pedal and hold it while setting the parking brake. To release: Pull up the lever slightly, press the thumb button, and lower. To remind you that the parking brake is set, the parking brake reminder light in the instrument panel remains on until you release the parking brake. CAUTION Before driving, be sure the parking brake is fully released and the parking brake reminder light is off. Cruise control The cruise control allows you to cruise the vehicle at a desired speed over 40 km/h (25 mph) even with your foot off the accelerator pedal. cxli ’99camry CNG Your cruising speed can be maintained up or down grades within the limits of engine performance, although a slight speed change may occur when driving up or down the grades. On steeper hills, a greater speed change will occur so it is better to drive without the cruise control. CAUTION
To help maintain maximum control of your vehicle, do not use the cruise control when driving in heavy or varying traffic, or on slippery (rainy, icy or snow–covered) or winding roads.
Avoid vehicle speed increases when driving downhill. If the vehicle speed is too fast in relation to the cruise control set speed, cancel the cruise control then downshift the transmission to use engine braking to slow down. TURNING ON THE SYSTEM cxlii ’99camry CNG To operate the cruise control, press the “CRUISE ON·OFF” button. This turns the system on. The indicator light in the instrument panel shows that you can now set the vehicle at a desired cruising speed. Another press will turn the system completely off. CAUTION To avoid accidental cruise control engagement, keep the “CRUISE ON·OFF” switch off when not using the cruise control. SETTING AT A DESIRED SPEED The transmission must be in “D” before you set the cruise control speed. Bring your vehicle to the desired speed, push the lever down in the “SET/COAST” direction and release it. This sets the vehicle at that speed. If the speed is not satisfactory, tap the lever up for a faster speed, or tap it down for a slower speed. cxliii ’99camry CNG Each tap changes the set speed by 1.6 km/h (1.0 mph). You can now take your foot off the accelerator pedal. If you need acceleration—for example, when passing—depress the accelerator pedal enough for the vehicle to exceed the set speed. When you release it, the vehicle will return to the speed set prior to the acceleration. CANCELLING THE PRESET SPEED You can cancel the preset speed by: a. Pulling the lever in the “CANCEL” direction and releasing it. b. Depressing the brake pedal. If the vehicle speed falls below about 40 km/h (25 mph), the preset speed will automatically cancel out. If the vehicle speed drops 16 km/h (10 mph) below the preset speed, the preset speed will also automatically cancel out. If the preset speed automatically cancels out other than for the above cases, have your vehicle checked by your authorized Toyota CNG dealer at the earliest opportunity. RESETTING TO A FASTER SPEED Push the lever up in the “RES/ACC” direction and hold it. Release the lever when the desired speed is attained. While the lever is held up, the vehicle will gradually gain speed. However, a faster way to reset is to accelerate the vehicle and then push the lever down in the “SET/COAST” direction. RESETTING TO A SLOWER SPEED cxliv ’99camry CNG Push the lever down in the “SET/COAST” direction and hold it. Release the lever when the desired speed is attained. While the lever is held down, the vehicle speed will gradually decrease. However, a faster way to reset is to depress the brake pedal and then push the lever down in the “SET/COAST” direction. Even if you turn off the overdrive switch, with the cruise control on, engine braking will not be applied because the cruise control is not cancelled. To decrease the vehicle speed, reset to a slower speed with the cruise control lever or depress the brake pedal. If you use the brake pedal, cruise control is cancelled. RESUMING THE PRESET SPEED If the preset speed is cancelled by pulling the control lever or by depressing the brake pedal or clutch pedal, pushing the lever up in the “RES/ACC” direction will restore the speed set prior to cancellation. However, once the vehicle speed falls below about 40 km/h (25 mph), the preset speed will not be resumed. CRUISE CONTROL FAILURE WARNING If the “CRUISE” indicator light in the instrument cluster flashes when using the cruise control, press the “CRUISE ON·OFF” button to turn the system off and then press it again to turn it on. If any of the following conditions then occurs, there is some trouble in the cruise control system.
The indicator light does not come on.
The indicator light flashes again.
The indicator light goes out after it comes on. If this is the case, contact your authorized Toyota CNG dealer and have your vehicle inspected. cxlv ’99camry CNG Reference Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–7 Car audio system
Reference
Using your audio system
Car audio system operating hints cxlvi ’99camry CNG Using your audio system— AM·FM ETRbasics radio/cassette player/compact disc auto changer controller —Some This section describes some of the basic features on Toyota audio systems. Some information may not pertain to your system. Your audio system works when the ignition key is in the “ACC” or “ON” position. TURNING THE SYSTEM ON AND OFF Push “VOL/PWR” to turn the audio system on and off. Push “AM”, “FM”, “TAPE” or “CD” to turn on that function without pushing “VOL/ PWR”. You can turn on each player by inserting a cassette tape or compact disc. You can turn off each player by ejecting the cassette tape or compact disc. If the audio system was previously off, then the entire audio system will be turned off when you eject the cassette tape or compact disc. If the another function was previously playing, it will come on again. SWITCHING BETWEEN FUNCTIONS Push “AM”, “FM”, “TAPE” or “CD” if the system is already on but you want to switch from one function to another. TONE AND BALANCE For details about your system’s tone and balance controls, see the description of your own system. Tone How good an audio program sounds to you is largely determined by the mix of the treble and bass levels. In fact, different kinds of music and vocal programs usually sound better with different mixes of treble and bass. cxlvii ’99camry CNG Balance A good balance of the left and right stereo channels and of the front and rear sound levels is also important. Keep in mind that if you are listening to a stereo recording or broadcast, changing the right/left balance will increase the volume of one group of sounds while decreasing the volume of another. YOUR RADIO ANTENNA NOTICE Attaching the film (especially conductive or metallic type) on the rear glass will noticeably reduce the sensitivity of the radio. YOUR CASSETTE PLAYER When you insert a cassette, the exposed tape should be to the right. NOTICE Do not oil any part of the player and do not insert anything other than cassette tapes into the slot, or the tape player may be damaged. —Controls and features Details of specific buttons, controls and features are described in the alphabetical listing that follows. cxlviii ’99camry CNG 1 2 3 4 5 6 (Preset buttons) These buttons are used to preset and tune in radio stations. To preset a station to a button: Tune in the desired station (see “TUNE” button). Push and hold down the button until you hear a beep—this will set the station to the button. The button number will appear on the display. To tune in to a preset station: Push the button for the station you want. The button number and station frequency will appear on the display. These systems can store one AM and two FM stations for each button (The display will show “AM”, “FM1” or “FM2” when you push “AM” or “FM”). (Eject button) Push this button to eject a cassette. After you turn the ignition to “LOCK”, you will be able to eject a cassette but you will not be able to reinsert it. (Reverse/Fast forward buttons) Cassette Player Push the fast forward button to fast forward a cassette tape. “FF” will appear on the display. Push the reverse button to rewind a tape. “REW” will appear on the display. To stop the tape while it is fast forwarding, push the fast forward button or “TAPE”; to stop the tape while it is rewinding, push the reverse button or “TAPE”. If a tape side rewinds completely, the cassette player will stop and then play that same side. If a tape fast forwards completely, the cassette player will play the other side of the tape, using the auto–reverse feature. Compact Disc Player cxlix ’99camry CNG If you want to fast forward or reverse through a compact disc track, push and hold in the fast forward or reverse button. When you release the button, the compact disc player will resume playing. AM Push “AM” to switch the AM band. “AM” will appear on the display. If the audio system is off, you can turn on the radio by pushing “AM”. Also, push “AM” to switch from cassette or compact disc operation to radio operation. AUDIO CONTROL / MODE Manual tone adjustment function— This knob is used to adjust the tone manually. For low–pitch tone adjustment, push “AUDIO CONTROL / MODE” repeatedly until “BAS” appears on the display. Then turn the knob to suit your preference. The display will show the range from “BAS –5” to “BAS 5”. For high–pitch tone adjustment, push “AUDIO CONTROL / MODE” repeatedly until “TRE” appears on the display. Then turn the knob to suit your preference. The display will show the range from “TRE –5” to “TRE 5”. Sound balance adjustment function— This knob is also used to adjust the sound balance between the front and rear, and the right and left speakers. For front/rear adjustment, push “AUDIO CONTROL / MODE” repeatedly until “FAd” appears on the display. Then turn the knob to adjust the front/rear balance. The display will show the range from “FAd F7” to “FAd R7”. For left/right adjustment, push “AUDIO CONTROL / MODE” repeatedly until “BAL” appears on the display. Then turn the knob to adjust the left/right balance. cl ’99camry CNG The display will show the range from “BAL L7” to “BAL R7”. CD (Compact Disc) Push “CD” to switch from radio or cassette operation to compact disc operation. If the audio system is off, you can turn on the compact disc player by pushing “CD”. In both cases, a disc must already be loaded in the player. When the audio is set into compact disc operation, the display shows the track or, track and disc number currently being played. Each time you push “CD”, the system changes between single disc player and automatic changer. If the player malfunctions, your audio system will display one of the six following error messages. If “WAIT” appears on the display, it indicates inside the player unit may be too hot due to the very high ambient temperature. Remove the disc or magazine from the player and allow the player to cool down. If “Err 1” appears on the display, it indicates the disc is dirty, damaged, or it was inserted up–side down. Clean the disc or insert it correctly. If “Err 2” appears on the display, it indicates no disc is loaded inside the magazine, insert a disc. If “Err 3” or “Err 4” on the display, it indicates there is a trouble inside the system. Eject the disc or magazine. Set the disc or magazine again. If “OPEn” appears on the display, it indicates the compact disc auto changer lid is open. Close the compact disc auto changer lid. If the malfunction is not rectified, take your vehicle to your authorized Toyota CNG dealer. DISC 
Compact disc auto changer only— cli ’99camry CNG By using this button, you can select a disc you wish to listen to. Push either side of the button until the number of the disc you want to listen to appears on the display. Dolby B NR∗ If you are listening to a tape that was recorded with Dolby B Noise Reduction, push the button marked with the double–D symbol. The double–D symbol will appear on the display. Push the button again to turn off Dolby B NR. The Dolby NR mode reduces tape noise by about 10 dB. For best sound reproduction, play your tapes with this button on or off according to the mode used for recording the tape. ∗ : Dolby noise reduction manufactured under license from Dolby Laboratories Licensing Corporation. “DOLBY” and the double D symbol are trademarks of Dolby Laboratories Licensing Corporation. FM Push “FM” to switch the FM band. “FM1” or “FM2” will appear on the display. This system allows you to set twelve FM stations, two for each button. If the audio system is off, you can turn on the radio by pushing “FM”. Also, push “FM” to switch from cassette or compact disc operation to radio operation. PROG (Program) Push “PROG” to select the other side of a cassette tape. The display indicates which side is currently selected (“ ” indicates top side, “ ” indicates bottom side). Auto–reverse feature: After the cassette player reaches the end of a tape side, it automatically reverses and begins to play the other side. This is true whether the cassette was playing or fast forwarding. RAND (Random) clii ’99camry CNG There are two random features—you can either listen to the tracks on all the compact discs in the magazine in random order, or only listen to the tracks on a specific compact disc in random order. Random playing for the tracks on a disc: Quickly push and release “RAND”. “RAND” will appear on the display. The disc you are listening to will play in random order. If you hear a beep, you held the button too long, and the player will play all the tracks in the magazine in random order. To turn off the random feature, push the “RAND” a second time. Compact disc auto changer only— Random playing for all the tracks in the magazine: Push and hold “RAND” until you hear a beep. “D·RAND” will appear on the display and the player will perform all the tracks on all the discs in the magazine in random order. To turn off the random feature, push “RAND” a second time. RPT (Repeat) There are two repeat features—you can either replay a disc track or a whole compact disc. Repeating a track: Quickly push and release “RPT” while the track is playing. “RPT” will appear on the display. If you hear a beep, you held the button too long, and the player will repeat the whole disc. When the track ends, it will automatically be replayed. This process will be continued until you push the button again to turn off the repeat feature. Compact disc auto changer only— Repeating a disc: Push and hold “RPT” until you hear a beep. “D·RPT” will appear on the display. The player will repeat all the tracks on the disc you are listening to. When the disc ends, the player will automatically go back to the top track of the disc and replay. cliii ’99camry CNG This process will be continued until you push the button again to turn off the repeat feature. SCAN Radio You can either scan all the frequencies on a band or scan only the preset stations for that band. To scan the preset stations: Push and hold “SCAN” until you hear a beep. The radio will tune in the next preset station up the band, stay there for a few seconds, and then move to the next preset station. To select a station, push “SCAN” a second time. To scan all the frequencies: Quickly push and release “SCAN”. If you hear a beep, you held the button too long, and the radio will scan the preset stations. The radio will find the next station up the station band, stay there for a few seconds, and then scan again. To select a station, push “SCAN” a second time. Compact disc player There are two scan features—you can either scan the tracks on a specific disc or scan the first tracks of all the discs in the magazine. Scanning for the tracks on a disc: Quickly push and release “SCAN”. “SCAN” will appear on the display and the player will scan all the tracks on the disc you are listening to. If you hear a beep, you held the button too long, and the player will scan the first tracks of all the discs in the magazine. To select a track, push the “SCAN” a second time. If the player scanned all the tracks on the disc, it will stop scanning. Compact disc auto changer only— cliv ’99camry CNG Scanning for the first tracks of all the discs in the magazine: Push and hold “SCAN” until you hear a beep. “D·SCAN” will appear on the display and the player will perform the first track of the next disc. To select a disc, push the “SCAN” a second time. If the player has scanned all the discs, it will stop scanning. ST (Stereo reception) display Your radio automatically changes to stereo reception when a stereo broadcast is received. “ST” appears on the display. If the signal becomes weak, the radio reduces the amount of channel separation to prevent the weak signal from creating noise. If the signal becomes extremely weak, the radio switches from stereo to mono reception. TAPE Push “TAPE” to switch from radio or compact disc operation to cassette operation. If the audio system is off, you can turn on the cassette player by pushing “TAPE”. In both cases, a cassette must already be loaded in the player. TRACK (Track up/down button): Compact disc player By using this button, you can skip up or down to a different track. Push either side of the track button until the number of the track you want to listen to appears on the display. If you want to return to the beginning of the current track, push the down side of the button one time, quickly. TUNE Tuning Your Toyota has an electronic tuning radio (ETR). Push and release the “
” (up) or “” (down) side of “TUNE” to step up or down the station band. (If you hear a beep, you held the button too long and the radio will go into the seek mode.) clv ’99camry CNG Car audio system operating Seeking hints In the seek mode, the radio finds and plays the next station up or down the station band. To seek a station, push and hold the “
” or “” side of “TUNE” until you hear a beep. Do this again to find another station. VOL/PWR (Volume/Power) Push “VOL/PWR” to turn the audio system on and off. Turn “VOL/PWR” to adjust the volume. NOTICE To ensure the correct audio system operation:  Be careful not to spill beverages over the audio system.  Do not put anything other than a cassette tape into the slot.  The use of cellular phone inside or near the vehicle may cause a noise from the speakers of the audio system which you are listening to. However, this does not indicate a malfunction. RADIO RECEPTION Usually, a problem with radio reception does not mean there is a problem with your radio—it is just the normal result of conditions outside the vehicle. For example, nearby buildings and terrain can interfere with FM reception. Power lines or telephone wires can interfere with AM signals. And of course, radio signals have a limited range, and the farther you are from a station, the weaker its signal will be. In addition, reception conditions change constantly as your vehicle moves. clvi ’99camry CNG Here are some common reception problems that probably do not indicate a problem with your radio: FM Fading and drifting stations—Generally, the effective range of FM is about 40 km (25 miles). Once outside this range, you may notice fading and drifting, which increase with the distance from the radio transmitter. They are often accompanied by distortion. Multi–path—FM signals are reflective, making it possible for two signals to reach your antenna at the same time. If this happens, the signals will cancel each other out, causing a momentary flutter or loss of reception. Static and fluttering—These occur when signals are blocked by buildings, trees, or other large objects. Increasing the bass level may reduce static and fluttering. Station swapping—If the FM signal you are listening to is interrupted or weakened, and there is another strong station nearby on the FM band, your radio may tune in the second station until the original signal can be picked up again. AM Fading—AM broadcasts are reflected by the upper atmosphere—especially at night. These reflected signals can interfere with those received directly from the radio station, causing the radio station to sound alternately strong and weak. Station interference—When a reflected signal and a signal received directly from a radio station are very nearly the same frequency, they can interfere with each other, making it difficult to hear the broadcast. Static—AM is easily affected by external sources of electrical noise, such as high tension power lines, lightening, or electrical motors. This results in static. CARING FOR YOUR CASSETTE PLAYER AND TAPES For high performance from your cassette player and tapes: clvii ’99camry CNG Clean the tape head and other parts regularly.
A dirty tape head or tape path can decrease sound quality and tangle your cassette tapes. The easiest way to clean them is by using a cleaning tape. (A wet type is recommended.) Use high–quality cassettes.
Low–quality cassette tapes can cause many problems, including poor sound, inconsistent playing speed, and constant auto–reversing. They can also get stuck or tangled in the cassette player.
Do not use a cassette if it has been damaged or tangled or if its label is peeling off.
Do not leave a cassette in the player if you are not listening to it, especially if it is hot outside.
Store cassettes in their cases and out of direct sunlight.
Avoid using cassettes with a total playing time longer than 100 minutes (50 minutes per side). The tape used in these cassettes is thin and could get stuck or tangled in the cassette player. clviii ’99camry CNG clix ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–8 Air conditioning system
Controls
Air flow selector settings
Operating tips
Side vents Controls 1. “A/C” Button 2. Air Intake Selector 3. Air Flow Selector 4. Temperature Selector 5. Fan Speed Selector clx ’99camry CNG Fan speed selector Turn the knob to adjust the fan speed—to the right to increase, to the left to decrease. Temperature selector Turn the knob to adjust the temperature—to the right to warm, to the left to cool. Air flow selector Turn the knob to select the vents used for air flow. 1. Panel—Air flows mainly from the instrument panel vents. 2. Bi–level—Air flows from both the floor vents and the instrument panel vents. 3. Floor—Air flows mainly from the floor vents. 4. Floor/Windshield—Air flows mainly from the floor vents and windshield vents. Use with the air intake selector positioned in Fresh. clxi ’99camry CNG 5. Windshield—Air flows mainly from the windshield vents. Use with the air intake selector positioned in Fresh. For details about air flow selector settings, see the illustration after “A/C” button. Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Air intake selector Move the lever to select the air source. 1. Recirculate—Recirculates the air inside the vehicle. 2. Fresh—Draws outside air into the system. “A/C” button clxii ’99camry CNG To turn on the air conditioning, press the “A/C” button. The “A/C” button indicator will come on. To turn the air conditioning off, press the button again. If the “A/C” button indicator flashes, there is a problem in the air conditioning system and the air conditioning automatically shuts off. If this happens, take your vehicle to your authorized Toyota CNG dealer for service. Air flow selector settings Operating tips
To cool off your Toyota after it has been parked in the hot sun, drive with the windows open for a few minutes. This vents the hot air, allowing the air conditioning to cool the interior more quickly.
Make sure the air intake grilles in front of the windshield are not blocked (by leaves or snow, for example).
On humid days, do not blow cold air on the windshield. The windshield could fog up because of the difference in air temperature on the inside and outside of the windshield.
Keep the area under the front seats clear to allow air to circulate throughout the vehicle.
On cold days, move the fan speed to “HI” for a minute to help clear the intake ducts of snow or moisture. This can reduce the amount of fogging on the windows.
When driving on dusty roads, close all windows. If dust thrown up by the vehicle is still drawn into the vehicle after closing the windows, it is recommended that the air intake selector be set to FRESH and the fan speed selector to any setting except “OFF”. clxiii ’99camry CNG
If following another vehicle on a dusty road, or driving in windy and dusty conditions, it is recommended that the air intake selector be temporarily set to RECIRCULATE, which will close off the outside passage and prevent outside air and dust from entering the vehicle interior. Heating For best results, set controls to: Fan speed—Any setting except “OFF” Temperature—Towards WARM (red zone) Air intake—FRESH (outside air) Air flow—FLOOR Air conditioning—OFF
For quick heating, select recirculated air for a few minutes. To keep the windows from fogging, select fresh after the vehicle interior has been warmed.
Press the “A/C” button on for dehumidified heating.
Choose floor/windshield air flow to heat the vehicle interior while defrosting or defogging the windshield. Air conditioning For best results, set controls to: Fan speed—Any setting except “OFF” Temperature—Towards COLD (blue zone) Air intake—FRESH (outside air) Air flow—PANEL Air conditioning—ON clxiv ’99camry CNG
For quick cooling, move the air intake selector to recirculate for a few minutes. Ventilation For best results, set controls to: Fan speed—Any setting except “OFF” Temperature—Towards COLD (blue zone) Air intake—FRESH (outside air) Air flow—PANEL Air conditioning—OFF Defogging The inside of the windshield For best results, set controls to: Fan speed—Any setting except “OFF” Temperature—Towards WARM (red zone) to heat; COLD (blue zone) to cool Air intake—FRESH (outside air) Air flow—WINDSHIELD Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Press the “A/C” button for dehumidified heating or cooling. This setting clears the front view more quickly.
On humid days, do not blow cold air on the windshield—the difference between the outside and inside temperatures could make the fogging worse. clxv ’99camry CNG Defrosting The outside of the windshield For best results, set controls to: Fan speed—Any setting except “OFF” Temperature—Towards WARM (red zone) Air intake—FRESH (outside air) Air flow—WINDSHIELD Turning the Air Flow Selector to windshield position turns on the defroster to clear the front view more quickly. Press the “A/C” button for dehumidified heating. This setting clears the front view more quickly.
To heat the vehicle interior while defrosting the windshield, choose floor/windshield air flow. Side vents clxvi ’99camry CNG If air flow control is not satisfactory, check the side vents. The side vents may be opened or closed as shown. clxvii ’99camry CNG clxviii ’99camry CNG Part 1 OPERATION OF INSTRUMENTS AND CONTROLS— Chapter 1–9 Other equipment
Clock
Cigarette lighter and ashtrays
Power outlet
Glove box
Garage door opener box
Miscellaneous box
Auxiliary box
Cup holder
Floor mat Clock clxix ’99camry CNG The digital clock indicates the time. The key must be in the “ACC” or “ON” position. To reset the hour: Push the “H” button. To reset the minutes: Push the “M” button. If the electrical power source has been disconnected from the clock, the time display will automatically be set to 1:00 (one o’clock). If quick adjustment to a full hour is desired, push the “:00” button. For example, if the “:00” button is depressed when the time is between 1:01—1:29, the time will change to 1:00. If the time is between 1:30—1:59, the time will change to 2:00. When the instrument panel lights are turned on, the brightness of the time indication will be reduced. Cigarette lighter and ashtrays clxx ’99camry CNG Cigarette lighter and front ashtray Rear ashtray (on some models) clxxi ’99camry CNG CIGARETTE LIGHTER To use the cigarette lighter, press it in. When it becomes heated, it automatically pops out ready for use. If the engine is not running, the key must be in the “ACC” position. Do not hold the cigarette lighter pressed in. Use a Toyota genuine cigarette lighter or equivalent for replacement. ASHTRAYS To use the ashtray, open out. When finished with your cigarette, thoroughly extinguish it in the ashtray to prevent other cigarette butts from catching fire. After using the ashtray, push it back in completely. To remove the ashtray, press down on the lock spring plate and pull out. CAUTION To reduce the chance of injury in case of an accident or sudden stop while driving, always push the ashtray back in completely after use. Power outlet clxxii ’99camry CNG The power outlet is designed for power supply for car accessories. The key must be in the “ACC” or “ON” position for the power outlet to be used. NOTICE  To prevent the fuse from being blown, do not use the electricity over the total vehicle capacity of 12V/120W.  To prevent the battery from being discharged, do not use the power outlet longer than necessary when the engine is not running.  Close the power outlet lid when the power outlet is not in use. Inserting a foreign object other than the appropriate plug that fits the outlet, or allowing any liquid into the outlet may cause electrical failure or short circuits. clxxiii ’99camry CNG Glove box To use the glove box, do this. To open: Pull the lever. With the instrument panel lights on, the glove box light will come on when the glove box is open. To lock: Insert the master key and turn it clockwise. CAUTION To reduce the chance of injury in case of an accident or a sudden stop, always keep the glove box door closed while driving. Garage door opener box clxxiv ’99camry CNG The box is designed to store a garage door opener transmitter. Open the cover and remove the Velcro loop. clxxv ’99camry CNG Remove the paper strip covering the adhesive on back side of loop and adhere loop to back side of the transmitter near center. Please note if transmitter has wire clip for sun visor, this clip must be removed prior to adhesion of the Velcro. clxxvi ’99camry CNG Place the transmitter with Velcro loop facing inside of box into the box. Make sure the transmitter button is located above button pins. clxxvii ’99camry CNG Remove spacers from the center panel. Place the largest spacer on the pin that would be below transmitter button when the cover is closed. Close the cover. When the garage door opener transmitter is properly installed, you can operate the transmitter by pushing the center panel of the cover. clxxviii ’99camry CNG If the center panel does not contact with your garage door opener transmitter:
Check to see if spacer is on correct pin.
Attach another spacer to the top of original spacer. Check operation. If required, continue add spacers until contact is achieved. If the transmitter is clattering during driving, fill in a piece of felt or pad to prevent the transmitter from clattering. CAUTION
To reduce the chance of injury in case of an accident or a sudden stop, always keep the garage door opener box closed while driving.
Keep the remained spacers away from children. clxxix ’99camry CNG The miscellaneous box and garage door opener box (stored in the glove box) are interchangeable. Removing the cover— Half open the cover. Pinch each hinge and pull it out of its pivot one by one as shown above. Do not remove the cover forcibly. clxxx ’99camry CNG Installing the cover— Align the hinges to the pivots, and press each hinge with a thumb until you hear a click. Make sure that the cover opens and closes smoothly. Miscellaneous box clxxxi ’99camry CNG To use the box, open it as shown above. CAUTION To reduce the chance of injury in case of an accident or a sudden stop, always keep the miscellaneous box closed while driving. NOTICE In hot weather, inside of the vehicle becomes very hot. Do not leave anything flammable or deformable such as a lighter, the glasses, etc. inside. Auxiliary box clxxxii ’99camry CNG To use the box, pull on the handle. CAUTION To reduce the chance of injury in case of an accident or a sudden stop, always keep the auxiliary box closed while driving. Cup holder clxxxiii ’99camry CNG Front Rear clxxxiv ’99camry CNG The cup holder is designed for holding cups or drink–cans securely in its holes. Front: To use the holder, open the lid. Rear: To use the holder, pull it out. CAUTION
Do not place anything else other than cups or drink–cans on the cup holder, as such items may be thrown about in the compartment and possibly injure people in the vehicle during sudden braking or in an accident.
To reduce the chance of injury in case of an accident or sudden stop while driving, keep the cup holder closed when it is not in use. Floor mat clxxxv ’99camry CNG Use a floor mat of the correct size. If the floor carpet and floor mat have a hole, then it is designed for use with a locking clip. Fix the floor mat with locking clip into the hole in the floor carpet. CAUTION Make sure the floor mat is properly placed on the floor carpet. If the floor mat slips and interferes with the movement of the pedals during driving, it may cause an accident. clxxxvi ’99camry CNG Part 7 DO–IT–YOURSELF MAINTENANCE— Chapter 7–1 Introduction
Engine compartment overview
Fuse locations
Do–it–yourself service precautions
Parts and tools Engine compartment overview 1. Power steering fluid reservoir 2. Engine coolant reservoir 3. Engine oil filler cap 4. Engine oil level dipstick 5. Brake fluid reservoir cclxxxii ’99camry CNG 6. Fuse blocks 7. Battery 8. Electric cooling fans 9. Windshield washer fluid tank Fuse locations cclxxxiii ’99camry CNG cclxxxiv ’99camry CNG Spare fuses cclxxxv ’99camry CNG Do–it–yourself service precautions If you perform maintenance by yourself, be sure to follow the correct procedure given in this part. You should be aware that improper or incomplete servicing may result in operating problems. Performing do–it–yourself maintenance during the warranty period may affect your warranty coverage. Read the separate Toyota Warranty statement for details and suggestions. This part gives instructions only for those items that are relatively easy for an owner to perform. As explained in Part 6, there are still a number of items that must be done by a qualified technician with special tools. For information on tools and parts for do–it–yourself maintenance, see “Parts and tools”. Utmost care should be taken when working on your vehicle to prevent accidental injury. Here are a few precautions that you should be especially careful to observe: cclxxxvi ’99camry CNG CAUTION
Never work on the fuel system by yourself. Any work on this system must be performed by your authorized Toyota CNG dealer. If an unqualified person works on it incorrectly causing fuel leaks etc., a fire hazard or explosion may occur, which is very dangerous.
When the engine is running, keep hands, clothing, and tools away from the moving fan and engine drive belts. (Removing rings, watches, and ties is advisable.)
Right after driving, the engine compartment—the engine, radiator, exhaust manifold and spark plug boots, etc.—will be hot. So be careful not to touch them. Oil, fluids and spark plugs may also be hot.
If the engine is hot, do not remove the radiator cap or loosen the drain plugs to prevent burning yourself.
Do not smoke, cause sparks or allow open flames around fuel or the battery. Their fumes are flammable. cclxxxvii ’99camry CNG
Be extremely cautious when working on the battery. It contains poisonous and corrosive sulfuric acid.
Do not get under your vehicle with just the body jack supporting it. Always use automotive jack stands or other solid supports.
Be sure that the ignition is off if you work near the electric cooling fans or radiator grille. With the ignition on, the electric cooling fans will automatically start to run if the engine coolant temperature is high and/or the air conditioning is on.
Use eye protection whenever you work on or under your vehicle where you may be exposed to flying or falling material, fluid spray, etc.
Used engine oil contains potentially harmful contaminants which may cause skin disorders such as inflammation or skin cancer, so care should be taken to avoid prolonged and repeated contact with it. To remove used engine oil from your skin, wash thoroughly with soap and water.
Do not leave used oil within the reach of children.
Dispose of used oil and filter only in a safe and acceptable manner. Do not dispose of used oil and filter in household trash, in sewers or onto the ground. Call your authorized Toyota CNG dealer or a service station for information concerning recycling or disposal. cclxxxviii ’99camry CNG NOTICE  Remember that battery and ignition cables carry high currents or voltages. Be careful of accidentally causing a short circuit.  Be careful not to touch the fuel pipe unintentionally. If an excessive force is applied on the pipe, gas may leak from its connections.  Add only demineralized or distilled water to fill the radiator. And if you spill some of the coolant, be sure to wash off with water to prevent it from damaging the parts or paint.  Do not allow dirt or anything else to fall through the spark plugholes.  Use only spark plugs of the specified type. Using other types will cause engine damage, loss of performance or radio noise.  Do not reuse platinum–tipped spark plugs by cleaning or regapping.  Do not overfill automatic transmission fluid, or the transmission could be damaged.  Do not drive with the air cleaner filter removed, or excessive engine wear could result. Also backfiring could cause a fire in the engine compartment.  Be careful not to scratch the glass surface with the wiper frame.  When closing the engine hood, check to see that you have not forgotten any tools, rags, etc. Parts and tools Here is a list of parts and tools you will need on performing do–it–yourself maintenance. Remember all Toyota parts are designed in metric sizes, so your tools must be metric. cclxxxix ’99camry CNG Checking the engine oil level Parts (if level is low):
Engine oil API grade SJ, “Energy–Conserving” or ILSAC multigrade having viscosity proper for your climate Tools:
Rag or paper towel
Funnel (only for adding oil) Checking the engine coolant level Parts (if level is low):
“TOYOTA Long Life Coolant” or equivalent See Chapter 7–2 for details about coolant type selection.
Demineralized or distilled water Tools:
Funnel (only for adding coolant) Checking brake fluid Parts (if level is low):
SAE J1703 or FMVSS No.116 DOT 3 brake fluid Tools:
Rag or paper towel
Funnel (only for adding fluid) Checking power steering fluid Parts (if level is low):
Automatic DEXRONII or III transmission fluid Tools:
Rag or paper towel
Funnel (only for adding fluid) ccxc ’99camry CNG Checking battery condition Tools:
Warm water
Baking soda
Grease
Conventional wrench (for terminal clamp bolts) Checking and replacing fuses Parts (if replacement is necessary):
Genuine Toyota fuse or equivalent with same amperage rating as original Adding washer fluid Parts:
Water
Washer fluid containing antifreeze (for winter use) Tools:
Funnel Replacing light bulbs Parts:
Bulb with same number and wattage rating as original (See charts in “Replacing light bulbs” in Chapter 7–3.) Tools:
Screwdriver
Flat–bladed screwdriver ccxci ’99camry CNG Part 7 DO–IT–YOURSELF MAINTENANCE— Chapter 7–2 Engine and Chassis
Checking the engine oil level
Checking the engine coolant level
Checking brake fluid
Checking power steering fluid
Checking tire pressure
Checking and replacing tires
Rotating tires
Installing snow tires and chains
Replacing wheels Checking the engine oil level ccxcii ’99camry CNG Low level Add oil Full level O.K. Too full With the engine at operating temperature and turned off, check the oil level on the dipstick. 1. To get a true reading, the vehicle should be on a level spot. After turning off the engine, wait a few minutes for the oil to drain back into the bottom of the engine. 2. Pull out the dipstick, and wipe it clean with a rag. 3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be correct. 4. Pull the dipstick out and look at the oil level on the end. CAUTION Be careful not to touch the hot exhaust manifold. ccxciii ’99camry CNG If the oil level is below or only slightly above the low level line, add engine oil of the same type as already in the engine. Remove the oil filler cap and add engine oil in small quantities at a time, checking the dipstick. The approximate quantity of oil needed to fill between the low level and the full level on the dipstick is indicated below for reference. When the level reaches within the correct range, install the filler cap hand–tight. Oil quantity, L (qt., lmp. qt.): 0.7 (0.7, 0.6) NOTICE  Avoid overfilling, or the engine could be damaged.  Check the oil level on the dipstick once again after adding the oil. Engine oil selection Use API grade SJ, “Energy–Conserving” or ILSAC multigrade engine oil. Recommended viscosity (SAE): ccxciv ’99camry CNG SAE 5W–30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather. If you use SAE 10W–30 engine oil in extremely low temperatures, the engine may become difficult to start, so SAE 5W–30engine oil is recommended. API service symbol ccxcv ’99camry CNG Checking the engine coolant level ILSAC certification mark Oil identification marks Either or both API registered marks are added to some oil containers to help you select the oil you should use. The API Service Symbol is located anywhere on the outside of the container. The top portion of the label shows the oil quality by API (American Petroleum Institute) designations such as SJ. The center portion of the label shows the SAE viscosity grade such as SAE 5W–30. “Energy–Conserving” shown in the lower portion, indicates that the oil has fuel–saving capabilities. The ILSAC (International Lubricant Standardization and Approval Committee) Certification Mark is displayed on the front of the container. Look at the see–through coolant reservoir when the engine is cold. The coolant level is satisfactory if it is between the “FULL” and “LOW” lines on the ccxcvi ’99camry CNG reservoir. If the level is low, add ethylene–glycol type coolant for a proper corrosion protection of aluminum components. The coolant level in the reservoir will vary with engine temperature. However, if the level is on or below the “LOW” line, add coolant. Bring the level up to the “FULL” line. Always use ethylene–glycol type coolant for a proper corrosion protection of aluminum components. See information in the next column. If the coolant level drops within a short time after replenishing, there may be a leak in the system. Visually check the radiator, hoses, radiator cap and drain cock and water pump. If you can find no leak, have your authorized Toyota CNG dealer test the cap pressure and check for leaks in the cooling system. CAUTION To prevent burning yourself, do not remove the radiator cap when the engine is hot. Coolant type selection Use of improper coolants may damage your engine cooling system. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of your engine that contains aluminum components. Use “TOYOTA Long Life Coolant” or equivalent. In addition to preventing freezing and subsequent damage to the engine, this type of coolant will also prevent corrosion. Further supplemental inhibitors or additives are neither needed nor recommended. Read the coolant container for information on freeze protection. Follow the manufacturer’s directions for how much to mix with plain water (preferably demineralized ccxcvii ’99camry CNG water or distilled water). The total capacity of the cooling system is given in Part 8. We recommend to use 50% solution for your Toyota, to provide protection down to about –35C (–31F). When it is extremely cold, to provide protection down to about –50°C (–58°F), 60% solution is recommended. Do not use more than 70% solution for better coolant performance. NOTICE Do not use alcohol type antifreeze or plain water alone. Checking brake fluid To check the fluid level, simply look at the see–through reservoir. The level should be between the “MAX” and “MIN” lines on the reservoir. ccxcviii ’99camry CNG It is normal for the brake fluid level to go down slightly as the brake pads wear. So be sure to keep the reservoir filled. If the reservoir needs frequent refilling, it may indicate a serious mechanical problem. If the level is low, add SAE J1703 or FMVSS No.116 DOT 3 brake fluid to the brake reservoir. Remove and replace the reservoir cover by hand. Use only newly opened brake fluid. Once opened, brake fluid absorbs moisture from the air, and excess moisture can cause a dangerous loss of braking. CAUTION Take care when filling the reservoir because brake fluid can harm your eyes and damage painted surfaces. If fluid gets in your eyes, flush your eyes with clean water. NOTICE If you spill some of the fluid, be sure to wash it off with water to prevent it from damaging the parts or paint. Checking power steering fluid ccxcix ’99camry CNG Open If hot O.K. Close If cold O.K. If cold add If hot add Check the fluid level through the reservoir. If necessary, add automatic transmission fluid DEXRONII or III. If the vehicle has been driven around 80 km/h (50 mph) for 20 minutes (a little more in frigid temperatures), the fluid is hot (60C—80C or 140F—175F). You may also check the level when the fluid is cold (about room temperature, 10C—30C or 50F—85F) if the engine has not been run for about five hours. Clean all dirt from outside of the reservoir tank and look at the fluid level. If the fluid is cold, the level should be in the “COLD” range. Similarly, if it is hot, the fluid level should be in the “HOT” range. If the level is at the low side of either range, add automatic transmission fluid DEXRONII or III to bring the level within the range. To remove the filler cap, turn it counterclockwise and lift up. To reinstall it, turn it clockwise. After replacing the filler cap, visually check the steering box case, vane pump and hose connections for leaks or damage. ccc ’99camry CNG CAUTION The reservoir tank may be hot so be careful not to burn yourself. NOTICE Avoid overfilling, or the power steering could be damaged. Checking tire pressure Keep your tire pressures at the proper level. The recommended cold tire pressures, tire size and the vehicle capacity weight are given in Part 8. They are also on the tire pressure label as shown. You should check the tire pressures every two weeks, or at least once a month. And don’t forget the spare! ccci ’99camry CNG Incorrect tire pressure can reduce tire life and make your vehicle less safe to drive. Low tire pressure results in excessive wear, poor handling, reduced fuel economy, and the possibility of blowouts from overheated tires. Also, low tire pressure can cause poor sealing of the tire bead. If the tire pressure is excessively low, there is the possibility of wheel deformation and/or tire separation. High tire pressure produces a harsh ride, handling problems, excessive wear at the center of the tire tread, and a greater possibility of tire damage from road hazards. If a tire frequently needs refilling, have it checked by your authorized Toyota CNG dealer. The following instructions for checking tire pressure should be observed:
The pressure should be checked only when the tires are cold. If your vehicle has been parked for at least 3 hours and has not been driven for more than 1.5 km or 1 mile since, you will get an accurate cold tire pressure reading.
Always use a tire pressure gauge. The appearance of a tire can be misleading. Besides, tire pressures that are even just a few pounds off can degrade handling and ride.
Take special care when adding air to the compact spare tire. The smaller tire size can gain pressure very quickly. Add compressed air in small quantities and check the pressure often until it reaches the specified pressure.
Do not bleed or reduce tire pressure after driving. It is normal for the tire pressure to be higher after driving.
Never exceed the vehicle capacity weight. The passenger and luggage weight should be located so that the vehicle is balanced. cccii ’99camry CNG
Be sure to reinstall the tire inflation valve caps. Without the valve caps, dirt or moisture could get into the valve core and cause air leakage. If the caps have been lost, have new ones put on as soon as possible. Checking and replacing tires Tread wear indicator CHECKING YOUR TIRES Check the tires tread for the tread wear indicators. If the indicators show, replace the tires. The tires on your Toyota have built–in tread wear indicators to help you know when the tires need replacement. When the tread depth wears to 1.6 mm (0.06 in.) or less, the indicators will appear. If you can see the indicators in two or more adjacent grooves, the tire should be replaced. The lower the tread, the higher the risk of skidding. The effectiveness of snow tires is lost if the tread wears down below 4 mm (0.16 in.). ccciii ’99camry CNG Check the tires regularly for damage such as cuts, splits and cracks. If any damage is found, consult with a technician and have the tire repaired or replaced. Even if the damage does not appear serious, a qualified technician should examine the damage. Objects which have penetrated the tire may have caused internal damage. Any tires which are over 6 years old must be checked by a qualified technician even if damage is not obvious. Tires deteriorate with age even if they have never or seldom been used. This applies also to the spare tire and tires stored for future use. REPLACING YOUR TIRES When replacing a tire, use only the same size and construction as originally installed and with the same or greater load capacity. Using any other size or type of tire may seriously affect handling, ride, speedometer/odometer calibration, ground clearance, and clearance between the body and tires or snow chains. CAUTION
Do not mix radial, bias belted, or bias–ply tires on your vehicle. It can cause dangerous handling characteristics, resulting in loss of control.
Do not use tires or wheels other than the manufacturer’s recommended size. Toyota recommends all four tires, or at least both of the front or rear tires be replaced at a time as a set. See “If you have a flat tire” in Part 4 for tire change procedure. ccciv ’99camry CNG When a tire is replaced, the wheel should always be balanced. An unbalanced wheel may affect vehicle handling and tire life. Wheels can get out of balance with regular use and should therefore be balanced occasionally. When replacing a tubeless tire, the air valve should also be replaced with a new one. Rotating tires To equalize the wear and help extend tire life, Toyota recommends that you rotate your tires approximately every 12000 km (7500 miles). However, the most appropriate timing for tire rotation may vary according to your driving habits and road surface conditions. See “If you have a flat tire” in Part 4 for tire change procedure. When rotating tires, check for uneven wear and damage. Abnormal wear is usually caused by incorrect tire pressure, improper wheel alignment, out–of–balance wheels, or severe braking. cccv ’99camry CNG Installing snow tires and chains CAUTION Do not include a compact spare tire when rotating the tires. It is designed for temporary use only. WHEN TO USE SNOW TIRES OR CHAINS Snow tires or chains are recommended when driving on snow or ice. On wet or dry roads, conventional tires provide better traction than snow tires. SNOW TIRE SELECTION If you need snow tires, select the same size, construction and load capacity as the original tires on your Toyota. Do not use tires other than those mentioned above. Do not install studded tires without first checking local regulations for possible restrictions. SNOW TIRE INSTALLATION Snow tires should be installed on all wheels. Installing snow tires on the front wheels only can lead to an excessive difference in road grip capability between the front and rear tires which could cause loss of vehicle control. When storing removed tires you should store them in a cool dry place. Mark the direction of rotation and be sure to install them in the same direction when replacing. cccvi ’99camry CNG CAUTION
Do not drive with the snow tires incorrectly inflated.
Never drive over 120 km/h (75 mph) with any type of snow tires. TIRE CHAIN SELECTION Use the tire chains of correct size and type. Use SAE Class “S” type radial tire chains except radial cable chains or V–bar type chains. Regulations regarding the use of tire chains vary according to location or type of road, so always check them before installing chains. CHAIN INSTALLATION Install the chains on the front tires as tightly as possible. Do not use tire chains on the rear tires. Retighten chains after driving 0.5—1.0 km (1/4—1/2 mile). When installing chains on your tires, carefully follow the instructions of the chain manufacturer. If wheel covers are used, they will be scratched by the chain band,so remove the covers before putting on the chains. cccvii ’99camry CNG CAUTION
Do not exceed 50 km/h (30 mph) or the chain manufacturer’s recommended speed limit, whichever is lower.
Drive carefully avoiding bumps, holes, and sharp turns, which may cause the vehicle to bounce.
Avoid sharp turns or locked–wheel braking, as use of chains may adversely affect vehicle handling. NOTICE Do not attempt to use a tire chain on the compact spare tire, as it may result in damage to the vehicle as well as the tire. Replacing wheels WHEN TO REPLACE YOUR WHEELS If you have wheel damage such as bending, cracks or heavy corrosion, the wheel should be replaced. If you fail to replace damaged wheels, the tire may slip off the wheel or they may cause loss of handling control. WHEEL SELECTION When replacing wheels, care should be taken to ensure that the wheels are replaced by ones with the same load capacity, diameter, rim width, and offset. This must be observed on compact spare tires, too. Correct replacement wheels are available at your authorized Toyota CNG dealer. A wheel of a different size or type may adversely affect handling, wheel and bearing life, brake cooling, speedometer/odometer calibration, stopping ability, headlight aim, cccviii ’99camry CNG bumper height, vehicle ground clearance, and tire or snow chain clearance to the body and chassis. Replacement with used wheels is not recommended as they may have been subjected to rough treatment or high mileage and could fail without warning. Also, bent wheels which have been straightened may have structural damage and therefore should not be used. Never use an inner tube in a leaking wheel which is designed for a tubeless tire. cccix ’99camry CNG cccx ’99camry CNG Checking battery condition— —Precautions Part 7 DO–IT–YOURSELF MAINTENANCE— Chapter 7–3 Electrical components
Checking battery condition
Battery recharging precautions
Checking and replacing fuses
Adding washer fluid
Replacing light bulbs cccxi ’99camry CNG CAUTION BATTERY PRECAUTIONS The battery produces flammable and explosive hydrogen gas.
Do not cause a spark from the battery with tools.
Do not smoke or light a match near the battery. The electrolyte contains poisonous and corrosive sulfuric acid.
Avoid contact with eyes, skin or clothes.
Never ingest electrolyte.
Wear protective safety glasses when working near the battery.
Keep children away from the battery. EMERGENCY MEASURES
If electrolyte gets in your eyes, flush your eyes with clean water immediately and get immediate medical attention. If possible, continue to apply water with a sponge or cloth while en route to the medical office.
If electrolyte gets on your skin, thoroughly wash the contact area. If you feel pain or burning, get medical attention immediately.
If electrolyte gets on your clothes, there is a possibility of its soaking through to your skin, so immediately take off the exposed clothing and follow the procedure above, if necessary.
If you happen to swallow electrolyte, drink a large quantity of water or milk. Follow with milk of magnesia, beaten raw egg or vegetable oil. Then go immediately for emergency help. cccxii ’99camry CNG —Checking battery exterior Terminals Ground cable Hold–down clamp Check the battery for corroded or loose terminal connections, cracks, or loose hold–down clamp. a. If the battery is corroded, wash it off with a solution of warm water and baking soda. Coat the outside of the terminals with grease to prevent further corrosion. b. If the terminal connections are loose, tighten their clamp nuts—but do not overtighten. c. Tighten the hold–down clamp only enough to keep the battery firmly in place. Overtightening may damage the battery case. cccxiii ’99camry CNG NOTICE  Be sure the engine and all accessories are off before performing maintenance.  When checking the battery, remove the ground cable from the negative terminal (“–” mark) first and reinstall it last.  Be careful not to cause a short circuit with tools.  Take care no solution gets into the battery when washing it. —Checking battery fluid Type A Dark Clear or light yellow White Red Green Type B Blue CHECKING BY THE HYDROMETER Check the battery condition by the hydrometer color. Hydrometer color Type A Type B Condition cccxiv ’99camry CNG GREEN BLUE DARK WHITE CLEAR or LIGHT YELLOW RED Good Charging necessary. Have battery checked by your authorized Toyota CNG dealer. Have battery checked by your authorized Toyota CNG dealer. Battery recharging precautions During recharging, the battery is producing hydrogen gas. Therefore, before recharging: 1. If recharging with the battery installed on the vehicle, be sure to disconnect the ground cable. 2. Be sure the power switch on the recharger is off when connecting the charger cables to the battery and when disconnecting them. CAUTION
Always charge the battery in an unconfined area. Do not charge the battery in a garage or closed room where there is not sufficient ventilation.
Only do a slow charge (5 A or less). Charging at a quicker rate is dangerous. The battery may explode, causing personal injuries. cccxv ’99camry CNG NOTICE Never recharge the battery while the engine is running. Also, be sure all accessories are turned off. Checking and replacing fuses cccxvi ’99camry CNG Type A Good Blown Type B Good Blown Type C Good Blown cccxvii ’99camry CNG If the headlights or other electrical components do not work, check the fuses. If any of the fuses are blown, they must be replaced. See “Fuse locations” in Chapter 7–1 for locations of the fuses. Turn the ignition switch and inoperative component off. Pull a suspected fuse straight out and check it. Determine which fuse may be causing the problem. The lid of the fuse box shows the name of the circuit for each fuse. See Part 8 of this manual for the functions controlled by each circuit. Type A fuses can be pulled out by the pull–out tool. The location of the pull–out tool is shown in the illustration. If you are not sure whether the fuse has blown, try replacing the suspected fuse with one that you know is good. If the fuse has blown, push a new fuse into the clip. Only install a fuse with the amperage rating designated on the fuse box lid. cccxviii ’99camry CNG If you do not have a spare fuse, in an emergency you can pull out the “MIRROR–HEATER”, “DOME” or “A/C” fuse, which may be dispensable for normal driving, and use it if its amperage rating is the same. If you cannot use one of the same amperage, use one that is lower,but as close as possible to, the rating. If the amperage is lower than that specified, the fuse might blow out again but this does not indicate anything wrong. Be sure to get the correct fuse as soon as possible and return the substitute to its original clip. It is a good idea to purchase a set of spare fuses and keep them in your vehicle for emergencies. If the new fuse immediately blows out, there is a problem with the electrical system. Have your authorized Toyota CNG dealer correct it as soon as possible. CAUTION Never use a fuse with a higher amperage rating, or any other object, in place of a fuse. This may cause extensive damage and possibly a fire. Adding washer fluid If any washer does not work or low windshield washer fluid level warning light comes on, the washer tank may be empty. Add washer fluid. You may use plain water as washer fluid. However, in cold areas where temperatures range below freezing point, use washer fluid containing antifreeze. This product is available at your authorized Toyota CNG dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water. cccxix ’99camry CNG NOTICE Do not use engine antifreeze or any other substitute because it may damage your vehicle’s paint. Replacing light bulbs— The following illustrations show how to gain access to the bulbs. When replacing a bulb, make sure the ignition switch and light switch are off. Use bulbs with the wattage ratings given in the table. CAUTION Halogen bulbs have pressurized gas inside and require special handling. They can burst or shatter if scratched or dropped. Hold a bulb only by its plastic or metal case. Do not touch the glass part of a bulb with bare hands. NOTICE Only use a bulb of the listed type. Light bulbs Headlights Parking, front side marker and front turn signal lights Bulb No. W Type HB2 60/55 A — 27/8 B cccxx ’99camry CNG Rear side marker lights 194 3.8 C Rear turn signal lights 3156 27 C Stop and tail lights 3157 27/8 C Tail light 904 9.3 C Back–up lights 921 18 C — 5 C 21CP 18 C Interior light — 10 D Glove box light — 1.2 C Trunk light — 3.8 C License plate lights High mounted stoplight A: B: C: D: HB2 halogen bulbs Single end bulbs Wedge base bulbs Double end bulbs —Headlights cccxxi ’99camry CNG 1. Open the hood. Unplug the connector. Remove the rubber cover. If the connector is tight, wiggle it. cccxxii ’99camry CNG —Parking, front side marker 2. Release bulbsignal retaining spring and remove the bulb. Install a new bulb and fronttheturn lights and the bulb retaining spring. To install a bulb, align the tabs of the bulb with the cutouts of the mounting hole. 3. Install the rubber cover with the “TOP” mark upward, and snuggle on the boss. Insert the connector. Then install the plastic cover. Make sure the rubber cover fits snugly on the connector and the headlight body. Aiming is not necessary after replacing the bulb. When aiming adjustment is necessary, contact your authorized Toyota CNG dealer. cccxxiii ’99camry CNG Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. cccxxiv ’99camry CNG Removing cover clips Installing cover clips cccxxv ’99camry CNG Use a flat–bladed screw driver. To protect the surface, place several sheets of paper over the surface. cccxxvi ’99camry CNG —Rear side maker, rear turn signal, stop and tail lights cccxxvii ’99camry CNG a: Rear side marker light b: Rear turn signal light c: Stop and tail light —Back–up and tail lights cccxxviii ’99camry CNG Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. cccxxix ’99camry CNG Removing the cover clips Installing the cover clips cccxxx ’99camry CNG a: Back–up light b: Tail light cccxxxi ’99camry CNG —License plate lights Use a flat–bladed screwdriver. Remove and install the cover clips as shown in the following illustrations. cccxxxii ’99camry CNG Removing cover clips Installing cover clips cccxxxiii ’99camry CNG —High mounted stoplight cccxxxiv ’99camry CNG cccxxxv ’99camry CNG cccxxxvi ’99camry CNG cccxxxvii ’99camry CNG Part 2 INFORMATION BEFORE DRIVING YOUR TOYOTA
Break–in period
Fuel
Fuel system
Operation in foreign countries
Three–way catalytic converter
Engine exhaust cautions
Facts about engine oil consumption
Twin ground electrode platinum–tipped spark plugs
Brake system
Brake pad wear limit indicators
Luggage stowage precautions
Your Toyota’s identification
Theft prevention labels
Suspension and chassis clxxxvii ’99camry CNG
Types of tires Break–in period Drive gently and avoid high speeds. Your vehicle does not need an elaborate break–in. But following a few simple tips for the first 1600 km (1000 miles) can add to the future economy and long life of your vehicle:






Do not drive over 88 km/h (55 mph). Run the engine at moderate speed between 2000 and 4000 rpm. Avoid full–throttle starts. Try to avoid hard stops during the first 300 km (200 miles). Do not drive slowly with the manual transmission in a high gear. Do not drive for a long time at any single speed, either fast or slow. Do not tow a trailer during the first 800 km (500 miles). Fuel Fuel used for your vehicle is compressed natural gas (CNG). The main ingredient of the natural gas is flammable, colorless methane, which generates lower emissions compared with a gasoline–engine vehicle. The natural gas you use for refueling must meet NFPA–52 and SAE–J1616 standards. If you smell natural gas or hear the sound of leaking fuel while refueling, stop refueling immediately. If you smell or hear fuel leaking other than when refueling, shut off the fuel system. (See “If you suspect the fuel is leaking” in Part 4.) clxxxviii ’99camry CNG Fuel system— —Components CAUTION
Natural gas is flammable and explosive. Take due care to keep away from fire and sparks at all times.
If you suspect the fuel is leaking while refueling, stop refueling immediately. If leaking fuel is ignited, an explosion or fire could occur, causing death or serious injury.
If you smell or hear natural gas leaking, shut off the fuel system immediately. If leaking fuel is ignited, an explosion or fire could occur, causing death or serious injury. NOTICE  Do not use improper fuel that does not meet the required standards. Using improper fuel may affect the engine performance or cause damage to the emission control system.  If you suspect any abnormality in the fuel system, have your vehicle inspected by your authorized Toyota CNG dealer as soon as possible. clxxxix ’99camry CNG 1. Fuel tank 2. Manual shut off valve Have the fuel system checked and maintained by your authorized Toyota CNG dealer. —Fuel tank The fuel tank on your vehicle conforms to ANSI/AGA NGV–2, NFPA–52 and DOT NHTSA FMVSS 304 safety standards. Removal, servicing, discharge of fuel and disposal of the tank should only be done by a qualified technician as prescribed by the fuel control regulation of NFPA–52, and all applicable federal, state and local regulations. Have the fuel tank inspected at the interval listed in the “Scheduled Maintenance Guide”. The fuel tank also requires inspection if the vehicle is involved in a collision or fire hazard. Warning labels on the fuel tank and the engine compartment indicate the service limit date of the tank. Do not remove or paint over the labels. cxc ’99camry CNG See instructions on fuel container for inspection and service life. CAUTION
This tank contains high pressure flammable natural gas. You must ensure that the tank is checked and inspected and properly maintained, as well as avoid overfilling or drilling holes in it, or damaging it in any other way because death or serious injury may result.
Do not allow any person other than a qualified technician to remove this tank from the vehicle. If residual gas in the tank is not discharged correctly, static electricity may be ignited, causing fire or explosion.
Do not leave the fuel tank where the temperature can exceed 80C (176F). The tank’s built–in pressure relief device may open and release all the fuel from under the floor. NOTICE  Do not damage the tank. If the tank is damaged, have it inspected by your authorized Toyota CNG dealer as soon as possible.  Do not expose the tank to chlorine, oxygen or other corrosive liquids.  This tank is intended for use with compressed natural gas—the fuel for this vehicle. Do not use it for any other purpose. cxci ’99camry CNG SERVICE PRESSURE: 24800 kPa (3600 psig) Equivalent gasoline capacity: 43 L (11.4 gal., 9.5 lmp.gal.) Water volume: 135 L (35.7 gal., 29.7 lmp.gal.) —Fuel shut off system If the engine stalls, fuel flow from the tank is automatically shut off. When restarting the engine after fuel flow is shut off, turn the ignition switch to “ACC” or “LOCK” once and then start it. The fuel flow from the tank will also be shut off automatically when an airbag inflates upon collision or if the piping is disconnected. CAUTION If the vehicle is involved in a collision and there is a chance that there may be fuel leakage, never restart the engine. Ignition of leaked natural gas may cause death or serious injury. Manual shut off valve This valve is for manually shutting off fuel from the tank. It is usually left open. Use this valve to shut off fuel if you suspect that the fuel is leaking or after you have been involved in a collision. Refer to “If you suspect the fuel is leaking” in Part 4 for how to operate the valve. Operation in foreign countries If you plan to drive your Toyota in another country... First, comply with the vehicle registration laws. cxcii ’99camry CNG Second, confirm the availability of the correct fuel and filling nozzles. Three–way catalytic converter The three–way catalytic converter is an emission control device installed in the exhaust system. The purpose is to reduce pollutants in the exhaust gas. CAUTION
Keep people and combustible materials away from the exhaust pipe while the engine is running. The exhaust gas is very hot.
Do not drive, idle or park your vehicle over anything that might burn easily such as grass, leaves, paper or rags. cxciii ’99camry CNG NOTICE A large amount of unburned gases flowing into the three–way catalytic converter may cause it to overheat and create a fire hazard. To prevent this and other damage, observe the following precautions:  Use only CNG (Compressed Natural Gas).  Do not drive with an extremely low fuel level; running out of fuel could cause the engine to misfire, creating an excessive load on the three–way catalytic converter.  Do not allow the engine to run at idle speed for more than 20 minutes.  Avoid racing the engine.  Do not push–start or pull–start your vehicle.  Do not turn off the ignition while the vehicle is moving. cxciv ’99camry CNG  Keep your engine in good running order. Malfunctions in the engine electrical system, electronic ignition system/distributor ignition system or fuel system could cause an extremely high three–way catalytic converter temperature.  If the engine becomes difficult to start or stalls frequently, take your vehicle in for a check–up as soon as possible. Remember, your authorized Toyota CNG dealer knows your vehicle and its three–way catalytic converter system best.  To ensure that the three–way catalytic converter and the entire emission control system operate properly, your vehicle must receive the periodic inspections required by the Toyota Maintenance Schedule. For scheduled maintenance information, refer to the separate “Owner’s Manual Supplement”. Engine exhaust cautions cxcv ’99camry CNG Facts about engine oil consumption CAUTION
Avoid inhaling the engine exhaust. It contains carbon monoxide, which is a colorless and odorless gas. It can cause unconsciousness or even death.
Make sure the exhaust system has no holes or loose connections. The system should be checked from time to time. If you hit something, or notice a change in the sound of the exhaust, have the system checked immediately.
Do not run the engine in a garage or enclosed area except for the time needed to drive the vehicle in or out. The exhaust gases cannot escape, making this a particularly dangerous situation.
Do not remain for a long time in a parked vehicle with the engine running. If it is unavoidable, however, do so only in an unconfined area and adjust the heating or cooling system to force outside air into the vehicle.
Keep the trunk lid closed while driving. An open or unsealed trunk lid may cause exhaust gases to be drawn into the vehicle.
To allow proper operation of your vehicle’s ventilation system, keep the inlet grilles in front of the windshield clear of snow, leaves, or other obstructions.
If you smell exhaust fumes in the vehicle, drive with the windows open and the trunk lid closed. Have the cause immediately located and corrected. FUNCTIONS OF ENGINE OIL cxcvi ’99camry CNG Engine oil has the primary functions of lubricating and cooling the inside of the engine, and plays a major role in maintaining the engine in proper working order. ENGINE OIL CONSUMPTION It is normal that an engine should consume some engine oil during normal engine operation. The causes of oil consumption in a normal engine are as follows.
Oil is used to lubricate pistons, piston rings and cylinders. A thin film of oil is left on the cylinder wall when a piston moves downwards in the cylinder. High negative pressure generated when the vehicle is decelerating sucks some of this oil into the combustion chamber. This oil as well as some part of the oil film left on the cylinder wall is burned by the high temperature combustion gases during the combustion process.
Oil is also used to lubricate the stems of the intake valves. Some of this oil is sucked into the combustion chamber together with the intake air and is burned along with the fuel. High temperature exhaust gases also burn the oil used to lubricate the exhaust valve stems. The amount of engine oil consumed depends on the viscosity of the oil, the quality of the oil and the conditions the vehicle is driven under. More oil is consumed by high–speed driving and frequent acceleration and deceleration. A new engine consumes more oil, since its pistons, piston rings and cylinder walls have not become conditioned. When judging the amount of oil consumption, note that the oil may become diluted and make it difficult to judge the true level accurately. As an example, if a vehicle is used for repeated short trips, and consumes a normal amount of oil, the dipstick may not show any drop in the oil level at all, even after 1000 km (600 miles) or more. This is because the oil is gradually cxcvii ’99camry CNG Twin ground electrode becoming diluted with fuel or moisture, platinum–tipped spark plugs making it appear that the oil level has not changed. The diluting ingredients evaporate out when the vehicle is then driven at high speeds, as on an express way, making it appear that oil is excessively consumed after driving at high speeds. IMPORTANCE OF ENGINE OIL LEVEL CHECK One of the most important points in proper vehicle maintenance is to keep the engine oil at the optimum level so that oil function will not be impaired. Therefore, it is essential that the oil level be checked regularly. Toyota recommends that the oil level be checked every time you refuel the vehicle. NOTICE Failure to check the oil level regularly could lead to serious engine trouble due to insufficient oil. For detailed information on oil level check, see “Checking the engine oil level” in Chapter 7–2. cxcviii ’99camry CNG Your engine is fitted with twin ground electrode platinum–tipped spark plugs. NOTICE For your engine performance, use only twin ground electrode platinum–tipped spark plugs specially designed for CNG vehicles. Spark plugs for gasoline– engined vehicles cannot be used for your vehicle. Brake system TANDEM MASTER CYLINDER BRAKE SYSTEM The tandem master cylinder brake system is a hydraulic system with two separate sub–systems. If either sub–system should fail, the other will still work. However, the pedal will be harder to press, and your stopping distance will be longer. Also, the brake system warning light may come on. cxcix ’99camry CNG CAUTION Do not drive your vehicle with only a single brake system. Have your brakes fixed immediately. BRAKE BOOSTER The brake booster uses engine vacuum to power–assist the brakes. If the engine should quit while you are driving, you can bring the vehicle to a stop with normal pedal pressure. There is enough reserved vacuum for one or two stops—but no more! CAUTION
Do not pump the brake pedal if the engine stalls. Each push on the pedal uses up your reserved vacuum.
Even if the power assist is completely lost, the brakes will still work. But you will have to push the pedal hard—much harder than normal. And your braking distance will be longer. ANTI–LOCK BRAKE SYSTEM The anti–lock brake system is designed to automatically help prevent lock–up of the wheels during sudden braking or braking on slippery road surfaces. This assists in providing directional stability and steering performance of the vehicle under these circumstances. The anti–lock brake system becomes operative after the vehicle has accelerated to a speed in excess of approximately 10 km/h (6 mph). It stops operating when the vehicle decelerate to a speed below approximately 5 km/h (3 mph). cc ’99camry CNG You may hear a sound in the engine compartment for a few seconds when the engine is started or just after the vehicle is started. This means that the anti–lock brake system is in the self check mode, and does not indicate a malfunction. Effective way to press the “ABS” brake pedal: When the anti–lock brake system function is in action, you may feel the brake pedal pulsating and hear a noise. In this situation, to let the anti–lock brake system work for you, just hold the brake pedal down more firmly. Do not pump the brake in a panic stop. Pumping the brake pedal makes the stopping distance longer. The brake pedal pulsation caused by the anti–lock brake system may indicate hazardous road surface conditions. Although the anti–lock brake system assists in providing vehicle control, it is still important to drive with all due care, because the anti–lock brake system cannot overcome the laws of physics that act on your vehicle:
Braking capability is dependent on tire friction with the road surface.
Even though the anti–lock brake system is operating, a driver cannot maintain full control on certain slippery road surfaces, when cornering at high speeds, or in violent maneuvers.
Avoid high speeds on wet roads. The anti–lock brake system cannot eliminate the risk of hydroplaning and loss of tire friction. Always maintain a safe distance from the vehicle in front of you. Compared with vehicles not fitted with an anti–lock brake system, your vehicle may require a longer stopping distance in the following cases:
Driving on rough, gravel or snow–covered roads.
Driving with tire chains installed. cci ’99camry CNG
Driving on roads where the road surface is pitted or has other differences in surface height. “ABS” warning light The light comes on when the ignition key is turned to the “ON” position. After a few seconds, the light will go off. If either of the following conditions occurs, this indicates a malfunction somewhere in the parts monitored by the warning light system. Contact your authorized Toyota CNG dealer as soon as possible to service the vehicle.
The light does not come on as described above, or remains on.
The light comes on while driving. Even if the anti–lock brake system should fail, the brake system will still operate conventionally. However, when the “ABS” warning light is on (and the brake system warning light is off), the anti–lock brake system is not assisting brake performance ccii ’99camry CNG so that the wheels can lock–up during sudden braking or braking on slippery road surfaces. Have your vehicle checked by your authorized Toyota CNG dealer as soon as possible. Brake pad wear limit indicators The brake pad wear limit indicators on your disc brakes give a warning noise when the brake pads are worn to where replacement is required. If you hear a squealing or scraping noise while driving, have the brake pads checked and replaced by your authorized Toyota CNG dealer as soon as possible. Expensive rotor damage can result if the pads are not replaced when necessary. Luggage stowage precautions When stowing luggage or cargo in the vehicle, observe the following:
Put luggage or cargo in the trunk when at all possible. Be sure all items are secured in place.
Be careful to keep the vehicle balanced. Locating the weight as far forward as possible helps maintain balance. cciii ’99camry CNG Your Toyota’s identification—
For better fuel economy, do not carry unneeded weight. —CNG identification CAUTION
Do not place anything on the filler panel behind the rear seatback. Such items may be thrown about and possibly injure people in the vehicle during sudden braking or an accident.
Do not drive with objects left on top of the instrument panel. They may interfere with the driver’s field of view. Or they may move during sharp vehicle acceleration or turning, and impair the driver’s control of the vehicle. In an accident they may injure the vehicle occupants. NOTICE  Ensure that all luggage placed in the trunk is secure. Extra care should be taken with heavy items and items with protrusions as they may get beyond the partition to the tank and damage the tank or fuel system components.  Do not load the vehicle beyond the vehicle capacity weight specified in Part 8. cciv ’99camry CNG —Vehicle identification number A special label is pasted close to the license plate on a CNG vehicle. Do not remove this label. ccv ’99camry CNG The vehicle identification number (VIN) is the legal identifier for your vehicle. This number is on the left top of the instrument panel, and can be seen through the windshield from outside. This is the primary identification number for your Toyota. It is used in registering the ownership of your vehicle. The vehicle identification number (VIN) is also on the Certification Label. —Engine number ccvi ’99camry CNG The engine number is stamped on the engine block as shown. Theft prevention labels Your new vehicle carries theft prevention labels which are approximately 56 mm (2.20 in.) by 16 mm (0.63 in.). The purpose of these labels is to reduce the incidence of vehicle thefts by facilitating the tracing and recovery of parts from stolen vehicles. The label is designed so that once it is applied to a surface, any attempt to remove it will result in destroying the integrity of the label. Transferring these labels intact from one part to another, will be impossible. NOTICE You should not attempt to remove the theft prevention labels as it may violate certain state or federal laws. Suspension and chassis ccvii ’99camry CNG CAUTION Do not modify the suspension/chassis with lift kits, spacers, springs, etc. It can cause dangerous vehicle handling characteristics, resulting in loss of control. Types of tires Determine what kind of tires your vehicle is originally equipped with. 1. Summer tires Summer tires are high–speed capability tires best suited to highway driving under dry conditions. Since summer tires do not have the same traction performance as snow tires, summer tires are inadequate for driving on snow–covered or icy roads. For driving on snow–covered or icy roads, we recommend using snow tires. If installing snow tires, be sure to replace all four tires. 2. All season tires All season tires are designed to provide better traction in snow and to be adequate for driving in most winter conditions, as well as for use all year round. All season tires, however, do not have adequate traction performance compared with snow tires in heavy or loose snow. Also, all season tires fall short in acceleration and handling performance compared with summer tires in highway driving. ccviii ’99camry CNG CAUTION
Do not mix summer and all season tires on your vehicle as this can cause dangerous handling characteristics, resulting in loss of control.
Do not use tires other than the manufacturer’s designated tires, and never mix tires or wheels of the sizes different from the originally equipped tires and wheels. ccix ’99camry CNG ccx ’99camry CNG How to start the engine— (a) Before Part 3 cranking STARTING AND DRIVING
Before starting the engine
How to start the engine
Tips for driving in various conditions
Winter driving tips
Trailer towing
How to save fuel and make your vehicle last longer, too Before starting the engine 1. Check the area around the vehicle before entering it. 2. Adjust seat position, seatback angle, head restraint height and steering wheel angle. 3. Adjust inside and outside rear view mirrors. 4. Lock all doors. 5. Fasten seat belts. 1. Apply the parking brake firmly. 2. Turn off unnecessary lights and accessories. ccxi ’99camry CNG 3. Put the selector lever in “P”. If you need to restart the engine while the vehicle is moving, put the selector lever in “N”. A starter safety device will prevent the starter from operating if the selector lever is in any drive position. 4. Depress the brake pedal and hold it to the floor until driving off. (b) Starting the engine Before starting the engine, be sure to follow the instructions in “(a) Before cranking”. Normal starting procedure The multiport fuel injection system/sequential multiport fuel injection system in your engine automatically controls the proper air–fuel mixture for starting. You can start a cold or hot engine as follows: 1. With your foot off the accelerator pedal, turn the key to “ON” and hold it there for a few seconds so that the fuel flows to the engine. Then crank the engine by turning the key to “START”. Release it when the engine starts. You will hear a click noise coming from the fuel tank, but this is normal. 2. After the engine runs for about 10 seconds, you are ready to drive. If the weather is below freezing, let the engine warm up for a few minutes before driving. If the engine stalls... Simply restart it, using the correct procedure given in normal starting. If the engine will not start... See “If your vehicle will not start” in Part 4. ccxii ’99camry CNG Tips for driving in various conditions NOTICE  Do not crank for more than 30 seconds at a time. This may overheat the starter and wiring systems.  Do not race a cold engine.  If the engine becomes difficult to start or stalls frequently, have the engine checked immediately.
Always slow down in gusty crosswinds. This will allow you much better control.
Drive slowly onto curbs and, if possible, at a right angle. Avoid driving onto high, sharp–edged objects and other road hazards. Failure to do so can lead to severe tire damage resulting in tire bursts.
When parking on a hill, turn the front wheels until they touch the curb so that the vehicle will not roll. Apply the parking brake, and place the transmission in “P”. If necessary, block the wheels.
Washing your vehicle or driving through deep water may get the brakes wet. To see whether they are wet, check that there is no traffic near you, and then press the pedal lightly. If you do not feel a normal braking force, the brakes are probably wet. To dry them, drive the vehicle cautiously while lightly pressing the brake pedal with the parking brake applied. If they still do not work safely, pull to the side of the road and call your authorized Toyota CNG dealer for assistance. ccxiii ’99camry CNG CAUTION
Before driving off, make sure that the parking brake is fully released and the parking brake reminder light is off.
Do not leave your vehicle unattended while the engine is running.
Do not rest your foot on the brake pedal while driving. It can cause dangerous overheating, needless wear, and poor fuel economy.
To drive down a long or steep hill, reduce your speed and downshift. Remember, if you ride the brakes excessively, they may overheat and not work properly.
Be careful when accelerating, upshifting, downshifting or braking on a slippery surface. Sudden acceleration or engine braking could cause the vehicle to spin or skid.
Do not drive in excess of the speed limit. Even if the legal speed limit permits it, do not drive over 140 km/h (85 mph) unless your vehicle has high–speed capability tires. Driving over 140 km/h (85 mph) may result in tire failure, loss of control and possible injury. Be sure to consult a tire dealer to determine whether the tires on your vehicle are high–speed capability tires or not before driving at such speeds.
Do not continue normal driving when the brakes are wet. If they are wet, your vehicle will require a longer stopping distance, and it may pull to one side when the brakes are applied. Also, the parking brake will not hold the vehicle securely. Winter driving tips ccxiv ’99camry CNG Make sure you have a proper freeze protection of engine coolant. Your coolant must contain ethylene–glycol type coolant for a proper corrosion protection of aluminum components. Use “TOYOTA Long Life Coolant” or equivalent. See Chapter 7–2 for details about coolant type selection. NOTICE Do not use alcohol type antifreeze or plain water alone. When it is extremely cold, we recommend to use 60% solution for your Toyota, to provide protection down to about –50°C (–58°F). Do not use more than 70% solution for better coolant performance. Check the condition of the battery and cables. Cold temperatures reduce the capacity of any battery, so it must be in top shape to provide enough power for winter starting. Chapter 7–3 tells you how to visually inspect the battery. Your authorized Toyota CNG dealer and most service stations will be pleased to check the level of charge. Make sure the engine oil viscosity is suitable for the cold weather. See Chapter 7–2 for recommended viscosity. Leaving a heavy summer oil in your vehicle during winter months may cause harder starting. If you are not sure about which oil to use, call your authorized Toyota CNG dealer—he will be pleased to help. Keep the door locks from freezing. Squirt lock de–icer or glycerine into the locks to keep them from freezing. To open a frozen look, try heating the key before inserting it. Use a washer fluid containing an antifreeze solution. ccxv ’99camry CNG This product is available at your authorized Toyota CNG dealer and most auto parts stores. Follow the manufacturer’s directions for how much to mix with water. NOTICE Do not use engine antifreeze or any other substitute because it may damage your vehicle’s paint. Do not use your parking brake when there is a possibility it could freeze. When parking, put the transmission into “P” and block the rear wheels. Do not use the parking brake, or snow or water accumulated in and around the parking brake mechanism may freeze, making it hard to release. Keep ice and snow from accumulating under the fenders. Ice and snow built up under your fenders can make steering difficult. During bad winter driving, stop and check under the fenders occasionally. Depending on where you are driving, we recommend you carry some emergency equipment. Some of the things you might put in the vehicle are tire chains, window scraper, bag of sand or salt, flares, small shovel, jumper cables, etc. Trailer towing Your vehicle is designed primarily as a passenger–carrying vehicle. Towing a trailer will have an adverse effect on handling, performance, braking, durability and driving economy (fuel consumption, etc.). Your safety and satisfaction depend on the proper use of correct equipment and cautious driving habits. For your safety and the safety of others, you must not overload your vehicle or trailer. Toyota warranties do not apply to damage or malfunction caused by towing a trailer for commercial purposes. Ask your authorized Toyota CNG dealer for further details before towing. WEIGHT LIMITS ccxvi ’99camry CNG Before towing, make sure the total trailer weight, gross vehicle weight, gross axle weight and trailer tongue load are all within the limits. The total trailer weight and tongue load can be measured with platform scales found at a highway weighing station, building supply company, trucking company, junk yard, etc. CAUTION
The total trailer weight (trailer weight plus its cargo load) must not exceed 907 kg (2000 lb.). Exceeding this weight is dangerous. ccxvii ’99camry CNG
Trailer hitch assemblies have different weight capacities established by the hitch manufacturer. Even though the vehicle may be physically capable of towing a higher weight, the operator must determine the maximum weight rating of the particular hitch assembly and never exceed the maximum weight rating specified for the trailer–hitch. Exceeding the maximum weight rating set by the trailer hitch manufacturer can cause an accident resulting in serious personal injuries.
The gross vehicle weight must not exceed the Gross Vehicle Weight Rating (GVWR) indicated on the Certification Label. The gross vehicle weight is the sum of weights of the unloaded vehicle, driver, passengers, luggage, hitch and trailer tongue load. It also includes the weight of any special equipment installed on your vehicle.
The load on either the front or rear axle resulting from distribution of the gross vehicle weight on both axles must not exceed the Gross Axle Weight Rating (GAWR) listed on the Certification Label. ccxviii ’99camry CNG Total trailer weight Tongue load Total trailer weight Tongue load
100 = 9 to 11%
The trailer cargo load should be distributed so that the tongue load is 9 to 11% of the total trailer weight, not exceeding the maximum of 90 kg (200 lb.). Never load the trailer with more weight in the back than in the front. About 60% of the trailer load should be in the front half of the trailer and the remaining 40% in the rear. HITCHES
Use only a hitch which is recommended by the hitch manufacturer and conforms to the total trailer weight requirement.
Follow the directions supplied by the hitch manufacturer. Lubricate the hitch ball with a light coat of grease.
Toyota recommends removing the trailer hitch whenever you are not towing a trailer to reduce the possibility of additional damage caused by the hitch if your vehicle is struck from behind. ccxix ’99camry CNG NOTICE Do not use axle–mounted hitches as they can cause damage to the axle housing, wheel bearings, wheels or tires. Also, never install a hitch which may interfere with the normal function of an Energy Absorbing Bumper, if so equipped. BRAKES AND SAFETY CHAINS
Toyota recommends trailers with brakes that conform to any applicable federal and state/provincial regulations.
A safety chain must always be used between the towing vehicle and the trailer. Leave sufficient slack in the chain for turns. The chain should cross under the trailer tongue to prevent the tongue from dropping to the ground in case it becomes damaged or separated. For correct safety chain procedures, follow the hitch or trailer manufacturer’s recommendations. CAUTION
If the total trailer weight exceeds 453 kg (1000 lb.), trailer brakes are required.
Never tap into your vehicle’s hydraulic system as it would lower its braking effectiveness.
Never tow a trailer without using a safety chain securely attached to both the trailer and the vehicle. If damage occurs to the coupling unit or hitch ball, there is danger of the trailer wandering over into another lane. TIRES ccxx ’99camry CNG
Ensure that your vehicle’s tires are properly inflated. Adjust the tire pressure to the recommended cold tire pressure indicated below (See Chapter 7–2 for instructions.): Tire pressure, kPa (kgf/cm2 or bar, psi) 220 (2.2, 32)
The trailer tires should be inflated to the pressure recommended by the trailer manufacturer in respect to the total trailer weight. TRAILER LIGHTS
Trailer lights must comply with federal, state/provincial and local regulations. See your local recreational vehicle dealer or rental agency for the correct type of wiring and relays for your trailer. Check for correct operation of the turn signals and stop lights each time you hitch up. Direct splicing may damage your vehicle’s electrical system and cause a malfunction of your lights. BREAK–IN SCHEDULE
Toyota recommends that you do not tow a trailer with a new vehicle or a vehicle with any new power train component (engine, transmission, differential, wheel bearing, etc.) for the first 800 km (500 miles) of driving. MAINTENANCE
If you tow a trailer, your vehicle will require more frequent maintenance due to the additional load. For this information, please refer to maintenance information in the “Owner’s Manual Supplement”. the scheduled
Retighten all fixing bolts of the towing ball and bracket after approximately 1000 km (600 miles) of trailer driving. PRE–TOWING SAFETY CHECK ccxxi ’99camry CNG
Check that your vehicle remains level when a loaded or unloaded trailer is hitched. Do not drive if the vehicle has an abnormal nose–up or nose–down condition, and check for improper tongue load, overload,worn suspension or other possible causes.
Make sure the trailer cargo is securely loaded so that it can not shift.
Check that your rear view mirrors conform to any applicable federal, state/provincial or local regulation. If not, install the rear view mirrors required for towing purpose. TRAILER TOWING TIPS When towing a trailer, your vehicle will handle differently than when not towing. The three main causes of vehicle–trailer accidents are driver error, excessive speed and improper trailer loading. Keep these in mind when towing:
Before starting out, check operation of the lights and all vehicle–trailer connections. After driving a short distance, stop and recheck the lights and connections. Before actually towing a trailer, practice turning, stopping and backing with a trailer in an area away from traffic until you learn the feel.
Backing with a trailer is difficult and requires practice. Grip the bottom of the steering wheel and move your hand to the left to move the trailer to the left. Move your hand to the right to move the trailer to the right. (This procedure is generally opposite to that when backing without a trailer). Also, just turn the steering wheel a little at a time, avoiding sharp or prolonged turning. Have someone guide you when backing to reduce the risk of an accident.
Because stopping distance may be increased, vehicle–to–vehicle distance should be increased when towing a trailer. For each 16 km/h (10 mph) of speed, allow at least one vehicle and trailer length between you and the vehicle ahead. Avoid sudden braking as you may skid, resulting in jackknifing and loss of control. This is especially true on wet or slippery surfaces. ccxxii ’99camry CNG
Avoid jerky starts or sudden acceleration. If your vehicle has a manual transmission, prevent excessive clutch slippage by keeping engine rpm low and not racing the engine. Always start out in first gear.
Avoid jerky steering and sharp turns. The trailer could hit your vehicle in a tight turn. Slow down before making a turn to avoid the necessity of sudden braking.
Remember that when making a turn, the trailer wheels will be closer than the vehicle wheels to the inside of the turn. Therefore, compensate for this by making a larger than normal turning radius with your vehicle.
Crosswinds and rough roads will adversely affect handling of your vehicle and trailer, causing sway. Pay attention to the rear from time to time to prepare yourself for being passed by large trucks or buses, which may cause your vehicle and trailer to sway. If swaying happens, firmly grip the steering wheel and reduce speed immediately but gradually. Never increase speed. Steer straight ahead. If you make no extreme correction with the steering or brakes, the vehicle and trailer will stabilize.
Be careful when passing other vehicles. Passing requires considerable distance. After passing a vehicle, do not forget the length of your trailer and be sure you have plenty of room before changing lanes.
In order to maintain engine braking efficiency do not use overdrive.
Because of the added load of the trailer, your vehicle’s engine may overheat on hot days (at temperatures over 30C [85F]) when going up a long or steep grade with a trailer. If the engine coolant temperature gauge indicates overheating, immediately turn off the air conditioning (if in use), pull off the road and stop in a safe spot. Refer to “If your vehicle overheats” in Part 4 of this manual. ccxxiii ’99camry CNG
Always place wheel blocks under both the vehicle and trailer wheels when parking. Apply the parking brake firmly. Put the transmission in “P”. Avoid parking on a slope with a trailer, but if it cannot be avoided, do so only after performing the following: 1. Apply the brakes and hold. 2. Have someone place wheel blocks under both the vehicle and trailer wheels. 3. When the wheel blocks are in place, release your brakes slowly until the blocks absorb the load. 4. Apply the parking brake firmly. 5. Shift into “P” and turn off the engine. When restarting out after parking on a slope: 1. With the transmission in “P” position, start the engine. (Be sure to keep the brake pedal depressed.) 2. Shift into gear. 3. Release the parking brake (also foot brake on automatic transmission vehicles) and slowly pull or back away from the wheel blocks. Stop and apply your brakes. 4. Have someone retrieve the blocks. ccxxiv ’99camry CNG How to save fuel and make your vehicle last longer, too CAUTION
Do not exceed 72 km/h (45 mph) or the posted towing speed limit,whichever is lower. Because instability (swaying) of a towing vehicle–trailer combination usually increases as the speed increases,exceeding 72 km/h (45 mph) may cause loss of control.
Slow down and downshift before descending steep or long downhill grades. Do not make sudden downshifts.
Avoid holding the brake pedal down too long or too frequently. This could cause the brakes to overheat and result in reduced braking efficiency. Getting more kilometers/mileage from a liter/gallon of fuel is easy—just take it easy. It will help make your vehicle last longer, too. Here are some specific tips on how to save money on both fuel and repairs:
Keep your tires inflated at the correct pressure. Underinflation causes tire wear and wastes fuel. See Chapter 7–2 for instructions.
Do not carry unneeded weight in your vehicle. Excess weight puts a heavier load on the engine, causing greater fuel consumption.
Avoid lengthy warm–up idling. Once the engine is running smoothly, begin driving—but gently. Remember, however, that on cold winter days this may take a little longer.
Accelerate slowly and smoothly. Avoid jackrabbit starts. Get into high gear as quickly as possible.
Avoid long engine idling. If you have a long wait and you are not in traffic, it is better to turn off the engine and start again later. ccxxv ’99camry CNG
Avoid engine lug or overrevving. Use a gear position suitable for the road on which you are travelling.
Avoid continuous speeding up and slowing down. Stop–and–go driving wastes fuel.
Avoid unnecessary stopping and braking. Maintain a steady pace. Try to time the traffic signals so you only need to stop as little as possible or take advantage of through streets to avoid traffic lights. Keep a proper distance from other vehicles to avoid sudden braking. This will also reduce wear on your brakes.
Avoid heavy traffic or traffic jams whenever possible.
Do not rest your foot on the brake pedal. This causes needless wear, overheating and poor fuel economy.
Maintain a moderate speed on highways. The faster you drive,the greater the fuel consumption. By reducing your speed, you will cut down on fuel consumption.
Keep the front wheels in proper alignment. Avoid hitting the curb and slow down on rough roads. Improper alignment not only causes faster tire wear but also puts an extra load on the engine, which, in turn, wastes fuel.
Keep the bottom of your vehicle free from mud, etc. This not only lessens weight but also helps prevent corrosion.
Keep your vehicle tuned–up and in top shape. A dirty air cleaner, improper valve clearance, dirty plugs, dirty oil and grease,brakes not adjusted, etc. all lower engine performance and contribute to poor fuel economy. For longer life of all parts and lower operating costs, keep all maintenance work on schedule, and if you often drive under severe conditions, see that your vehicle receives more frequent maintenance (For scheduled maintenance information, please refer to the separate “Owner’s Manual Supplement”. ccxxvi ’99camry CNG CAUTION Never turn off the engine to coast down hills. Your power steering and brake booster will not function without the engine running. Also, the emission control system operates properly only when the engine is running. ccxxvii ’99camry CNG If your vehicle will not start— (a) Simple Part 4 checks IN CASE OF AN EMERGENCY
If your vehicle will not start
If your engine stalls while driving
If your vehicle overheats
If you have a flat tire
If your vehicle needs to be towed
If you cannot shift automatic transmission selector lever
If you lose your keys
If you suspect the fuel is leaking Before making these checks, make sure you have followed the correct starting procedure given in “How to start the engine” in Part 3 and that you have sufficient fuel. If the engine is not turning over or is turning over too slowly— 1. Check that the battery terminals are tight and clean. 2. If the battery terminals are O.K., switch on the interior light. ccxxviii ’99camry CNG 3. If the light is out, dim or goes out when the starter is cranked, the battery is discharged. You may try jump starting. See “(c) Jump starting” for further instructions. If the light is O.K., but the engine still will not start, it needs adjustment or repair. Call your authorized Toyota CNG dealer or a qualified repair shop. NOTICE Do not pull– or push–start the vehicle. It may damage the vehicle or cause a collision when the engine starts. Also the three–way catalytic converter may overheat and become a fire hazard. If the engine turns over at its normal speed but will not start— 1. Check that all the push–on connectors are tight. (For example, connectors at the spark plugs, ignition coil and/or distributor) 2. If the connectors are O.K., the engine may be flooded because of repeated cranking. See “(b) Starting a flooded engine” for further instructions. 3. If the engine still does not start, manual shut–off valve may be closed. Open the manual shut–off valve. (See “If you suspect the fuel is leaking” in this chapter.) (b) Starting a flooded engine If the engine will not start, your engine may be flooded because of repeated cranking. If this happens, turn the key to “START” with the accelerator pedal held down. Keep the key and accelerator pedal so for 15 seconds and release them. Then try starting the engine with your foot off the accelerator pedal. If the engine does not start after 30 seconds of cranking, release the key, wait a few minutes and try again. ccxxix ’99camry CNG If the engine still will not start, it needs adjustment or repair. Call your authorized Toyota CNG dealer or a qualified repair shop for assistance. NOTICE Do not crank for more than 30 seconds at a time. This may overheat the starter and wiring systems. (c) Jump starting To avoid serious personal injury and damage to your vehicle which might result from battery explosion, acid burns, electrical burns, or damaged electronic components, these instructions must be followed precisely. If you are unsure about how to follow this procedure, we strongly recommend that you seek the help of a competent mechanic or towing service. CAUTION
Batteries contain sulfuric acid which is poisonous and corrosive. Wear protective safety glasses when jump starting, and avoid spilling acid on your skin, clothing, or vehicle.
If you should accidentally get acid on yourself or in your eyes, remove any contaminated clothing and flush the affected area with water immediately. Then get immediate medical attention. If possible, continue to apply water with a sponge or cloth while enroute to the medical office.
The gas normally produced by a battery will explode if a flame or spark is brought near. Use only standardised jumper cables and do not smoke or light a match while jump starting. ccxxx ’99camry CNG NOTICE The battery used for boosting must be 12 V. Do not jump start unless you are sure that the booster battery is correct. JUMP STARTING PROCEDURE 1. If the booster battery is installed in another vehicle, make sure the vehicles are not touching. Turn off all unnecessary lights and accessories. 2. If required, remove all the vent plugs from the booster and discharged batteries. Lay a cloth over the open vents on the batteries. (This helps reduce the explosion hazard, personal injuries and burns.) 3. If the engine in the vehicle with the booster battery is not running, start it and let it run for a few minutes. During jump starting run the engine at about 2000 rpm with the accelerator pedal lightly depressed. Discharged battery Booster battery Positive Jumper terminal (“+” mark) cable Positive terminal (“+” mark) ccxxxi ’99camry CNG 4. Make the cable connections in the order a, b, c, d. a. Connect the clamp of the positive (red) jumper cable to the positive ( ) terminal on the discharged battery. b. Connect the clamp at the other end of the positive (red) jumper cable to the positive ( ) terminal on the booster battery. Jumper cable Discharged battery Negative terminal (“–” mark) Booster battery c. Connect the clamp of the negative (black) jumper cable to the negative ( ) terminal on the booster battery. d. Connect the clamp at the other end of the negative (black) jumper cable to a solid, stationary, unpainted, metallic point of the vehicle with the discharged battery. The recommended connecting point is shown in the following illustration: ccxxxii ’99camry CNG Connecting point Do not connect it to or near any part that moves when the engine is cranked. CAUTION When making the connections, to avoid serious injury, do not lean over the battery or accidentally let the jumper cables or clamps touch anything except the correct battery terminals or the ground. 5. Start your engine in the normal way. After starting, run it at about 2000 rpm for several minutes with the accelerator pedal lightly depressed. 6. Carefully disconnect the cables in the exact reverse order: the negative cable and then the positive cable. 7. Carefully dispose of the battery cover cloths—they may now contain sulfuric acid. ccxxxiii ’99camry CNG If your engine stalls while 8. removed, replace all the battery vent plugs. If Ifyour vehicle overheats driving If the cause of your battery discharging is not apparent (for example, lights left on), you should have it checked. If your engine stalls while driving... 1. Reduce your speed gradually, keeping a straight line. Move cautiously off the road to a safe place. 2. Turn on your emergency flashers. 3. Move the ignition key back to “ACC” or “LOCK”, then try starting the engine again. If the engine will not start, see “If your vehicle will not start”. CAUTION If the engine is not running, the power assist for the brakes and steering will not work so steering and braking will be much harder than usual. If your engine coolant temperature gauge indicates overheating, if you experience a loss of power, or if you hear a loud knocking or pinging noise, the engine has probably overheated. You should follow this procedure... 1. Pull safely off the road, stop the vehicle and turn on your emergency flashers. Put the transmission in “P” and apply the parking brake. Turn off the air conditioning if it is being used. 2. If coolant or steam is boiling out of the radiator or reservoir, stop the engine. Wait until the steam subsides before opening the hood. If there is no coolant boiling over or steam, leave the engine running and make sure the electric cooling fan is operating. If it is not, turn the ignition off. ccxxxiv ’99camry CNG CAUTION To help avoid personal injury, keep the hood closed until there is no steam. Escaping steam or coolant is a sign of very high pressure. 3. Look for obvious coolant leaks from the radiator, hoses,and under the vehicle. However, note that water draining from the air conditioning is normal if it has been used. CAUTION When the engine is running, keep hands and clothing away from the moving fan and engine drive belts. 4. If the coolant is leaking, stop the engine immediately. Call your authorized Toyota CNG dealer for assistance. 5. If there are no obvious leaks, check the coolant reservoir. If it is dry, add coolant to the reservoir while the engine is running. Fill it about half full. CAUTION Do not attempt to remove the radiator cap when the engine and radiator are hot. Serious injury could result from scalding hot fluid and steam blown out under pressure. ccxxxv ’99camry CNG 6. After the engine coolant temperature has cooled to normal, again check the coolant level in the reservoir. If necessary, bring it up to half full again. Serious coolant loss indicates a leak in the system. You should have it checked as soon as possible at your authorized Toyota CNG dealer. If you have a flat tire— 1. Reduce your speed gradually, keeping a straight line. Move cautiously off the road to a safe place well away from the traffic. Avoid stopping on the center divider of a highway. Park on a level spot with firm ground. 2. Stop the engine and turn on your emergency flashers. 3. Firmly set the parking brake and put the transmission in “P”. 4. Have everyone get out of the vehicle on the side away from traffic. 5. Read the following instructions thoroughly. CAUTION When jacking, be sure to observe the following to reduce the possibility of personal injury:
Follow jacking instructions.
Do not put any part of your body under the vehicle supported by the jack. Personal injury may occur.
Do not start or run the engine while your vehicle is supported by the jack. ccxxxvi ’99camry CNG
Stop the vehicle on a level firm ground, firmly set the parking brake and put the transmission in “P”. Block the wheel diagonally opposite to the one being changed if necessary.
Make sure to set the jack properly in the jack point. Raising the vehicle with jack improperly positioned will damage the vehicle or may allow the vehicle to fall off the jack and cause personal injury.
Never get under the vehicle when the vehicle is supported by the jack alone.
Use the jack only for lifting your vehicle during wheel changing.
Do not raise the vehicle with someone in the vehicle.
When raising the vehicle, do not put an object on or under the jack.
Raise the vehicle only high enough to remove and change the tire. NOTICE Do not continue driving with a deflated tire. Driving even a short distance can damage a tire beyond repair. ccxxxvii ’99camry CNG Compact spare tire The compact spare tire is designed for temporary emergency use only. The compact spare tire is identified by the distinctive wheel design and color and special wording “TEMPORARY USE ONLY” molded into the side wall of the tire. The standard tire should be repaired and replaced as soon as possible. To keep the compact spare tire noticeable, do not hide the wheel by a wheel cover or such. The compact spare tire saves space in your trunk, and its lighter weight helps to improve fuel economy and permits easier installation in case of a flat tire. The compact spare tire can be used many times, if necessary. It has tread life of up to 4800 km (3000 miles) depending on road conditions and your driving habits. When tread wear indicators appear on the tire, replace the tire. See also the tire section in Chapter 7–2 for details on the tread wear indicators and other service information. ccxxxviii ’99camry CNG —Required tools and spare tire CAUTION
The compact spare tire was designed especially for your Toyota. Do not use it on any other vehicle.
Do not exceed 80 km/h (50 mph) when driving with the compact spare tire.
Avoid sudden acceleration, sudden deceleration and sharp turns with the compact spare tire. NOTICE Your ground clearance is reduced when the compact spare tire is installed so avoid driving over obstacles and drive slowly on rough, unpaved roads and speed bumps. Also, do not attempt to go through an automatic car wash as the vehicle may get caught, resulting in damage. ccxxxix ’99camry CNG 1. Get the required tools and spare tire. 1. 2. 3. 4. Wheel nut wrench Jack handle Jack Spare tire To prepare yourself for an emergency, you should familiarize yourself with the use of the jack, each of the tools and their storage locations. ccxl ’99camry CNG Turn the jack joint by hand. To remove: Turn the joint in direction 1 until the jack is free. To store: Turn the joint in direction 2 until the jack is firmly secured to prevent it flying forward during a collision or sudden braking. ccxli ’99camry CNG To remove the spare tire: 1. Remove the spare tire cover. 2. Loosen the bolt and remove it. 3. Remove the spacer. Then take the spare tire out of the vehicle. When storing the spare tire, put it in place with the outer side of the wheel facing up. Then secure the tire by repeating the above removal steps in reverse order to prevent it from flying forward during a collision or sudden braking. —Blocking the wheel ccxlii ’99camry CNG 2. Block the wheel diagonally opposite the flat tire to keep the vehicle from rolling when it is jacked up. When blocking the wheel, place a wheel block from the front for the front wheels or from the rear for the rear wheels. —Removing wheel ornament ccxliii ’99camry CNG 3. Remove the wheel ornament. Pry off the wheel ornament, using the beveled end of the wheel nut wrench as shown. CAUTION Do not try to pull off the ornament by hand. Take due care in handling the ornament to avoid unexpected personal injury. —Loosening wheel nuts ccxliv ’99camry CNG 4. Loosen all the wheel nuts. Always loosen the wheel nuts before raising the vehicle. The nuts turn counterclockwise to loosen. To get maximum leverage, fit the wrench to the nut so that the handle is on the right side, as shown above. Grab the wrench near the end of the handle and pull up on the handle. Be careful that the wrench does not slip off the nut. Do not remove the nuts yet—just unscrew them about one–half turn. —Positioning the jack ccxlv ’99camry CNG 5. Position the jack at the correct jack point as shown. Make sure the jack is positioned on a level and solid place. —Raising your vehicle ccxlvi ’99camry CNG 6. After making sure that no one is in the vehicle, raise it high enough so that the spare tire can be installed. Remember you will need more ground clearance when putting on the spare tire than when removing the flat tire. To raise the vehicle, insert the jack handle into the jack (it is a loose fit) and turn it clockwise. As the jack touches the vehicle and begins to lift, double–check that it is properly positioned. CAUTION Never get under the vehicle when the vehicle is supported by the jack alone. —Changing wheels 7. Remove the wheel nuts and change tires. ccxlvii ’99camry CNG Lift the flat tire straight off and put it aside. Roll the spare wheel into position and align the holes in the wheel with the bolts. Then lift up the wheel and get at least the top bolt started through its hole. Wiggle the tire and press it back over the other bolts. Before putting on wheels, remove any corrosion on the mounting surfaces with a wire brush or such. Installation of wheels without good metal–to–metal contact at the mounting surface can cause wheel nuts to loosen and eventually cause a wheel to come off while driving. Therefore after the first 1600 km (1000 miles), check to see that the wheel nuts are tight. —Reinstalling wheel nuts ccxlviii ’99camry CNG 8. Reinstall all the wheel nuts finger tight. Reinstall the wheel nuts (tapered end inward) and tighten them as much as you can by hand. Press back on the tire and see if you can tighten them more. —Lowering your vehicle ccxlix ’99camry CNG 9. Lower the vehicle completely and tighten the wheel nuts. Turn the jack handle counterclockwise to lower the vehicle. Use only the wheel nut wrench to tighten the nuts. Do not use other tools or any additional leverage other than your hands, such as a hammer, pipe or your foot. Make sure the wrench is securely engaged over the nut. Tighten each nut a little at a time in the order shown. Repeat the process until all the nuts are tight. CAUTION When lowering the vehicle, make sure all portions of your body and all other persons around will not be injured as the vehicle is lowered to the ground. —Reinstalling wheel ornament ccl ’99camry CNG 10. Reinstall the wheel ornament. 1. Put the wheel ornament into position. Align the cutout of the wheel ornament with the valve stem as shown. 2. Then tap it firmly with the side or heel of your hand to snap it into place. CAUTION Take due care in handling the ornament to avoid unexpected personal injury. —After changing wheels 11. Check the air pressure of the replaced tire. Adjust the air pressure to the specification designed in Part 8. If the pressure is lower, drive slowly to the nearest service station and fill to the correct pressure. ccli ’99camry CNG If your vehicle needs to be Do not forget to reinstall the tire inflation valve cap as dirt and moisture could get towed— into the valve core and possibly cause air leakage. If the cap is missing, have a new one put on as soon as possible. 12. Restow all the tools, jack and flat tire securely. As soon after changing wheels as possible, tighten the wheel nuts to the torque specified in Part 8 with a torque wrench and have a technician repair the flat tire. CAUTION Before driving, make sure all the tools, jack and flat tire are securely in place in their storage location to reduce the possibility of personal injury during a collision or sudden braking. cclii ’99camry CNG (a) Towing with wheel lift type truck— —From front —From rear (b) Using flat bed truck ccliii ’99camry CNG If towing is necessary, we recommend you to have it done by your authorized Toyota CNG dealer or a commercial tow truck service. In consultation with them, have your vehicle towed using either (a) or (b). Only when you cannot receive a towing service from your authorized Toyota CNG dealer or a commercial tow truck service, tow your vehicle carefully in accordance with the instructions given in “—Emergency towing” in this part. Proper equipment will help ensure that your vehicle is not damaged while being towed. Commercial operators are generally aware of the state/provincial and local laws pertaining to towing. Your vehicle can be damaged if it is towed incorrectly. Although most operators know the correct procedure, it is possible to make a mistake. To avoid damage to your vehicle, make sure the following few precautions are observed. If necessary, show this page to the tow truck driver. TOWING PRECAUTIONS: Use a safety chain system for all towing, and abide by the state/provincial and local laws. The wheels and axle on the ground must be in good condition. If they are damaged, use a towing dolly. (a) Towing with wheel lift type truck From front—Release the parking brake. NOTICE When lifting wheels, take care to ensure adequate ground clearance for towing at the opposite end of the raised vehicle. Otherwise, the bumper and/or underbody of the towed vehicle will be damaged during towing. From rear—Use a towing dolly under the front wheels. ccliv ’99camry CNG NOTICE Never tow a vehicle with an automatic transmission from the rear with the front wheels on the ground, as this may cause serious damage to the transmission. (b) Using flat bed truck (c) Towing with sling type truck (c) Towing with sling type truck NOTICE Do not tow with sling type truck, either from the front or rear. This may cause body damage. —Emergency towing cclv ’99camry CNG If towing is necessary, we recommend you to have it done by your authorized Toyota CNG dealer or a commercial tow truck service. If towing service is not available in an emergency, your vehicle may be temporarily towed by a cable or chain secured to one of the emergency towing eyelets under the vehicle. Use extreme caution when towing vehicles. A driver must be in the vehicle to steer it and operate the brakes. Towing in this manner may be done only on hard–surfaced roads for a short distance and at low speeds. Also, the wheels, axles, drive train,steering and brakes must all be in good condition. cclvi ’99camry CNG If you cannot shift automatic transmission selector lever CAUTION Use extreme caution when towing vehicles. Avoid sudden starts or erratic driving maneuvers which would place excessive stress on the emergency towing eyelets and towing cable or chain. The eyelets and towing cable or chain may break and cause serious injury or damage. NOTICE Use only a cable or chain specifically intended for use in towing vehicles. Securely fasten the cable or chain to the towing eyelets provided. Before towing, release the parking brake and put the transmission in “N”. The key must be in “ACC” (engine off) or “ON” (engine running). CAUTION If the engine is not running, the power assist for the brakes and steering will not work so steering and braking will be much harder than usual. cclvii ’99camry CNG If you cannot shift the selector lever out of “P” position to other positions even though the brake pedal is depressed, use the shift lock override button as follows: 1. Turn the ignition key to “LOCK” position. Make sure the parking brake is on. 2. Pry up the cover with a flat–bladed screwdriver or equivalent. cclviii ’99camry CNG 3. Insert your finger into the hole to push down the shift lock override button. You can shift out of “P” position only while pushing the button. 4. Shift into “N” position. 5. Insert the cover. 6. Start the engine. For your safety, keep the brake pedal depressed. Be sure to have the system checked by your authorized Toyota CNG dealer as soon as possible. If you lose your keys Your authorized Toyota CNG dealer can make a new key if you can give them the key number. See the suggestion given in “Keys” in Chapter 1–2. If your keys are locked in the vehicle and you cannot get a duplicate, your authorized Toyota CNG dealer can still open the door for you, using their special tools. If you must break a window to get in, we suggest breaking the smallest side cclix ’99camry CNG If you suspect the fuel is window because it is the least expensive to replace. Be extremely cautious to avoid leaking cuts from the glass. cclx ’99camry CNG Open Close cclxi ’99camry CNG If you smell fuel or hear the sound of leaking fuel at anytime or if your vehicle is involved in an accident, immediately close the manual shut off valve to shut the fuel off. The manual shut off valve is intended to shut the fuel from the tank off. Normally it is left open. To close: Turn the lever clockwise 90°. To open: Turn the lever counterclockwise 90°. If you suspect a fuel leakage, close the manual shut off valve and have your vehicle serviced by your authorized Toyota CNG dealer as soon as possible. If, due to a collision or similar circumstances, the fuel system may be damaged, close the manual shut off value, and contact your authorized Toyota CNG dealer to have the fuel system checked for fuel leakage. CAUTION
If you smell or hear fuel leaking, shut off the fuel system immediately. If leaking fuel is ignited, an explosion or fire could occur, causing death or serious injury.
Do not inhale a large amount of leaked fuel. Inhaling the natural gas continuously may cause the lack of oxygen in your body.
If you suspect a fuel leakage, do not park the vehicle in an enclosed area such as a garage, or the leaked fuel may fill the area and cause a fire or explosion.
If you suspect the fuel is leaking while refueling, stop refueling immediately. If leaking fuel is ignited, an explosion or fire could occur, causing death or serious injury. cclxii ’99camry CNG cclxiii ’99camry CNG Protecting your Toyota from corrosion Part 5 CORROSION PREVENTION AND APPEARANCE CARE
Protecting your Toyota from corrosion
Washing and waxing your Toyota
Cleaning the interior Toyota, through its diligent research, design and use of the most advanced technology available, has done its part to help prevent corrosion and has provided you with the finest quality vehicle construction. Now, it is up to you. Proper care of your Toyota can help ensure long–term corrosion prevention. The most common causes of corrosion to your vehicle are:
The accumulation of road salt, dirt and moisture in hard–to–reach areas under the vehicle.
Chipping of paint, or undercoating caused by minor accidents or by stones and gravel. Care is especially important if you live in particular areas or operate your vehicle under certain environmental conditions:
Road salt or dust control chemicals will accelerate corrosion, as will the presence of salt in the air near the sea–coast or in areas of industrial pollution.
High humidity accelerates corrosion especially when temperatures range just above the freezing point. cclxiv ’99camry CNG
Wetness or dampness to certain parts of your vehicle for an extended period of time, may cause corrosion even though other parts of the vehicle may be dry.
High temperatures will cause corrosion to those components of the vehicle which are prevented from quick–drying due to lack of proper ventilation. The above signifies the necessity to keep your vehicle, particularly the underside, as clean as possible and to repair any damage to paint or protective coatings as soon as possible. To help prevent corrosion on your Toyota, follow these guidelines: Wash your vehicle frequently. It is, of course, necessary to keep your vehicle clean by regular washing, but to prevent corrosion, the following points should be observed:
If you drive on salted roads in the winter or if you live near the ocean, you should hose off the undercarriage at least once a month to minimize corrosion.
High pressure water or steam is effective for cleaning the vehicle’s underside and wheel housings. Pay particular attention to these areas as it is difficult to see all the mud and dirt. It will do more harm than good to simply wet the mud and debris without removing them. The lower edge of doors, rocker panels and frame members have drain holes which should not be allowed to clog with dirt as trapped water in these areas can cause corrosion.
Wash the underside of the vehicle thoroughly when winter is over. See “Washing and waxing your Toyota” for more tips. Check the condition of your vehicle’s paint and trim. If you find any chips or scratches in the paint, touch them up immediately to prevent corrosion from starting. If the chips or scratches have gone through the bare metal, have a qualified body shop make the repair. cclxv ’99camry CNG Washing and waxing your Toyota Check the interior of your vehicle. Water and dirt can accumulate under the floor mats and could cause corrosion. Occasionally check under the mats to make sure the area is dry. Be particularly careful when transporting chemicals, cleansers, fertilizers, salt, etc.; these should be transported in proper containers. If a spill or leak should occur, immediately clean and dry the area. Use mud shields on your wheels. If you drive on salted or gravel roads, mud shields help protect your vehicle. Full–size shields, which come as near to the ground as possible, are the best. We recommend that the fittings and the area where the shields are installed be treated to resist corrosion. Your authorized Toyota CNG dealer will be happy to assist in supplying and installing the shields if they are recommended for your area. Keep your vehicle in a well ventilated garage or a roofed place. Do not park your vehicle in a damp, poorly ventilated garage. If you wash your vehicle in the garage, or if you drive it in covered with water or snow, your garage may be so damp it will cause corrosion. Even if your garage is heated, a wet vehicle can corrode if the ventilation is poor. Washing your Toyota Keep your vehicle clean by regular washing. The following cases may cause weakness to the paint or corrosion to the body and parts. Wash your vehicle as soon as possible.



When driving in a coastal area When driving on a road sprinkled with antifreeze When having stuck of coal tar, tree sap, bird droppings and carcass of an insect When driving in the areas where there is a lot of smoke, soot, dust, iron dust and chemical substance
When the vehicle becomes remarkably dirty with dust and mud cclxvi ’99camry CNG Hand–washing your Toyota Work in the shade and wait until the vehicle body is not hot to the touch. CAUTION When cleaning under floor or chassis, be careful not to injure your hands. 1. Rinse off loose dirt with a hose. Remove any mud or road salt from the underside of the vehicle or in the wheel wells. 2. Wash with a mild car–wash soap, mixed according to the manufacturer’s instructions. Use a soft cotton mitt and keep it wet by dipping it frequently into the wash water. Do not rub hard—let the soap and water remove the dirt. Plastic bumpers: Wash carefully. Do not scrub with abrasive cleaners. The bumper faces are soft. Road tar: Remove with turpentine or cleaners that are marked safe for painted surfaces. NOTICE Do not use gasoline or strong solvents, which may be toxic or cause damage. 3. Rinse thoroughly—dried soap can cause streaking. In hot weather you may need to rinse each section right after you wash it. 4. To prevent water spots, dry the vehicle using a clean soft cotton towel. Do not rub or press hard—you might scratch the paint. Automatic car wash cclxvii ’99camry CNG Your vehicle may be washed in an automatic car wash, but remember that the paint can be scratched by some type of brushes, unfiltered washing water, or the washing process itself. Scratching reduces paint durability and gloss, especially on darker colors. The manager of the car wash should be able to advise you whether the process is safe for the paint on your vehicle. Waxing your Toyota Polishing and waxing is recommended to maintain the original beauty of your Toyota’s finish. Once a month or if the vehicle does not repel water well, apply wax. 1. Always wash and dry the vehicle before you begin waxing, even if you are using a combined cleaner and wax. 2. Use a good quality polish and wax. If the finish has become extremely weathered, use a car–cleaning polish, followed by a separate wax. Carefully follow the manufacturer’s instructions and precautions. Be sure to polish and wax the chrome trim as well as the paint. 3. Wax the vehicle again when water does not bead but remains on the surface in large patches. NOTICE Always remove the plastic bumpers if your vehicle is re–painted and placed in a high heat paint waxing booth. High temperatures could damage the bumpers. Cleaning the interior cclxviii ’99camry CNG CAUTION Do not wash the vehicle floor with water, or allow water to get onto the floor when cleaning the vehicle interior or exterior. Water may get into audio components or other electrical components above or under the floor carpet (or mat) and cause a malfunction; and it may cause body corrosion. Vinyl interior The vinyl upholstery may be easily cleaned with a mild soap or detergent and water. First vacuum over the upholstery to remove loose dirt. Then, using a sponge or soft cloth, apply the soap solution to the vinyl. After allowing it to soak in for a few minutes to loosen the dirt, remove the dirt and wipe off the soap with a clean damp cloth. If all the dirt do not come off, repeat the procedure. Commercial foaming–type vinyl cleaners are also available which work well. Follow the manufacturer’s instructions. NOTICE Do not use solvent, thinner, gasoline or window cleaner on the interior. Carpets Use a good foam–type shampoo to clean the carpets. Begin by vacuuming thoroughly to remove as much dirt as possible. Several types of foam cleaners are available; some are in aerosol can sand others are powders or liquids which you mix with water to produce a foam. To shampoo the carpets, use a sponge or brush to apply the foam. Rub in overlapping circles. cclxix ’99camry CNG Do not apply water—the best results are obtained by keeping the carpet as dry as possible. Read the shampoo instructions and follow them closely. Seat belts The seat belts may be cleaned with mild soap and water or with lukewarm water. Use a cloth or sponge. As you are cleaning, check the belts for excessive wear, fraying, or cuts. NOTICE  Do not use dye or bleach on the belts—it may weaken them.  Do not use the belts until they become dry. Windows The windows may be cleaned with any household window cleaner. NOTICE When cleaning the inside of the windows, be careful not to scratch or damage the heater wires on the rear window. Air conditioning control panel, car audio, instrument panel, console panel, and switches Use a soft damp cloth for cleaning. Soak a clean soft cloth in water or lukewarm water then lightly wipe off dirt. cclxx ’99camry CNG NOTICE  Do not use organic substances (solvents, kerosene, alcohol, gasoline, etc.) or alkaline or acidic solutions. These chemicals can cause discoloring, staining or peeling of the surface.  If you use cleaners or polishing agents, make sure their ingredients do not include the substances mentioned above.  If you use a liquid car freshener, do not spill the liquid onto the vehicle’s interior surfaces. It may contain the ingredients mentioned above. Immediately clean any spill using the method mentioned above. If you have any questions about the cleaning of your Toyota, your authorized Toyota CNG dealer will be pleased to answer them. cclxxi ’99camry CNG cclxxii ’99camry CNG Part 6 VEHICLE MAINTENANCE AND CARE
Maintenance requirements
General maintenance
Does your vehicle need repairing? For scheduled maintenance information, please refer to the separate “Owner’s Manual Supplement”. Maintenance requirements Your Toyota vehicle has been designed to for fewer maintenance requirements with longer service intervals to save both your time and money. However, each regular cclxxiii ’99camry CNG maintenance, as well as day–to–day care, is more important than ever before to ensure smooth, trouble–free, safe, and economical drivings. It is the owner’s responsibility to make sure the specified maintenance, including general maintenance service, is performed. Note that both the new vehicle and emission control system warranties specify that proper maintenance and care must be performed. See “Owner’s Manual Supplement”. General maintenance General maintenance items are those day–to–day care practices that are important to your vehicle for proper operation. It is the owner’s responsibility to insure that the general maintenance items are performed regularly. These checks or inspections can be done either by yourself or a qualified technician, or if you prefer, your authorized Toyota CNG dealer will be pleased to do them at a nominal cost. Scheduled maintenance The scheduled maintenance items listed in the “Owner’s Manual Supplement” are those required to be serviced at regular intervals. For details of your maintenance schedule, read the separate “Owner’s Manual Supplement”. It is recommended that any replacement parts used for maintenance or for the repair of the emission control system be Toyota supplied. The owner may elect to use non–Toyota supplied parts for replacement purposes without invalidating the emission control system warranty. However, use of replacement parts which are not of equivalent quality may impair the effectiveness of the emission control systems. You may also elect to have maintenance, replacement, or repair of the emission control devices and system performed by any automotive repair cclxxiv ’99camry CNG establishment or individual without invalidating this warranty. See “Owner’s Manual Supplement” for complete warranty information. Where to go for service? Toyota technicians are well–trained specialists and are kept up to date with the latest service information through technical bulletins, service tips, and in–dealership training programs. They learn to work on Toyotas before they work on your vehicle, rather than while they are working on it. You can be confident that your authorized Toyota CNG dealer’s service department performs the best job to meet the maintenance requirements on your vehicle—reliably and economically. Your copy of the repair order is proof that all required maintenance has been performed for warranty coverage. And if any problems should arise with your vehicle while under warranty, your authorized Toyota CNG dealer will promptly take care of it. Again, be sure to keep a copy of the repair order for any service performed on your Toyota. What about do–it–yourself maintenance? Many of the maintenance items are easy to do yourself if you have a little mechanical ability and a few basic automotive tools. Simple instructions for how to perform them are presented in Part 7. If you are a skilled do–it–yourself mechanic, the Toyota service manuals are recommended. Please be aware that do–it–yourself maintenance can affect your warranty coverage. See “Owner’s Manual Supplement” for the details. General maintenance Listed below are the general maintenance items that should be performed as frequently as specified. In addition to checking the items listed, if you notice any unusual noise, smell or vibration, you should investigate the cause or take your cclxxv ’99camry CNG vehicle to your authorized Toyota CNG dealer or a qualified service shop immediately. It is recommended that any problem you notice be brought to the attention of your dealer or the qualified service shop for their advice. CAUTION Make these checks only where adequate ventilation can be obtained if you run the engine. OUTSIDE THE VEHICLE Items listed below should be performed from time to time, unless otherwise specified. Tire pressure Check the pressure with a gauge every two weeks, or at least once a month. See Chapter 7–2 for additional information. Tire surface and wheel nuts Check the tires carefully for cuts, damage or excessive wear. See Chapter 7–2 for additional information. When checking the tires, make sure no nuts are missing, and check the nuts for looseness. Tighten them if necessary. Tire rotation Rotate the tires every 12000 km (7500 miles). See Chapter 7–2 for additional information. Fluid leaks Check underneath for leaking oil, water or other fluid after the vehicle has been parked for a while. If you smell fuel fumes or notice any leak, have the cause found and corrected immediately. cclxxvi ’99camry CNG Doors and engine hood Check that all doors including trunk lid operate smoothly and all latches lock securely. Make sure the engine hood secondary latch secures the hood from opening when the primary latch is released. INSIDE THE VEHICLE Items listed below should be checked regularly, e.g. while performing periodic services, cleaning the vehicle, etc. Lights Make sure the headlights, stop lights, tail lights, turn signal lights, and other lights are all working. Check headlight aim. Service reminder indicators and warning buzzers Check that all service reminder indicators and warning buzzers function properly. Steering wheel Be alert for changes in steering condition, such as hard steering or strange noise. Seats Check that all front seat controls such as seat adjusters, seatback recliner, etc. operate smoothly and that all latches lock securely in any position. Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. Seat belts Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. Make sure that the belt webbings not cut, frayed, worn or damaged. Accelerator pedal Check the pedal for smooth operation and uneven pedal effort or catching. cclxxvii ’99camry CNG Brake pedal Check the pedal for smooth operation and that the pedal has the proper clearance. Check the brake booster function. Brakes At a safe place, check that the brakes do not pull to one side when applied. Parking brake Check that the lever has the proper travel and that, on a safe incline, your vehicle is held securely with only the parking brake applied. Automatic transmission “Park” mechanism Check the lock release button of the selector lever for proper and smooth operation. On a safe incline, check that your vehicle is held securely with the selector lever in “P” position and all brakes released. IN THE ENGINE COMPARTMENT Items listed below should be checked from time to time, e.g. each time when refueling. Washer fluid Make sure there is sufficient fluid in the tank. See Chapter 7–3 for additional information. Engine coolant level Make sure the coolant level is between the “FULL” and “LOW” lines on the see– through reservoir when the engine is cold. See Chapter 7–2 for additional information. Battery electrolyte level Make sure the electrolyte level of all battery cells is between upper and lower level lines on the case. Add only distilled water when replenishing. See Chapter 7–3 for additional information. cclxxviii ’99camry CNG Does your vehicle need Brake fluid level repairing? Make sure the brake fluid level is correct. See Chapter 7–2 for additional information. Engine oil level Check the level on the dipstick with the engine turned off and the vehicle parked on a level spot. See Chapter 7–2 for additional information. Power steering fluid level Check the level through the reservoir. The level should be in the “HOT” or “COLD” range depending on the fluid temperature. See Chapter 7–2 for additional information. Exhaust system If you notice any change in the sound of the exhaust or smell exhaust fumes, have the cause located and corrected immediately. (See engine exhaust cautions in Part 2.) Be on the alert for changes in performance, sounds, and visual tip–offs that indicate service is needed. Some important clues are as follows:



Engine missing, stumbling, or pinging Appreciable loss of power Strange engine noises A leak under the vehicle (however, water dripping from the air conditioning after use is normal.)
Change in exhaust sound (This may indicate a dangerous carbon monoxide leak. Drive with the windows open and have the exhaust system checked immediately.)
Flat–looking tire; excessive tire squeal when cornering; uneven tire wear
Vehicle pulls to one side when driving straight on a level road cclxxix ’99camry CNG
Strange noises related to suspension movement
Loss of brake effectiveness; spongy feeling brake; pedal almost touches floor; vehicle pulls to one side when braking
Engine coolant temperature continually higher than normal If you notice any of these clues, take your vehicle to your authorized Toyota CNG dealer as soon as possible. It probably needs adjustment or repair. CAUTION Do not continue driving with the vehicle unchecked. It could result in serious vehicle damage and possibly personal injury. cclxxx ’99camry CNG cclxxxi ’99camry CNG Part 8 SPECIFICATIONS
Dimensions and weight
Engine
Fuel
Service specifications
Tires
Fuses Dimensions and weight Overall length mm (in.) 4783 (188.3) Overall width mm (in.) 1780 (70.1) Overall height mm (in.) 1419 (55.9)∗ Wheelbase mm (in.) 2670 (105.1) Front tread mm (in.) 1547 (61.0) Rear tread mm (in.) 1520 (59.8) Vehicle capacity weight (occupants + luggage) kg (lb) 410 (900) ∗: Unladen vehicle Engine Model: 5S–FNE cccxxxviii ’99camry CNG Type: 4 cylinder in line, CNG (Compressed Natural Gas) Bore and stroke, mm (in.): 87.0
91.0 (3.43
3.58) Displacement, cm3 (cu. in.): 2164 (132.0) Fuel Fuel type: Compressed natural gas Service pressure: 24800 kPa (3600 psig) Equivalent gasoline capacity: 43 L (11.4 gal., 9.5 lmp.gal.) Water volume: 135 L (35.7 gal., 29.7 lmp.gal.) Service specifications ENGINE Valve clearance (engine cold), mm (in.): Intake 0.19—0.29 (0.007—0.011) Exhaust 0.28—0.38 (0.011—0.015) Spark plug type: DENSO PK20TR8–G Spark plug gap, mm(in.): 0.8 (0.031) Drive belt tension measured with Borroughs drive belt tension gauge No.BT–33–73F (used belt), Ibf: With air conditioning Generator belt 13010 cccxxxix ’99camry CNG Power steering pump belt Without air conditioning Generator belt Power steering pump belt 8020 6520 8020 ENGINE LUBRICATION Oil capacity (drain and refill), L (qt., Imp. qt.): With filter Without filter 3.6 (3.8, 3.2) 3.4 (3.6, 3.0) Oil grade: API grade SJ, “Energy–Conserving” or ILSAC multigrade engine oil is recommended. Recommended oil viscosity (SAE): COOLING SYSTEM Total capacity, L (qt., Imp. qt.): 6.9 (7.3, 6.1) cccxl ’99camry CNG Coolant type: “TOYOTA Long Life Coolant” or equivalent With ethylene–glycol type coolant for a proper corrosion protection of aluminum components Do not use alcohol type antifreeze or plain water alone. BATTERY Open voltage∗ at 20C (68F): 12.6—12.8V Fully charged 12.2—12.4V Half charged 11.8—12.0V Discharged ∗: Voltage that is checked 20 minutes after the key is removed with all the lights turned off Charging rates: 5 A max. AUTOMATIC TRANSAXLE Automatic transmission Fluid capacity (drain and refill), L (qt., Imp. qt.): Up to 2.5 (2.6, 2.2) Fluid type: Automatic transmission fluid D–ll or DEXRONIIl (DEXRONII) Differential Fluid capacity L (qt., Imp. qt.): 1.6 (1.7, 1.4) Fluid type: Automatic transmission fluid D–II or DEXRONIII (DEXRONII) cccxli ’99camry CNG BRAKES Minimum pedal clearance when depressed with the pressure of 490 N (50 kgf, 110 Tire size: lbf) with the engine running, mm (in.): Spare tire T145/80R16 105M 70 (2.8) Except spare mm tire (in.):P205/65R15 92H Pedal free play, Tire pressure, kPa (kgf/cm2 or bar, psi): 1—6 (0.04—0.24) Pad Spare wear tire limit, mm (in.): 420 (4.2, 60) 1.0Except (0.04) spare tire Lining wear limit, mm (in.): For all loads including full rated loads 220 (2.2, 32) 1.0 Normal (0.04) driving For reduced loads (1 to 4 passengers) 200 (2.0, 29) Parking brake adjustment when pulled with the force of 196 N (20 kgf, 44 lbf): 220 (2.2, 32) 5—8 Trailer clicks driving When driving under the above vehicle load conditions at sustained high speeds above 160 km/h (100 mph), in countries where such speeds are permitted Fluid type: by–law, inflate the front and rear tires to 240 kPa (2.4 kgf/cm2 or bar, 35 psi) SAE J1703 or FMVSS No.116 DOT 3 provided that it dose not exceed the maximum cold tire pressure molded on STEERING the tire sidewall. Wheelfree size: Wheel play: Less than in.) Spare tire30 mm (1.2 4T Power steering Except sparefluid tire type: 15
6JJ Automatic transmission fluid DEXRONII or III Wheel nut torque, N·m (kgf·m, ft·lbf): Tires 104 (10.5, 77) Fuses cccxlii ’99camry CNG Engine compartment cccxliii ’99camry CNG Engine compartment Fuses (type A) 1. A/C 10 A: Air conditioning system 2. SPARE 10 A: Spare fuse 3. SPARE 15 A: Spare fuse 4. SPARE 30 A: Spare fuse 5. ALT–S 5 A: Charging system 6. HEAD (RH) 15 A: Right–hand headlight 7. EFI 15 A: Multiport fuel injection system/sequential multiport fuel injection system, A/F sensor 8. HORN 10 A: Horn 9. HAZARD 10 A: Emergency flasher cccxliv ’99camry CNG Instrument panel 10. AM2 30 A: Gauge and meter, SRS airbag system, seat belt pretensioners, multiport fuel injection system/sequential multiport fuel injection system, “IGN” and “STARTER” fuses 11. TEL 5 A: No circuit 12. HEAD (LH) 15 A: Left–hand headlight 13. RADIO NO.1 20 A: Audio system 14. DOME 7.5 A: Clock, ignition switch light, personal light, trunk light, interior light, power door lock system 15. ECU–B 10 A: Anti–lock brake system, SRS airbag system, seat belt pretensioners 16. A/F HTR 25 A: No circuit cccxlv ’99camry CNG 17. SEAT–HEATER 20 A: No circuit 18. HEATER 10 A: Air conditioning system, rear window defogger 19. GAUGE 10 A: Gauges and meters, back–up lights, cruise control system, charging system, power windows, service reminder indicators and warning buzzers 20. WIPER 25 A: Windshield wipers and washer 21. MIRROR–HEATER 10 A: Outside rear view mirror defogger 22. ECU–IG 15 A: Cruise control system, anti–lock brake system, power antenna, SRS airbag system, seat belt pretensioners, shift lock control system, multiport fuel injection system/sequential multiport fuel injection system 23. IGN 5 A: Gauges and meters, charging system, SRS airbag system, seat belt pretensioners, multiport fuel injection system/sequential multiport fuel injection system 24. STOP 15 A: Stop lights, cruise control system, high–mounted stoplight, anti–lock brake system, shift lock control system, multiport fuel injection system/sequential multiport fuel injection system 25. TAIL 10 A: Parking lights, license plate lights, tail lights, front side marker lights, multiport fuel injection system/sequential multiport fuel injection system 26. POWER–OUTLET 15 A: Power outlet 27. OBD 7.5 A: On–board diagnosis system 28. FOG 15 A: No circuit 29. STARTER 5 A: Gauges and meters, multiport fuel injection system/sequential multiport fuel injection system 30. DOOR 25 A: Power door lock system cccxlvi ’99camry CNG 31. PANEL 7.5 A: Gauge and meter, audio system, cigarette lighter, glove box light, clock, instrument panel light control, service reminder indicators, air conditioning control panel lights, ashtray light, emergency flasher, rear window defogger, electronically controlled automatic transmission system 32. TURN 7.5 A: Emergency flasher 33. RAD–NO.2 7.5 A: Audio system 34. CIG 15 A: Cigarette lighter, shift lock control system, power rear view mirror controls, power door lock system, SRS airbag system, seat belt pretensioners, air conditioning system Fuses (type B) 35. CDS 30 A: Electric cooling fans 36. RDI 30 A: Electric cooling fans 37. MAIN 40 A: “HEAD RH”, “HEAD LH”, fuses 38. HTR 50 A: “AM1” and “A/C” fuses 39. DEF 40 A: Rear window defogger 40. PWR 30 A: Power window control system 41. AM1 40 A: “POWER–OUTLET”, “CIG”, “RAD–NO.2”, “SEAT–HEATER”, “TURN”, “WIP”, “ECU–IG”, “GAUGE”, and “HTR” fuses 42. CDS NO.2 30 A: No Circuit Fuses (type C) 43. ALT 100 A: “RDI” and “CDS” fuses 44. ABS 60 A: Anti–lock brake system cccxlvii ’99camry CNG Reporting safety defects for U.S. Part 9 owners REPORTING SAFETY DEFECTS FOR U.S. OWNERS AND UNIFORM TIRE QUALITY GRADING
Reporting safety defects for U.S. owners
Uniform tire quality grading If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Toyota Motor Sales, U.S.A., Inc. (Toll–free: 1–800–331–4331). If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or Toyota Motor Sales, U.S.A., Inc. To contact NHTSA, you may either call the Auto Safety Hotline toll– free at 1–800–424–9393 (or 366–0123 in Washington, D.C. area) or cccxlviii ’99camry CNG write to: NHTSA. U.S. Department of Transportation. Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline. Uniform tire quality grading This information has been prepared in accordance with regulations issued by the National Highway Traffic Safety Administration of the U.S. Department of Transportation. It provides the purchasers and/or prospective purchasers of Toyota vehicles with information on uniform tire quality grading. Your authorized Toyota CNG dealer will help answer any questions you may have as you read this information. DOT quality grades—All passenger vehicle tires must conform to Federal Safety Requirements in addition to these grades. These quality grades are molded on the sidewall. Treadwear—The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire graded 150 would wear one and a half (1–1/2) times as well on the government course as a tire graded 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices and differences in road characteristics and climate. Traction AA, A, B, C—The traction grades, from highest to lowest, are AA, A, B, and C, and they represent the tire’s ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance. Warning: The traction grade assigned to this tire is based on braking (straight ahead) traction tests and does not include cornering (turning) traction. cccxlix ’99camry CNG Temperature A, B, C—The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law. Warning: The temperature grades for this tire are established for a tire that is properly inflated and not overloaded. Excessive speed, underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure. cccl ’99camry CNG Part 10 INDEX cccli Foreword Welcome to the growing group of value–conscious people who drive Toyotas. We are proud of the advanced engineering and quality construction of each vehicle we build. This Owner’s Manual explains the features of your new Toyota. Please read it and follow the instructions carefully so that you can enjoy many years of safe motoring. When it comes to service, remember that your authorized Toyota CNG dealer knows your vehicle best and is interested in your complete satisfaction. He will provide quality maintenance and any other assistance you may require. Please leave this Owner’s Manual in this vehicle at the time of resale. The next owner will need this information also. All information and specifications in this manual are current at the time of printing. However, because of Toyota’s policy of continual product improvement, we reserve the right to make changes at any time without notice. Please note that this manual applies to all models and explains all equipment, including options. Therefore, you may find some explanations for equipment not installed on your vehicle.  1999 TOYOTA MOTOR CORPORATION All rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. i Important information about this manual Safety and vehicle damage warnings Safety symbol In this manual, you will see CAUTION and NOTICE warnings. These are used in the following ways: CAUTION This is a warning against something which may cause injury to people if the warning is ignored. You are informed what you must or must not do in order to avoid or reduce the risk to yourself and other people. NOTICE This is a warning against something which may cause damage to the vehicle or its equipment if the warning is ignored. You are informed what you must or must not do in order to avoid or reduce the risk of damage to your vehicle and its equipment. ccclv In this manual, you will also see a circle with a slash through it. This means “Do not”, “Do not do this”, or “Do not let this happen”. U−1 Quick index
If a service reminder indicator or warning buzzer comes on . . . . . . . . cxxiii
If your vehicle will not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ccxxviii
If your engine stalls while driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ccxxxiv
If your vehicle overheats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ccxxxiv
If you have a flat tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ccxxxvi
If your vehicle needs to be towed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cclii
Tips for driving during break–in period . . . . . . . . . . . . . . . . . . . . . . . . . . clxxxviii
How to start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ccxi
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cclxxv
Complete index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cccli Gas station information Fuel type: Compressed natural gas See page clxxxviii for detailed information. Service pressure: 24800 kPa (3600 psig) Equivalent gasoline capacity: 43 L (11.4 gal., 9.5 lmp. gal.) Water volume: 135 L (35.7 gal., 29.7 lmp. gal.) See page cxcii for detailed information. Engine oil: API grade SJ, “Energy–Conserving” or ILSAC multigrade engine oil is recommended. See page ccxciv for detailed information. Automatic transmission fluid: Automatic transmission fluid D–II or DEXRONIII (DEXRONII) Tire information: See pages ccci through cccviii. Tire pressure: See page cccxlii. Publication No. OM33502U Part No. 01999-33502 Printed in Japan 01–9903–00 CNG ( U) I New vehicle warranty Accessories, spare parts and modification of your Toyota Your new vehicle is covered by the following Toyota limited warranties: A wide variety of non–genuine spare parts and accessories for Toyota vehicles are currently available in the market. You should know that Toyota does not warrant these products and is not responsible either for their performance, repair or replacement, or for any damage they may cause to, or adverse effect they may have on, your Toyota vehicle.
New vehicle warranty
Emission control systems warranty
Others For further information, please refer to the separate “Owner’s Manual Supplement”. Your responsibility for maintenance It is owner’s responsibility to make sure that the specified maintenance is performed. Part 6 gives details of these maintenance requirements. Also included in Part 6 is general maintenance. For scheduled maintenance information, please refer to the separate “Owner’s Manual Supplement”. ccclii This vehicle should not be modified with non–genuine Toyota products. Modification with non–genuine Toyota products could affect its performance, safety or durability, and may even violate governmental regulations. In addition, damage or performance problems resulting from the modification may not be covered under warranty. Installation of a mobile two–way radio system Precautions for CNG Your vehicle may use compressed natural gas (CNG) for fuel. As the installation of a mobile two–way radio system in your vehicle could affect electronic systems such as multiport fuel injection system/sequential multiport fuel injection system, cruise control system, anti–lock brake system, SRS airbag system and seat belt pretensioner system, be sure to check with your authorized Toyota CNG dealer for precautionary measures or special instructions regarding installation.
Handle the CNG vehicle with care as the fuel tank and pipes of it are filled with extremely high pressure gas. In this case, close the manual shut off valve and have your authorized Toyota CNG dealer carry out an inspection.
You will be able to tell if fuel is leaking out of the vehicle by the sound of the leaking fuel and the smell of the fuel.
Be careful not to run out of fuel. There are less CNG stations than gasoline stations so we recommend that you refuel early. Scrapping of your Toyota For details, see “Fuel” and “Fuel system” in Part 2. The SRS airbag and seat belt pretensioner devices in your Toyota contain explosive chemicals. If the vehicle is scrapped with the airbags and pretensioners left as they are, it may cause an accident such as a fire. Be sure to have the systems of the SRS airbag and seat belt pretensioner removed and disposed of by the qualified service shop or by your authorized Toyota CNG dealer before you dispose of your vehicle. cccliii Refueling station information For information on refueling stations for CNG, contact Natural Gas Vehicle Coalition (NGVC) at the address and numbers listed below. Natural Gas Vehicle Coalition 1515 Wilson Blvd. Arlington, Va. 22209 Phone: (703) 527–3022 cccliv 1 9 9 9 Scheduled Maintenance Everyda y Guide People Table of Contents INTRODUCTION The Importance of Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance and Toyota Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TOYOTA MAINTENANCE & REPAIR SUPPORT Toyota Dealership Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Toyota Express Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Genuine Toyota Parts and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lifetime Guarantee Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 TrueStart™ Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Collision Repair Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Do- It-Yourself Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Toyota Parts Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Toyota Service Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Service Agreements and Pre- Paid Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SCHEDULED MAINTENANCE LOGS Determining Your Vehicle’s Maintenance Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Explanation of Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Maintenance Log: Cars and Sienna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Maintenance Log: SUVs and Tacoma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 1 The Importance of Scheduled Maintenance egular maintenance is essential to obtaining the highest level of performance, safety and reliability from your Toyota. It can also enhance your vehicle’s resale value. This booklet is designed to help you make sure your vehicle receives proper and timely maintenance. It includes factoryrecommended maintenance guidelines along with information on the extensive maintenance and repair support available through Toyota and your dealership. You’ll also find space to document your vehicle’s maintenance history. R In addition to scheduled maintenance, your Toyota requires ongoing general maintenance which includes checking fluid levels and making periodic visual inspections. These items are explained under the “General Maintenance” heading in the “Vehicle Maintenance and Care” section of the Owner’s Manual. Be sure to follow these guidelines carefully to ensure the most trouble- free operation of your vehicle. 2 INTRODUCTION With proper maintenance and care, your vehicle will last longer and deliver more dependable, economical performance. Follow this booklet’s recommendations and you’ll enjoy maximum reliability and peace of mind from your Toyota for many years to come. Maintenance & Toyota Warranty Coverage Maintaining your vehicle according to the recommendations in this booklet is required to ensure that your warranty coverage remains in force. You should keep detailed records of vehicle maintenance, including date of service, mileage at time of service and a description of service and/or parts installation performed. The Scheduled Maintenance Log in this booklet is a good place to record this information. If you sell your vehicle, be sure to give your maintenance records to the new owner. Toyota will not deny a warranty claim solely because you do not have records to show that you maintained your vehicle. However, damage or failures caused by lack of proper maintenance are not covered under warranty. Your dealer may recommend more frequent maintenance intervals or more maintenance services than those listed in the Scheduled Maintenance Log. These additional services are not required to maintain your warranty coverage. Ask your dealer for an explanation of any recommended maintenance not included in the Scheduled Maintenance Log. For a complete description of Toyota warranty coverages, see the booklet entitled 1999 Owner’s Warranty Information in your vehicle’s glove box. Maintenance and repair services may be performed by you or by any automotive service provider you choose. Toyota will not deny a warranty claim solely because you used a service provider other than a Toyota dealership for maintenance and repairs. However, damage or failures caused by improper maintenance or repairs are not covered under warranty. INTRODUCTION 3 Toyota Dealership Service To ensure that your vehicle receives first- quality service and factory- authorized parts, Toyota recommends having maintenance performed by an authorized Toyota dealership. Toyota dealership technicians are experts in the maintenance and repair of Toyota vehicles. They stay current on the latest service information through Toyota technical bulletins, service publications and training courses. Many are also certified through the Toyota Certified Technician Program, which requires completion of Toyota’s specialized, state- of- the- art training as well as rigorous exams through both Toyota and the National Institute for Automotive Service Excellence. Feel free to ask any Toyota dealership to show you its technicians’ credentials. You can be confident you’re getting the best possible service for your vehicle when you take it to a Toyota dealership. Why trust your investment to anything but a team of highly qualified Toyota specialists? 4 TOYOTA MAINTENANCE & R E PA I R SUPPORT Toyota Express Lube With Toyota Express Lube, you get the convenience of a quicklube shop and the quality and expertise you count on when you go to a Toyota dealership. You also get the Express Lube guarantee: a complete oil- and- filter change and 19- point inspection in 29 minutes or less, or the next one is free. You never need an appointment to use Express Lube at a Toyota dealership. Just follow the signs and drive up to the Express Lube lane — you’ll be waited on promptly, and your oil- and- filter change will be done while you wait. Express Lube delivers outstanding value as well, since the service is priced very competitively with franchised quick- lube centers. More than 400 Toyota dealerships now offer Express Lube service. Call (800) 331- 4331 for the Express Lube location nearest you. TOYOTA MAINTENANCE & R E PA I R SUPPORT 5 Genuine Toyota Parts & Accessories To safeguard the quality, reliability and value of your vehicle, Toyota recommends using only Genuine Toyota Parts for maintenance and repairs. Like all Toyota products, Genuine Toyota Parts are built to the highest standards of quality and performance. They are also designed to fit your vehicle’s exact specifications. For all your maintenance and repair needs, insist on the quality and peace of mind you only get with Genuine Toyota Parts. Your Toyota dealership maintains an extensive inventory of Genuine Toyota Parts to meet your vehicle service needs. And because it is linked electronically to Toyota’s Parts Distribution Centers, the dealership has quick access to any parts it may not have in stock. When installed by a Toyota dealership, Genuine Toyota Parts are warranted for 12 months (regardless of mileage) or the remainder of any applicable NewVehicle Limited Warranty, whichever is longer. Selected Toyota replacement parts are covered by a lifetime warranty (see page 8). Non- Genuine Toyota Parts — and any damage or failures resulting from their use — are not covered by any Toyota warranty. 6 TOYOTA MAINTENANCE & R E PA I R SUPPORT Genuine Toyota Parts & Accessories When you want to personalize your Toyota vehicle, be sure to do it without sacrificing Toyota quality and performance. How? By choosing Genuine Toyota Accessories. VIP SECURITY SYSTEM RS3000 Only Genuine Toyota Accessories are designed and manufactured specifically for Toyota vehicles. In addition, they undergo rigorous testing to ensure first- rate quality, precise fit and longterm durability. Aftermarket accessories don’t always meet these same high standards. The quality of Genuine Toyota Accessories is also backed by the integrity of a Toyota warranty. Coverage is for 12 months from date of purchase, regardless of mileage. If the accessory is installed at the time of new- vehicle purchase, coverage is extended to 36 months/36,000 miles. See your dealer for details. And remember that Genuine Toyota Accessories can only be purchased from an authorized Toyota dealership. COROLLA REAR SPOILER & GOLD PACKAGE CAMRY FOG LIGHTS SIENNA RUNNING BOARDS TOYOTA MAINTENANCE & R E PA I R SUPPORT 7 Lifetime Guarantee Replacement Parts Toyota’s confidence in its products and commitment to customer satisfaction are demonstrated by outstanding warranty coverage — including a lifetime guarantee on replacement mufflers, exhaust pipes, shock absorbers, struts and strut cartridges. When purchased at and installed by a Toyota dealership, these Genuine Toyota Parts are guaranteed to the original purchaser for the life of the vehicle. This includes coverage for parts and labor. Compare the guarantees offered on these parts by aftermarket repair shops — many don’t offer the extensive coverage Toyota does. And remember that only Genuine Toyota Parts are manufactured to your vehicle’s exact specifications. So don’t compromise; when replacement time comes, count on your Toyota dealer for quality, performance and the peace of mind that comes with a factory- backed lifetime guarantee. Compare Lifetime Guarantee Coverage Toyota vs. Others • Muffler - Labor to replace • Tail Pipe - Labor to replace • Exhaust Pipes - Labor to replace Toyota Others* Yes Yes Yes Yes Yes No Yes No Yes No Yes No We Cover The Muffler, Pipes And Labor Too! Theirs Ours For complete details of the Toyota Lifetime Guarantee, see an authorized Toyota dealer. 8 TOYOTA MAINTENANCE & R E PA I R SUPPORT * Some muffler shops–read their fine print and compare. TrueStart Batteries whichever is longer. Following the free replacement period, warranty coverage is prorated based on the battery’s time in use. See your Toyota dealer for more details. The reputation for quality and reliability was likely a key reason behind your decision to buy a Toyota. That overall quality is present in each of the components of your car or truck, including the battery. When it’s time for a replacement, your Toyota dealer is the only place to find a batterywith the power to start and operate your vehicle like new. Don’t entrust your Toyota’s performance to anything less than the best: Genuine Toyota TrueStart™ Batteries. To maintain the original performance designed into your Toyota, a replacement battery must meet Toyota’s specifications for Cold Cranking Amps (CCA) and Reserve Capacity (RC). RC, a specification often not met by aftermarket brands, supplies the power you need during high- demand conditions such as driving in heavy traffic. RC is also what gives you the power to operate electronic accessories with the engine off. By choosing a TrueStart,™ you can be confident your battery will meet your needs, every day. Warranty coverage is another important consideration when selecting a replacement battery. TrueStart™ batteries feature a free replacement period of 18 months (regardless of mileage) or the remainder of the Toyota NewVehicle Limited Warranty, TOYOTA MAINTENANCE & R E PA I R SUPPORT 9 Collision Repair Parts Insist on Genuine Toyota Quality If you’re involved in a collision, you want your vehicle to be returned to its pre- accident condition when repaired. To maintain your Toyota’s value, it’s important to make sure it’s repaired with Genuine Toyota Parts. Some repair shops and insurance companies may suggest using imitation or used salvage parts to save money. However, these parts do not meet Toyota’s high standards for quality, fit and corrosion resistance. In addition, imitation and used salvage parts are not covered by any Toyota warranty (see box at right). To maintain the appearance, performance and safety of your Toyota, make sure only Genuine Toyota Parts are used for collision repairs. Protect your investment — insist on Genuine Toyota quality. 10 TOYOTA MAINTENANCE & R E PA I R Toyota warranty coverage remains intact when vehicle repairs are completed with Genuine Toyota Parts. Toyota warranties do not cover imitation or used salvage parts or any damage or failures caused by the use of such parts. In Case of Accident, Be an Informed Owner Toyota believes customers have the right to choose the types of parts used in the repair of their vehicles. That’s why Toyota supports full disclosure by repair shops and insurance companies regarding parts used for collision repair. The following information is provided to help you understand the differences in the types of parts that could be used in the repair of your vehicle. General Information “Collision repair parts” or “replacement crash parts” are the parts typically replaced during the repair of a vehicle that has been damaged in a collision. These parts include exterior sheet metal such as fenders, hoods, doors and related components; and plastic components such as bumper covers and lamp assemblies. SUPPORT Collision Repair Parts Warranty Coverage Warranties for collision repair parts are provided by the manufacturer or distributor of the parts. Warranty coverage varies. Your insurance company or collision repair facility should provide you with written warranty statements for all parts used in the repair of your vehicle. Types of Collision Repair Parts New Original-Equipment Manufacturer (OEM) Parts that are made by the vehicle manufacturer or one of its licensees and distributed through its normal channels. These parts maintain the manufacturer’s vehicle warranty. Recycled or Used Salvage Used parts and assemblies that have been removed from another vehicle. There are no systems in place to regulate the quality or safety of these parts. Remanufactured Parts that have been returned to like- new condition through repair, refurbishing or rebuilding. Due to the critical nature of Supplemental Restraint Systems (also known as air bags), Toyota does not support the use of imitation or used parts for their repair. Only new Genuine Toyota Parts should be used to repair/replace Supplemental Restraint Systems. Aftermarket or Imitation Parts that are made by companies other than the vehicle manufacturer or its licensees. TOYOTA MAINTENANCE & R E PA I R SUPPORT 11 Do-It-Yourself Products When it’s time to replace key wear items on your vehicle, don’t settle for less than Genuine Toyota Parts. Available exclusively through Toyota dealerships, Genuine Toyota Parts meet the highest standards of quality and performance and are built to exact factory specifications. Here are a few of your vehicle’s components that are particularly subject to wear and some benefits of replacing them with Genuine Toyota Parts. Genuine Toyota Platinum Spark Plugs * • Designed to last at least 60,000 miles. • Provide the maximum spark required by Toyota’s highcompression engines. • Resist fouling and misfires for more efficient combustion and better fuel economy. Genuine Toyota Brake Pads • Friction materials selected for optimum performance when matched with Toyota brake drums or rotors. • Precision- machined backing plates allow pads to move freely within the calipers for smooth, efficient braking. Genuine Toyota Wiper Inserts • Cut to match the exact length and shape of your vehicle’s wiper blades for a proper and secure fit. • Constructed of compression- molded natural rubber — not synthetic — for superior wiping performance. * Available for selected models. See your dealer for details. 12 TOYOTA MAINTENANCE & R E PA I R SUPPORT Do-It-Yourself Products Genuine Toyota Chemicals Genuine Toyota Motor Oil Toyota offers a complete line of products to help you keep your Toyota looking and running like new. To safeguard your vehicle’s appearance, you’ll find everything from fabric spot remover and glass cleaner to liquid car wash and touch- up paint. When it’s time to get under the hood (or under the car), products such as fuel injector cleaner, brake fluid and silicone spraywill help you get the job done. All of these products are formulated specifically for use with Toyota vehicles, so you can be confident you’re giving your vehicle the best care possible, inside and out. Your Toyota’s engine features highly advanced technology to ensure superior performance, reliability and fuel economy. Genuine Toyota Motor Oil is formulated with a special combination of lube- base stocks and an additive blend to maximize the benefits of this technology. Make sure you’re getting the most out of your engine by always putting the best into it: Genuine Toyota Motor Oil. Genuine Toyota Antifreeze Coolant Genuine Toyota Long Life Antifreeze Coolant is the same high quality, factory- fill product found in all new Toyotas. You’ll know it by its distinctive red color. It provides maximum protection and durability without the use of harmful silicates. And because it’s compatible with non- metallic materials, it helps extend the life of water- pump seals. Don’t trust your engine to anything less than the best: Genuine Toyota Long Life Antifreeze Coolant. TOYOTA MAINTENANCE & R E PA I R SUPPORT 13 Toyota Parts Centers If you plan to perform your own maintenance or repairs on your Toyota, be sure to check out your nearby Toyota Parts Center (TPC). More than 475 Toyota dealerships now have a TPC, which is an in- dealership parts store offering a wide selection of automotive products. All TPCs feature a complete line of Genuine Toyota maintenance parts and car- care products for “do- it- yourselfers.” In addition to Toyota maintenance and repair products, TPCs offer free technical advice to Toyota owners who want to service their own vehicles. You’ll also find model- specific parts application guides and how- to brochures covering most common maintenance jobs. Both are provided to customers free of charge. Toyota Parts Centers are open during regular dealership hours; many also have extended evening and weekend hours. If you’re a do- it- yourselfer, stop by and experience the service, selection and value offered by your local TPC. 14 TOYOTA MAINTENANCE & R E PA I R SUPPORT Toyota Service Manuals If you’ll be doing some of your own maintenance and repair work on your vehicle, a Toyota service manual will be one of your most valuable tools. Toyota offers three types of manuals to assist do- it- yourselfers. To order any of the following manuals, call Toyota’s service publications department at (800) 622- 2033. For information on basic do- it- yourself maintenance items, see the “General Maintenance and Care” and “Do- ItYourself Maintenance” sections of your Owner’s Manual. Vehicle Repair Manual This is the same manual used by professional technicians in Toyota dealerships throughout the United States. It is fully illustrated and includes maintenance and repair procedures for all vehicle mechanical systems. It also includes instructions for vehicle tune- ups. Electrical Systems Manual This manual provides detailed wiring diagrams for each electrical system in your vehicle, along with troubleshooting tips and repair procedures. Automatic Transmission/Transaxle Repair Manual This manual includes complete procedures for overhauling the automatic transmission/transaxle of your vehicle. TOYOTA MAINTENANCE & R E PA I R SUPPORT 15 Service Agreements & Pre-Paid Maintenance Vehicle Service Agreements By covering the cost of repairs that are no longer covered by warranty, a vehicle service agreement protects you from unexpected repair costs down the road. Many service agreements also cover services such as towing and car rental that minimize the inconvenience of a mechanical breakdown. Through Genuine Toyota Financial Services, Toyota offers service agreement plans to meet the needs of almost every customer. Under these plans, repairs are made only by authorized Toyota dealerships using Genuine Toyota Parts. This means you always get original- equipment quality installed by factory- trained technicians. Your Toyota dealer can help you select the service agreement plan that’s best for you. Be sure to request a plan from Genuine Toyota Financial Services to get the highest level of quality, service and peace of mind. 16 TOYOTA MAINTENANCE & R E PA I R Pre-Paid Maintenance An excellent way to ensure that your Toyota receives regular maintenance — and to protect yourself from increases in vehicle service costs — is to pay for maintenance services in advance. Toyota offers pre- paid maintenance plans for both new and used vehicles. Both plans cover oil- and- filter changes, lubrication of key chassis parts and a 19- point vehicle inspection. The plans also include 24- hour roadside assistance, timed service reminders and a computerized history of each service visit. To meet differing customer needs, Toyota’s pre- paid maintenance plans offer a variety of options for service intervals and coverage length. Ask your Toyota dealer to help you select the options that are best for you. SUPPORT Determining Your Vehicle’s Maintenance Needs Determining the Proper Maintenance Interval Depending on your circumstances, you should obtain maintenance for your Toyota every 5,000 miles or every 7, 500 miles. Follow these guidelines to determine which interval to use. 5,000-Mile Intervals Use 5,000- mile intervals if you primarily operate your vehicle under any of the following conditions: • Driving on unpaved or dusty roads. • Towing a trailer or using a camper or car- top carrier. • Repeated trips of less than five miles in temperatures below freezing. 7,500-Mile Intervals Use 7, 500- mile intervals if you primarily operate your vehicle under conditions other than those listed above. Following the Maintenance Log Charts The Scheduled Maintenance Log identifies the maintenance required at each mileage interval and corresponding time interval based on mileage of 1, 250 miles per month. If you drive more than 1, 250 miles per month, you should obtain maintenance at the indicated mileage interval rather than the indicated time interval. If you choose 5,000- mile intervals, follow the maintenance instructions shown below non- shaded headings such as this one: 5,000 Miles or 4 Months If you choose 7, 500- mile intervals, follow the maintenance instructions shown below shaded headings such as this one: 7, 500 Miles or 6 Months At 15,000- mile increments, the 5,000- mile and 7, 500- mile intervals coincide. Therefore, shaded and non- shaded headings appear together, as in this example: 15,000 Miles or 12 Months 15,000 Miles or 12 Months SCHEDULED MAINTENANCE LOGS 17 Determining Your Vehicle’s Maintenance Needs Special Operating Conditions In addition to standard maintenance items, the Scheduled Maintenance Log indicates services that should be performed on vehicles that are driven under especially demanding conditions. Specific conditions require specific services, as indicated below. The Scheduled Maintenance Log indicates at which mileage/time intervals each service should be performed. • Inspect steering linkage • Re- torque drive shaft flange bolts* • Lubricate propeller shaft and re- torque bolts* You should perform these additional maintenance services if you drive primarily under any of the conditions noted. If you drive only occasionally under these conditions, it is not necessary to perform the additional services. • Inspect brake linings/drums and brake pads/discs • Inspect or change engine air filter • Lubricate propeller shaft and re- torque bolts * Driving on Rough, Muddy or Snow-Melted Roads Extensive Idling or Low-Speed Driving for Long Distances • • • • • Rotate tires Inspect ball joints and dust cover Inspect brake linings/drums and brake pads/discs Inspect drive shaft boots Inspect nuts and bolts on chassis and body Driving on Salt-Covered Roads • Lubricate propeller shaft and re- torque bolts* Driving on Unpaved or Dusty Roads • Inspect brake linings/drums and brake pads/discs * Applies to selected models. See the Scheduled Maintenance Log for details. 18 SCHEDULED MAINTENANCE LOGS Determining Your Vehicle’s Maintenance Needs Towing a Trailer or Using a Camper or Car-Top Carrier • • • • • • Inspect brake linings/drums and brake pads/discs Inspect nuts and bolts on chassis and body Replace differential oil Replace transmission fluid or oil Replace transfer oil* Lubricate propeller shaft and re- torque bolts* Off-Road Maintenance If you own a Land Cruiser or a four- wheel drive RAV4, Tacoma or 4Runner, you should check the following items daily whenever you drive off- road through deep sand, mud or water: • • • • • • • • Brake lines and hoses Brake linings/drums and brake pads/discs Engine air filter Differential oil Steering linkage Transfer oil Transmission fluid or oil Wheel bearings For all four- wheel drive vehicles except RAV4, you should also lubricate the propeller shafts daily. SCHEDULED MAINTENANCE LOGS 19 Explanation of Maintenance Items The following descriptions are provided to give you a better understanding of the maintenance items that should be performed on your vehicle. The Scheduled Maintenance Log indicates at which mileage/time intervals each item should be performed. Please note that many maintenance items should be performed only by a qualified technician. For further information on maintenance items you can perform yourself, see the “General Maintenance and Care” and “Do- It-Yourself Maintenance” sections ofyour Owner’s Manual. Automatic Transmission Fluid or Manual Transmission Oil Inspect each component for signs of leakage. If you discover any leakage, have it repaired by a qualified technician immediately. Ball Joints and Dust Covers Check the suspension and steering linkage ball joints for looseness and damage. Check all dust covers for deterioration and damage. A qualified technician should perform these inspections. Brake Lines and Hoses Visually inspect for proper installation. Check for chafing, cracks, deterioration and evidence of leaking. Replace any deteriorated or damaged parts immediately. A qualified technician should perform these operations. 20 SCHEDULED MAINTENANCE LOGS Explanation of Maintenance Items Brake Linings/Drums and Brake Pads/Discs Drive Shaft Boots Check the brake linings (shoes) and drums for scoring, burning, fluid leakage, broken parts and excessive wear. Check the pads for excessive wear and the discs for runout, excessive wear and fluid leakage. A qualified technician should perform these inspections. Check the drive shaft boots and clamps for cracks, deterioration and damage. Replace any damaged parts and, if necessary, repack the grease. Selected models also require periodic inspection of the flange bolts for proper torque. A qualified technician should perform these operations. Charcoal Canister (CA, MA and NY vehicles) Check for internal damage and clogging. If necessary, clean with compressed air or replace. A qualified technician should perform these operations. Engine Air Filter Check for damage, excessive wear and oiliness. Replace if necessary. Engine Coolant Differential Oil Inspect each component for signs of leakage. If you discover any leakage, have it repaired by a qualified technician immediately. Drain and flush the cooling system and refill with an ethyleneglycol type coolant. A qualified technician should perform this operation. Drive Belts Engine Oil and Oil Filter Inspect for cracks, excessive wear and oiliness. Check the belt tension and adjust if necessary. Replace the belts if they are damaged. Change the oil filter and replace the engine oil with API SH, Energy- Conserving II multigrade or ILSAC multigrade oil. For recommended viscosity, refer to your Owner’s Manual. SCHEDULED MAINTENANCE LOGS 21 Explanation of Maintenance Items 22 Engine Valves Nuts and Bolts on Chassis and Body Inspect for excessive lifter noise and engine vibration and adjust if necessary. A qualified technician should perform this operation. Re- tighten the seat mounting bolts and front/rear suspension member retaining bolts to specified torque. Exhaust Pipes and Mountings Propeller Shaft Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration and damage. Start the engine and listen carefully for any exhaust gas leakage. Tighten connections or replace parts as necessary. Lubricate the propeller shaft spiders and slide yokes with lithium- base chassis grease and the double cardan joint with molybdenum- disulfide lithium- base chassis grease, and retorque the flange bolts. Only a qualified technician should re- torque the flange bolts. Fuel Lines and Connections, Fuel Tank Band and Fuel Tank Vapor Vent System Hoses Spark Plugs Visually inspect for corrosion, damage, cracks and loose or leaking connections. Tighten connections or replace parts as necessary. Install new plugs of the same type as originally equipped. A qualified technician should perform this operation. Fuel Tank Cap Gasket Steering Gear Box Visually inspect for cracks, deterioration and damage and replace if necessary. Inspect for signs of leakage. If you discover any leakage, have it repaired immediately by a qualified technician. SCHEDULED MAINTENANCE LOGS Explanation of Maintenance Items Steering Linkage Wheel Bearing and Drive Shaft Bushing Grease With the vehicle stopped, check for excessive freeplay in the steering wheel. Inspect the linkage for bending and damage and the dust boots for deterioration, cracks and damage. Replace any damaged parts. A qualified technician should perform these operations. Repack the wheel bearings with wheel bearing grease and the front drive shaft bushings with molybdenum- disulfide lithiumbase chassis grease. A qualified technician should perform these operations. Timing Belt Replace every 90,000 miles. A qualified technician should perform this operation. Tire Rotation Tires should be rotated according to the instructions in the Owner’s Manual. When rotating tires, check for damage and uneven wear. Transfer Case Oil Inspect each component for signs of leakage. If you discover any leakage, have it repaired by a qualified technician immediately. SCHEDULED MAINTENANCE LOGS 23 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 5,000 Miles or 4 Months 10,000 Miles or 8 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 7,500 Miles or 6 Months 24 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 15,000 Miles or 12 Months 15,000 Miles or 12 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace automatic transmission fluid ❑ Replace differential oil DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ SCHEDULED MAINTENANCE LOGS 25 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 20,000 Miles or 16 Months 25,000 Miles or 20 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 22,500 Miles or 18 Months 26 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 30,000 Miles or 24 Months 30,000 Miles or 24 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace non-platinum spark plugs (Corolla, Paseo, Tercel)1 ❑ Repack front wheel bearings (Paseo, Tercel) ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts (non-ribbed) __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Drive shaft boots __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 Required under the terms of the Emission Control Warranty. SCHEDULED MAINTENANCE LOGS 27 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 35,000 Miles or 28 Months 40,000 Miles or 32 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 37,500 Miles or 30 Months 28 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 45,000 Miles or 36 Months 45,000 Miles or 36 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace differential oil ❑ Replace automatic transmission fluid DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ SCHEDULED MAINTENANCE LOGS 29 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 50,000 Miles or 40 Months 55,000 Miles or 44 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 52,500 Miles or 42 Months 30 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 60,000 Miles or 48 Months 60,000 Miles or 48 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace platinum spark plugs1 ❑ Replace non-platinum spark plugs (Corolla, Paseo, Tercel)1 ❑ Repack front wheel bearings (Paseo, Tercel) ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Charcoal canister2 __ Differential oil __ Drive belts __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Drive shaft boots __ Engine valves __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 Required under the terms of the Emission Control Warranty. 2 Inspect at 60,000 miles or 72 months, whichever comes first, for Avalon, 6-cyl. Camry, 6-cyl. Camry Solara, Paseo, Sienna and Tercel. Required only for vehicles in California, Massachusetts and New York. SCHEDULED MAINTENANCE LOGS 31 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 65,000 Miles or 52 Months 70,000 Miles or 56 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 67,500 Miles or 54 Months 32 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 75,000 Miles or 60 Months 75,000 Miles or 60 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace differential oil ❑ Replace automatic transmission fluid DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ SCHEDULED MAINTENANCE LOGS 33 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 80,000 Miles or 64 Months 85,000 Miles or 68 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 82,500 Miles or 66 Months 34 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 90,000 Miles or 72 Months 90,000 Miles or 72 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace non-platinum spark plugs (Corolla, Paseo, Tercel)1 ❑ Repack front wheel bearings (Paseo, Tercel) ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Replace timing belt (except Corolla) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts (non-ribbed) __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Drive shaft boots __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 Required under the terms of the Emission Control Warranty. SCHEDULED MAINTENANCE LOGS 35 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 95,000 Miles or 76 Months 100,000 Miles or 80 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 97,500 Miles or 78 Months 36 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 105,000 Miles or 84 Months 105,000 Miles or 84 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace differential oil ❑ Replace automatic transmission fluid DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ SCHEDULED MAINTENANCE LOGS 37 Maintenance Log. Cars & Sienna 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 110,000 Miles or 88 Months 115,000 Miles or 92 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Rotate tires ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Re-torque drive shaft flange bolts (Sienna) DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION Mileage: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. SCHEDULED MAINTENANCE Date: Mileage: 112,500 Miles or 90 Months* 38 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. Cars & Sienna 120,000 Miles or 96 Months 120 Months 120,000 Miles or 96 Months 120 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace platinum spark plugs1 ❑ Replace non-platinum spark plugs (Corolla, Paseo, Tercel)1 ❑ Repack front wheel bearings (Paseo, Tercel) ❑ Re-torque drive shaft flange bolts (Sienna) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Charcoal canister2 __ Differential oil __ Drive belts __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses ❑ Inspect SRS Air Bag DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ __ Drive shaft boots __ Engine valves __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 Required under the terms of the Emission Control Warranty. 2 Inspect at 120,000 miles or 144 months, whichever comes first, for Avalon, 6-cyl. Camry, 6-cyl. Camry Solara, Paseo, Sienna and Tercel. Required only for vehicles in California, Massachusetts and New York. SCHEDULED MAINTENANCE LOGS 39 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 5,000 Miles or 4 Months 10,000 Miles or 8 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 7,500 Miles or 6 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 40 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 15,000 Miles or 12 Months 15,000 Miles or 12 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Limited-slip differential oil (Land Cruiser, 4WD RAV4)1 __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace automatic transmission fluid ❑ Replace differential oil (including limited-slip) DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 If vehicle is equipped with limited-slip differential. SCHEDULED MAINTENANCE LOGS 41 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 20,000 Miles or 16 Months 25,000 Miles or 20 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 22,500 Miles or 18 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 42 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 30,000 Miles or 24 Months 30,000 Miles or 24 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace limited-slip differential oil (Land Cruiser)1 ❑ Replace non-platinum spark plugs (Tacoma, 4Runner)2 ❑ Repack front wheel bearings (Tacoma 2WD) ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Lubricate drive shaft bushings (4WD Tacoma without ADD) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts (non-ribbed) __ Drive shaft boots __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Limited-slip differential oil (4WD RAV4)1 __ Steering gear box __ Steering linkage __ Transfer case oil (4WD models) __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil (including limited-slip) ❑ Replace transfer case oil (4WD models) ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ 1 If vehicle is equipped with limited-slip differential. 2 Required under the terms of the Emission Control Warranty. Mileage: _______________ SCHEDULED MAINTENANCE LOGS 43 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 35,000 Miles or 28 Months 40,000 Miles or 32 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 37,500 Miles or 30 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 44 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 45,000 Miles or 36 Months 45,000 Miles or 36 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Limited-slip differential oil (Land Cruiser, 4WD RAV4)1 __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace automatic transmission fluid ❑ Replace differential oil (including limited-slip) DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 If vehicle is equipped with limited-slip differential. SCHEDULED MAINTENANCE LOGS 45 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 50,000 Miles or 40 Months 55,000 Miles or 44 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 52,500 Miles or 42 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 46 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 60,000 Miles or 48 Months 60,000 Miles or 48 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace limited-slip differential oil (Land Cruiser, RAV4 4WD)1 ❑ Replace platinum spark plugs (RAV4)2 ❑ Replace non-platinum spark plugs (Tacoma, 4Runner)2 ❑ Repack front wheel bearings (Tacoma 2WD) ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Lubricate drive shaft bushings (4WD Tacoma without ADD) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Charcoal canister 3 __ Differential oil __ Drive belts __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Drive shaft boots __ Engine valves __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transfer case oil (4WD models) __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transfer case oil (4WD models) ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ 1 If vehicle is equipped with limited-slip differential. 2 Required under the terms of the Emission Control Warranty. 3 Inspect at 60,000 miles or 72 months, whichever comes first. Required only for vehicles in California, Massachusetts and New York. Mileage: _______________ SCHEDULED MAINTENANCE LOGS 47 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 65,000 Miles or 52 Months 70,000 Miles or 56 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 67,500 Miles or 54 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 48 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 75,000 Miles or 60 Months 75,000 Miles or 60 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Limited-slip differential oil (Land Cruiser, 4WD RAV4)1 __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace automatic transmission fluid ❑ Replace differential oil (including limited-slip) DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ 1 If vehicle is equipped with limited-slip differential. SCHEDULED MAINTENANCE LOGS 49 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 80,000 Miles or 64 Months 85,000 Miles or 68 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 82,500 Miles or 66 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 50 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 90,000 Miles or 72 Months 90,000 Miles or 72 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace limited-slip differential oil (Land Cruiser)1 ❑ Replace iridium spark plugs (Land Cruiser)2 ❑ Replace non-platinum spark plugs (Tacoma, 4Runner)2 ❑ Replace timing belt (except 4-cyl. Tacoma and 4Runner) ❑ Repack front wheel bearings (Tacoma 2WD) ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Lubricate drive shaft bushings (4WD Tacoma without ADD) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Differential oil __ Drive belts __ Drive shaft boots __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Limited-slip differential oil (4WD RAV4)1 __ Steering gear box __ Steering linkage __ Transfer case oil (4WD models) __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil (including limited-slip) ❑ Replace transfer case oil (4WD models) ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ 1 If vehicle is equipped with limited-slip differential. 2 Required under the terms of the Emission Control Warranty. Mileage: _______________ SCHEDULED MAINTENANCE LOGS 51 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 95,000 Miles or 76 Months 100,000 Miles or 80 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 97,500 Miles or 78 Months SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 52 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 105,000 Miles or 84 Months 105,000 Miles or 84 Months ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Automatic transmission fluid __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Limited-slip differential oil (Land Cruiser, 4WD RAV4)1 __ Differential oil __ Drive shaft boots __ Exhaust pipes and mountings __ Steering gear box __ Steering linkage Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect engine air filter ❑ Inspect nuts and bolts on chassis and body ❑ Replace automatic transmission fluid ❑ Replace differential oil (including limited-slip) DEALER SERVICE VERIFICATION Date: __________________ Mileage: _______________ SCHEDULED MAINTENANCE LOGS 53 Maintenance Log. SUVs & Tacoma 5,000-Mile Maintenance Intervals 7,500-Mile Maintenance Intervals 110,000 Miles or 88 Months 115,000 Miles or 92 Months ❑ Replace engine oil and oil filter ❑ Replace engine oil and oil filter Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect the following: __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) DEALER SERVICE VERIFICATION __ Ball joints and dust covers __ Brake linings/drums and brake pads/discs __ Drive shaft boots DEALER SERVICE VERIFICATION Date: DEALER SERVICE VERIFICATION ❑ Replace engine oil and oil filter Date: ❑ Rotate tires Mileage: * Specific services apply to specific operating conditions. See pages 18–19 for details. MAINTENANCE Date: Mileage: 112,500 Miles or 90 Months* SCHEDULED __ Engine air filter __ Nuts and bolts on chassis and body __ Steering linkage ❑ Rotate tires ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) Mileage: 54 To determine the appropriate maintenance interval for your vehicle, see page 17. LOGS Maintenance Log. SUVs & Tacoma 120,000 Miles or 96 Months 120 Months 120,000 Miles or 96 Months 120 Months ❑ Replace engine air filter ❑ Replace engine coolant ❑ Replace engine oil and oil filter ❑ Rotate tires ❑ Replace limited-slip differential oil (Land Cruiser, RAV4 4WD)1 ❑ Replace platinum spark plugs (RAV4)2 ❑ Replace non-platinum spark plugs (Tacoma, 4Runner)2 ❑ Repack front wheel bearings (Tacoma 2WD) ❑ Lubricate propeller shaft and re-torque bolts (all 4WD except RAV4) ❑ Lubricate drive shaft bushings (4WD Tacoma without ADD) ❑ Re-torque drive shaft flange bolts (all 4WD except Land Cruiser) ❑ Inspect the following: __ Ball joints and dust covers __ Brake lines and hoses __ Brake linings/drums and brake pads/discs __ Charcoal canister 3 __ Differential oil __ Drive belts __ Drive shaft boots __ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses ❑ Inspect SRS Air Bag Date: __________________ DEALER SERVICE VERIFICATION Mileage: _______________ __ Engine valves __ Exhaust pipes and mountings __ Fuel tank cap gasket __ Steering gear box __ Steering linkage __ Transfer case oil (4WD models) __ Transmission fluid or oil Additional Maintenance Items for Special Operating Conditions:* ❑ Inspect nuts and bolts on body and chassis ❑ Replace differential oil ❑ Replace transfer case oil (4WD models) ❑ Replace transmission fluid or oil DEALER SERVICE VERIFICATION Date: __________________ 1 If vehicle is equipped with limited-slip differential. 2 Required under the terms of the Emission Control Warranty. 3 Inspect at 120,000 miles or 144 months, whichever comes first. Required only for vehicles in California, Massachusetts and New York. Mileage: _______________ SCHEDULED MAINTENANCE LOGS 55 Vehicle Identification Model Mileage at delivery Body style Key number Model year Selling dealership In-service date Selling dealership phone number Vehicle identification number 56 SCHEDULED MAINTENANCE LOGS w w w .t o y o ta .c o m 00400-01999-SMG1 Printed in U.S.A. 6/98 SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT SS0ZS–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt 4 Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 Author: Date: 164 SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZT–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 – 60 145 290 540 850 – 52 in.·lbf 10 21 39 61 – 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 – 75 175 360 670 1,050 – 65 in.·lbf 13 26 48 76 – 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 – 90 210 440 810 1,250 – 78 in.·lbf 15 32 59 90 – 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 – 120 290 590 1,050 1,700 – 9 21 43 76 123 – 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 Author: Date: 165 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more Author: Date: 166 SS–4 SERVICE SPECIFICATIONS – MAINTENANCE MAINTENANCE SS074–01 SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm (0 in.) Author: Date: 167 SS–5 SERVICE SPECIFICATIONS – MAINTENANCE SS075–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Front seat mount bolts 37 375 27 Front suspension member x Body 181 1,850 134 Rear suspension member x Body 51 520 38 Author: Date: 168 SS–6 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) ENGINE MECHANICAL (5S–FE) SS0AD–03 SERVICE DATA Compression pressure at 250 rpm STD 1,226 kPa (12.5 kgf/cm2, 178 psi) or more Minimum 981 kPa (10.0 kgf/cm2, 142 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) or less Valve clearance Adjusting shim (for repair part) Ignition timing w/ Terminals TE1 and E1 connected of DLC1 Idle speed Free length Installed load at 50.5 mm (1.988 in.) Cylinder head Warpage Cylinder block side Manifold side Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing Inside diameter Outside diameter (for repair part) Valve Valve overall length Vale face angle Stem diameter Stem oil clearance Margin thickness Deviation Free length Installed tension at 34.7 mm (1.366 in.) 0.19 – 0.29 mm (0.007 – 0.011 in.) 0.28 – 0.38 mm (0.011 – 0.015 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 8 – 12° BTDC @ idle 700 ± 50 rpm – Idler pulley tension spring Valve spring at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 42.0 mm (1.654 in.) 32 – 37 N (3.25 – 3.75 kgf, 7.2 – 8.3 lbf) Maximum 0.05 mm (0.0020 in.) Maximum 0.08 mm (0.0031 in.) 30°, 45°, 75° 45° 1.0 – 1.4 mm (0.039 – 0.055 in.) STD O/S 0.05 6.010 – 6.030 mm (0.2366 – 0.2374 in.) 11.048 – 11.059 mm (0.4331 – 0.4342 in.) 11.050 – 11.077 mm (0.4350 – 0.4361 in.) STD Intake Exhaust Minimum Intake Exhaust 97.40 – 97.80 mm (3.8346 – 3.8504 in.) 98.25 – 98.65 mm (3.8681 – 3.8839 in.) 97.1 mm (3.823 in.) 98.0 mm (3.858 in.) 44.5° Intake 5.970 – 5.985 mm (0.2350 – 0.2356 in.) Exhaust E h t 5.965 5 965 – 5.980 5 980 mm (0.2348 (0 2348 – 0.2354 0 2354 in.) i ) STD Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 0.8 – 1.2 mm (0.031 – 0.047 in.) Minimum 0.5 mm (0.020 in.) Maximum 2.0 mm (0.079 in.) 40.95 – 42.80 mm (1.6122 – 1.6850 in.) 164 – 189 N (16.7 – 19.3 kgf, 36.8 – 42.5 lbf) Author: Date: 169 SS–7 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) Valve lifter Lifter diameter Lifter bore diameter Oil clearance 30.966 – 30.976 mm (1.2191 – 1.2195 in.) 31.000 – 31.018 mm (1.2205 – 1.2212 in.) STD 0.024 – 0.052 mm (0.0009 – 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Manifold Warpage Maximum 0.30 mm (0.0118 in.) Camshaft Thrust clearance Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance STD Intake Exhaust Maximum Intake Exhaust STD Maximum 0.045 – 0.100 mm (0.0018 – 0.0039 in.) 0.030 – 0.085 mm (0.0012 – 0.0033 in.) 0.12 mm (0.0047 in.) 0.10 mm (0.0039 in.) 0.025 – 0.062 mm (0.0010 – 0.0024 in.) 0.10 mm (0.0039 in.) 26.959 – 26.975 mm (1.0614 – 1.0620 in.) Maximum 0.04 mm (0.0016 in.) STD Intake 42.01 – 42.11 mm (1.6539 – 1.6579 in.) Exhaust 40.06 – 40.16 mm (1.5772 – 1.5811 in.) Minimum Intake 41.90 mm (1.6496 in.) Exhaust 39.95 mm (1.5728 in.) STD 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 22.5 – 22.9 mm (0.886 – 0.902 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Maximum STD Mark 1 Mark 2 Mark 3 Maximum STD O/S 0.50 0.05 mm (0.0020 in.) 87.000 – 87.010 mm (3.4252 – 3.4256 in.) 87.010 – 87.020 mm (3.4256 – 3.4260 in.) 87.020 – 87.030 mm (3.4260 – 3.4264 in.) 87.23 mm (3.4342 in.) 87.73 mm (3.4350 in.) Piston and piston ring Piston diameter STD Mark 1 Mark 2 Mark 3 O/S 0.50 STD Maximum No.1, No.2 STD No.1 No.2 Oil (side rail) Maximum No.1 No.2 Oil (side rail) 86.815 – 86.825 mm (3.4179 – 3.4183 in.) 86.825 – 86.835 mm (3.4183 – 3.4186 in.) 86.835 – 86.845 mm (3.4201 – 3.4205 in.) 87.350 – 87.380 mm (3.4375 – 3.4387 in.) 0.175 – 0.195 mm (0.0068 – 0.0076 in.) 0.215 mm (0.0085 in.) 0.030 – 0.070 mm (0.0012 – 0.0028 in.) 0.270 – 0.490 mm (0.0106 – 0.0192 in.) 0.450 – 0.670 mm (0.0177 – 0.0263 in.) 0.100 – 0.470 mm (0.0039 – 0.0185 in.) 1.09 mm (0.0429 in.) 1.27 mm (0.0499 in.) 1.07 mm (0.0421in.) Piston oil clearance Piston ring groove clearance Piston ring end gap Connecting rod Thrust clearance STD 0.160 – 0.312 mm (0.0063 – 0.0123 inb.) Maximum 0.35 mm (0.0138 in.) Connecting rod bearing center wall thickness Reference STD Mark 1 Mark 2 Mark 3 Connecting rod oil clearance STD STD U/S 0.25 Maximum Rod bend Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Piston pin oil clearance STD Maximum Connecting rod bolt outside diameter STD Minimum 1.484 – 1.488 mm (0.0584 – 0.0586 in.) 1.488 – 1.492 mm (0.0586 – 0.0587 in.) 1.492 – 1.496 mm (0.0587 – 0.0589 in.) 0.024 – 0.055 mm (0.0009 – 0.0022 in.) 0.023 – 0.069 mm (0.0009 – 0.0027 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 – 22.017 mm (0.8663 – 0.8668 in.) 21.997 – 22.009 mm (0.8660 – 0.8665 in.) 0.005 – 0.011 mm (0.0002 – 0.0004 in.) 0.05 mm (0.0020 in.) 7.860 – 8.000 mm (0.3094 – 0.3150 in.) 7.60 mm (0.2992 in.) Author: Date: 170 SS–8 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) Crankshaft Thrust clearance STD 0.020 – 0.220 mm (0.0008 – 0.0087 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 2.440 – 2.490 mm (0.0961 – 0.0980 in.) Main journal oil clearance STD No.3 STD 0.025 – 0.044 mm (0.0010 – 0.0017 in.) U/S 0.25 0.027 – 0.067 mm (0.0011 – 0.0026 in.) Others STD 0.015 – 0.034 mm (0.0006 – 0.0013 in.) U/S 0.25 0.019 – 0.059 mm (0.0007 – 0.0023 in.) Maximum 0.08 mm (0.0031 in.) Main journal diameter STD 54.988 – 55.003 mm (2.1653 – 2.1655 in.) U/S 0.25 54.745 – 54.755 mm (2.1553 – 2.1557 in.) Main bearing center wall thickness (Reference) STD No.3 Mark 1 1.992 – 1.995 mm (0.0784 – 0.0785 in.) Mark 2 1.995 – 1.998 mm (0.0785 – 0.0787 in.) Mark 3 1.998 – 2.001 mm (0.0787 – 0.0788 in.) Mark 4 2.001 – 2.004 mm (0.0788 – 0.0789 in.) Mark 5 2.004 – 2.007 mm (0.0789 – 0.0790 in.) Others Mark 1 1.997 – 2.000 mm (0.0786 – 0.0787 in.) Mark 2 2.000 – 2.003 mm (0.0787 – 0.0789 in.) Mark 3 2.003 – 2.006 mm (0.0789 – 0.0790 in.) Mark 4 2.006 – 2.009 mm (0.0790 – 0.0791 in.) Mark 5 2.009 – 2.012 mm (0.0791 – 0.0792 in.) Crank pin diameter STD 51.985 – 52.000 mm (2.0466 – 2.0472 in.) U/S 0.25 51.745 – 51.755 mm (2.0372 – 2.0376 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out–of–round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out–of–round Maximum 0.02 mm (0.0008 in.) Balance shaft Thrust clearance Backlash Crankshaft to No.1 Balance shaft Off–vehicle On–vehicle Adjusting spacer thickness STD 0.060 – 0.110 mm (0.0024 – 0.0043 in.) Maximum 0.11 mm (0.0043 in.) STD at punch mark A at punch mark B STD at punch mark A at punch mark B No.01 No.03 No.05 No.07 No.09 No.11 No.13 No.15 No.17 No.19 No.21 No.23 No.25 No.27 No.29 No.31 No.33 No.35 No.37 No.39 0.005 – 0.040 mm (0.002 – 0.0016 in.) 0.005 – 0.060 mm (0.002 – 0.0024 in.) 0.025 – 0.065 mm (0.0010 – 0.0026 in.) 0.025 – 0.085 mm (0.0010 – 0.0033 in.) 1.74 mm (0.0685 in.) 1.76 mm (0.0693 in.) 1.78 mm (0.0701 in.) 1.80 mm (0.0709 in.) 1.82 mm (0.0717 in.) 1.84 mm (0.0724 in.) 1.86 mm (0.0732 in.) 1.88 mm (0.0740 in.) 1.90 mm (0.0748 in.) 1.92 mm (0.0756 in.) 1.94 mm (0.0764 in.) 1.96 mm (0.0772 in.) 1.98 mm (0.0780 in.) 2.00 mm (0.0787 in.) 2.02 mm (0.0795 in.) 2.04 mm (0.0803 in.) 2.06 mm (0.0811 in.) 2.08 mm (0.0819 in.) 2.10 mm (0.0827 in.) 2.12 mm (0.0835 in.) Author: Date: 171 SS–9 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) SS0AE–03 TORQUE SPECIFICATION Part tightened Oil pump pulley x Oil pump drive shaft N·m kgf·cm ft·lbf 24 245 18 No.2 idler pulley x Oil pump 42 425 31 Crankshaft pulley x Crankshaft 108 1,100 80 54 37 550 380 40 27 42 425 31 49 Turn 90° 500 Turn 90° 36 Turn 90° Water bypass pipe x Cylinder head 19 195 14 Spark plug tube x Cylinder head 49 500 36 Camshaft bearing cap x Cylinder head 19 190 14 Cylinder head cover x Cylinder head 44 450 33 RH engine hanger x Generator bracket 25 250 18 Generator bracket x Cylinder head 42 425 31 LH engine hanger x Cylinder head 25 250 18 No.3 timing belt cover x Cylinder head 7.8 80 69 in.·lbf Delivery pipe x Cylinder head 13 130 9 Intake manifold x Cylinder head 19 195 14 34 29 350 300 25 21 EGR valve x intake manifold 13.3 130 10 EGR pipe x Cylinder head 61.2 600 45 Intake manifold stay x Intake manifold 39 398 29 Intake manifold stay x Stiffening plate 39 398 29 Water outlet x Cylinder head 15 150 11 No.2 intake manifold stay x Cylinder head 21 214 15 No.2 intake manifold stay x Intake manifold 42 428 31 Exhaust manifold x Cylinder head 49 500 36 No.1 exhaust manifold stay x Exhaust manifold 42 425 31 No.1 exhaust manifold stay x Transaxle 42 425 31 No.2 exhaust manifold stay x Exhaust manifold 42 425 31 58 42 591 425 43 31 No.1 rear end plate x Cylinder block 9.3 95 82 in.·lbf Flywheel (M/T) x Crankshaft 88 900 65 83 850 61 46 64 470 650 34 47 Transaxle (A/T) x Cylinder block 66 670 48 Drive plate x Torque converter clutch 27 280 20 No.2 rear end plate x Cylinder block 9.3 95 82 in.·lbf Exhaust pipe bracket, No.2 rear end plate x Transaxle 19 195 14 RH stiffener plate x Cylinder block 39 398 29 RH stiffener plate x Transaxle 39 398 29 Camshaft timing pulley x Camshaft for use with SST No.1 idler pulley x Cylinder head Cylinder head x Cylinder block 1st 2nd Fuel inlet hose x Delivery pipe for use with SST No.2 exhaust manifold stay, LH stiffener plate x Cylinder block TMC made TMMK made Drive plate (A/T) x Crankshaft Transaxle (M/T) x Cylinder block 14 mm head 17 mm head Author: Date: 172 SS–10 SERVICE SPECIFICATIONS LH stiffener plate x Transaxle – ENGINE MECHANICAL (5S–FE) 37 42 380 430 27 31 No.2 RH engine mounting bracket x Cylinder block 52 530 38 No.2 RH engine mounting bracket x Generator bracket 52 530 38 Rear engine mounting insulator x Cylinder block 64 650 47 Front engine mounting insulator x Cylinder block 64 650 47 Engine moving control rod x No.2 RH engine mounting bracket 64 650 47 Engine moving control rod x Body 64 650 47 80 44 66 820 450 670 59 32 49 Rear engine mounting insulator x Front frame 66 670 49 LH engine mounting insulator x Frount frame 80 820 59 LH engine mounting insulator x Transaxle 64 650 47 PS pump x PS pump bracket 43 440 32 25.5 260 19 Fuel inlet hose x Fuel filter 29 300 21 Main bearing cap x Cylinder block 59 600 43 25 Turn 90° 250 Turn 90° 18 Turn 90° Engine balancer x Cylinder block 49 500 36 Rear oil seal retainer x Cylinder block 13 130 9 Water pump x Cylinder block 8.8 90 78 in.·lbf Generator drive belt adjusting bar x Cylinder block 22 224 16 PS pump bracket x Cylinder block 43 440 32 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center pipe 56 570 41 Center exhaust pipe x Tailpipe 56 570 41 Support bracket for front exhaust pipe x Exhaust pipe bracket on No.2 rear end plate 33 330 24 Support stay for front exhaust pipe x Support bracket 33 330 24 Support bracket for front exhaust pipe x Front frame 33 330 24 Support bracket for center exhaust pipe x Body 19 195 14 Support bracket for tailpipe x Body 33 330 24 Front engine mounting insulator x Front frame M/T A/T TMC made TMMK made for silver color for green color A/C compressor x Cylinder block Connecting rod cap x Connecting rod 1st 2nd Author: Date: 173 SS–11 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) ENGINE MECHANICAL (1MZ–FE) SS076–02 SERVICE DATA Compression pressure at 250 rpm STD 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less Valve clearance at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 Adjusting shim for repair part Ignition timing w/ Terminals TE1 and E1 connected of DLC1 Idle speed Protrusion from housing side Cylinder head Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter 8 – 12° BTDC @ idle 700 ± 50 rpm – Timing belt tensioner 0.15 – 0.25 mm (0.006 – 0.010 in.) 0.25 – 0.35 mm (0.010 – 0.014 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 10.0 – 10.8 mm (0.394 – 0.425 in.) Maximum 0.10 mm (0.039 in.) STD O/S 0.05 30°, 45°, 75° 45° 1.0 – 1.4 mm (0.039 – 0.055 in.) 10.295 – 10.313 mm (0.4053 – 0.4080 in.) 10.345 – 10.363 mm (0.4073 – 0.4080 in.) 12 pointed head cylinder head bolt diameter at tension portion STD 8.95 – 9.05 mm (0.3524 – 0.3563 in.) Minimum 8.75 mm (0.3445 in.) Valve guide bushing Inside diameter Outside diameter for repair part Valve Valve overall length Valve face angle Stem diameter Stem oil clearance Margin thickness STD O/S 0.05 5.510 – 5.530 mm (0.2169 – 0.2177 in.) 10.333 – 10.344 mm (0.4068 – 0.4072 in.) 10.383 – 10.394 mm (0.4088 – 0.4092 in.) STD Intake Exhaust Minimum Intake Exhaust 95.45 mm (3.5779 in.) 95.40 mm (3.7559 in.) 94.95 mm (3.7382 in.) 94.90 mm (3.7362 in.) 44.5° Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.) Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.) STD Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.0 mm (0.039 in.) Maximum 0.5 mm (0.020 in.) Author: Date: 174 SS–12 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) Maximum 2.0 mm (0.079 in.) 45.50 mm (1.7913 in.) 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) Valve lifter Lifter diameter Lifter bore diameter Oil clearance 30.966 – 30.976 mm (1.2191 – 2.2195 in.) 31.000 – 31.016 mm (1.2205 – 1.2211 in.) STD 0.024 – 0.050 mm (0.0009 – 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Camshaft Thrust clearance Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance STD Maximum STD Intake Exhaust Maximum Intake Exhaust 0.040 – 0.090 mm (0.0016 – 0.0035 in.) 0.12 mm (0.0047 in.) 0.035 – 0.072 mm (0.0014 – 0.0028 in.) 0.025 – 0.062 mm (0.0010 – 0.0024 in.) 0.10 mm (0.0039 in.) 0.09 mm (0.0035 in.) 26.959 – 26.975 mm (1.0613 – 1.0620 in.) Maximum 0.06 mm (0.0024 in.) STD Intake 42.11 – 42.21 mm (1.6579 – 1.6618 in.) Exhaust 41.96 – 42.06 mm (1.6520 – 1.6559 in.) Minimum Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) STD 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 18.2 – 18.8 mm (0.712 – 0.740 in.) Air intake chamber Warpage Maximum 0.10 mm (0.0039 in.) Intake manifold Warpage Air intake chamber side Cylinder head side Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Exhaust manifold Warpage Maximum 0.50 mm (0.0196 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Maximum 0.07 mm (0.0028 in.) 87.500 – 87.512 mm (3.4449 – 3.4453 in.) Maximum 87.52 mm (3.4457 in.) 12 pointed head main bearing cap bolt diameter at tension portion STD 7.500 – 7.600 mm (0.2953 – 0.2992 in.) Minimum 7.20 mm (0.2835 in.) Piston and piston ring Piston diameter AISIN made at 23.2 mm (0.913 in.) from the piston head 87.406 – 87.416 mm (3.4412 – 3.4416 in.) at 41.2 mm (1.622 in.) from the piston head Piston oil clearance AISIN made STD Maximum MAHLE made STD Maximum Piston ring groove clearance No.1 No.2 Piston ring end gap STD No.1 No.2 Oil Maximum No.1 No.2 Oil 87.453 – 87.467 mm (3.4430 – 3.4436 in.) MAHLE made 0.084 – 0.106 mm (0.0033 – 0.0042) 0.13 mm (0.0051 in.) 0.033 – 0.059 mm (0.0013 – 0.0023) 0.08 mm (0.0031 in.) 0.020 – 0.070 mm (0.0008 – 0.0028 in.) 0.020 – 0.060 mm (0.0008 – 0.0024 in.) 0.25 – 0.35 mm (0.0098 – 0.0138 in.) 0.35 – 0.45 mm (0.0138 – 0.0177 in.) 0.15 – 0.40 mm (0.0059 – 0.0157 in.) 0.95 mm (0.0374 in.) 1.05 mm (0.0413 in.) 1.00 mm (0.0394 in.) Author: Date: 175 SS–13 SERVICE SPECIFICATIONS Connecting rod Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference – ENGINE MECHANICAL (1MZ–FE) STD 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum 0.35 mm (0.0138 in.) 20.80 – 20.85 mm (0.8189 – 0.8209 in.) Mark 1 Mark 2 Mark 3 Mark 4 Connecting rod oil clearance STD Maximum Rod out–of–alignment Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum Crankshaft 1.484 – 1.487 mm (0.0584 – 0.0585 in.) 1.487 – 1.490 mm (0.0585 – 0.0587 in.) 1.490 – 1.493 mm (0.0587 – 0.0588 in.) 1.493 – 1.496 mm (0.0588 – 0.0589 in.) 0.038 – 0.064 mm (0.0015 – 0.0025 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 – 22.014 mm (0.8663 – 0.8667 in.) 21.997 – 22.006 mm (0.8660 – 0.8664 in.) 0.005 – 0.011 mm (0.0002 – 0.0004 in) 0.05 mm (0.0020 in.) 7.2 – 7.3 mm (0.284 – 0.287 in.) 7.0 mm (0.276 in.) Thrust clearance STD 0.04 – 0.24 mm (0.0016 – 0.0095 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 – 1.980 mm (0.0760 – 0.0780 in.) Main journal oil clearance STD No.1 and No.4 0.014 – 0.036 mm (0.0006 – 0.0014 in.) No.2 and No.3 0.026 – 0.048 mm (0.0010 – 0.0019 in.) Maximum No.1 and No.4 0.05 mm (0.0020 in.) No.2 and No.3 0.06 mm (0.0024 in.) Main journal diameter 60.988 – 61.000 mm (2.4011 – 2.4016 in.) Main bearing center wall thickness Reference (TMC made) Mark 1 2.486 – 2.489 mm (0.0979 – 0.0980 in.) Mark 2 2.489 – 2.492 mm (0.0980 – 0.0981 in.) Mark 3 2.492 – 2.495 mm (0.0981 – 0.0982 in.) Mark 4 2.495 – 2.498 mm (0.0982 – 0.0983 in.) M k 5 2.498 Mark 2 498 – 2 2.501 501 mm (0 (0.0983 0983 – 0 0.0985 0985 iin.)) Mark 6 2.501 – 2.504 mm (0.0985 – 0.0986 in.) Mark 7 2.504 – 2.507 mm (0.0986 – 0.0987 in.) Reference (TMMK made) Mark 1 2.485 – 2.488 mm (0.0978 – 0.0980 in.) Mark 2 2.488 – 2.491 mm (0.0980 – 0.0981 in.) Mark 3 2.491 – 2.494 mm (0.0981 – 0.0982 in.) Mark 4 2.494 – 2.497 mm (0.0982 – 0.0983 in.) Mark 5 2.497 – 2.500 mm (0.0983 – 0.0984 in.) Mark 6 2.500 – 2.503 mm (0.0984 – 0.0985 in.) Mark 7 2.503 – 2.506 mm (0.0985 – 0.0987 in.) Crank pin diameter 52.992 – 53.000 mm (2.0863 – 2.0866 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out–of–round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out–of–round Maximum 0.02 mm (0.0008 in.) Author: Date: 176 SS–14 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) SS077–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Timing belt plate x Oil pump 8 80 69 in.·lbf No.1 idler pulley x Oil pump 34 350 25 No.2 idler pulley x No.2 idler pulley bracket 43 440 32 125 88 1,300 900 94 65 Timing belt tensioner x Oil pump 27 280 20 RH engine mounting bracket x Cylinder block 28 290 21 No.2 timing belt cover x No.3 timing belt cover 8.5 85 74 in.·lbf No.1 timing belt cover x Oil pump 8.5 85 74 in.·lbf Crankshaft pulley x Crankshaft 215 2,200 159 No.2 generator bracket x Engine RH mounting bracket 28 290 21 54 Turn 90° 18.5 550 Turn 90° 185 40 Turn 90° 13 Camshaft bearing cap x Cylinder head 16 160 12 Cylinder head cover x Cylinder head 8 80 69 in.·lbf Exhaust manifold x Cylinder head 49 500 36 20 34 200 350 15 25 20 34 200 350 15 25 No.1 EGR pipe x RH exhaust manifold 12 120 9 No.1 EGR pipe x EGR cooler 12 120 9 PS pump bracket x RH cylinder head 43 440 32 Camshaft timing pulley x Camshaft for SST Cylinder head x Cylinder block 12 pointed head bolt 1st 2nd Recessed head bolt Exhaust manifold stay x Exhaust manifold Except California A/T and all M/T California A/T and all M/T Exhaust manifold stay x Transmission housing Except California A/T California A/T Oil dipstick guide x LH cylinder head 8 80 69 in.·lbf 19.5 200 14 8 80 69 in.·lbf No.3 timing belt cover x Cylinder head 8.5 85 74 in.·lbf Water outlet x Intake manifold 15 150 11 Fuel inlet hose x Fuel filter 29 300 21 Intake manifold x Cylinder head 15 150 11 Air intake chamber x Intake manifold 43 440 32 No.2 EGR pipe x Air intake chamber 12 120 9 No.2 EGR pipe x EGR cooler 12 120 9 No.1 engine hanger x Air intake chamber 39 400 29 No.1 engine hanger x RH cylinder head 39 400 29 Air intake chamber stay x Air intake chamber 19.5 200 14 Air intake chamber stay x RH cylinder head 19.5 200 14 Rear engine mounting insulator x Cylinder block 64 650 47 Front engine mounting insulator x Cylinder block 64 650 47 Engine moving control rod x RH engine mounting bracket 64 650 47 Engine moving control rod x RH fender apron 64 650 47 No.2 RH engine mounting stay x No.2 RH engine mounting bracket 64 650 47 Water inlet pipe x LH cylinder head Cylinder head rear plate x LH cylinder head Author: Date: 177 SS–15 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) No.2 RH engine mounting stay x No.2 Generator bracket 64 650 47 RH engine mounting stay x Water outlet 32 320 23 RH engine mounting stay x Engine moving control rod 32 320 23 RH engine mounting stay x No.2 RH engine mounting bracket 32 320 23 80 44 66 820 450 670 59 32 48 Engine mounting absorber x Front frame 48 490 35 Engine mounting absorber x Transaxle 48 490 35 Rear engine mounting insulator x Front frame 66 670 48 LH engine mounting insulator x Transaxle 64 650 47 PS pump x PS pump bracket 43 440 31 A/C compressor x Housing bracket 25 250 18 A/C compressor x No.1 oil pan 25 250 18 Generator adjusting bar x Drive belt adjusting bar bracket 18 185 13 12 pointed head bolt 1st 2nd 6 pointed head bolt 22 Turn 90° 27 225 Turn 90° 275 16 Turn 90° 20 1st 2nd 24.5 Turn 90° 250 Turn 90° 18 Turn 90° Rear oil seal retainer x Cylinder block 8 80 69 in.·lbf EGR cooler x Cylinder block 9 90 78 in.·lbf Engine coolant drain union x Cylinder block 39 400 29 Water seal plate x Cylinder block 18 180 13 Oil filter union x Cylinder block 30 310 22 Water inlet housing x Cylinder block 8 80 69 in.·lbf Knock sensor x Cylinder block 39 400 29 No.2 idler pulley bracket x Cylinder block 28 290 21 A/C compressor housing bracket x Cylinder block 25 250 18 Generator bracket x Cylinder block 43 440 32 Drive plate x Crankshaft 83 850 61 Flywheel x Crankshaft 83 850 61 Front exhaust pipe support bracket x No.1 oil pan 21 210 15 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Center exhaust pipe x Tailpipe 56 570 41 Front exhaust pipe bracket x Sub frame 33 330 24 Front exhaust pipe support bracket x Front exhaust pipe stay 33 330 24 Heated oxygen sensor x Center exhaust pipe 44 450 33 Front engine mounting insulator x Front frame TMC made TMMK made Main bearing cap x Cylinder block Silver color bolt Green color bolt Connecting rod cap x Connecting rod Author: Date: 178 SS–16 SERVICE SPECIFICATIONS – EMISSION CONTROL (5S–FE) EMISSION CONTROL (5S–FE) SS0AF–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 13.3 136 10 EGR valve x EGR pipe 10 102 7 Exhaust manifold x Cylinder head 49 500 36 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 EGR valve x Intake manifold Author: Date: 179 SS–17 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) EMISSION CONTROL (1MZ–FE) SS078–01 SERVICE DATA EGR valve position sensor Resistance (VC – E2) Power source voltage (VC– E2) Power output voltage (EGLS – E2) at vacuum (17.3 kPa, 130 mmHg, 5.1 in.Hg) at no vacuum 1.5 – 4.3 kΩ 4.5 – 5.5 V 3.2 – 5.1 V 0.4 – 1.6 V Author: Date: 180 SS–18 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) SS079–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf EGR valve position sensor x EGR valve 2 20 17 in.·lbf EGR pipe x EGR valve 12 120 9 EGR pipe x EGR cooler 12 120 9 EGR valve x Air intake chamber 12 120 9 EGR gas temperature sensor x EGR valve 20 200 14 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Front exhaust pipe bracket x Sub frame 33 330 24 Front exhaust pipe support bracket x Front exhaust pipe stay 33 330 24 Author: Date: 181 SS–19 SERVICE SPECIFICATIONS – SFI (5S–FE) SFI (5S–FE) SS0AG–03 SERVICE DATA Fuel pressure regulator Fuel pressure Fuel pump Resistance at 20°C (68°F) Injector Resistance at 20°C (68°F) Injection volume Difference between each cylinder Fuel leakage Throttle body at no vacuum Throttle body fully closed angle Throttle opener setting speed 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) 0.2 – 3.0 Ω 13.4 – 14.2 Ω 54 – 69 cm3 (3.3 – 4.2 cu in.) per 15 seconds 7 cm3 (0.4 cu in.) or less One drop or less per minute 6° 1,300 – 1,500 rpm (w/ Cooling fan OFF) Throttle position sensor Clearance between stop screw and lever 0 mm (0 in.) Throttle valve fully open – IAC valve Resistance (+B – ISCC or ISCO) VSV for EVAP Resistance at 20°C (68°F) 30 – 34 Ω VSV for vapor pressure sensor Resistance at 20°C (68°F) 33 – 39 Ω VSV for EGR Resistance at 20°C (68°F) 33 – 39 Ω ECT sensor Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ IAT sensor Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ MAP sensor Power source voltage 4.5 – 5.5 V Vapor Pressure Sensor Power sorce voltage 4.5 – 5.5 V A/F sensor Resistance at 20°C (68°F) 0.8 – 1.4 Ω Heated oxygen sensor Resistance at 20°C (68°F) 11 – 16 Ω Fuel cut rpm Fuel return rpm VTA – E2 VTA – E2 VC – E2 0.2 – 5.7 kΩ 2.0 – 10.2 kΩ 2.5 – 5.9 kΩ at cold at hot 17.0 – 24.5 Ω 21.5 – 28.5 Ω 1,500 rpm Author: Date: 182 SS–9 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (5S–FE) SS0AE–03 TORQUE SPECIFICATION Part tightened Oil pump pulley x Oil pump drive shaft N·m kgf·cm ft·lbf 24 245 18 No.2 idler pulley x Oil pump 42 425 31 Crankshaft pulley x Crankshaft 108 1,100 80 54 37 550 380 40 27 42 425 31 49 Turn 90° 500 Turn 90° 36 Turn 90° Water bypass pipe x Cylinder head 19 195 14 Spark plug tube x Cylinder head 49 500 36 Camshaft bearing cap x Cylinder head 19 190 14 Cylinder head cover x Cylinder head 44 450 33 RH engine hanger x Generator bracket 25 250 18 Generator bracket x Cylinder head 42 425 31 LH engine hanger x Cylinder head 25 250 18 No.3 timing belt cover x Cylinder head 7.8 80 69 in.·lbf Delivery pipe x Cylinder head 13 130 9 Intake manifold x Cylinder head 19 195 14 34 29 350 300 25 21 EGR valve x intake manifold 13.3 130 10 EGR pipe x Cylinder head 61.2 600 45 Intake manifold stay x Intake manifold 39 398 29 Intake manifold stay x Stiffening plate 39 398 29 Water outlet x Cylinder head 15 150 11 No.2 intake manifold stay x Cylinder head 21 214 15 No.2 intake manifold stay x Intake manifold 42 428 31 Exhaust manifold x Cylinder head 49 500 36 No.1 exhaust manifold stay x Exhaust manifold 42 425 31 No.1 exhaust manifold stay x Transaxle 42 425 31 No.2 exhaust manifold stay x Exhaust manifold 42 425 31 58 42 591 425 43 31 No.1 rear end plate x Cylinder block 9.3 95 82 in.·lbf Flywheel (M/T) x Crankshaft 88 900 65 83 850 61 46 64 470 650 34 47 Transaxle (A/T) x Cylinder block 66 670 48 Drive plate x Torque converter clutch 27 280 20 No.2 rear end plate x Cylinder block 9.3 95 82 in.·lbf Exhaust pipe bracket, No.2 rear end plate x Transaxle 19 195 14 RH stiffener plate x Cylinder block 39 398 29 RH stiffener plate x Transaxle 39 398 29 Camshaft timing pulley x Camshaft for use with SST No.1 idler pulley x Cylinder head Cylinder head x Cylinder block 1st 2nd Fuel inlet hose x Delivery pipe for use with SST No.2 exhaust manifold stay, LH stiffener plate x Cylinder block TMC made TMMK made Drive plate (A/T) x Crankshaft Transaxle (M/T) x Cylinder block 14 mm head 17 mm head Author: Date: 172 SS–10 SERVICE SPECIFICATIONS LH stiffener plate x Transaxle – ENGINE MECHANICAL (5S–FE) 37 42 380 430 27 31 No.2 RH engine mounting bracket x Cylinder block 52 530 38 No.2 RH engine mounting bracket x Generator bracket 52 530 38 Rear engine mounting insulator x Cylinder block 64 650 47 Front engine mounting insulator x Cylinder block 64 650 47 Engine moving control rod x No.2 RH engine mounting bracket 64 650 47 Engine moving control rod x Body 64 650 47 80 44 66 820 450 670 59 32 49 Rear engine mounting insulator x Front frame 66 670 49 LH engine mounting insulator x Frount frame 80 820 59 LH engine mounting insulator x Transaxle 64 650 47 PS pump x PS pump bracket 43 440 32 25.5 260 19 Fuel inlet hose x Fuel filter 29 300 21 Main bearing cap x Cylinder block 59 600 43 25 Turn 90° 250 Turn 90° 18 Turn 90° Engine balancer x Cylinder block 49 500 36 Rear oil seal retainer x Cylinder block 13 130 9 Water pump x Cylinder block 8.8 90 78 in.·lbf Generator drive belt adjusting bar x Cylinder block 22 224 16 PS pump bracket x Cylinder block 43 440 32 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center pipe 56 570 41 Center exhaust pipe x Tailpipe 56 570 41 Support bracket for front exhaust pipe x Exhaust pipe bracket on No.2 rear end plate 33 330 24 Support stay for front exhaust pipe x Support bracket 33 330 24 Support bracket for front exhaust pipe x Front frame 33 330 24 Support bracket for center exhaust pipe x Body 19 195 14 Support bracket for tailpipe x Body 33 330 24 Front engine mounting insulator x Front frame M/T A/T TMC made TMMK made for silver color for green color A/C compressor x Cylinder block Connecting rod cap x Connecting rod 1st 2nd Author: Date: 173 SS–11 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) ENGINE MECHANICAL (1MZ–FE) SS076–02 SERVICE DATA Compression pressure at 250 rpm STD 1,500 kPa (15.3 kgf/cm2, 218 psi) Minimum 1,000 kPa (10.2 kgf/cm2, 145 psi) Difference of pressure between each cylinder 100 kPa (1.0 kgf/cm2, 15 psi) or less Valve clearance at cold Intake Exhaust Mark 2.500 Mark 2.550 Mark 2.600 Mark 2.650 Mark 2.700 Mark 2.750 Mark 2.800 Mark 2.850 Mark 2.900 Mark 2.950 Mark 3.000 Mark 3.050 Mark 3.100 Mark 3.150 Mark 3.200 Mark 3.250 Mark 3.300 Adjusting shim for repair part Ignition timing w/ Terminals TE1 and E1 connected of DLC1 Idle speed Protrusion from housing side Cylinder head Warpage Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing bore diameter 8 – 12° BTDC @ idle 700 ± 50 rpm – Timing belt tensioner 0.15 – 0.25 mm (0.006 – 0.010 in.) 0.25 – 0.35 mm (0.010 – 0.014 in.) 2.500 mm (0.0984 in.) 2.550 mm (0.1004 in.) 2.600 mm (0.1024 in.) 2.650 mm (0.1043 in.) 2.700 mm (0.1063 in.) 2.750 mm (0.1083 in.) 2.800 mm (0.1102 in.) 2.850 mm (0.1122 in.) 2.900 mm (0.1142 in.) 2.950 mm (0.1161 in.) 3.000 mm (0.1181 in.) 3.050 mm (0.1201 in.) 3.100 mm (0.1220 in.) 3.150 mm (0.1240 in.) 3.200 mm (0.1260 in.) 3.250 mm (0.1280 in.) 3.300 mm (0.1299 in.) 10.0 – 10.8 mm (0.394 – 0.425 in.) Maximum 0.10 mm (0.039 in.) STD O/S 0.05 30°, 45°, 75° 45° 1.0 – 1.4 mm (0.039 – 0.055 in.) 10.295 – 10.313 mm (0.4053 – 0.4080 in.) 10.345 – 10.363 mm (0.4073 – 0.4080 in.) 12 pointed head cylinder head bolt diameter at tension portion STD 8.95 – 9.05 mm (0.3524 – 0.3563 in.) Minimum 8.75 mm (0.3445 in.) Valve guide bushing Inside diameter Outside diameter for repair part Valve Valve overall length Valve face angle Stem diameter Stem oil clearance Margin thickness STD O/S 0.05 5.510 – 5.530 mm (0.2169 – 0.2177 in.) 10.333 – 10.344 mm (0.4068 – 0.4072 in.) 10.383 – 10.394 mm (0.4088 – 0.4092 in.) STD Intake Exhaust Minimum Intake Exhaust 95.45 mm (3.5779 in.) 95.40 mm (3.7559 in.) 94.95 mm (3.7382 in.) 94.90 mm (3.7362 in.) 44.5° Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.) Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.) STD Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) Maximum Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) STD 1.0 mm (0.039 in.) Maximum 0.5 mm (0.020 in.) Author: Date: 174 SS–12 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) Valve spring Deviation Free length Installed tension at 33.8 mm (1.331 in.) Maximum 2.0 mm (0.079 in.) 45.50 mm (1.7913 in.) 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) Valve lifter Lifter diameter Lifter bore diameter Oil clearance 30.966 – 30.976 mm (1.2191 – 2.2195 in.) 31.000 – 31.016 mm (1.2205 – 1.2211 in.) STD 0.024 – 0.050 mm (0.0009 – 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Camshaft Thrust clearance Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance STD Maximum STD Intake Exhaust Maximum Intake Exhaust 0.040 – 0.090 mm (0.0016 – 0.0035 in.) 0.12 mm (0.0047 in.) 0.035 – 0.072 mm (0.0014 – 0.0028 in.) 0.025 – 0.062 mm (0.0010 – 0.0024 in.) 0.10 mm (0.0039 in.) 0.09 mm (0.0035 in.) 26.959 – 26.975 mm (1.0613 – 1.0620 in.) Maximum 0.06 mm (0.0024 in.) STD Intake 42.11 – 42.21 mm (1.6579 – 1.6618 in.) Exhaust 41.96 – 42.06 mm (1.6520 – 1.6559 in.) Minimum Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) STD 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum 0.30 mm (0.0188 in.) 18.2 – 18.8 mm (0.712 – 0.740 in.) Air intake chamber Warpage Maximum 0.10 mm (0.0039 in.) Intake manifold Warpage Air intake chamber side Cylinder head side Maximum 0.15 mm (0.0059 in.) Maximum 0.08 mm (0.0031 in.) Exhaust manifold Warpage Maximum 0.50 mm (0.0196 in.) Cylinder block Cylinder head surface warpage Cylinder bore diameter Maximum 0.07 mm (0.0028 in.) 87.500 – 87.512 mm (3.4449 – 3.4453 in.) Maximum 87.52 mm (3.4457 in.) 12 pointed head main bearing cap bolt diameter at tension portion STD 7.500 – 7.600 mm (0.2953 – 0.2992 in.) Minimum 7.20 mm (0.2835 in.) Piston and piston ring Piston diameter AISIN made at 23.2 mm (0.913 in.) from the piston head 87.406 – 87.416 mm (3.4412 – 3.4416 in.) at 41.2 mm (1.622 in.) from the piston head Piston oil clearance AISIN made STD Maximum MAHLE made STD Maximum Piston ring groove clearance No.1 No.2 Piston ring end gap STD No.1 No.2 Oil Maximum No.1 No.2 Oil 87.453 – 87.467 mm (3.4430 – 3.4436 in.) MAHLE made 0.084 – 0.106 mm (0.0033 – 0.0042) 0.13 mm (0.0051 in.) 0.033 – 0.059 mm (0.0013 – 0.0023) 0.08 mm (0.0031 in.) 0.020 – 0.070 mm (0.0008 – 0.0028 in.) 0.020 – 0.060 mm (0.0008 – 0.0024 in.) 0.25 – 0.35 mm (0.0098 – 0.0138 in.) 0.35 – 0.45 mm (0.0138 – 0.0177 in.) 0.15 – 0.40 mm (0.0059 – 0.0157 in.) 0.95 mm (0.0374 in.) 1.05 mm (0.0413 in.) 1.00 mm (0.0394 in.) Author: Date: 175 SS–13 SERVICE SPECIFICATIONS Connecting rod Thrust clearance Connecting rod thickness Connecting rod bearing center wall thickness Reference – ENGINE MECHANICAL (1MZ–FE) STD 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum 0.35 mm (0.0138 in.) 20.80 – 20.85 mm (0.8189 – 0.8209 in.) Mark 1 Mark 2 Mark 3 Mark 4 Connecting rod oil clearance STD Maximum Rod out–of–alignment Maximum per 100 mm (3.94 in.) Rod twist Maximum per 100 mm (3.94 in.) Bushing inside diameter Piston pin diameter Bushing oil clearance STD Maximum Connecting rod bolt diameter at tension portion STD Minimum Crankshaft 1.484 – 1.487 mm (0.0584 – 0.0585 in.) 1.487 – 1.490 mm (0.0585 – 0.0587 in.) 1.490 – 1.493 mm (0.0587 – 0.0588 in.) 1.493 – 1.496 mm (0.0588 – 0.0589 in.) 0.038 – 0.064 mm (0.0015 – 0.0025 in.) 0.08 mm (0.0031 in.) 0.05 mm (0.0020 in.) 0.15 mm (0.0059 in.) 22.005 – 22.014 mm (0.8663 – 0.8667 in.) 21.997 – 22.006 mm (0.8660 – 0.8664 in.) 0.005 – 0.011 mm (0.0002 – 0.0004 in) 0.05 mm (0.0020 in.) 7.2 – 7.3 mm (0.284 – 0.287 in.) 7.0 mm (0.276 in.) Thrust clearance STD 0.04 – 0.24 mm (0.0016 – 0.0095 in.) Maximum 0.30 mm (0.0118 in.) Thrust washer thickness 1.930 – 1.980 mm (0.0760 – 0.0780 in.) Main journal oil clearance STD No.1 and No.4 0.014 – 0.036 mm (0.0006 – 0.0014 in.) No.2 and No.3 0.026 – 0.048 mm (0.0010 – 0.0019 in.) Maximum No.1 and No.4 0.05 mm (0.0020 in.) No.2 and No.3 0.06 mm (0.0024 in.) Main journal diameter 60.988 – 61.000 mm (2.4011 – 2.4016 in.) Main bearing center wall thickness Reference (TMC made) Mark 1 2.486 – 2.489 mm (0.0979 – 0.0980 in.) Mark 2 2.489 – 2.492 mm (0.0980 – 0.0981 in.) Mark 3 2.492 – 2.495 mm (0.0981 – 0.0982 in.) Mark 4 2.495 – 2.498 mm (0.0982 – 0.0983 in.) M k 5 2.498 Mark 2 498 – 2 2.501 501 mm (0 (0.0983 0983 – 0 0.0985 0985 iin.)) Mark 6 2.501 – 2.504 mm (0.0985 – 0.0986 in.) Mark 7 2.504 – 2.507 mm (0.0986 – 0.0987 in.) Reference (TMMK made) Mark 1 2.485 – 2.488 mm (0.0978 – 0.0980 in.) Mark 2 2.488 – 2.491 mm (0.0980 – 0.0981 in.) Mark 3 2.491 – 2.494 mm (0.0981 – 0.0982 in.) Mark 4 2.494 – 2.497 mm (0.0982 – 0.0983 in.) Mark 5 2.497 – 2.500 mm (0.0983 – 0.0984 in.) Mark 6 2.500 – 2.503 mm (0.0984 – 0.0985 in.) Mark 7 2.503 – 2.506 mm (0.0985 – 0.0987 in.) Crank pin diameter 52.992 – 53.000 mm (2.0863 – 2.0866 in.) Circle runout Maximum 0.06 mm (0.0024 in.) Main journal taper and out–of–round Maximum 0.02 mm (0.0008 in.) Crank pin taper and out–of–round Maximum 0.02 mm (0.0008 in.) Author: Date: 176 SS–14 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) SS077–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Timing belt plate x Oil pump 8 80 69 in.·lbf No.1 idler pulley x Oil pump 34 350 25 No.2 idler pulley x No.2 idler pulley bracket 43 440 32 125 88 1,300 900 94 65 Timing belt tensioner x Oil pump 27 280 20 RH engine mounting bracket x Cylinder block 28 290 21 No.2 timing belt cover x No.3 timing belt cover 8.5 85 74 in.·lbf No.1 timing belt cover x Oil pump 8.5 85 74 in.·lbf Crankshaft pulley x Crankshaft 215 2,200 159 No.2 generator bracket x Engine RH mounting bracket 28 290 21 54 Turn 90° 18.5 550 Turn 90° 185 40 Turn 90° 13 Camshaft bearing cap x Cylinder head 16 160 12 Cylinder head cover x Cylinder head 8 80 69 in.·lbf Exhaust manifold x Cylinder head 49 500 36 20 34 200 350 15 25 20 34 200 350 15 25 No.1 EGR pipe x RH exhaust manifold 12 120 9 No.1 EGR pipe x EGR cooler 12 120 9 PS pump bracket x RH cylinder head 43 440 32 Camshaft timing pulley x Camshaft for SST Cylinder head x Cylinder block 12 pointed head bolt 1st 2nd Recessed head bolt Exhaust manifold stay x Exhaust manifold Except California A/T and all M/T California A/T and all M/T Exhaust manifold stay x Transmission housing Except California A/T California A/T Oil dipstick guide x LH cylinder head 8 80 69 in.·lbf 19.5 200 14 8 80 69 in.·lbf No.3 timing belt cover x Cylinder head 8.5 85 74 in.·lbf Water outlet x Intake manifold 15 150 11 Fuel inlet hose x Fuel filter 29 300 21 Intake manifold x Cylinder head 15 150 11 Air intake chamber x Intake manifold 43 440 32 No.2 EGR pipe x Air intake chamber 12 120 9 No.2 EGR pipe x EGR cooler 12 120 9 No.1 engine hanger x Air intake chamber 39 400 29 No.1 engine hanger x RH cylinder head 39 400 29 Air intake chamber stay x Air intake chamber 19.5 200 14 Air intake chamber stay x RH cylinder head 19.5 200 14 Rear engine mounting insulator x Cylinder block 64 650 47 Front engine mounting insulator x Cylinder block 64 650 47 Engine moving control rod x RH engine mounting bracket 64 650 47 Engine moving control rod x RH fender apron 64 650 47 No.2 RH engine mounting stay x No.2 RH engine mounting bracket 64 650 47 Water inlet pipe x LH cylinder head Cylinder head rear plate x LH cylinder head Author: Date: 177 SS–15 SERVICE SPECIFICATIONS – ENGINE MECHANICAL (1MZ–FE) No.2 RH engine mounting stay x No.2 Generator bracket 64 650 47 RH engine mounting stay x Water outlet 32 320 23 RH engine mounting stay x Engine moving control rod 32 320 23 RH engine mounting stay x No.2 RH engine mounting bracket 32 320 23 80 44 66 820 450 670 59 32 48 Engine mounting absorber x Front frame 48 490 35 Engine mounting absorber x Transaxle 48 490 35 Rear engine mounting insulator x Front frame 66 670 48 LH engine mounting insulator x Transaxle 64 650 47 PS pump x PS pump bracket 43 440 31 A/C compressor x Housing bracket 25 250 18 A/C compressor x No.1 oil pan 25 250 18 Generator adjusting bar x Drive belt adjusting bar bracket 18 185 13 12 pointed head bolt 1st 2nd 6 pointed head bolt 22 Turn 90° 27 225 Turn 90° 275 16 Turn 90° 20 1st 2nd 24.5 Turn 90° 250 Turn 90° 18 Turn 90° Rear oil seal retainer x Cylinder block 8 80 69 in.·lbf EGR cooler x Cylinder block 9 90 78 in.·lbf Engine coolant drain union x Cylinder block 39 400 29 Water seal plate x Cylinder block 18 180 13 Oil filter union x Cylinder block 30 310 22 Water inlet housing x Cylinder block 8 80 69 in.·lbf Knock sensor x Cylinder block 39 400 29 No.2 idler pulley bracket x Cylinder block 28 290 21 A/C compressor housing bracket x Cylinder block 25 250 18 Generator bracket x Cylinder block 43 440 32 Drive plate x Crankshaft 83 850 61 Flywheel x Crankshaft 83 850 61 Front exhaust pipe support bracket x No.1 oil pan 21 210 15 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Center exhaust pipe x Tailpipe 56 570 41 Front exhaust pipe bracket x Sub frame 33 330 24 Front exhaust pipe support bracket x Front exhaust pipe stay 33 330 24 Heated oxygen sensor x Center exhaust pipe 44 450 33 Front engine mounting insulator x Front frame TMC made TMMK made Main bearing cap x Cylinder block Silver color bolt Green color bolt Connecting rod cap x Connecting rod Author: Date: 178 SS–16 SERVICE SPECIFICATIONS – EMISSION CONTROL (5S–FE) EMISSION CONTROL (5S–FE) SS0AF–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 13.3 136 10 EGR valve x EGR pipe 10 102 7 Exhaust manifold x Cylinder head 49 500 36 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 EGR valve x Intake manifold Author: Date: 179 SS–17 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) EMISSION CONTROL (1MZ–FE) SS078–01 SERVICE DATA EGR valve position sensor Resistance (VC – E2) Power source voltage (VC– E2) Power output voltage (EGLS – E2) at vacuum (17.3 kPa, 130 mmHg, 5.1 in.Hg) at no vacuum 1.5 – 4.3 kΩ 4.5 – 5.5 V 3.2 – 5.1 V 0.4 – 1.6 V Author: Date: 180 SS–18 SERVICE SPECIFICATIONS – EMISSION CONTROL (1MZ–FE) SS079–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf EGR valve position sensor x EGR valve 2 20 17 in.·lbf EGR pipe x EGR valve 12 120 9 EGR pipe x EGR cooler 12 120 9 EGR valve x Air intake chamber 12 120 9 EGR gas temperature sensor x EGR valve 20 200 14 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 Front exhaust pipe bracket x Sub frame 33 330 24 Front exhaust pipe support bracket x Front exhaust pipe stay 33 330 24 Author: Date: 181 SS–19 SERVICE SPECIFICATIONS – SFI (5S–FE) SFI (5S–FE) SS0AG–03 SERVICE DATA Fuel pressure regulator Fuel pressure Fuel pump Resistance at 20°C (68°F) Injector Resistance at 20°C (68°F) Injection volume Difference between each cylinder Fuel leakage Throttle body at no vacuum Throttle body fully closed angle Throttle opener setting speed 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) 0.2 – 3.0 Ω 13.4 – 14.2 Ω 54 – 69 cm3 (3.3 – 4.2 cu in.) per 15 seconds 7 cm3 (0.4 cu in.) or less One drop or less per minute 6° 1,300 – 1,500 rpm (w/ Cooling fan OFF) Throttle position sensor Clearance between stop screw and lever 0 mm (0 in.) Throttle valve fully open – IAC valve Resistance (+B – ISCC or ISCO) VSV for EVAP Resistance at 20°C (68°F) 30 – 34 Ω VSV for vapor pressure sensor Resistance at 20°C (68°F) 33 – 39 Ω VSV for EGR Resistance at 20°C (68°F) 33 – 39 Ω ECT sensor Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ IAT sensor Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ MAP sensor Power source voltage 4.5 – 5.5 V Vapor Pressure Sensor Power sorce voltage 4.5 – 5.5 V A/F sensor Resistance at 20°C (68°F) 0.8 – 1.4 Ω Heated oxygen sensor Resistance at 20°C (68°F) 11 – 16 Ω Fuel cut rpm Fuel return rpm VTA – E2 VTA – E2 VC – E2 0.2 – 5.7 kΩ 2.0 – 10.2 kΩ 2.5 – 5.9 kΩ at cold at hot 17.0 – 24.5 Ω 21.5 – 28.5 Ω 1,500 rpm Author: Date: 182 SS–20 SERVICE SPECIFICATIONS – SFI (5S–FE) SS0AH–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 29 28 300 285 21 21 Fuel pump assembly x Fuel tank 4 40 35 in.·lbf Fuel filter x Fuel pump bracket 2 20 17 in.·lbf Fuel pressure regulator x Fuel pump bracket 2 20 17 in.·lbf Delivery pipe x Cylinder head 13 130 9 Fuel tank band x Body 39 400 29 Throttle body x Intake manifold 19 195 14 Knock sensor 1 x Cylinder block 44 450 32 A/F sensor x Exhaust manifold 44 450 32 Oxygen sensor (bank 1 sensor 1) x Exhaust manifold 44 450 32 Oxygen sensor (bank 1 sensor 2) x Front exhaust pipe 44 450 32 Fuel line Union bolt type Flare nut type for use with SST Author: Date: 183 SS–21 SERVICE SPECIFICATIONS – SFI (1MZ–FE) SFI (1MZ–FE) SS109–02 SERVICE DATA Fuel pressure Fuel pump Resistance Injector Resistance Injection volume Difference between each cylinder Fuel leakage MAF meter Resistance (THA – E2) Throttle body Throttle opener setting speed Throttle position sensor Resistance Throttle valve fully closed Throttle valve fully open – IAC valve Resistance (+B – RSO or RSC) VSV for EGR Resistance at 20°C (68°F) 27 – 33 Ω VSV for EVAP Resistance at 20°C (68°F) 27 – 33 Ω VSV for ACIS Resistance at 20°C (68°F) 33 – 39 Ω Resistance at 20°C (68°F) 33 – 39 Ω VSV for Vapor Pressure Sensor at no vacuum 301 – 347 kPa (3.1 – 3.5 kgf/cm2, 44 – 50 psi) Fuel pressure regulator at 20°C (68°F) 0.2 – 3.0 Ω 13.4 − 14.2 Ω 60 – 73 cm3 (3.4 – 4.5 cu in.) per 15 sec. 13 cm3 (0.8 cu in.) or less 1 drop or less per 12 minute at –20°C (–4°F) at 20°C (68°F) at 60°C (140°F) 14.6 – 17.8 kΩ 2.21 – 2.69 kΩ 0.29 – 0.35 kΩ 900 – 1,950 rpm VTA – E2 VTA – E2 VC – E2 0.2 – 6.3 kΩ 2.0 – 10.2 kΩ 2.5 – 5.9 kΩ at cold at hot 17.0 – 25.0 Ω 21.5 – 29.5 Ω Vapor Pressure Sensor Power source voltage 4.5 – 5.5 V ECT sensor Resistance at –20°C (–4°F) at 0°C (32°F) at 20°C (68°F) at 40°C (104°F) at 60°C (140°F) at 80°C (176°F) 10 – 20 kΩ 4 – 7 kΩ 2 – 3 kΩ 0.9 – 1.3 kΩ 0.4 – 0.7 kΩ 0.2 – 0.4 kΩ EGR gas temperature sensor Resistance at 50°C (122°F) at 100°C (212°F) at 150°C (302°F) 64 – 97 kΩ 11 – 16 kΩ 2 – 4 kΩ A/F sensor Heater coil resistance at 20°C (68°F) at 800°C (1472°F) 0.8 – 1.4 Ω 1.8 – 3.2 Ω Heated oxygen sensor Heater coil resistance at 20°C (68°F) at 800°C (1472°F) 11 – 16 Ω 23 – 32 Ω Fuel cut rpm Fuel return rpm 1,200 rpm Author: Date: 184 SS–22 SERVICE SPECIFICATIONS – SFI (1MZ–FE) SS10A–01 TORQUE SPECIFICATION Part tightened Fuel line (Union bolt type) Fuel line (Flare nut type) kgf·cm ft·lbf 29 300 21 28 285 21 Fuel pump assembly x Fuel tank 4 40 35 in.·lbf Fuel filter x Fuel pump bracket 2 20 17 in.·lbf Fuel pressure regulator x Fuel pump bracket 2 20 17 in.·lbf Delivery pipe x Intake manifold 10 100 7 No.1 fuel pipe x Intake manifold 19.5 200 14 39 400 29 Throttle body x Air intake chamber 19.5 200 14 Intake air control valve x Air intake chamber 14.5 145 10 ECT sensor x Water outlet 20 200 14 Knock sensor x Cylinder block 39 400 29 A/F sensor x Exhaust manifold 44 450 32 Heated oxygen sensor (Bank 1, 2 sensor 1) x Exhaust manifold 44 450 32 Heated oxygen sensor (Bank 1 sensor 2) x Exhaust pipe 44 450 32 Fuel tank band x Body using SST N·m Author: Date: 185 SS–23 SERVICE SPECIFICATIONS – COOLING (5S–FE) COOLING (5S–FE) SS0AI–03 SERVICE DATA Thermostat Valve opening temperature Valve lift Radiator cap Relief valve opening pressure Electric cooling fan Rotating amperage at 95°C (203°F) 80 – 84°C (176 – 183°F) 8 mm (0.31 in.) or more STD 74 – 103 kPa (0.75 – 1.05 kgf/cm2, 10.7 – 14.9 psi) Minimum 59 kPa (0.6 kgf/cm2, 8.5 psi) 4.9 – 8.5 A Author: Date: 186 SS–24 SERVICE SPECIFICATIONS – COOLING (5S–FE) SS0AJ–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Cylinder block x Drain plug 25 250 18 Water pump x Water pump cover, Cylinder block 8.8 90 78 in.·lbf Water bypass pipe x Water pump cover 9.3 95 82 in.·lbf Generator drive belt adjusting bar x Cylinder block 22 224 16 Water inlet x Water pump cover 8.8 90 78 in.·lbf Oil cooler x Radiator lower tank 8.3 85 74 in.·lbf Oil cooler pipe x Oil cooler 14.7 150 11 Upper radiator support x Body 12.8 130 9 Electric cooling fan x Radiator 5.0 50 44 in.·lbf Author: Date: 187 SS–25 SERVICE SPECIFICATIONS – COOLING (1MZ–FE) COOLING (1MZ–FE) SS07C–01 SERVICE DATA Thermostat Valve opening pressure Valve lift Radiator cap Relief valve opening pressure Radiator Plate height Cooling fan Rotating amperage at 95°C (203°F) 80 – 84°C (176 – 183°F) 10.0 mm (0.394 in.) or more STD 83 – 113 kPa (0.85 – 1.15 kgf/cm2, 12.1 – 16.4 psi) Minimum 69 kPa (0.7 kgf/cm2, 10.0 psi) 7.4 – 7.8 mm (0.2959 – 0.3119 in.) at 20°C (68°F) No.1 No.2 8.3 – 11.3 A 8.3 – 11.3 A Author: Date: 188 SS–26 SERVICE SPECIFICATIONS – COOLING (1MZ–FE) SS07D–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf RH engine drain plug x EGR cooler 7 70 61 in.·lbf LH engine drain plug x Union on cylinder block 13 130 9 Water pump x Cylinder block 8 80 69 in.·lbf Water inlet x Water inlet housing 8 80 69 in.·lbf Water inlet pipe x LH cylinder head 19.5 200 14 Radiator support x Body 12.8 130 9 No.1 cooling fan shroud x Radiator 5.0 50 44 in.·lbf No.2 cooling fan shroud x Radiator 5.0 50 44 in.·lbf Radiator oil cooler x Radiator lower tank 8.3 85 74 in.·lbf Radiator inlet pipe x Radiator lower tank 14.7 150 11 Author: Date: 189 SS–27 SERVICE SPECIFICATIONS – LUBRICATION (5S–FE) LUBRICATION (5S–FE) SS0AK–03 SERVICE DATA Oil pressure Oil pump at idle speed at 3,000 rpm Body clearance Tip clearance STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 4.3 psi) or more 245 – 490 kPa (2.5 – 5.0 kgf/cm2, 36 – 71 psi) 0.10 – 0.16 mm (0.0039 – 0.0063 in.) 0.20 mm (0.0079 in.) 0.04 – 0.16 mm (0.0016 – 0.0063 in.) 0.20 mm (0.0079 in.) Author: Date: 190 SS–28 SERVICE SPECIFICATIONS – LUBRICATION (5S–FE) SS0AL–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Oil pan x Drain plug 37 375 27 Oil pump body cover x Oil pump body 8.8 90 78 in.·lbf Oil pump x Cylinder block 8.8 90 78 in.·lbf Oil strainer x Engine balancer 5.4 55 48 in.·lbf Oil strainer x Oil pump 5.4 55 48 in.·lbf Oil pan x Cylinder block 5.4 55 48 in.·lbf Oil pan x Oil pump 5.4 55 48 in.·lbf 78.5 9.0 800 92 58 80 in.·lbf Oil cooler x Cylinder block Union bolt Nut Author: Date: 191 SS–29 SERVICE SPECIFICATIONS – LUBRICATION (1MZ–FE) LUBRICATION (1MZ–FE) SS07E–01 SERVICE DATA Oil pressure Oil pump at idle speed at 3,000 rpm Side clearance Body clearance Tip clearance STD Maximum STD Maximum STD Maximum 29 kPa (0.3 kgf/cm2, 43 psi) or more 294 – 539 kPa (3.0 – 5.5 kgf/cm2, 43 – 78 psi) 0.030 – 0.090 mm (0.0012 – 0.0035 in.) 0.15 mm (0.0059 in.) 0.100 – 0.175 mm (0.0039 – 0.0069 in.) 0.30 mm (0.0118 in.) 0.110 – 0.240 mm (0.0043 – 0.0094 in.) 0.35 mm (0.0138 in.) Author: Date: 192 SS–30 SERVICE SPECIFICATIONS – LUBRICATION (1MZ–FE) SS07F–03 TORQUE SPECIFICATION Part tightened Oil pressure switch x Cylinder block No.2 oil pan x Drain plug N·m kgf·cm ft·lbf 13 130 9 45 460 33 36.8 375 37 8 19.5 80 200 69 in.·lbf 14 Crankshaft position sensor x Oil pump 8 80 69 in.·lbf Oil pan baffle plate x No.1 oil pan 8 80 69 in.·lbf 19.5 200 14 8 19.5 80 200 69 in.·lbf 14 8 80 69 in.·lbf 37.2 380 27 Oil strainer x Main bearing cap 8 80 69 in.·lbf Oil strainer x Oil pump 8 80 69 in.·lbf Oil pump x Relief valve plug Oil pump x Cylinder block 10 mm head 12 mm head No.1 oil pan x Cylinder block No.1 oil pan x Oil pump No.1 oil pan x Rear oil seal retainer No.1 oil pan x Transaxle No.2 oil pan x No.1 oil pan 10 mm head 12 mm head 8 80 69 in.·lbf Flywheel housing under cover x Transaxle 7.8 80 69 in.·lbf A/C compressor x A/C compressor housing bracket 25 250 18 PS pump x PS pump bracket 43 440 32 PS pump drive belt adjusting strut x PS pump 43 440 32 PS pump drive belt adjusting strut x Oil pump 43 440 32 Exhaust pipe bracket x No.1 oil pan 21 210 15 Author: Date: 193 SS–31 SERVICE SPECIFICATIONS – IGNITION (5S–FE) IGNITION (5S–FE) SS0AM–03 SERVICE DATA Firing order – High–tension cord Resistance Spark plug Recommended spark plug 1–3–4–2 Maximum 25 kΩ per cord DENSO made NGK made Correct electrode gap for new spark plug Maximum electrode gap for used spark plug PK20TR11 BKR6EKPB11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) Ignition coil Secondary coil resistance at cold at hot 9.7 – 16.7 kΩ 12.4 – 19.6 kΩ Camshaft position sensor Resistance at cold at hot 835 – 1,400 Ω 1,060 – 1,645 Ω Crankshaft position sensor Resistance at cold at hot 985 – 1,600 Ω 1,265 – 1,890 Ω Author: Date: 194 SS–32 SERVICE SPECIFICATIONS – IGNITION (5S–FE) SS0AN–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 18 180 13 Ignition coil x No.2 intake manifold stay 9.8 100 87 in.·lbf No.2 intake manifold stay x Cylinder head 21 214 15 No.2 intake manifold stay x Intake manifold 42 428 31 Camshaft position sensor assembly x Cylinder head 9.5 97 84 in.·lbf Crankshaft position sensor x Oil pump 9.5 97 84 in.·lbf Author: Date: 195 SS–33 SERVICE SPECIFICATIONS – IGNITION (1MZ–FE) IGNITION (1MZ–FE) SS07G–02 SERVICE DATA Firing order – High–tension cord Resistance Spark plug Recommended spark plug 1–2–3–4–5–6 Maximum 25 kΩ per cord DENSO made NGK made Correct electrode gap for new plug Maximum electrode gap for used plug Ignition coil Primary coil resistance Secondary coil resistance AISAN made Diamond made Camshaft position sensor Resistance DENSO made Wabash made Crankshaft position sensor Resistance PK20TR11 BKR6EKPB11 1.1 mm (0.043 in.) 1.3 mm (0.051 in.) at cold at hot 0.70 – 0.94 Ω 0.85 – 1.10 Ω at cold at hot at cold at hot 10.8 – 14.9 kΩ 13.1 – 17.5 kΩ 6.8 – 11.7 kΩ 8.6 – 13.7 kΩ at cold at hot at cold at hot 835 – 1,400 Ω 1,060 – 1,645 Ω 1,690 – 2,560 Ω 2,145 – 3,010 Ω at cold at hot 1,630 – 2,740 Ω 2,065 – 3,225 Ω Author: Date: 196 SS–34 SERVICE SPECIFICATIONS – IGNITION (1MZ–FE) SS07H–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Spark plug x Cylinder head 18 180 13 Ignition coil x Cylinder head 8 80 69 in.·lbf Camshaft position sensor x Cylinder head 8 80 69 in.·lbf Crankshaft position sensor x Oil pump 8 80 69 in.·lbf Author: Date: 197 SS–35 SERVICE SPECIFICATIONS – STARTING (5S–FE) STARTING(5S–FE) SS0AO–01 SERVICE DATA Starter Rated voltage and output power No–load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD 1.2 kW 1.4 kW Minimum 1.2 kW 1.4 kW STD Minimum STD Minimum Maximum 12 V 1.2 kW, 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) 13.7 – 19.6 N (1.4 – 2.0 kgf, 3.0 – 4.4 lbf) 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf) 9.8 N (1.0 kgf, 2.2 lbf) 11.8 N (1.2 kgf, 2.6 lbf) 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.) Maximum 0.9 mm (0.035 in.) Author: Date: 198 SS–36 SERVICE SPECIFICATIONS – STARTING (5S–FE) SS0AP–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter mounting bolt 37 380 27 End cover x Field frame 1.5 15 13 in.·lbf Starter housing x Magnetic switch 5.9 60 52 in.·lbf Field frame x Armature assembly 5.9 60 52 in.·lbf Lead wire x Terminal C of starter 5.9 60 52 in.·lbf Terminal nut x Terminal C of starter 17 173 13 Terminal nut x Terminal 30 of starter 17 173 13 Magnetic switch end cover x Magnetic switch housing 2.5 26 23 in.·lbf Author: Date: 199 SS–37 SERVICE SPECIFICATIONS – STARTING (1MZ–FE) STARTING (1MZ–FE) SS07I–01 SERVICE DATA Starter Rated voltage and output power No–load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout Magnetic switch Contact plate for wear Current rpm STD Minimum STD Minimum 12 V 1.4 kW 90 A or less at 11.5 V 3,000 rpm or more 15.5 mm (0.610 in.) 10.0 mm (0.394 in.) 17.6 – 23.5 N (1.8 – 2.4 kgf, 3.9 – 5.3 lbf) 11.8 N (1.2 kgf, 2.6 lbf) STD Minimum STD Minimum Maximum 30.0 mm (1.181 in.) 29.0 mm (1.142 in.) 0.6 mm (0.024 in.) 0.2 mm (0.008 in.) 0.05 mm (0.0020 in.) Maximum 0.9 mm (0.035 in.) Author: Date: 200 SS–38 SERVICE SPECIFICATIONS – STARTING (1MZ–FE) SS07J–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter mounting bolt 37 380 27 End cover x Field frame 1.5 15 13 in.·lbf Starter housing x Magnetic switch 5.9 60 52 in.·lbf Field frame x Armature assembly 5.9 60 52 in.·lbf Lead wire x Terminal C of starter 5.9 60 52 in.·lbf Terminal nut x Terminal C of starter 17 170 12 Terminal nut x Terminal 30 of starter 17 170 12 Magnetic switch end cover x Magnetic switch housing 2.5 26 23 in.·lbf Author: Date: 201 SS–39 SERVICE SPECIFICATIONS – CHARGING (5S–FE) CHARGING(5S–FE) SS0AQ–01 SERVICE DATA Battery Specific gravity (Except maintenance–free battery) at 20°C (68°F) Voltage (Maintenance–free battery) at 20°C (68°F) Drive belt Tension Generator Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator Regulating voltage w/ A/C New belt Used belt w/o A/C New belt Used belt at 20°C (68°F) STD Minimum STD Minimum 1.25 – 1.29 12.5 – 12.9 V 165 ± 25 lbf 110 ± 10 lbf 125 ± 25 lbf 95 ± 20 lbf 12 V 80 A 2.7 – 3.1 Ω 14.2 – 14.4 mm (0.559 – 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.5 – 15.1 V Author: Date: 202 SS–40 SERVICE SPECIFICATIONS – CHARGING (5S–FE) SS0AR–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 3.0 31 27 in.·lbf Rectifier end frame x Drive end frame 4.5 46 40 in.·lbf Wire clip x Rectifier end frame 5.4 55 48 in.·lbf 110.5 1,125 81 Rectifier holder x Coil lead on rectifier end frame 2.9 30 26 in.·lbf Voltage regulator x Rectifier end flame 2.0 20 18 in.·lbf Voltage regulator x Rectifier holder 2.0 20 18 in.·lbf Brush holder x Rectifier holder 2.0 20 18 in.·lbf Brush holder x Voltage regulator 2.0 20 18 in.·lbf Rear end cover x Rectifier holder 4.4 45 39 in.·lbf 4.4 3.9 45 39 39 in.·lbf 35 in.·lbf Generator pulley x Rotor Plate terminal x Rectifier holder Nut Bolt Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf Generator x Generator bracket 52 530 38 Generator x Adjusting bar 18 185 13 Author: Date: 203 SS–41 SERVICE SPECIFICATIONS – CHARGING (1MZ–FE) CHARGING (1MZ–FE) SS07K–01 SERVICE DATA Battery Voltage Drive belt Tension New belt Used belt Generator Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator Regulating voltage at 20°C (68°F) 12.5 – 12.9 V 175 ± 5 lbf 115 ± 20 lbf at 20°C (68°F) STD Limit STD Limit 12 V 80 A 2.1 – 2.5 Ω 14.2 – 14.4 mm (0.559 – 0.567 in.) 12.8 mm (0.504 in.) 10.5 mm (0.413 in.) 1.5 mm (0.059 in.) 13.5 – 15.1 V Author: Date: 204 SS–42 SERVICE SPECIFICATIONS – CHARGING (1MZ–FE) SS07L–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Bearing retainer x Drive end frame 3.0 31 27 in.·lbf Rectifier end frame x Drive end frame 4.5 46 40 in.·lbf Cord clip x Rectifier end frame 5.4 55 48 in.·lbf 110.5 1,125 81 Rectifier holder x Coil lead on rectifier end frame 2.9 30 26 in.·lbf Voltage regulator and brush holder x Rectifier end frame 2.0 20 18 in.·lbf 4.4 3.9 45 39 39 in.·lbf 35 in.·lbf Rear end cover x Rectifier holder 4.4 45 39 in.·lbf Terminal insulator x Rectifier holder 4.1 42 36 in.·lbf Generator x Generator bracket 56 570 41 Generator x Adjusting bar 18 180 13 Generator pulley x Rotor Plate terminal x Rectifier holder Nut Screw Author: Date: 205 SS–43 SERVICE SPECIFICATIONS – CLUTCH CLUTCH SS09Q–01 SERVICE DATA Pedal height from asphalt sheet 1MZ–FE 161.8 – 171.8 mm (6.370 – 6.764 in.) Pedal height from asphalt sheet 5S–FE 156.8 – 166.8 mm (6.173 – 6.567 in.) Push rod play at pedal top 1.0 – 5.0 mm (0.039 – 0.197 in.) Pedal freeplay 5.0 – 15.0 mm (0.197 – 0.591 in.) Clutch start switch ON–OFF Stroke 5.0 ± 0.5 mm (0.197 ± 0.020 in.) Clutch release point from pedal full stroke end position 25 mm (0.98 in.) or more Disc rivet head depth Min. 0.3 mm (0.012 in.) Disc runout Max. 0.8 mm (0.031 in.) Flywheel runout Max. 0.1 mm (0.004 in.) Diaphragm spring finger wear Max. depth 0.6 mm (0.024 in.) Diaphragm spring finger wear Max. width 5.0 mm (0.197 in.) Max. 0.5 mm (0.020 in.) Diaphragm spring tip non–alignment Author: Date: 206 SS–44 SERVICE SPECIFICATIONS – CLUTCH SS09R–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder installation nut 12 120 9 Clutch line 15 155 11 Release cylinder installation bolt 12 120 9 Bleeder plug 8.4 85 74 in.·lbf Cruise control actuator bracket x Body 13 130 9 Starter x Transaxle 39 400 29 Clutch accumulator installation bolt 21 210 15 Clutch accumulator installation nut 27 270 20 Release fork support 1MZ–FE 47 480 35 Release fork support 5S–FE 39 400 29 19 195 14 Clutch cover x Flywheel Author: Date: 207 SS–45 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) MANUAL TRANSAXLE (E153) SS09O–01 SERVICE DATA Input shaft 3rd & 4th gears journal diameter 5th gear journal diameter Runout Min. 35.950 mm (1.4154 in.) Min. 27.950 mm (1.1004 in.) Max. 0.05 mm (0.0020 in.) Output shaft 1st & 2nd gears journal diameter Runout Min. 38.950 mm (1.5335 in.) Max. 0.06 mm (0.0024 in.) Oil pump clearance Rotor body STD Max. STD Max. STD Max. 0.10 – 0.16 mm (0.0039 – 0.0063 in.) 0.30 mm (0.0118 in.) 0.08 – 0.15 mm (0.0031 – 0.0059 in.) 0.30 mm (0.0118 in.) 0.03 – 0.08 mm (0.0012 – 0.0031 in.) 0.15 mm (0.0059 in.) STD Max. STD Max. STD Max. STD Max. 0.10 – 0.35 mm (0.0039 – 0.0138 in.) 0.40 mm (0.0157 in.) 0.10 – 0.45 mm (0.0039 – 0.0177 in.) 0.50 mm (0.0197 in.) 0.10 – 0.55 mm (0.0039 – 0.0217 in.) 0.60 mm (0.0236 in.) 0.10 – 0.57 mm (0.0039 – 0.0224 in.) 0.65 mm (0.0256 in.) Gear radial clearance 1st & 4th 2nd & 3rd 5th 1st, 2nd, 3rd, 4th & 5th STD STD STD Max. 0.009 – 0.051 mm (0.0004 – 0.0020 in.) 0.009 – 0.053 mm (0.0004 – 0.0021 in.) 0.009 – 0.050 mm (0.0004 – 0.0020 in.) 0.070 mm (0.0028 in.) Shift fork to hub sleeve clearance Max. 1.0 mm (0.039 in.) Synchronizer ring to gear clearance 1st, 4th & 5th 2nd & 3rd Min. 0.8 mm (0.031 in.) Min. 0.7 mm (0.028 in.) Rotor tip Rotor side Gear thrust clearance 1st & 3rd 2nd 4th 5th Drive in depth Control shaft cover oil seal Select inner lever slotted spring pin No.1 shift inner lever slotted spring pin No.2 shift inner lever slotted spring pin Input shaft snap ring thickness No.2 clutch hub 0 – 1.0 mm (0 – 0.039 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 0 ± 0.5 mm (0 ± 0.020 in.) Mark H J K L M N P 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) Author: Date: 208 SS–46 SERVICE SPECIFICATIONS Input shaft snap ring thickness No.3 clutch hub – MANUAL TRANSAXLE (E153) Mark a b c d e f g h j 1 2 3 4 5 6 7 8 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0729 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0847 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) Output shaft snap ring thickness No.1 clutch hub Mark A B C D E F G 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) 2.90 mm (0.1142 in.) 2.95 mm (0.1161 in.) 3.00 mm (0.1181 in.) 3.05 mm (0.1201 in.) 3.10 mm (0.1220 in.) Differential pinion to side gear backlash STD 0.05–0.20 mm (0.0020–0.0079 in.) Ball bearing Differential side gear thrust washer thickness 0.80 mm (0.0315 in.) 0.90 mm (0.0354 in.) 1.00 mm (0.0394 in.) 1.10 mm (0.0433 in.) 1.20 mm (0.0472 in.) 1.30 mm (0.0512 in.) 1.40 mm (0.0551 in.) Differential case side bearing preload (at starting) New bearing (Output shaft preload plus) Reused bearing (Output shaft preload plus) Differential side bearing adjusting shim thickness 0.2 – 0.3 N·m (1.8 – 3.5 kgf·cm, 1.6 – 3.0 in.·lbf) 0.1 – 0.2 N·m (1.1 – 2.2 kgf·cm, 1.0 – 1.9 in.·lbf) Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F G H 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) 2.55 mm (0.1004 in.) 2.60 mm (0.1024 in.) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm (0.1102 in.) 2.85 mm (0.1122 in.) Author: Date: 209 SS–47 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) Output shaft bearing preload (at starting) New bearing Reused bearing Output shaft rear bearing adjusting shim thickness 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf) Mark 0 1 2 3 4 5 6 7 8 9 A B C D E F G H J K L M N P Q 1.30 mm (0.0512 in.) 1.35 mm (0.0531 in.) 1.40 mm (0.0551 in.) 1.45 mm (0.0571 in.) 1.50 mm (0.0591 in.) 1.55 mm (0.0610 in.) 1.60 mm (0.0630 in.) 1.65 mm (0.0650 in.) 1.70 mm (0.0669 in.) 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0728 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 in.) Author: Date: 210 SS–48 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) SS09P–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 64 46 37 650 470 380 47 34 27 Cruise control actuator x Body (w/ Cruise control) 13 130 9 Starter x Transaxle 39 400 29 Clutch release cylinder x Transaxle 12 120 9 21 26 210 270 15 20 Clutch line bracket x Transaxle 12 120 9 Front wheel 103 1,050 76 Exhaust pipe support stay 33 330 24 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 No.1 exhaust pipe support bracket x Front suspension member 33 330 24 Stabilizer bar link x Stabilizer bar 39 400 29 Stabilizer bar bracket x Front suspension member 19 195 14 PS gear assembly x Front suspension member 181 1,850 134 Front engine absorber x Transaxle 48 490 35 RH exhaust manifold stay 20 200 14 44 66 450 670 33 48 LH engine mounting insulator x Front suspension member 80 820 59 LH engine mounting bracket x Transaxle 64 650 47 Rear engine mounting insulator x Front suspension member 66 670 48 Transaxle x Engine (See page MX–4) 17 mm head 14 mm head A 14 mm head B Clutch acummulator x Transaxle Front engine mounting insulator x Front suspension member Bolt Nut Silver bolt Green bolt Steering return pipe x Front suspension member 10 100 7 181 32 36 1,850 330 370 134 24 27 Flywheel housing under cover x Transaxle 7.8 80 69 in.·lbf Shift cable grommet retainer x Body 4.9 50 43 in.·lbf Shift lever assembly x Body 12 120 9 No.2 selecting bellcrank with selecting bellcrank support 20 200 14 Shift and select lever shaft lock bolt 49 500 36 Shift and select lever shaft assembly x Transmission case 20 200 14 Transmission case cover x Transmission case 29 300 22 Front suspension member with lower suspension arm (See page MX–4) Bolt A Bolt B Nut C Breather plug 49 500 36 Output shaft lock nut 123 1,250 90 Shift fork and shift head set bolt 24 240 17 Rear bearing retainer x Transmission case 42 430 31 Straight screw plug 25 250 18 Straight screw plug (Reverse restrict pin) 13 130 9 Reverse idler gear shaft lock bolt 29 300 22 Transmission case x Transaxle case 29 300 22 Transmission oil pipe x Transaxle case 17 175 13 Reverse shift arm bracket assembly x Transaxle case 17 175 13 Author: Date: 211 SS–49 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E153) Transmission oil pump assembly x Transaxle case 17 175 13 Transaxle case receiver x Transaxle case 7.4 75 65 in.·lbf Clutch release fork support 47 480 35 Control lever housing support bracket x Transaxle case 17 175 13 Vehicle speed sensor 17 175 13 Clutch release line bracket x Transaxle case 17 175 13 Back–up light switch 40 410 30 Filler and drain plug 49 500 36 No.1 and No.2 oil receiver pipe x Transmission case 17 175 13 Transmission oil cooler sub–assembly x Elbow 34 350 25 Elbow x Transaxle case 27 275 20 Transmission oil pump case x Oil pump cover 10 105 8 Transaxle case cover x Transaxle case 54 550 40 Differential left case x Differential right case 63 640 46 Ring gear set bolt 124 1,260 91 Author: Date: 212 SS–50 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) MANUAL TRANSAXLE (S51) SS09M–01 SERVICE DATA Input shaft roller bearing journal diameter Min. 29.970 mm (1.799 in.) Input shaft 3rd gear journal diameter Min. 33.090 mm (1.3028 in.) Input shaft 4th gear journal diameter Min. 32.470 mm (1.2783 in.) Input shaft 5th gear journal diameter Min. 26.970 mm (1.0618 in.) Input shaft runout Max. Output shaft roller bearing journal diameter Min. 31.970 mm (1.2587 in.) Output shaft 1st gear journal diameter Min. 37.970 mm (1.4949 in.) Output shaft 2nd gear journal diameter Min. 31.990 mm (1.2594 in.) Output shaft runout Max. 0.05 mm (0.0020 in.) 0.05 mm (0.0020 in.) Gear thrust clearance 1st STD Max. 0.10 – 0.29 mm (0.0039 – 0.0114 in.) 0.35 mm (0.0138 in.) Gear thrust clearance 2nd STD Max. 0.20 – 0.44 mm (0.0079 – 0.0173 in.) 0.50 mm (0.0197 in.) Gear thrust clearance 3rd STD Max. 0.10 – 0.25 mm (0.0039 – 0.098 in.) 0.30 mm (0.0118 in.) Gear thrust clearance 4th STD Max. 0.20 – 0.45 mm (0.0079 – 0.0177 in.) 0.50 mm (0.0197 in.) Gear thrust clearance 5th STD Max. 0.20 – 0.40 mm (0.0079 – 0.0157 in.) 0.45 mm (0.0177 in.) Gear radial clearance 1st, 2nd, 3rd, and 4th STD Max. 0.009 – 0.053 mm (0.0004 – 0.0021 in.) 0.070 mm (0.0028 in.) Gear radial clearance 5th STD Max. 0.009 – 0.050 mm (0.0004 – 0.0020 in.) 0.070 mm (0.0028 in.) Max. 1.0 mm (0.039 in.) Shift fork to hub sleeve clearance Synchronizer ring to gear clearance 1st, 3rd and 4th Min. 0.6 mm (0.024 in.) Synchronizer ring to gear clearance 2nd Min. 0.7 mm (0.028 in.) Differential case side bearing preload (at starting)(For use with SST) 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) Differential pinion to side gear backlash 0.05 – 0.20 mm (0.0020 – 0.0079 in.) Drive in depth In Input ut shaft front oil seal Reverse restrict pin in slotted spring s ring pin in Shift and select lever shaft slotted spring pin 0 – 0.5 mm (0 – 0.020 in.) 13.5 ± 0.5 mm (0.531 ± 0.020 in.) 23.5 ± 1.0 mm (0.925 ± 0.039 in.) Differential side gear thrust washer thickness 0 95 mm (0 0.95 (0.0374 0374 in in.)) 1 1.00 00 mm (0 (0.0394 0394 in in.)) 1 05 mm (0.0413 1.05 (0 0413 in.) in ) 1 10 mm (0.0433 1.10 (0 ( 0433 in.) i ) 1.15 mm (0.0453 ( in.)) 1.20 mm (0.0472 in.) Author: Date: 213 SS–51 SERVICE SPECIFICATIONS Input shaft snap ring thickness No.2 clutch hub No.3 clutch hub Rear bearing – MANUAL TRANSAXLE (S51) Mark 1 Mark 2 Mark 3 M k4 Mark Mark 5 Mark 6 Mark 13 Mark 14 Mark 15 M k 16 Mark Mark 17 Mark 18 Mark 19 Mark 20 Mark 21 Mark 22 Mark 23 Mark 24 Mark 25 Mark 26 Mark 27 Mark A Mark B Mark C Mark D Mark E 1.95 – 2.00 mm (0.0768 – 0.0787 in.) 2.00 – 2.05 mm (0.0787 ( – 0.0807 in.)) 2.05 – 2.10 mm (0.0807 – 0.0827 in.) 2 10 – 2.15 2.10 2 15 mm (0.0827 (0 0827 – 0.0846 0 0846 in.) i ) 2 15 – 2.20 2.15 2 20 mm (0 (0.0846 0846 – 0.0866 0 0866 in.) in ) 2.20 – 2.25 mm (0.0866 – 0.0886 in.) 2.20 – 2.25 mm (0.0866 – 0.0886 in.) 2.25 – 2.30 mm (0.0886 ( – 0.0906 in.)) 2.30 – 2.35 mm (0.0906 – 0.0925 in.) 2 35 – 2.40 2.35 2 40 mm (0.0925 (0 0925 – 0.0945 0 0945 in.) i ) 2 40 – 2 2.40 2.45 45 mm (0 (0.0945 0945 – 0 0.0965 0965 in in.)) 2.45 – 2.50 mm (0.0965 – 0.0984 in.) 2.50 – 2.55 mm (0.0984 – 0.01004 in.) 2.55 – 2.60 mm (0.1004 ( – 0.01024 in.)) 2.60 – 2.65 mm (0.1024 – 0.01043 in.) 2 65 – 2.70 2.65 2 70 mm (0.1043 (0 1043 – 0.01063 0 01063 in.) in ) 2 70 – 2.75 2.70 2 75 mm (0.1063 (0 1063 – 0.01083 0 01083 in in.)) 2.75 – 2.80 mm (0.1083 – 0.01102 in.) 2.80 – 2.85 mm (0.1102 – 0.01122 in.) 2.85 – 2.90 mm (0.1122 – 0.01142 in.) 2.90 – 2.95 mm (0.1142 – 0.01161 in.) 2 15 – 2 2.15 2.20 20 mm (0 (0.0846 0846 – 0 0.0866 0866 in in.)) 2 20 – 2.25 2.20 2 25 mm (0 (0.0866 0866 – 0.0886 0 0886 in in.)) 2.25 – 2.30 mm (0.0886 – 0.0906 in.) 2.30 – 2.35 mm (0.0906 – 0.0925 in.) 2.35 – 2.40 mm (0.0925 – 0.0945 in.) Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Mark 6 Mark 7 Mark 8 Mark 9 Mark 10 Mark 11 Mark 12 Mark 13 Mark 14 Mark 15 Mark 16 Mark 17 Mark 18 M k 19 Mark 1.90 1 90 mm (0.0748 (0 0748 in.) in ) 1 95 mm (0 1.95 (0.0768 0768 in in.)) 2 2.00 00 mm (0 (0.0787 0787 in in.)) 2 2.05 05 mm (0 (0.0807 0807 in in.)) 2.10 mm (0.0827 in.) 2.15 mm (0.0846 in.) 2.20 mm (0.0866 in.) 2.25 mm (0.0886 in.) 2.30 mm (0.0906 in.) 2.35 mm (0.0925 in.) 2.40 mm (0.0945 in.) 2.45 mm (0.0965 in.) 2.50 mm (0.0984 ( in.)) 2.55 mm (0.1004 ( in.)) 2.60 mm (0.1024 ( in.)) 2.65 mm (0.1043 in.) 2.70 mm (0.1063 in.) 2.75 mm (0.1083 in.) 2.80 mm ((0.1102 iin.)) Differential side bearing adjusting shim thickness Author: Date: 214 SS–52 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) SS09N–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 64 46 650 470 47 34 Cruise control actuator x Body (w/ Cruise control) 13 130 9 Starter x Transaxle 37 378 28 Clutch release cylinder x Transaxle 12 120 9 Bolt A Bolt B 12 6.9 120 70 9 61 in.·lbf Manifold stay Front side 42 425 31 Manifold stay Rear side Transaxle x Engine Clutch line bracket x Transaxle (See page MX–4) 17 mm head 14 mm head 39 400 29 103 1,050 76 19 33 195 330 14 24 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41 No.1 exhaust pipe support bracket x Front suspension member 33 330 24 Stabilizer bar link x Stabilizer bar 39 400 29 Stabilizer bar bracket x Front suspension member 19 195 14 PS gear assembly x Front suspension member 181 1,850 134 44 66 450 670 33 48 LH engine mounting insulator x Front suspension member 80 820 59 LH engine mounting bracket x Transaxle 64 650 47 Rear engine mounting insulator x Front suspension member 66 670 48 Steering return pipe x Front suspension member 10 100 7 181 32 36 1,850 330 370 134 24 27 37 380 27 RH stiffener plate 39 400 29 Rear end plate 9.3 95 82 in.·lbf Shift cable grommet retainer x Body 4.9 50 43 in.·lbf Shift lever assembly x Body 12 120 9 Transmission case x Transaxle case 29 300 22 Transmission case x Case cover 29 300 22 Transmission case protector 18 185 13 Rear bearing retainer 42 430 31 Output shaft front bearing lock plate 18 185 13 Front wheel Exhaust pipe i e bracket Front engine mounting insulator x Front sus suspension ension member Front suspension sus ension member with lower suspension sus ension arm (See page MX–4) LH stiffener plate Bolt Nut Silver bolt Green bolt Bolt A Bolt B Nut C Transaxle case receiver set bolt 7.4 75 65 in.·lbf 5th driven gear lock nut 123 1,250 90 Reverse idler shaft lock bolt 29 300 22 Control shaft cover 37 375 27 Control shift lever x Lever shaft 6.4 65 56 in.·lbf Ring gear x Differential case 83 850 61 Selecting bellcrank x Transmission case 37 380 27 Author: Date: 215 SS–53 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S51) Engine mount bracket x Transaxle 52 530 38 Reverse shift arm bracket 18 185 13 No.3 shift fork x Shift fork shaft 18 185 13 Lock ball assembly 29 300 22 Filler and Drain plugs 49 500 36 Back–up light switch 44 450 33 Differential side bearing retainer 18 185 13 Release bearing retainer 7.4 75 65 in.·lbf Straight screw plug 13 130 9 Vehicle speed sensor driven gear 5.4 55 48 in.·lbf Clutch release fork support 39 400 29 Author: Date: 216 SS–54 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A140E) AUTOMATIC TRANSAXLE (A140E) SS0AS–01 SERVICE DATA Line pressure (Wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position Engine stall revolution Time lag Engine idle speed D and R positions N → D position N → R position A/C OFF and N range Throttle cable adjustment (Throttle valve fully opened) Drive plate runout Torque converter runout Torque converter installation distance Differential oil seal drive in depth Shift point D position (Throttle valve fully opened) (Throttle valve fully closed) 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) 363 – 422 kPa (3.7 – 4.3 kgf/cm2, 53 – 61 psi) 618 – 794 kPa (6.3 – 8.1 kgf/cm2, 90 – 115 psi) 735 – 862 kPa (7.5 – 8.8 kgf/cm2, 107 – 125 psi) 1,373 – 1,608 kPa (14.0 – 16.4 kgf/cm2, 199 – 233 psi) 2,450 ± 150 rpm Less than 1.2 seconds Less than 1.5 seconds 750 ± 50 rpm Between boot end face and inner cable stopper 0 – 1 mm (0 – 0.04 in.) Max. Max. LH side RH side 0.20 mm (0.0079 in.) 0.30 mm (0.0118 in.) More than 13.0 mm (0.512 in.) 2.7 ± 0.5 mm (0.106 ± 0.020 in.) 0 ± 0.5 mm (0 ± 0.020 in.) 1→2 2→3 3 → O/D O/D → 3 3→2 2→1 O/D → 3 3 → O/D 58 – 63 km/h (36 – 39 mph) 109 – 117 km/h (68 – 73 mph) 145 – 151 km/h (90 – 94 mph) 138 – 146 km/h (86 – 91 mph) 100 – 108 km/h (62 – 67 mph) 51 – 56 km/h (32 – 35 mph) 38 – 43 km/h (24 – 27 mph) 18 – 22 km/h (11 – 14 mph) 1→2 3→2 2→1 58 – 63 km/h (36 – 39 mph) 106 – 114 km/h (66 – 71 mph) 51 – 56 km/h (32 – 35 mph) 2→1 47 – 51 km/h (29 – 32 mph) *1: The maximum vehicle speed for manual shift down when shifting down from D to 2. *2: The maximum vehicle speed for manual shift down when shifting down from 2 to L. Lock–up point (Throttle valve fully opened) D position 3rd Gear (O/D main switch OFF) Lock–up ON Lock–up OFF 67 – 72 km/h (42 – 45 mph) 64 – 69 km/h (40 – 43 mph) Lock–up ON Lock–up OFF 67 – 72 km/h (42 – 45 mph) 64 – 69 km/h (40 – 43 mph) O/D gear Author: Date: 217 SS–55 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A140E) SS0AT–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transaxle x Starter 42 430 31 Transaxle x Rear end plate 25 250 18 Transaxle x No.1 exhaust pipe support bracket 19 195 14 Transaxle x Engine 66 670 48 Torque converter clutch x Drive plate 27 280 20 Body x Front lower brace Bolt Nut 181 36 1,850 370 134 27 Body x Rear lower brace 19 mm head bolt 14 mm head bolt Nut 181 32 36 1,850 330 370 134 24 27 Front suspension member x FR engine mounting TMC made TMMK made: Green color bolt TMMK made: Silver color bolt 80 66 44 820 670 450 59 48 32 Front suspension member x RR engine mounting 66 670 48 Front suspension member x LH engine mounting 80 820 59 Transaxle x LH engine mounting 64 650 47 Front suspension member x Steering return pipe mounting bracket 10 100 7 Front suspension member x Stabilizer bar bracket 19 195 14 Stabilizer bar x Stabilizer bar link 39 400 29 Ball joint x Lower suspension arm 127 1,300 94 Steering gear housing set bolt x Nut 181 1,850 134 Exhaust manifold x Front exhaust pipe 62 630 46 Front suspension member x Exhaust pipe No.1 support bracket 33 330 24 Front exhaust pipe x Center exhaust pipe 56 570 41 No.1 exhaust pipe support bracket x Exhaust pipe clamp 33 330 24 Axle hub nut 294 3,000 217 Steering knuckle x Tie rod end 49 500 36 Vehicle speed sensor x Transaxle 16 160 12 5.4 6.9 55 70 48 in.·lbf 61 in.·lbf Park/neutral position switch x Control shaft lever 13 130 9 Control shaft lever x Control cable 15 150 11 Oil pan x Drain plug 49 500 36 Oil pan x Transaxle 4.9 50 43 in.·lbf Valve body x Manual valve body 10 100 7 Valve body x Transaxle 10 100 7 Drive shaft center bearing lock bolt 32 330 24 Park/neutral position switch x Transaxle Bolt Nut Stiffener plate Front side Rear side 42 39 430 400 31 29 Exhaust manifold stay Front side Rear side 42 39 430 400 31 29 Author: Date: 218 SS–56 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) AUTOMATIC TRANSAXLE (A541E) SS0BL–01 SERVICE DATA Line pressure (wheel locked) Engine idling D position R position at stall (Throttle valve fully opened) D position R position 1,138 – 1,236 kPa (11.6 – 12.6 kgf/cm2, 165 – 179 psi) 1,716 – 1,854 kPa (17.5 – 18.9 kgf/cm2, 249 – 269 psi) 2,600 ± 150 rpm Engine stall revolution Time lag 401 – 461 kPa (4.1 – 4.7 kgf/cm2, 58 – 66 psi) 804 – 882 kPa (8.2 – 9.0 kgf/cm2, 117 – 128 psi) N → D position N → R position Less than 1.2 seconds Less than 1.5 seconds Engine idle speed (A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Drive plate runout Torque converter clutch runout Torque converter clutch installation distance Between boot and face and inner cable stopper 0 – 1 mm (0 – 0.04 in.) Max. Max. Lock–up point (Throttle valve opening 5%) 3rd gear (O/D main switch OFF) Lock–up ON Lock–up OFF O/D gear Lock–up ON Lock–up OFF Shift schedule D position (Throttle valve fully opened) (Throttle valve fully closed) 2 position (Throttle valve fully opened) L position (Throttle valve fully opened) 700 ± 50 rpm 1→2 2→3 3 → O/D O/D → 3 3→2 2→1 3 → O/D O/D → 3 0.3 mm (0.0118 in.) 0.20 mm (0.0079 in.) More than 13.7 mm (0.539 in.) 60 – 65 km/h (37 – 40 mph) 53 – 58 km/h (33 – 36 mph) 60 – 64 km/h (37 – 40 mph) 53 – 58 km/h (33 – 36 mph) 60 – 66 km/h (37 – 41 mph) 112 – 121 km/h (70 – 75 mph) 174 – 183 km/h (108 – 114 mph) 167 – 176 km/h (104 – 109 mph) 104 – 112 km/h (65 – 70 mph) 50 – 55 km/h (31 – 34 mph) 35 – 40 km/h (22 – 25 mph) 20 – 25 km/h (12 – 16 mph) 1→2 3→2 2→1 60 – 66 km/h (37 – 41 mph) 122 – 130 km/h (76 – 81 mph) 50 – 55 km/h (31 – 34 mph) 3→2 2→1 106 – 115 km/h (66 – 71 mph) 54 – 59 km/h (34 – 37 mph) Author: Date: 219 SS–57 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) SS0BM–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 80 820 59 66 44 670 450 48 32 Rear engine mounting insulator x Front frame assembly 80 820 59 LH transaxle mounting insulator x Transaxle 64 650 47 Engine mounting absorber x Front frame assembly 48 490 35 Front engine front mounting insulator x Front frame assembly TMC: TMMK: Green color bolt Silver color bolt Transaxle x Engine 17 mm bolt 66 670 48 Transaxle x Engine 12 mm bolt 48 490 35 Torque converter clutch x Drive plate 41 420 30 Valve body x Transaxle case 11 110 8 Oil strainer x Valve body 11 110 8 Oil pan x Transaxle case 7.8 80 69 in.·lbf Oil pan drain plug 49 500 36 Park/Neutral position switch x Transaxle case (bolt) 5.4 55 48 in.·lbf Park/Neutral position switch (nut) 6.9 70 61 in.·lbf B3 apply pipe retainer 11 110 8 Connector clamp 11 110 8 Manual valve body x Transaxle case 11 110 8 Detent spring x Manual valve body 11 110 8 Oil pipe bracket 10 100 7 Steering gear housing x Front suspension member 181 1,850 134 Stabilizer bar bracket 19 195 14 Vehicle speed sensor x Transaxle case 4.9 50 43 in.·lbf Direct clutch speed sensor x Transaxle case 11 110 8 Transfer lubrication apply pipe retainer 11 110 8 Exhaust manifold bracket x Transaxle case Except California California 20 34 200 350 14 25 Exhaust manifold plate Except California California 20 34 200 350 14 25 Front frame x Body 19 mm 181 1,850 134 Front frame x Body 14 mm 32 330 24 Front frame x Body Nut 36 370 27 Exhaust front pipe x Exhaust center pipe 56 570 41 Exhaust manifold x Exhaust front pipe 62 630 46 Exhaust front pipe support stay x Exhaust front pipe support bracket 33 330 24 Exhaust pipe support x Front frame 33 330 24 Starter x Torque converter clutch housing 39 400 29 Transaxle control shaft lever x Park/neutral position switch 15 150 11 Throttle cable adjusting nut 15 150 11 Drive plate x Crankshaft 83 850 61 Shift control cable x Transaxle control shaft lever 15 150 11 Throttle cable retaining plate set bolt 5.4 55 48 in.·lbf Shift solenoid valve No.1, No.2, SL, SLN x Valve body 6.6 67 58 in.·lbf Author: Date: 220 SS–58 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A541E) Front wheel nut 103 1,050 76 Exhaust front pipe support bracket x Body 21 210 15 PS reseroir pipe x Front frame 10 100 7 Engine hood x Hood hinge 26 265 19 Author: Date: 221 SS–59 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SUSPENSION AND AXLE SS04W–01 SERVICE DATA P195/70R14 90S Cold tire inflation pressure (Normal driving) P205/65R15 92H P195/70R14 90S Cold tire inflation pressure (Trailer towing) Front, Rear*1 210 kPa (2.1 kgf/cm2, 30 psi) Front, Rear*2 210 kPa (2.1 kgf/cm2, 30 psi) Front, Rear*1 220 kPa (2.2 kgf/cm2, 32 psi) Front, Rear*2 200 kPa (2.0 kgf/cm2, 29 psi) Front, Rear*3 210 kPa (2.1 kgf/cm2, 30 psi) Front, Rear*4 240 kPa (2.4 kgf/cm2, 35 psi) Rear*3 220 kPa (2.2 kgf/cm2, 32 psi) Front, Rear*4 240 kPa (2.4 kgf/cm2, 35 psi) Front, P205/65R15 92H V hi l h Vehicle height i ht 195/70R14 205/65R15 Camber 5S – FE 1MZ – FE Left – right error Caster 5S – FE 1MZ – FE Front wheel alignment Left – right error Steering axis inclination 5S – FE 1MZ – FE Left – right error Toe–in (Total) Front*5 212 mm (8.35 in.) Rear*6 264 mm (10.39 in.) Front*5 215 mm (8.46 in.) Rear*6 266 mm (10.49 in.) –0 36 ± 45 –0°36’ 45’ (0.6 (0.6° ± 0.75°) 0.75 ) –0°37’ –0 37 ± 45’ 45 (0.62 (0.62° ± 0.75°) 0.75 ) 45’ (0.75°) or less 2°10’ ± 45’ (2.17° ± 0.75°) 2°11’ ± 45’ (2.18° ± 0.75°) 45’ (0.75°) or less 13°01’ ± 45’ (13.02° ± 0.75°) 13°04’ ± 45’ (13.07° ± 0.75°) 45’ (0.75°) or less 0° ± 12’ (0° ± 0.2°) 0 ± 2 mm (0 ± 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less 37°12’ ± 2° (37.2° ± 2°) Inside wheel Wh l angle Wheel l 195/70R14 32°21’ (32.45°) Outside wheel 35°47’ ± 2° (35.78° ± 2°) Inside wheel 205/65R15 Camber Rear wheel alignment li t 5S – FE 1MZ – FE Left – right error Toe–in (Total) 31°25’ (31.42°) Outside wheel –0°42’ ± 45’ (–0.7° ± 0.75°) –0°45’ ± 45’ (–0.75° ± 0.75°) 45’ (0.75°) or less 0°24’ ± 12’ (0.4° ± 0.2°) 4 ± 2 mm (0.16 ± 0.08 in.) No.2 lower suspension arm length difference 1 mm (0.04 in.) or less *1: For all loads including rated loads *2: For reduced loads (1 to 4 passengers) *3: For driving under 160 km/h (100 mph) *4: For driving at 160 km/h (100 mph) or over *5: Front measuring point Measure from the ground to the center of the front side lower suspension arm mounting bolt. *6: Rear measuring point Measure from the ground to the center of the strut rod mounting bolt. Author: Date: 222 SS–60 SERVICE SPECIFICATIONS F t axle Front l 0.05 mm (0.0020 in.) Axle hub deviation 0.05 mm (0.0020 in.) 1MZ – FE (M/T) 1MZ – FE (A/T) F t suspension Front i R Rear axle l R Rear suspension i SUSPENSION AND AXLE Axle bearing backlash Drive shaft standard length 5S – FE Front drive shaft – LH RH LH RH LH RH 609.2 ± 2.0 mm (23.984 ± 0.079 in.) 867.3 ± 2.0 mm (34.146 ± 0.079 in.) 601.5 ± 2.0 mm (23.681 ± 0.079 in.) 871.6 ± 2.0 mm (34.315 ± 0.079 in.) 586.0 ± 2.0 mm (23.071 ± 0.079 in.) 881.6 ± 2.0 mm (34.709 ± 0.079 in.) Lower ball joint turning torque 1.0 – 3.4 N·m (10 – 35 kgf·cm, 8.7 – 30 in.·lbf) Stabilizer bar link turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Axle bearing backlash 0.05 mm (0.0020 in.) Axle hub deviation 0.07 mm (0.0028 in.) No.2 lower suspension arm length 512.3 mm (20.169 in.) Stabilizer bar link turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Author: Date: 223 SS–61 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SS04X–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Hub nut 103 1,050 76 Tie rod end lock nut 74 750 54 Steering knuckle x Shock absorber 211 2,150 156 Steering knuckle x Brake caliper 107 1,090 79 Steering knuckle x Tie rod end 49 500 36 Axle hub x Drive shaft 294 3,000 217 Lower ball joint x Lower suspension arm 127 1,300 94 Lower ball joint x Steering knuckle 123 1,250 90 Steering knuckle x Disc brake dust cover 8.3 85 74 in.·lbf Drive shaft center bearing lock bolt 32 330 24 Suspension support x Body 80 820 59 Suspension support x Piston rod 49 500 36 ABS speed sensor set bolt 8.0 82 71 in.·lbf Flexible hose and ABS speed sensor wire harness x Shock absorber 29 300 22 Lower suspension arm set bolt 206 2,100 152 Stabilizer bar bracket x Suspension member 19 195 14 Stabilizer bar link set bolt 39 400 29 Hub nut 103 1,050 76 No.2 lower suspension arm lock nut 56 570 41 Brake caliper x Rear axle carrier 47 475 34 Axle hub bearing set bolt 80 820 59 255 196 2,600 2,000 188 145 Flexible hose x Shock absorber 29 300 22 ABS speed sensor set bolt 8.0 82 71 in.·lbf ABS speed sensor wire harness x Shock absorber 5.5 56 49 in.·lbf Rear side seatback set bolt 18 185 13 Suspension support x Body 39 400 29 Suspension support x Piston rod 49 500 36 Exhaust center pipe set nut 56 570 41 Parking brake cable set bolt 5.4 55 48 in.·lbf Lower suspension arm x Suspension member 181 1,850 134 Lower suspension arm x Rear axle carrier 181 1,850 134 Strut rod x Body 113 1,150 83 Strut rod x Rear axle carrier 113 1,150 83 Suspension member x Body 51 520 38 Suspension member lower stopper sub–assembly x Body 38 390 28 Stabilizer bar bracket x Suspension member 19 195 14 Stabiliser bar link set nut 39 400 29 FRONT: REAR: Shock absorber x Rear axle carrier New nut Reused nut (apply engine oil the threads) Author: Date: 224 SS–62 SERVICE SPECIFICATIONS – BRAKE BRAKE SS09X–01 SERVICE DATA Brake pedal height (from asphalt sheet) 152.0 – 162.0 mm (5.984 – 6.378 in.) Brake pedal freeplay 1 – 6 mm (0.04 – 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) More than 70 mm (2.76 in.) Brake booster push rod to piston clearance (w/SST) 0 mm (0 in.) Front brake pad thickness (5S–FE engine) STD 12.0 mm (0.472 in.) Front brake pad thickness (1MZ–FE engine) STD 11.0 mm (0.433 in.) Front brake pad thickness Front brake disc thickness Minimum 1.0 mm (0.039 in.) STD 28.0 mm (1.102 in.) Front brake disc thickness Minimum 26.0 mm (1.024 in.) Front brake disc runout Maximum 0.05 mm (0.0020 in.) Rear brake drum inside diameter Rear brake drum inside diameter Rear brake shoe lining thickness Rear brake shoe lining thickness STD Maximum 230.6 mm (9.079 in.) STD Rear brake pad thickness Rear brake disc thickness 5.0 mm (0.197 in.) Minimum 1.0 mm (0.039 in.) Rear brake drum to shoe clearance Rear brake pad thickness 228.6 mm (9.000 in.) 0.6 mm (0.024 in.) STD 10.0 mm (0.394 in.) Minimum 1.0 mm (0.039 in.) STD 10.0 mm (0.394 in.) Rear brake disc thickness Minimum 9.0 mm (0.354 in.) Rear brake disc runout Maximum 0.15 mm (0.0059 in.) Rear brake disc inside diameter Rear brake disc inside diameter Parking brake lining thickness for rear disc brake Parking brake lining thickness for rear disc brake STD 170 mm (6.69 in.) Maximum 171 mm (6.73 in.) STD 2.0 mm (0.079 in.) Minimum 1.0 mm (0.039 in.) Parking brake lever travel at 196 N (20 kgf, 44 lbf) 5 – 8 clicks Parking brake clearance between rear shoe and lever Less than 0.35 mm (0.0138 in.) Parking brake adjusting shim thickness for rear disc brake 0.3 mm (0.012 in.) 0.6 mm (0.024 in.) 0.9 mm (0.035 in.) Author: Date: 225 SS–63 SERVICE SPECIFICATIONS – BRAKE SS09Y–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Master cylinder x Piston stopper bolt 10 100 7 Master cylinder x Reservoir 1.7 18 16 in.·lbf Master cylinder x Brake booster 13 130 9 10 mm nut 15 155 11 12 mm nut 20 200 14 Brake booster clevis lock nut 25 260 19 Brake booster x Pedal bracket 13 130 9 Brake pedal x Pedal bracket 39 400 29 Pedal bracket x Instrument panel reinforcement 13 130 9 Front brake caliper installation bolt 34 350 25 Brake line union nut Bleeder plug 8.3 85 74 in.·lbf Front brake torque plate x Steering knuckle 107 1,090 79 Front brake caliper x Flexible hose 29 300 21 Flexible hose x Shock absorber bracket 29 300 21 Rear drum brake wheel cylinder x Backing plate 10 100 7 Parking brake cable bracket x Backing plate 7.8 80 69 in.·lbf Rear brake caliper installation bolt 20 200 14 Rear disc brake cariper main pin installation bolt 26 270 20 Rear brake caliper x Flexible hose 29 300 21 Rear brake torque plate x Rear axle carrier 47 475 34 Proportioning valve installation bolt 8.8 90 78 in.·lbf ABS actuator x Actuator bracket DENSO type 5.4 55 48 in.·lbf ABS actuator x Actuator bracket BOSCH type 9.0 92 80 in.·lbf ABS actuator x ECU BOSCH type 2.6 27 23 in.·lbf ABS & TRAC actuator x Actuator bracket 5.4 55 48 in.·lbf ABS (& TRAC) actuator bracket x Body 19 195 14 Front speed sensor installation bolt 7.8 80 69 in.·lbf Front speed sensor harness clamp bolt 5.4 55 48 in.·lbf Rear speed sensor installation bolt 7.8 80 69 in.·lbf Rear speed sensor harness clamp bolt 5.4 55 48 in.·lbf Author: Date: 226 SS–64 SERVICE SPECIFICATIONS – STEERING STEERING SS06L–03 SERVICE DATA ON–VEHICLE INSPECTION Steering wheel freeplay Maximum 30 mm (1.18 in.) 5S–FE Engine : Drive belt tension New belt 95 – 145 lbf Drive belt tension Used belt 60 – 100 lbf Drive belt tension New belt 150 – 185 lbf Drive belt tension Used belt 95 – 135 lbf 1MZ–FE Engine : Fluid level rise Maximum 5 mm (0.20 in.) Minimum 7,845 kPa (80 kgf/cm2, 1,138 psi) Fluid pressure at idle speed with valve closed Steering effort at idle speed Maximum 5.9 N·m (60 kgf·cm, 52 in.·lbf) PS VANE PUMP 5S–FE and 1MZ–FE Engines: Vane pump rotating torque Maximum 0.3 N·m (2.8 kgf·cm, 2.4 in.·lbf) Oil clearance between pump shaft and bushing Oil clearance between pump shaft and bushing STD 0.03 – 0.05 mm (0.0012 – 0.0020 in.) Maximum 0.07 mm (0.0028 in.) Vane plate height Minimum 8.6 mm (0.339 in.) Vane plate thickness Minimum 1.397 mm (0.0550 in.) Vane plate length Minimum 14.991 mm (0.5902 in.) Clearance between the rotor groove and plate Vane plate length Spring free length Maximum 0.035 mm (0.0014 in.) Pump rotor and cam ring mark NONE 14.999 – 15.001 mm (0.59051 – 0.59059 in.) 1 14.997 – 14.999 mm (0.59043 – 0.59051 in.) 2 14.995 – 14.997 mm (0.59035 – 0.59043 in.) 3 14.993 – 14.995 mm (0.59027 – 0.59035 in.) 4 14.991 – 14.993 mm (0.59020 – 0.59027 in.) Minimum 32.3 mm (1.272 in.) PS GEAR Steering rack runout Total preload (Control valve rotating torque) Maximum 0.30 mm (0.0118 in.) 0.8 – 1.4 N·m (8 – 14 kgf·cm, 6.9 – 12.2 in.·lbf) Author: Date: 227 SS–65 SERVICE SPECIFICATIONS – STEERING SS06M–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf STEERING COLUMN Steering wheel pad set screw (Torx screw) 7.1 72 63 in.·lbf Steering wheel set nut 35 360 26 Intermediate shaft assembly x Control valve shaft 35 360 26 Steering column assembly x Intermediate shaft assembly 35 360 26 Steering column assembly set nut 25 260 19 Turn signal bracket x Column tube 7 70 61 in.·lbf Lower column tube attachment x Column tube 19 195 14 5S–FE Engine 32 (25) 326 (250) 24 (18) 1MZ–FE Engine 20 (25) 203 (250) 15 (18) PS VANE PUMP 5S–FE and 1MZ–FE Engines: Pressure feed tube x Control valve housing Pressure feed tube x Pressure feed tube Clamp plate set nut 5S–FE Engine 10 100 7 Clamp plate set nut 1MZ–FE Engine 7.8 80 69 in.·lbf PS vane pump set bolt A bolt 29 (43) 293 (440) 21 (32) PS vane pump set bolt B bolt 43 440 32 Oil pressure switch x Union bolt 21 210 15 Union bolt x Pressure feed tube 52 525 38 Vane pump pulley set nut 43 440 32 Front bracket x Rear bracket 43 440 32 Suction port union set bolt 13 130 9 Pressure port union 83 850 62 Rear housing set bolt 24 240 17 10 100 7 32 (25) 326 (250) 24 (18) 19 195 14 PS GEAR Pressure feed tube clamp plate set nut Pressure feed and return tubes x Control valve housing Stabilizer bar set bolt PS gear assembly set bolt and nut 181 1,850 134 10 (13) 102 (130) 7 (9) 74 750 54 Rack x Rack end 60 (83) 615 (850) 45 (62) Rack guide spring cap lock nut 50 (69) 513 (700) 37 (51) Rack housing cap 59 600 43 Selt–locking nut 25 250 18 Control valve housing set bolt 18 185 13 Turn pressure tube union nut Tie rod end lock nut ( ): For use without SST Author: Date: 228 SS–66 SERVICE SPECIFICATIONS – SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM SS061–17 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel 35 360 26 Steering wheel pad 7.1 72 63 in.·lbf Front passenger airbag assembly x Instrument panel reinforcement 20 205 15 37 375 27 18 15 185 150 13 11 Airbag sensor assembly 20 205 15 Front airbag sensor 20 205 15 Side airbag sensor assembly 20 205 15 7.5 42 76 430 66 in.·lbf 31 Front seat installation bolt Seatback frame set bolt (See page RS–49) Front seat outer belt retractor Bolt A Bolt B Upper bolt Lower bolt Author: Date: 229 SS–67 SERVICE SPECIFICATIONS – BODY ELECTRICAL BODY ELECTRICAL SS0B0–05 SERVICE DATA TURN SIGNAL FLASHER Flashes/ Minute 60 – 120 SPEEDOMETER (ON–VEHICLE) USA: Standard indication (mph) Allowable range (mph) 20 18 – 24 40 38 – 44 60 56 – 66 80 78 – 88 100 98 – 110 120 118 – 132 Standard indication (km/h) Allowable range (km/h) 20 17 – 24 40 38 – 46 60 57.5 – 67 80 77 – 88 100 96 – 109 120 115 – 130 140 134 – 151.5 160 153 – 173 CANADA: TACHOMETER (ON–VEHICLE)/ DC 13.5 V 25 °C at (77 °F) Standard indication Allowable range 700 630 – 770 1,000 900 – 1,100 2,000 1,850 – 2,150 3,000 2,800 – 3,200 4,000 3,800 – 4,200 5,000 4,800 – 5,200 6,000 5,750 – 6,250 7,000 6,700 – 7,300 A–B Approx. 126.2 Ω A–C Approx. 280.5 Ω B–C Approx. 154.3 Ω Float position mm (in.) Resistance (Ω) F: Approx. –91.1 (–3.587) Approx. 3.0 1/2: Approx. –34.2 (–1.346) Approx. 31.7 E: Approx. 30.8 (1.213) Approx. 110.0 FUEL RECEIVER GAUGE FUEL SENDER GAUGE ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (Resistance) A–B Approx. 175.7 Ω A–C Approx. 54.0 Ω Author: Date: 230 SS–68 SERVICE SPECIFICATIONS – BODY ELECTRICAL Approx. 229.7 Ω B–C ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature °C (°F) Resistance (Ω) 50 (122.0) 274 120 (248.0) 26.4 Author: Date: 231 SS–69 SERVICE SPECIFICATIONS – BODY BODY SS0BY–01 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf – – – Front bumper cover x Body 5.5 55 49 in.·lbf Front bumper reinforcement x Body 34 350 25 FRONT BUMPER REAR BUMPER – – – Rear bumper cover x Body 5.0 50 43 in.·lbf Rear bumper reinforcement x Body 34 350 25 – – – Hood hinge x Hood 26 260 19 Hood lock x Body 8.0 80 71 in.·lbf FRONT AND REAR DOOR – – – Front door hinge x Body 31 310 22 Rear door hinge x Body 26 260 19 Door hinge x Door panel 26 260 19 Door lock striker x Body 26 260 19 Outside rear view mirror x Front door panel 5.5 55 49 Door inside handle x Door panel 3.5 35 31 in.·lbf Door glass x Window regulator 8.0 80 71 in.·lbf Window regulator x Door panel 5.5 55 49 in.·lbf Door lock x Door panel 5.0 50 43 in.·lbf Door outside handle x Door panel 7.0 70 61 in.·lbf Door check x Body 30 300 22 Door check x Door panel 8.0 80 71 in.·lbf – – – Luggage door hinge x Luggage door 8.0 80 71 in.·lbf Luggage door lock striker x Body 5.5 55 49 in.·lbf Luggage door lock x Luggage door 5.5 55 49 in.·lbf FRONT WIPER AND WASHER – – – Wiper motor assembly x Body 24 245 18 Wiper arm x Wiper pivot 5.5 55 49 in.·lbf HOOD LUGGAGE COMPARTMENT DOOR AND HINGE SLIDING ROOF – – – 5.5 55 49 in.·lbf – – – Front passenger airbag assembly x Reinforcement 20 200 14 Steering wheel lock nut 35 360 26 SEAT – – – Front Seat (Power Seat for TMC Made) – – – Hinge cover x Seatback frame 18 185 13 Seatback frame x Power seat adjuster 15 150 11 Seatback frame x Side airbag assembly 6.0 61 53 in.·lbf – – – 37 375 27 Sliding roof assembly x Body INSTRUMENT PANEL Front Seat (Manual Seat for TMC Made) Front seat adjuster x Body Author: Date: 232 SS–70 SERVICE SPECIFICATIONS – BODY Front seat inner upper track x Seat cushion 18 185 13 Side Airbag assembly x Seatback frame 18 185 13 Seatback assembly x Seat cushion frame 6.0 61 53 in.·lbf – – – 6.0 61 53 in.·lbf – – – 6.0 61 53 in.·lbf – – – 18 185 13 17.5 178 12.5 – – – Seatback pad (RH bolt) x Body 7.8 79 69 in.·lbf Seatback pad (center bolt) x Body 42 428 31 Child restraint seat x Body 13 130 9 Seatback hinge x Body 18 185 13 17.5 178 12.5 SEAT BELT – – – Front Seat belt – – – Shoulder anchor x Adjustable anchor 42 420 31 Adjustable anchor x Body 42 420 31 Inner belt x Seat 42 420 31 Retractor x Body 7.8 79 69 in.·lbf Floor anchor x Body 42 420 31 – – – Lap outer belt anchor x Body 42 420 31 ELR x Body 42 420 31 Inner belt x Body 42 420 31 Center belt x Body 42 420 31 Front Seat (Power Seat for TMMK Made) Side airbag assembly x Seat cushion frame Front Seat (Manual Seat for TMC Made) Side airbag assembly x Seat cushion frame Rear Seat (TMC Made) Seatback hinge x Body Rear seatback lock control x Rear seatback frame Rear Seat (TMMK Made) Rear seatback lock control x Rear seatback frame Rear Seat Belt Author: Date: 233 SS–71 SERVICE SPECIFICATIONS – AIR CONDITIONING AIR CONDITIONING SS05V–02 SERVICE DATA 800 ± 50 g (28.22 ± 1.76 oz.) Refrigerant charge volume Drive belt tension – New belt 165 ± 26 lbf Used belt 110 ± 11 lbf Idle–up speed Magnetic clutch clearance – Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 700 ± 50 rpm 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) Author: Date: 234 SS–72 SERVICE SPECIFICATIONS – AIR CONDITIONING SS05W–06 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Condenser x Disaharge hose 10 100 7 Condenser x Liquid tube 14 140 10 Receiver x Liquid tube 5.4 55 48 in.·lbf Expansion valve x Evaporator 5.4 55 48in.·lbf Compressor x Engine 25 250 18 Compressor x Compressor bracket (1MZ–FE Only) 25 250 18 Drive belt adjusting bar bracket x Compressor 25 250 18 Drive belt adjusting bar bracket x Adjusting bar 18 185 13 Pivot bolt 52 520 38 56 570 41 Adjusting lock bolt 18 185 13 Pressure switch x Liquied tube 10 100 7 Pressure plate x Compressor 13.2 135 9 Suction line (Piping joint) 32 330 24 Suction line (Block joint) 10 100 7 5S 5S–FE FE 1MZ–FE Author: Date: 235 SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT STANDARD BOLT SS0ZS–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt 4 Class 4T No Mark No Mark No Mark 5 5T 6 6T w/ Washer w/ Washer 7 7T 8 8T 9 9T 10 10T 11 11T B06431 Author: Date: 59 SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZT–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Class Diameter mm Pitch mm Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 4T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 5 12.5 26 47 74 115 55 130 260 480 760 1,150 48 in.·lbf 9 19 35 55 83 6 14 29 53 84 – 60 145 290 540 850 – 52 in.·lbf 10 21 39 61 – 5T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 6.5 15.5 32 59 91 140 65 160 330 600 930 1,400 56 in.·lbf 12 24 43 67 101 7.5 17.5 36 65 100 – 75 175 360 670 1,050 – 65 in.·lbf 13 26 48 76 – 6T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 8 19 39 71 110 170 80 195 400 730 1,100 1,750 69 in.·lbf 14 29 53 80 127 9 21 44 80 125 – 90 210 440 810 1,250 – 78 in.·lbf 15 32 59 90 – 7T 6 8 10 12 14 16 1 1.25 1.25 1.25 1.5 1.5 10.5 25 52 95 145 230 110 260 530 970 1,500 2,300 8 19 38 70 108 166 12 28 58 105 165 – 120 290 590 1,050 1,700 – 9 21 43 76 123 – 8T 8 10 12 1.25 1.25 1.25 29 61 110 300 620 1,100 22 45 80 33 68 120 330 690 1,250 24 50 90 9T 8 10 12 1.25 1.25 1.25 34 70 125 340 710 1,300 25 51 94 37 78 140 380 790 1,450 27 57 105 10T 8 10 12 1.25 1.25 1.25 38 78 140 390 800 1,450 28 58 105 42 88 155 430 890 1,600 31 64 116 11T 8 10 12 1.25 1.25 1.25 42 87 155 430 890 1,600 31 64 116 47 97 175 480 990 1,800 35 72 130 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Hexagon Nut Old Standard Hexagon Nut Cold Forging Nut Class Cutting Processed Nut 4N No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 6N 6N 7N (5T) * 8N 8N 10N (7T) 10N No Mark 11N 11N 12N 12N *: Nut with 1 or more marks on one side surface of the nut. B06432 HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut. Example: Bolt = 4T Nut = 4N or more SS–4 SERVICE SPECIFICATIONS – ENGINE MECHANICAL ENGINE MECHANICAL SS0AD–04 SERVICE DATA Compression pressure at 250 rpm STD 1,736 kPa (17.7 kgf/cm2, 252 psi) or more Minimum 1,393 kPa (14.2 kgf/cm2, 202 psi) Difference of pressure between each cylinder 98 kPa (1.0 kgf/cm2, 14 psi) or less Valve clearance Adjusting shim (for repair part) at cold Intake Exhaust Shim No.00 Shim No.04 Shim No.08 Shim No.02 Shim No.16 Shim No.20 Shim No.24 Shim No.28 Shim No.32 Shim No.36 Shim No.40 Shim No.44 Shim No.48 Shim No.52 Shim No.56 Shim No.60 Shim No.64 Shim No.68 Shim No.72 Shim No.76 Shim No.80 0.19 – 0.29 mm (0.007 – 0.011 in.) 0.28 – 0.38 mm (0.011 – 0.015 in.) 2.000 mm (0.0787 in.) 2.040 mm (0.0803 in.) 2.080 mm (0.0819 in.) 2.120 mm (0.0835 in.) 2.160 mm (0.0850 in.) 2.200 mm (0.0866 in.) 2.240 mm (0.0882 in.) 2.280 mm (0.0898 in.) 2.320 mm (0.0913 in.) 2.360 mm (0.0929 in.) 2.400 mm (0.0945 in.) 2.440 mm (0.0961 in.) 2.480 mm (0.0976 in.) 2.520 mm (0.0992 in.) 2.560 mm (0.1008 in.) 2.600 mm (0.1024 in.) 2.640 mm (0.1039 in.) 2.680 mm (0.1055 in.) 2.720 mm (0.1071 in.) 2.760 mm (0.1087 in.) 2.800 mm (0.1102 in.) Valve spring Deviation Free length Installed tension at 35 mm (1.378 in.) Camshaft Cam lobe height STD Intake Exhaust Minimum Intake Exhaust 42.21 – 42.31 mm (1.6618 – 1.6657 in.) 40.62 – 40.72 mm (1.5992 – 1.6031 in.) 42.10 mm (1.6575 in.) 40.51 mm (1.5949 in.) Piston and piston ring Piston diameter STD Mark 1 Mark 2 Mark 3 O/S 0.50 STD Maximum No.1 No.2 STD No.1 No.2 Oil (side rail) Maximum No.1 No.2 Oil (side rail) 86.815 – 86.825 mm (3.4179 – 3.4183 in.) 86.825 – 86.835 mm (3.4183 – 3.4186 in.) 86.835 – 86.845 mm (3.4201 – 3.4205 in.) 87.350 – 87.380 mm (3.4375 – 3.4387 in.) 0.175 – 0.195 mm (0.0068 – 0.0076 in.) 0.215 mm (0.0085 in.) 0.020 – 0.070 mm (0.0008 – 0.0003 in.) 0.020 – 0.055 mm (0.0008 – 0.0022 in.) 0.220 – 0.440 mm (0.0087 – 0.0173 in.) 0.600 – 0.820 mm (0.0177 – 0.0322 in.) 0.100 – 0.470 mm (0.0039 – 0.0185 in.) 1.04 mm (0.0409 in.) 1.42 mm (0.0559 in.) 1.07 mm (0.0421in.) Piston oil clearance Piston ring groove clearance Piston ring end gap Maximum 2.0 mm (0.079 in.) 45.9 – 47.9 mm (1.8071 – 1.8858 in.) 169 – 184 N (17.2 – 18.8 kgf, 37.9 – 41.4 lbf) Author: Date: 62 SS–5 SERVICE SPECIFICATIONS – SFI SFI SS0AG–04 SERVICE DATA Fuel pressure Fuel pressure between fuel tank and pressure regulatorat 20°C (68°F) between pressure regulator and injector 24,800 kPa (250 kgf/cm2, 3,600 psi) 834 – 932 kPa (8.5 – 9.5 kgf/cm2, 121 – 135 psi) Injector Resistance at 20°C (68°F) 2.65 – 3.0 Ω Fuel shutoff valve for delivery pipe Resistance at 20°C (68°F) 1.8 – 2.2 Ω Fuel shutoff valve for fuel pressure regulator Resistance at 20°C (68°F) 1.4 – 1.8 Ω Fuel shutoff valve for fuel tank Resistance at 20°C (68°F) Approx 19 Ω Fuel temperature sensor for delivery pipe Resistance at –20°C (–4°F) at 20°C (68°F) at 80°C (176°F) 13.9 – 16.3 kΩ 2.32 – 2.59 kΩ 0.31 – 0.326 kΩ Fuel temperature sensor for fuel tank Resistance at –30°C (–22°F) at 25°C (77°F) at 40°C (104°F) at 100°C (212°F) 80 – 100 kΩ 4.80 – 5.20 kΩ 2.51 – 2.81 kΩ 0.30 – 0.37 kΩ Fuel pressure sensor for delivery pipe Power source voltage Power output voltage at 20°C (68°F) at 20°C (68°F) 4.5 – 5.5 V 3.1 – 3.6 V Fuel pressure sensor for fuel pipe Power source voltage Power output voltage Needle position of fuel level gauge at 20°C (68°F) at 20°C (68°F) at 4/4 at 3/4 at 2/4 at 1/4 4.5 – 5.5 V Fuel cut rpm Fuel return rpm A/C OFF Approx. 2.8 V Approx. 2.4 V Approx. 1.8 V Approx. 1.3 V 1,400 rpm Author: Date: 63 SS–6 SERVICE SPECIFICATIONS – SFI SS0AH–04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf 42 28 428 286 31 21 Fuel filter x Drain plug 10.8 110 8 Fuel filter x Fuel filter bracket 21.5 219 16 31 316 23 24.5 250 18 20 200 15 9.9 19.6 100 200 88 in.·lbf 14 Fuel relief pipe x Fuel pressure regulator 42 428 31 Delivery pipe x cylinder head 13 130 10 Fuel tank band x Fuel tank frame 52 530 38 Rear side plate x Front side plate 100 1,020 74 31 18 316 184 23 13 8.2 84 73 in.·lbf Fuel line for union for fuel inlet coupler for others Fuel filter x Union Oil separator x Fuel pressure regulator Fuel pressure regulator x Bracket Fuel pressure regulator bracket x Body Union x Fuel shutoff valve Fuel tank bracket x Fuel tank valve case for 10 mm head bolt for 12 mm head bolt for fuel pipe filter pipe for others Fuel tank valve cover x Fuel tank valve case 8.2 84 73 in.·lbf Fuel tank frame x Body 60.2 614 44 Performance rod x Body 39.2 400 29 Performance rod x Fuel tank band 18.1 185 13 Fuel shutoff valve core x Delivery pipe 35 357 26 Fuel shutoff valve coil x Core 15 153 11 Fuel temperature sensor x Delivery pipe 20.4 208 15 Fuel pressure sensor x Delivery pipe 24.6 251 18 Fuel pressure sensor x Fuel main pipe 68.6 700 51 Fuel inlet hose x Fuel pressure regulator 9.9 100 88 in.·lbf SS–7 SERVICE SPECIFICATIONS – IGNITION IGNITION SS0AM–04 SERVICE DATA Spark plug Recommended spark plug DENSO made Correct electrode gap for new spark plug Maximum electrode gap for used spark plug SK20R11–G 1.1 mm (0.043 in.) 1.2 mm (0.047 in.) Author: Date: 65 SS–8 SERVICE SPECIFICATIONS – IGNITION SS0AN–04 TORQUE SPECIFICATION Part tightened Spark plug x Cylinder head N·m kgf·cm ft·lbf 18 180 13 SS–9 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SUSPENSION AND AXLE SS04W–03 SERVICE DATA Vehicle height Tire size: 205/65R15 218 mm (8.58 in.) Rear*6 270 mm (10.63 in.) Ri h l f error Right–left –0°36’ 0°36’ ± 45’ (0 (0.6° 6° ± 0.75°) 0 75°) 45’ (0 (0.75°) 75°) or lless Right–left error 2°10’ ± 45’ (2.17° ± 0.75°) 45’ (0.75°) or less Right–left error 13°01’ ± 45’ (13.02° ± 0.75°) 45’ (0.75°) or less Camber Caster Front wheel alignment Front*5 Steering axis inclination Toe–in (Total) 0° ± 12’ (0° ± 0.2° 0 ± 2 mm 0 ± 0.08 in.) Rack end length difference 1.5 mm (0.059 in.) or less Wheel angle Camber Right–left error Rear wheel alignment Toe–in (total) 35°50’ ± 2° (35.84° ± 2°) Inside wheel Outside wheel 31°28’ (31.47°) –0°45’ ± 45’ (–0.75° ± 0.75°) 45’ (0.75°) or less 0°24’ ± 12’ (0.4° ± 0.2°) 4 ± 2 mm (0.16 ± 0.08 in.) No. 2 lower suspension arm length difference 1 mm (0.04 in.) or less *1: Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. *2: Rear measuring point Measure the distance from the ground to the center of the front side strut rod mounting bolt. F t axle Front l Axle bearing backlash Maximum 0.05 mm (0.0020 in.) Axle hub deviation Maximum 0.05 mm (0.0020 in.) Drive shaft standard length Front drive shaft F t suspension Front i R Rear axle l R Rear suspension i LH RH 609.2 ± 2.0 mm (23.984 ± 0.079 in.) 842.9 ± 2.0 mm (33.185 ± 0.079 in.) Lower ball joint turning torque 1.0 – 3.4 N·m (10 – 35 kgf·cm, 8.7 – 30 in.·lbf) Stabilizer bar link turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Axle bearing backlash 0.05 mm (0.0020 in.) Axle hub deviation 0.07 mm (0.0028 in.) No. 2 lower suspension arm length 512.3 mm (20.169 in.) Stabilizer bar link turning torque 0.05 – 1.0 N·m (0.5 – 10 kgf·cm, 0.4 – 8.7 in.·lbf) Author: Date: 67 SS–10 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SS04X–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Hub nut 103 1,050 76 Steering knuckle x Shock absorber 211 2,150 156 Steering knuckle x Brake caliper 107 1,090 79 Steering knuckle x Tie rod end 49 500 36 Axle hub x Drive shaft 294 3,000 217 Lower ball joint x Lower suspension arm 127 1,300 94 Lower ball joint x Steering knuckle 123 1,250 90 ABS speed sensor set bolt 8.0 82 71 in.·lbf Tie lod end lock nut 74 750 54 32 330 24 Suspension support x Body 80 820 59 Suspension support x Piston rod 49 500 36 Flexible hose and ABS speed sensor wire harness x Shock absorber 29 300 22 Lower suspension arm set bolt 206 2,100 152 Stabilizer bar link set bolt 39 400 29 Hub nut 103 1,050 76 Axle hub set bolt 80 820 59 Shock absorber x Rear axle carrier New nut Reused nut (Apply engine oil to the threads.) 255 196 2,600 2,000 188 145 No. 1, No. 2 lower suspension arm x Rear axle carrier 181 1,850 134 Strut rod x Rear axle carrier 113 1,150 83 Flexible hose x Shock absorber 29 300 22 ABS speed sensor set bolt 8.0 82 71 in.·lbf ABS speed sensor wire harness x Shock absorber 5.4 55 48 in.·lbf Rear seat outer belt lower side set bolt 42 430 31 Suspension support x Body 39 400 29 Suspension support x Piston rod 49 500 36 Parking brake cable set bolt 5.4 55 48 in.·lbf No. 2 lower suspension arm lock nut 56 570 41 No. 1, No. 2 lower suspension arm x Suspension member 181 1,850 134 Strut rod x Body 113 1,150 83 Stabilizer bar bracket x Suspension member 19 195 14 Stabilizer bar link set nut 39 400 29 FRONT AXLE FRONT DRIVE SHAFT Drive shaft center bearing lock bolt FRONT SUSPENSION REAR AXLE REAR SUSPENSION SS–11 SERVICE SPECIFICATIONS – BODY ELECTRICAL BODY ELECTRICAL SS0B0–06 SERVICE DATA FUEL RECEIVER GAUGE A–B Approx. 270.1 Ω A–C Approx. 141.3 Ω B–C Approx. 128.8 Ω ENGINE COOLANT TEMPERATURE RECEIVER GAUGE (Resistance) A–B Approx. 175.7 Ω A–C Approx. 54.0 Ω B–C Approx. 229.7 Ω ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resistance) Temperature °C (°F) Resistance (Ω) 50 (122.0) 160 – 240 120 (248.0) 17.1 – 21.2 Author: Date: 69 SS–12 SERVICE SPECIFICATIONS – BODY SS13F–01 TORQUE SPECIFICATION Part tightened REAR BUMPER N·m kgf·cm ft·lbf – – – Rear bumper cover x Body 4.9 51 43 in.·lbf Rear bumper reinforcement x Body 34 350 25 Rear bumper side retainer x Body 4.9 51 43 in.·lbf – – – Door lock striker x Body 5.4 55 49 in.·lbf Door lock x Door panel 5.4 55 49 in.·lbf Luggage compartment door hinge x Door panel 7.8 80 69 in.·lbf – – – 18 185 13 SEAT BELT – – – Front seat belt – – – Upper: 7.8 80 69 in.·lbf Lower: 41 420 30 Inner belt x Seat 41 420 30 Shoulder anchor x Body 41 420 30 Floor anchor x Body 41 420 30 Rear seat belt – – – Retractor x Body 41 420 30 Floor anchor x Body 41 420 30 RH center belt x Body 41 420 30 LH center belt x Body 41 420 30 LUGGAGE COMPARTMENT DOOR AND HINGE REAR SEAT Rear seatback x Body Retractor x Body Author: Date: 70 EC–1 EMISSION CONTROL (5S–FE) – EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM EC039–05 PURPOSE The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the engine ((3), (4) and (5)), to prevent the atmospheric release of blow–by gas–containing HC (1) and evaporated fuel containing HC being released from the fuel tank (2). The function of each system is shown in the following table. System (1) Positive Crankcase Ventilation (2) Evaporative Emission Control (3) Exhaust Gas Recirculation (4) Three–Way Catalytic Converter (5) Sequential Multiport Fuel Injection* Abbreviation PCV EVAP EGR TWC SFI Function Reduces HC Reduces evaporated HC Reduces NOx Reduces HC, CO and NOx Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SFI section in this manual. Author: Date: 1399 EC–2 EMISSION CONTROL (5S–FE) – PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC03A–03 LOCATION EGR Vacuum Modulator EGR Valve PCV Valve TWC (Except California) Rear TWC (California) VSV for EGR Front TWC (California) VSV for EVAP EVAP Service Port Vapor Pressure Sensor VSV for Vapor Pressure Sensor Vent Line Charcoal Canister Cutoff Valve Fuel Tank Cap Fuel Tank EVAP Line Fill Check Valve Air Drain Hose Filler Pipe Purge Line Air Inlet Line B06542 Author: Date: 1400 EC–3 EMISSION CONTROL (5S–FE) – PARTS LAYOUT AND SCHEMATIC DRAWING EC03B–03 DRAWING EVAP Service Port EGR Vacuum Modulator VSV for EVAP EGR Valve Front TWC (California) VSV for EGR TWC (Except California) Rear TWC (California) Purge Line Fuel Tank Cap EVAP Line Filler Pipe Vent Line Fuel Tank Charcoal Canister Vapor Pressure Sensor VSV for Vapor Pressure Sensor Air Inlet Line Air Drain Hose B06549 Author: Date: 1401 EC–4 EMISSION CONTROL (5S–FE) – POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC03C–05 INSPECTION 1. (a) INSPECT PCV VALVE Remove the PCV valve. (b) (c) Install a clean hose to the PCV valve. Inspect the PCV valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Clean Hose Cylinder Head Side B01531 Intake Manifold Side Clean Hose (2) Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. (d) Remove the clean hose from the PCV valve. (e) Reinstall the PCV valve. B01532 2. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. S01846 Author: Date: 1402 EC–5 EMISSION CONTROL (5S–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC03D–05 COMPONENTS Charcoal Canister VSV for Vapor Pressure Sensor Connector EVAP Line Hose Vapor Pressure Sensor Mounting Bolt Vent Line Hose Air Inlet Line Hose Vapor Pressure Sensor Connector Purge Line Hose Air Drain Hose Charcoal Canister Assembly 39.2 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque B06534 Author: Date: 1403 EC–6 EMISSION CONTROL (5S–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC03E–05 INSPECTION 1. INSPECT LINES AND CONNECTORS Visually check for loose connections, sharp bends or damage. 2. INSPECT FUEL TANK FILLER PIPE Visually check for deformation, cracks or fuel leakage. 3. INSPECT FUEL TANK CAP Visually check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. Type A Gasket Type B Gasket B01082 B04812 B06707 4. (a) Vacuum Gauge (b) INSPECT EVAP SYSTEM LINE Warm up the engine and stop the engine. Allow the engine to warm up to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. B06544 (c) TOYOTA Hand–Held Tester: Forced driving of the VSV for the EVAP. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Start the engine. (3) Push the TOYOTA hand–held tester main switch ON. (4) Use the ACTIVE TEST mode on the TOYOTA hand–held tester to operate the VSV for the EVAP. S05331 Author: Date: 1404 EC–7 EMISSION CONTROL (5S–FE) Battery – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (d) If you have no TOYOTA Hand–Held Tester: Forced driving of the VSV for the EVAP. (1) Disconnect the VSV connector for the EVAP. (2) Connect the positive (+) and negative (–) leads from the battery to the VSV terminals for the EVAP. (3) Start the engine. (e) Check the vacuum at idle. Vacuum: Maintain at 0.368 – 19.713 in.Hg (5 – 268 in.Aq) for over 5 seconds B06548 B06545 HINT: If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (f) TOYOTA Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the TOYOTA hand–held tester from the DLC3. (g) If you have no TOYOTA Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the positive (+) and negative (–) leads from the battery from the VSV terminals for the EVAP. (3) Connect the VSV connector for the EVAP. (h) Disconnect the vacuum gauge from the EVAP service port on the purge line. (i) Connect a pressure gauge to the EVAP service port on the purge line. (j) Hose Clipper Check the pressure. (1) Close off the air drain hose at the marked position of the canister with a hose clipper or similar instrument. Air Drain Hose B06543 Author: Date: 1405 EC–8 EMISSION CONTROL (5S–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (2) Add the pressure (13.5 – 15.5 in.Aq) from the EVAP service port. Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 – 8.8 in.Aq. Pressure Gauge Pressure B06546 HINT: If you can’t add pressure, you can conclude that the hose connecting the VSV
canister
fuel tank has slipped off or the VSV is open. (3) Fuel Tank Cap Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the filler cap is removed, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc. (k) Disconnect the pressure gauge from the EVAP service port on the purge line. B06547 EVAP Line Hose Air Disconnect B01250 EVAP Line Hose 5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the EVAP line hose from the charcoal canister side and then pressurize and make the internal pressure in the fuel tank 4 kPa (41 gf/cm2, 0.58 psi). (b) Check that the internal pressure of the fuel tank can be hold for 1 minute. (c) Check the connected portions of each hose and pipe. (d) Check the installed parts on the fuel tank. If there is no abnormality, replace the fuel tank and filler pipe. (e) Reconnect the EVAP line hose to the charcoal canister. 6. (a) Disconnect Disconnect Cap Purge Line Hose Purge Port Air (b) (c) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the purge line hose and EVAP line hose from the charcoal canister. Plug the cap to the air drain hose. Pressurize 4 kPa (41 gf/cm2, 0.58 psi) to the purge port and check that there is ventilation through the EVAP line hose. B01251 Author: Date: 1406 EC–9 EMISSION CONTROL (5S–FE) Air Inlet Line Hose Disconnect Air B01252 Push Pinch A A – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM HINT: In the condition that the fuel fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume). (d) Check if there is any struck in the vent line hose and EVAP line hose. If there is no stuck in hoses, replace the fuel cutoff valve and fill check valve. (e) Reconnect the purge line hose and EVAP line hose to the charcoal canister. 7. CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister. (b) Check that there is ventilation in the air inlet line. (c) Reconnect the air inlet line hose to the charcoal canister. 8. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the VSV connector. (b) Disconnect the vapor pressure sensor connector. (c) Disconnect the purge line hose, EVAP line hose and air inlet line hose from the charcoal canister. (d) Disconnect the vent line hose from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. (e) Remove the 2 charcoal canister mounting bolts. (f) Remove the vapor pressure sensor mounting bolt. (g) Remove the charcoal canister assembly. Pinch B01253 9. (a) INSPECT CHARCOAL CANISTER Visually check the charcoal canister for cracks or damage. (b) Inspect the charcoal canister operation. (1) Plug the vent port with a cap. (2) While holding the purge port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air flows from the air drain port. B01148 Purge Port Vent Port Cap Air Air Drain Port E VA P Port B01149 Author: Date: 1407 EC–10 EMISSION CONTROL (5S–FE) Purge Port Air Inlet Port EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (3) While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air does not flow from the air inlet port. (4) Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released. Air Drain Port Air – EVAP Port B01150 Air Inlet Port Vacuum Air Inlet Port Purge Port B01151 Purge Port EVAP Port Vacuum B01152 (5) While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port and check that air flows into the purge port. If operation is not as specified, replace the charcoal canister. (6) Remove the cap from the vent port. 10. INSPECT VSV FOR EVAP (See page SF–45) 11. INSPECT VSV FOR VAPOR PRESSURE SENSOR (See page SF–47) 12. INSPECT VAPOR PRESSURE SENSOR (See page SF–55) 13. REINSTALL CHARCOAL CANISTER ASSEMBLY Author: Date: 1408 EC–11 EMISSION CONTROL (5S–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC03F–03 COMPONENTS EGR Valve Vacuum Hose Vacuum Hose EGR Valve
Gasket
Gasket
Non–reusable part S05556 Author: Date: 1409 EC–12 EMISSION CONTROL (5S–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC03G–04 INSPECTION 1. (a) Cap Filter S05568 HINT: Install the filter with the coarser surface facing the atmospheric side (outward). (b) Vacuum Gauge INSPECT EGR SYSTEM Inspect and clean the filter in the EGR vacuum modulator. (1) Remove the cap and filter. (2) Check the filter for contamination or damage. (3) Using compressed air, clean the filter. (4) Reinstall the filter and cap. (c) Using a 3–way connector, connect a vacuum gauge to the hose between the EGR valve and VSV. Inspect seating of the EGR valve. Start the engine and check that the engine starts and runs at idle. 3–Way Connector B06540 TE1 (d) E1 (e) SST Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843–18020 Inspect the VSV operation with the cold engine. (1) The engine coolant temperature should be below 55°C (131°F). (2) Check that the vacuum gauge indicates zero at 2,500 rpm. A07370 HOT High Vacuum at 2,500 rpm Port R Disconnect B06541 (f) Inspect the operation of the VSV and EGR vacuum modulator with the hot engine. (1) Warm up the engine to above 60°C (140°F). (2) Check that the vacuum gauge indicates low vacuum at 2,500 rpm. (3) Disconnect the vacuum hose port R of the EGR vacuum modulator and connect port R directly to the intake manifold with another hose. (4) Check that the vacuum gauge indicates high vacuum at 2,500 rpm. Author: Date: 1410 EC–13 EMISSION CONTROL (5S–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM HINT: As a large amount of exhaust gas enters, the engine will misfire slightly. (g) Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations. (h) Disconnect B06539 HINT: As exhaust gas is increasingly recirculated, the engine will start to misfire. (i) Remove the SST from the DLC1. SST 09843–18020 2. (a) Engine Stopped Inspect the EGR valve. (1) Apply vacuum directly to the EGR valve with the engine idling. (2) Check that the engine runs rough or dies. (3) Reconnect the vacuum hoses to the proper locations. Air (b) (c) INSPECT EGR VACUUM MODULATOR Disconnect the vacuum hoses from ports P, Q and R of the EGR vacuum modulator. Block ports P and R with your finger. Blow air into port Q, and check that the air passes through to the air filter side freely. S05567 (d) (e) Engine at 2,500 rpm Air (f) Start the engine, and maintain speed at 2,500 rpm. Repeat the above test. Check that there is a strong resistance to air flow. Reconnect the vacuum hoses to the proper locations. S05566 Author: Date: 1411 EC–14 EMISSION CONTROL (5S–FE) 3. (a) (b) S05559 If a (c) 4. – EXHAUST GAS RECIRCULATION (EGR) SYSTEM INSPECT EGR VALVE Remove the EGR valve. (1) Disconnect the 2 vacuum hoses from the EGR valve. (2) Remove the 2 bolts, 2 nuts, EGR valve and 2 gaskets. Check the EGR valve for sticking and heavy carbon deposits. problem is found, replace the valve. Reinstall the EGR valve. (1) Temporarily 2 new gasket and the EGR valve with the 2 nuts and 2 bolts. (2) Tighten the nuts. Torque: 13.3 N·m (136 kgf·cm, 10 ft·lbf) (3) Tighten the bolts. Torque: 10 N·m (102 kgf·cm, 7 ft·lbf) (4) Connect the 2 vacuum hoses to the EGR valve. INSPECT VSV FOR EGR (See page SF–43) Author: Date: 1412 EMISSION CONTROL (5S–FE) – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC–15 THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC03H–03 ON–VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE ASSEMBLY (a) Check the connections for looseness or damage. (b) Check the clamps for weakness, cracks or damage. 2. INSPECT REAR TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT REAR TWC HEAT INSULATOR (a) Check the heat insulator for damage. (b) Check for adequate clearance between the catalytic converter and heat insulator. Author: Date: 1413 EC–16 EMISSION CONTROL (5S–FE) – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC03I–04 COMPONENTS Front TWC (California) A/F Sensor Connector
Gasket No.1 Exhaust Manifold Heat Insulator 49 (500, 36) Exhaust Manifold (Front TWC) x6 No.3 Exhaust Manifold Heat Insulator No.2 Exhaust Manifold Stay (TMMK Made) (TMC Made) No.1 Exhaust Manifold Stay A/F Sensor 44 (450, 32) Clamp

62 (630,46)
Gasket
No.2 Exhaust Manifold Heat Insulator N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06537 Author: Date: 1414 EMISSION CONTROL (5S–FE) – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC–17 TWC (Except California) Rear TWC (California) 56 (570, 41)
Gasket
Gasket
TWC (Except California) Rear TWC (California)

62 (630, 46) Front Exhaust Pipe Stay Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06538 Author: Date: 1415 EC–1 EMISSION CONTROL (1MZ–FE) – EMISSION CONTROL SYSTEM EMISSION CONTROL SYSTEM EC01U–03 PURPOSE The emission control systems are installed to reduce the amount of CO, HC and NOx exhausted from the engine ((3), (4), (5) and (6)), to prevent the atmospheric release of blow–by gas–containing HC (1) and evaporated fuel containing HC being released from the fuel tank (2). The function of each system is shown in these table. System (1) Positive Crankcase Ventilation (2) Evaporative Emission Control (3) Exhaust Gas Recirculation (4) Warm Up Three–Way Catalytic Converter (5) Three–Way Catalytic Converter (6) Sequential Multiport Fuel Injection* Abbreviation PCV EVAP EGR WU–TWC TWC SFI Function Reduces HC Reduces evaporated HC Reduces NOx Reduces HC, CO and NOx Reduces HC, CO and NOx Injects a precisely timed, optimum amount of fuel for reduced exhaust emissions Remark: * For inspection and repair of the SFI system, refer to the SF section of this manual. Author: Date: 1416 EC–2 EMISSION CONTROL (1MZ–FE) – PARTS LAYOUT AND SCHEMATIC DRAWING PARTS LAYOUT AND SCHEMATIC DRAWING EC01V–03 LOCATION Vacuum Surge Tank EGR Valve VSV for EGR VSV for EVAP Vacuum Surge Tank EVAP Service Port VCV Vapor Pressure Sensor Charcoal Canister VSV for Vapor Pressure Sensor Vent Line EVAP Line Fuel Tank Fill Check Valve Fuel Tank Cap Air Drain Hose Filler Pipe Purge Line Cut Off Valve Air Inlet Line B06386 Author: Date: 1417 EC–3 EMISSION CONTROL (1MZ–FE) – PARTS LAYOUT AND SCHEMATIC DRAWING EC01W–03 DRAWING VSV for EGR VCV EVAP Service Port Vacuum Surge Tank Purge Line VSV for EVAP EVAP Line EGR Valve Position Sensor Vent Line Vapor Pressure Sensor Fuel Tank Charcoal Canister Air Inlet Line VSV for Vapor Pressure Sensor Air Drain Hose A/F Sensor (California A/T) Heated Oxygen Sensor (Bank 1 Sensor 1/ Except California A/T) A/F Sensor (California A/T) Heated Oxygen Sensor (Bank 2 Sensor 1/ Except California A/T) WU–TWC (California A/T) WU–TWC (California A/T) TWC Heated Oxygen Sensor (Bank 1 Sensor 2) B06721 Author: Date: 1418 EC–4 EMISSION CONTROL (1MZ–FE) – POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM EC01X–03 INSPECTION 1. (a) INSPECT PCV VALVE Remove the PCV valve. (b) (c) Install clean hose to the PCV valve. Inspect the PCV valve operation. (1) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. Clean Hose Cylinder Head side P02006 (2) Air Intake Chamber Side Blow air into the air intake chamber side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. (d) Remove clean hose from the PCV valve. (e) Reinstall the PCV valve. P02477 2. INSPECT HOSES, CONNECTIONS AND GASKETS Visually check for cracks, leaks or damage. P12931 Author: Date: 1419 EC–5 EMISSION CONTROL (1MZ–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0AU–01 COMPONENTS VSV Connector for Vapor Pressure Sensor EVAP Line Hose Vapor Pressure Sensor Vent Line Hose Air Inlet Line Hose Vapor Pressure Sensor Connector Purge Line Hose Air Drain Hose VSV for Vapor Pressure Sensor Charcoal Canister 39.2 (400, 29) N·m (kgf·cm, ft·lbf) : Specified torque B01507 Author: Date: 1420 EC–6 EMISSION CONTROL (1MZ–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM EC0AV–01 INSPECTION 1. INSPECT LINES AND CONNECTORS Visually check for loose connections, sharp bends or damage. 2. INSPECT FUEL TANK FILLER PIPE Visually check for deformation, cracks or fuel leakage. 3. INSPECT FUEL TANK CAP Visually check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. Type A Gasket Type B Gasket B01082 B04812 B06707 4. (a) Vacuum Gauge (b) INSPECT EVAP SYSTEM LINE Warm up the engine and stop the engine. Allow the engine to warm up to normal operating temperature. Install a vacuum gauge (EVAP control system test equipment vacuum gauge) to the EVAP service port on the purge line. B06544 TOYOTA Hand–Held Tester DLC3 (c) TOYOTA Hand–Held Tester: Forced driving of the VSV for the EVAP. (1) Connect a TOYOTA hand–held tester to the DLC3. (2) Start the engine. (3) Push the TOYOTA hand–held tester main switch ON. (4) Use the ACTIVE TEST mode on the TOYOTA hand–held tester to operate the VSV for the EVAP. S05331 Author: Date: 1421 EC–7 EMISSION CONTROL (1MZ–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (d) If you have no TOYOTA Hand–Held Tester: Forced driving of the VSV for the EVAP. (1) Disconnect the VSV connector for the EVAP. (2) Connect the positive (+) and negative (–) leads from the battery to the VSV terminals for the EVAP. (3) Start the engine. (e) Check the vacuum at idle. Vacuum: Maintain at 0.368 – 19.713 in.Hg (5 – 268 in.Aq) for over 5 seconds Battery B06722 B06545 HINT: If the vacuum does not change, you can conclude that the hose connecting the VSV to the service port has come loose or is blocked, or the VSV is malfunctioning. (f) TOYOTA Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the TOYOTA hand–held tester from the DLC3. (g) If you have no TOYOTA Hand–Held Tester: Conclude forced driving of the VSV for the EVAP. (1) Stop the engine. (2) Disconnect the positive (+) and negative (–) leads from the battery from the VSV terminals for the EVAP. (3) Connect the VSV connector for the EVAP. (h) Disconnect the vacuum gauge from the EVAP service port on the purge line. (i) Connect a pressure gauge to the EVAP service port on the purge line. (j) Hose Clipper Check the pressure. (1) Close off the air drain hose at the marked position of the canister with a hose clipper or similar instrument. Air Drain Hose B06543 Author: Date: 1422 EC–8 EMISSION CONTROL (1MZ–FE) – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (2) Add the pressure (13.5 – 15.5 in.Aq) from the EVAP service port. Pressure: 2 minutes after the pressure is added, the gauge should be over 7.7 – 8.8 in.Aq. Pressure Gauge Pressure B06546 HINT: If you can’t add pressure, you can conclude that the hose connecting the VSV
canister
fuel tank has slipped off or the VSV is open. (3) Fuel Tank Cap Check if the pressure decreases when the fuel tank cap is removed while adding pressure. HINT: If the pressure does not decrease when the filler cap is removed, then you can conclude that the hose connecting the service port to the fuel tank is blocked, etc. (k) Disconnect the pressure gauge from the EVAP service port on the purge line. B06547 EVAP Line Hose Air Disconnect B01250 EVAP Line Hose 5. CHECK AIRTIGHTNESS IN FUEL TANK AND FILLER PIPE (a) Disconnect the EVAP line hose from the charcoal canister side and then pressurize and make the internal pressure in the fuel tank 4 kPa (41 gf/cm2, 0.58 psi). (b) Check that the internal pressure of the fuel tank can be hold for 1 minute. (c) Check the connected portions of each hose and pipe. (d) Check the installed parts on the fuel tank. If there is no abnormality, replace the fuel tank and filler pipe. (e) Reconnect the EVAP line hose to the charcoal canister. 6. (a) Disconnect Disconnect Cap Purge Line Hose Purge Port Air (b) (c) INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE Disconnect the purge line hose and EVAP line hose from the charcoal canister. Plug the cap to the air drain hose. Pressurize 4 kPa (41 gf/cm2, 0.58 psi) to the purge port and check that there is ventilation through the EVAP line hose. B01251 Author: Date: 1423 EC–9 EMISSION CONTROL (1MZ–FE) Air Inlet Line Hose Disconnect Air B01252 Push Pinch A A – EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM HINT: In the condition that the fuel fuel is full, as the float value of the fill check valve is closed and has no ventilation, it is necessary to check the fuel amount (volume). (d) Check if there is any struck in the vent line hose and EVAP line hose. If there is no stuck in hoses, replace the fuel cutoff valve and fill check valve. (e) Reconnect the purge line hose and EVAP line hose to the charcoal canister. 7. CHECK AIR INLET LINE (a) Disconnect the air inlet line hose from the charcoal canister. (b) Check that there is ventilation in the air inlet line. (c) Reconnect the air inlet line hose to the charcoal canister. 8. REMOVE CHARCOAL CANISTER ASSEMBLY (a) Disconnect the VSV connector. (b) Disconnect the vapor pressure sensor connector. (c) Disconnect the purge line hose, EVAP line hose and air inlet line hose from the charcoal canister. (d) Disconnect the vent line hose from the charcoal canister. (1) Push the connector deep inside. (2) Pinch portion A. (3) Pull out the connector. (e) Remove the 2 charcoal canister mounting bolts. (f) Remove the vapor pressure sensor mounting bolt. (g) Remove the charcoal canister assembly. Pinch B01253 9. (a) INSPECT CHARCOAL CANISTER Visually check the charcoal canister for cracks or damage. (b) Inspect the charcoal canister operation. (1) Plug the vent port with a cap. (2) While holding the purge port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air flows from the air drain port. B01148 Purge Port Vent Port Cap Air Air Drain Port E VA P Port B01149 Author: Date: 1424 EC–10 EMISSION CONTROL (1MZ–FE) Purge Port Air Inlet Port EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (3) While holding the purge port and the air drain port closed, blow air (1.76 kPa, 18 gf/cm2, 0.26 psi) into the EVAP port and check that air does not flow from the air inlet port. (4) Apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the purge port, check that the vacuum does not decrease when the air inlet port is closed, and check that the vacuum decreases when the air inlet port is released. Air Drain Port Air – EVAP Port B01150 Air Inlet Port Vacuum Air Inlet Port Purge Port B01151 Purge Port EVAP Port Vacuum B01152 (5) While holding the air inlet port closed, apply vacuum (3.43 kPa, 25.7 mmHg, 1.01 in.Hg) to the EVAP port and check that air flows into the purge port. If operation is not as specified, replace the charcoal canister. (6) Remove the cap from the vent port. 10. INSPECT VSV FOR EVAP (See page SF–58) 11. INSPECT VSV FOR VAPOR PRESSURE SENSOR (See page SF–62) 12. INSPECT VAPOR PRESSURE SENSOR (See page SF–65) 13. REINSTALL CHARCOAL CANISTER ASSEMBLY Author: Date: 1425 EC–11 EMISSION CONTROL (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM EXHAUST GAS RECIRCULATION (EGR) SYSTEM EC0AW–01 INSPECTION 1. 2. (a) Ohmmeter Disconnect E2 VC S05477 VC(+) INSPECT EGR SYSTEM (See page DI–358) INSPECT EGR VALVE POSITION SENSOR Inspect the resistance of the EGR valve position sensor. (1) Disconnect the EGR valve position sensor connector. (2) Using an ohmmeter, measure the resistance between the terminals VC and E2. Resistance: 1.5 – 4.3 kΩ If the resistance is not as specified, replace the EGR valve position sensor. (3) Reconnect the EGR valve position sensor connector. (b) E2(–) Inspect the power output voltage of the EGR valve position sensor. (1) Disconnect the vacuum hose from the EGR valve. (2) Turn the ignition switch ON. (3) Connect a voltmeter to terminals VC and E2 of the ECM, and measure the power source voltage. Voltage: 4.5 – 5.5 V B01480 Author: Date: 1426 EC–12 EMISSION CONTROL (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM (4) Connect a voltmeter to terminals EGLS and E2 of the ECM, and measure the power outlet voltage under the following conditions:
Using a MITYVAC (Hand–Held Vacuum Pump), apply a vacuum (17.3 kPa, 130 mmHg, 5.1 in.Hg) to the EGR valve. Voltage: 3.2 – 5.1 V
Release the vacuum from the EGR valve. Voltage: 0.4 – 1.6 V If the voltage is not as specified, replace the EGR valve position sensor. (5) Reconnect the vacuum hose to the EGR valve. 3. REMOVE EGR POSITION SENSOR Remove the 3 nuts and EGR valve position sensor from the EGR valve. Torque: 2 N·m (20 kgf·cm, 17 in.·lbf) 4. REINSTALL EGR POSITION SENSOR Installation is the reverse order of removal. Disconnect EGLS(+) E2(–) B01482 5. (a) S05452 (2) HINT: At the time of installation, please refer to the following items. Install 2 new gaskets. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) (b) Disconnect the EGR gas temperature sensor connector and clamp. (c) (1) (3) S05455 REMOVE EGR VALVE Remove the EGR pipe.
Remove the 4 nuts, EGR pipe and 2 gaskets. Remove the EGR valve. (1) Disconnect the EVAP hose from the EGR valve hook. (2) Disconnect the vacuum hose from the EGR valve. (3) Disconnect the EGR valve position sensor connector. Remove the 3 nuts, EGR valve and gasket. (d) HINT: At the time of installation, please refer to the following items. Install a new gasket. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) (e) Remove the EGR gas temperature sensor. Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) Author: Date: 1427 EC–13 EMISSION CONTROL (1MZ–FE) – EXHAUST GAS RECIRCULATION (EGR) SYSTEM 6. INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the EGR valve. 7. REINSTALL EGR VALVE Installation is the reverse order of removal. 8. REMOVE VCV S05454 9. (a) (b) INSPECT VCV Connect the MITYVAC (Hand–Held Vacuum Pump) to port S of the VCV. Plug port Z completely with fingers. Z Port S Port S05478 (c) Vacuum (kPa, mmHg, in.Hg) Pumping (3 Times) 10 sec. Time S05476 Perform pumping 3 times and apply vacuum as shown in the illustration. (d) Stop the performing pumping and check the indicated value of the MITYVAC after about 10 seconds. Standard value: 15 – 24 kPa (112 – 180 mmHg, 4.4 – 7.1 in.Hg) If the indicated value is not as specified, replace the VCV. 10. REINSTALL VCV 11. INSPECT VSV FOR EGR (See page SF–56) Author: Date: 1428 EC–14 EMISSION CONTROL (1MZ–FE) – WARM UP THREE–WAY CATALYTIC CONVERTER (WU–TWC) SYSTEM (California A/T) WARM UP THREE–WAY CATALYTIC CONVERTER (WU–TWC) SYSTEM (California A/T) EC020–04 ON–VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE ASSEMBLY (a) Check the connections for looseness or damage. (b) Check the clamps for weakness, cracks or damage. 2. INSPECT WU–TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the WU–TWC, repair or replace it. 3. INSPECT WU–TWC HEAT INSULATOR (a) Check the heat insulator for damage. (b) Check for adequate clearance between the catalytic converter and heat insulator. Author: Date: 1429 EMISSION CONTROL (1MZ–FE) – WARM UP THREE–WAY CATALYTIC CONVERTER (WU–TWC) SYSTEM (California A/T) EC–15 EC021–04 COMPONENTS WU–TWC for Bank 1 56 (570, 41) Bracket 21 (210, 15)
Gasket
Gasket
WU–TWC 62 (630, 46) Front Exhaust Pipe (Type A) 33 (330, 24) Stay
62 (630, 46) 33 (330, 24) Type B WU–TWC Front Exhaust Pipe N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06395 Author: Date: 1430 EC–16 EMISSION CONTROL (1MZ–FE) – WARM UP THREE–WAY CATALYTIC CONVERTER (WU–TWC) SYSTEM (California A/T) WU–TWC for Bank 2 A/F Sensor Connector
Gasket LH Exhaust Manifold (with WU–TWC) 49 (500, 63) x6 LH Exhaust Manifold Heat Insulator
Gasket A/F Sensor 44 (450, 32) LH Exhaust Manifold Stay
62 (630, 46) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06478 Author: Date: 1431 EMISSION CONTROL (1MZ–FE) – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC–17 THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC022–04 ON–VEHICLE INSPECTION 1. INSPECT EXHAUST PIPE ASSEMBLY (a) Check the connections for looseness or damage. (b) Check the clamps for weakness, cracks or damage. 2. INSPECT TWC Check for dents or damage. If any part of the protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. 3. INSPECT TWC HEAT INSULATOR (a) Check the heat insulator for damage. (b) Check for adequate clearance between the catalytic converter and heat insulator. Author: Date: 1432 EC–18 EMISSION CONTROL (1MZ–FE) – THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM EC023–04 COMPONENTS 56 (570, 41) Bracket 21 (210, 15)
Gasket
Gasket
Gasket TWC 62 (630, 46) Bracket Front Exhaust Pipe (California A/T Type A) Stay 33 (330, 24) 33 (330, 24)
62 (630, 46) California A/T (Type B) TWC Front Exhaust Pipe M/T Except M/T and california A/T TWC TWC Front Exhaust Pipe Front Exhaust Pipe N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06396 Author: Date: 1433 BE–1 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BODY ELECTRICAL SYSTEM BE09Y–01 PRECAUTION Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts. 1. HEADLIGHT SYSTEM
Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM)
The CAMRY is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 3. AUDIO SYSTEM
If the negative (–) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so make sure to note the stations and reset them after the negative (–) terminal cable is reconnected to the battery.
If the negative (–) terminal cable is disconnected from the battery, the ”ANTI–THEFT SYSTEM” will operate when the cable is reconnected, but the radio, tape player and CD player will not operate. Be sure to input the correct ID number so that the radio, tape player and CD player can be operated again. 4. MOBILE COMMUNICATION SYSTEM
If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. Author: Date: 2221 BE–2 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM BE09Z–03 PROBLEM SYMPTOMS TABLE POWER OUTLET Symptom Electric power source cannot be taken out of the power outlet Suspect Area See page 11.Battery 12.POWER OUTLET Fuse (I/P J/B No.1) 13.Wire Harness – – – HEADLIGHT AND TAILLIGHT SYSTEM (USA) Symptom Suspect Area See page Headlight does not light. (Taillight is normal) 1. HEAD–(LH, RH) Fuse (E/G Room J/B No.2) 2. Headlight Bulb 3. Wire Harness Headlight does not light. (Taillight does not light up) 1. 2. 3. 4. Only one side light does not light. 1. HEAD–(LH, RH) Fuse (E/G Room J/B No.2) 2. Headlight Bulb 3. Wire Harness ”Lo–Beam” does not light. 1. Headlight Bulb 2. Light Control Switch 3. Wire Harness – BE–24 – ”Hi–Beam” does not light. 1. Headlight Dimmer Switch 2. Light Control Switch 3. Wire Harness BE–24 BE–24 – ”Flash” does not light. 1. Headlight Dimmer Switch 2. Wire Harness BE–24 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. 5. 6. – – BE–14 BE–24 BE–14 – Taillight does not light. (Headlight does not light) 1. Light Control Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness BE–24 BE–14 – Taillight does not light. (Headlight is normal) 1. 2. 3. 4. 5. – BE–24 BE–24 BE–14 – Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Bulb 2. Light Failure Sensor 3. Wire Harness – BE–37 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. – BE–14 BE–32 – HEAD–(LH, RH) Fuse (E/G Room J/B No.2) Headlight Control Relay (E/G Room J/B No.2) Headlight Bulb Wire Harness GAUGE Fuse (I/P J/B No.1) DOME Fuse (E/G Room J/B No.2) Integration Relay (I/P J/B No.2) Door Courtesy Switch (Driver’s) Ignition Switch Wire Harness TAIL Fuse (I/P J/B No.1) Taillight Control Relay (I/P J/B No.1) Light Control Switch Integration Relay (I/P J/B No.1) Wire Harness – – – – BE–24 – – – – – – – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Door Courtesy Switch (Driver’s) Wire Harness Author: Date: 2222 BE–3 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM (CANADA) Symptom Suspect Area See page Headlight does not light. (Taillight is normal) 1. Wire Harness – Headlight does not light. (Taillight does not light up) 1. Wire Harness – Only one side light does not light. 1. Headlight Bulb 2. HEAD LO (LH, RH) Fuse (E/G Room R/B No.2) 3. Wire Harness – – – ”Lo–Beam” does not light. 1. 2. 3. 4. 5. 6. Headlight Bulb HEAD LO (LH, RH) Fuse (E/G Room R/B No.2) Headlight Control Relay (E/G Room J/B No.2) Integration Relay (I/P J/B No.1) Light Control Switch Wire Harness – – BE–24 BE–14 BE–24 – 1. 2. 3. 4. 5. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) DRL Fuse (E/G Room R/B No.2) Daytime Running Light Relay No.2 (E/G Room R/B No.2) 6. Daytime Running Light Relay No.3 (E/G Room R/B No.2) 7. Daytime Running Light Relay No.4 (E/G Room R/B No.2) 8. Daytime Running Light Relay (Main) 9. Headlight Dimmer Switch 10.Wire Harness – – – – – BE–24 – BE–24 – BE–24 BE–24 BE–24 – 1. 2. 3. 4. 5. ”Flash” does not light. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) DRL Fuse (E/G Room R/B No.2) Daytime Running Light Relay No.2 (E/G Room R/B No.2) 6. Daytime Running Light Relay No.3 (E/G Room R/B No.2) 7. Daytime Running Light Relay No.4 (E/G Room R/B No.2) 8. Daytime Running Light Relay (Main) 9. Headlight Dimmer Switch 10.Wire Harness – – – – – BE–24 – BE–24 – BE–24 BE–24 BE–24 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. 5. 6. GAUGE Fuse (I/P J/B No.1) DOME Fuse (E/G Room J/B No.2) Integration Relay (I/P J/B No.2) Door Courtesy Switch (Driver’s) Ignition Switch Wire Harness – – BE–14 BE–24 BE–14 – Headlight does not light with engine running and light control SW OFF. 1. 2. 3. 4. 5. 6. 7. Headlight Bulb ECU–B Fuse (E/G Room J/B No.2) GAUGE Fuse (I/P J/B No.1) HEAD HI (LH, RH) Fuse (E/G Room J/B No.2) Daytime Running Light Relay (Main) Wire Harness Other Parts* – – – – BE–24 – – ”Hi–Beam” does not light. Author: Date: 2223 BE–4 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM Taillight does not light. (Headlight does not light) 1. Integration Relay (I/P J/B No.1) 2. Light Control Switch 3. Wire Harness BE–14 BE–24 – Taillight does not light. (Headlight is normal) 1. 2. 3. 4. 5. – BE–24 BE–14 BE–24 – Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Bulb 2. Light Failure Sensor 3. Wire Harness – BE–37 – ”Auto Turn–off System” does not operate. 1. 2. 3. 4. – BE–14 BE–24 – TAIL Fuse (I/P J/B No.1) Taillight Control Relay (I/P J/B No.1) Integration Relay (I/P J/B No.1) Light Control Switch Wire Harness – – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Door Courtesy Switch (Driver’s) Wire Harness *Terminal L of generator and parking brake switch TURN SIGNAL AND HAZARD WARNING SYSTEM Symptom Suspect Area See page ”Hazard” and ”Turn” do not light up. 1. Hazard Warning Switch 2. Turn Signal Flasher 3. Wire Harness BE–30 BE–30 – The flashing frequency is abnormal. 1. Bulb 2. Turn Signal Switch 3. Wire Harness – BE–30 – Hazard warning light does not light up. (Turn is normal.) 1. HORN Fuse (E/G Room J/B No.2) 2. Wire Harness Hazard warning light does not light up in one direction. 1. Hazard Warning Switch 2. Wire Harness BE–30 – *1Turn signal does not light up. 1. 2. 3. 4. Ignition Switch TURN Fuse (I/P J/B No.1) Turn Signal Switch Wire Harness BE–14 – BE–30 – *2Turn signal does not light up. 1. TURN Fuse (I/P J/B No.1) 2. Turn Signal Switch 3. Wire Harness – BE–30 – Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness BE–30 – Only one bulb does not light up. 1. Bulb 2. Wire Harness – – – – *1: Combination meter, wiper and washer do not operate. *2: Combination meter, wiper and washer are normal. INTERIOR LIGHT SYSTEM Symptom Suspect Area See page ”Illuminated Entry System” does not operate. 1. Door Courtesy Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness Only one interior light does not light up. 1. Bulb 2. Wire Harness – – Interior light does not light up (All). 1. DOME Fuse (E/G Room J/B No.2) 2. Wire Harness – – Author: BE–32 BE–14 – Date: 2224 BE–5 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM Dome light does not light up. 1. Bulb 2. Dome Light 3. Wire Harness – BE–32 – Map Light does not light up. 1. Bulb 2. Map Light 3. Wire Harness – BE–32 – Luggage compartment light does not light up. 1. Bulb 2. Luggage compartment door courtesy switch 3. Wire Harness – BE–32 – BACK–UP LIGHT SYSTEM Symptom Back–Up Light does not light up. Back–Up Light remains always ON. Only one light does not light up. Suspect Area 1. 2. 3. 4. See page GAUGE Fuse (I/P J/B No.1) Ignition Switch Wire Harness Bulb 1. Back–Up Light Switch (M/T) 2. Park/Neutral Position Switch (A/T) – BE–14 – – 3. Wire Harness BE–35 DI–424 DI–479 – 1. Bulb 2. Wire Harness – – (A140E) (A541E) STOP LIGHT SYSTEM Symptom Suspect Area See page Stop light does not light up. 1. STOP Fuse (I/P J/B No.1) 2. Stop Light Switch 3. Wire Harness – BE–37 – Only one light always lights up. 1. Wire Harness – Only one light does not light. 1. Bulb 2. Wire Harness – – WIPER AND WASHER SYSTEM *1: Inspect wiper arm and blade set position Symptom Suspect Area See page Wiper and washers do not operate. 1. 2. 3. 4. WIPER Fuse (I/P J/B No.1) Wiper Switch Wiper Motor Wire Harness Wipers do not operate in LO or HI. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–40 BE–40 – Wipers do not operate in INT. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness BE–40 BE–40 – Washer motor does not operate. 1. Washer Switch 2. Washer Motor 3. Wire Harness BE–40 BE–40 – Wipers do not operate when washer switch in ON. 1. Washer Motor 2. Wire Harness BE–40 – Author: – BE–40 BE–40 – Date: 2225 BE–6 BODY ELECTRICAL Washer fluid does not operate.
In wiper switch HI position, the wiper blade is in contact with the body.
When the wiper switch is OFF, the wiper blade does not retract or the retract position is wrong. – BODY ELECTRICAL SYSTEM 1. Washer Hose and Nozzle – *1Wiper 1. Switch 2. Wire Harness BE–40 – COMBINATION METER METER, GAUGES AND ILLUMINATION: Symptom Suspect Area See page Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–46 – Speedometer does not operate. 1. No.1 Vehicle Speed Sensor 2. Meter Circuit Plate 3. Wire Harness BE–47 BE–46 – 1. Igniter 2. Meter Circuit Plate 3. Wire Harness IG–1 IG–1 BE–46 – Fuel Gauge does not operate or abnormal operation. 1. 2. 3. 4. Fuel Receiver Gauge Fuel Sender Gauge Meter Circuit Plate Wire Harness BE–47 BE–47 BE–46 – Engine Coolant Temperature Gauge does not operate or abnormal operation 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness BE–47 BE–47 BE–46 – All illumination lights do not light up. 1. TAIL Fuse (I/P J/B No.1) 2. Light Control Rheostat 3. Wire Harness Brightness does not change even when rheostat turned. 1. Bulb 2. Wire Harness – – Only one illumination light does not light up. 1. Bulb 2. Wire Harness – – Tachometer does not operate. (5S–FE) (1MZ–FE) – BE–47 – COMBINATION METER WARNING LIGHTS: Symptom Suspect Area See page Warning lights do not light up. (Except Discharge, Open Door and SRS) 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–46 – Low Oil Pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – Fuel Level warning light does not light up. 1. 2. 3. 4. Bulb Fuel Level Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – ABS warning light does not light up. 1. Bulb 2. ABS ECU 3. Wire Harness – IN–31 – Author: Date: 2226 BE–7 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 1. 2. 3. 4. Bulb Seat Belt Buckle Switch Integration Relay (I/P J/B No.1) Wire Harness – BE–47 BE–47 – 1. 2. 3. 4. IGN Fuse (I/P J/B No.1) Bulb Wire Harness Generator – – – CH–1 CH–1 Light Failure warning light does not light up. 1. 2. 3. 4. 5. Bulb Light Failure Sensor Bulb Check Relay Wire Harness Taillight system – BE–37 BE–47 – BE–24 Brake warning light does not light up. 1. 2. 3. 4. 5. 6. Bulb Parking Brake Switch Brake Fluid Level Warning Switch Bulb Check Relay Meter Circuit Plate Wire Harness – BE–47 BE–47 BE–47 BE–46 – SRS Warning light does not light up. 1. 2. 3. 4. 5. ECU–B Fuse (E/G Room J/B No.2) Bulb Airbag Sensor Assembly Meter Circuit Plate Wire Harness – – DI–626 BE–46 – Open Door warning light does not light up. 1. 2. 3. 4. 5. DOME Fuse (E/G Room J/B No.2) Bulb Door Courtesy Switch Meter Circuit Plate Wire Harness – – BE–32 BE–46 – Washer Level warning light does not light up. 1. 2. 3. 4. Bulb Washer Fluid Level Warning Switch Meter Circuit Plate Wire Harness – BE–47 BE–46 – Seat Belt warning light does not light up. Discharge warning light does not light up. (5S–FE) (1MZ–FE) COMBINATION METER INDICATOR LIGHTS: Symptom Suspect Area 1. Bulb 2. O/D OFF Switch See page 3. Meter Circuit Plate 4. Wire Harness – DI–431 DI–487 BE–46 – Cruise Control indicator light does not light up. 1. 2. 3. 4. Bulb Cruise Control ECU Meter Circuit Plate Wire Harness – IN–31 BE–46 – High beam indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Headlight System – BE–46 – BE–22 Turn indicator light does not light up. 1. 2. 3. 4. Bulb Meter Circuit Plate Wire Harness Turn Signal and Hazard Warning System – BE–46 – BE–29 O/D OFF indicator light does not light up. Author: (A140E) (A541E) Date: 2227 BE–8 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM 4. Wire Harness – BE–46 DI–424 DI–479 – Only one shift indicator does not light up. 1. Bulb 2. Meter Circuit Plate – BE–46 Malfunction indicator light does not light up. 1. 2. 3. 4. Bulb ECM Meter Circuit Plate Wire Harness – – BE–46 – SLIP indicator light does not light up. 1. 2. 3. 4. Bulb Traction ECU Meter Circuit Plate Wire Harness – – BE–46 – TRAC OFF indicator light does not light up. 1. 2. 3. 4. Bulb Traction ECU Meter Circuit Plate Wire Harness – – BE–46 – Security indicator light does not light up. 1. 2. 3. 4. Bulb Security ECU Meter Circuit Plate Wire Harness – – BE–46 – Indicator lights do not light up. (Except Turn, Hi–beam and security) 1. GAUGE Fuse (I/P J/B No.1) 2. Wire Harness Shift indicator lights do not light up. 1. Bulb 2. Meter Circuit Plate 3. Park/Neutral Position Switch (A140E) (A541E) – – DEFOGGER SYSTEM Symptom Suspect Area See page All defogger systems do not operate. 1. 2. 3. 4. 5. DEFOG M–Fuse (I/P J/B No.1) HTR Fuse (I/P J/B No.1) Defogger Relay (I/P J/B No.1) Defogger Switch Wire Harness – – BE–56 BE–56 – Rear window defogger does not operate. 1. Defogger Wire 2. Choke Coil 3. Wire Harness BE–56 – – Mirror defogger does not operate. 1. MIR/HTR Fuse (I/P J/B No.1) 2. Mirror Defogger 3. Wire Harness – BE–56 – POWER WINDOW CONTROL SYSTEM Symptom Suspect Area See page Power window does not operate (ALL). (Power Door Lock does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Power Main Relay (I/P J/B No.1) 3. Wire Harness – BE–60 – Power window does not operate (ALL). (Power Door Lock is normal) 1. Ignition Switch 2. Power Window Master Switch 3. Wire Harness BE–14 BE–60 – ”One Touch Power Window System” does not operate. 1. Power Window Master Switch BE–60 Only one window glass does not move. 1. 2. 3. 4. Power Window Master Switch Power Window Switch Power Window Motor Wire Harness BE–60 BE–60 BE–60 – ”Window Lock System” does not operate. 1. Power Window Master Switch BE–60 Author: Date: 2228 BE–9 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM ”Window Lock Illumination” does not light up. 1. Power Window Master Switch BE–60 Key–off power window does not operate. 1. 2. 3. 4. 5. – BE–60 BE–14 BE–32 – GAUGE Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Ignition Switch Door Courtesy Switch Wire Harness POWER DOOR LOCK CONTROL SYSTEM Symptom Suspect Area See page ”Door lock system” does not operate at all. 1. 2. 3. 4. 5. POWER M–Fuse (I/P J/B No.1) CIG Fuse (I/P J/B No.1) DOOR Fuse (I/P J/B No.1) Integration Relay (I/P J/B No.1) Wire Harness – – – BE–70 – Door lock system does not operate by manual switch. 1. 2. 3. 4. Power Window Master Switch Door Lock Manual Switch Integration Relay (I/P J/B No.1) Wire Harness BE–60 BE–70 BE–70 – Door lock system does not operate by door key. 1. 2. 3. 4. Door Key Lock and Unlock Switch Integration Relay (I/P J/B No.1) Wire Harness Door Lock Link Disconnected BE–70 BE–70 – – Fault in 2–Operation unlock function of Driver’s side door key lock and unlock switch. 1. Door Key Lock and Unlock Switch 2. Integration Relay (I/P J/B No.1) 3. Wire Harness BE–70 BE–70 – Fault in key confine prevention operate. 1. 2. 3. 4. BE–70 BE–14 BE–32 – Only one door lock does not operate. 1. Door Lock Motor 2. Wire Harness Integration Relay (I/P J/B No.1) Key Unlock Warning Switch Door Courtesy Switch Wire Harness BE–70 – SLIDING ROOF SYSTEM Symptom Suspect Area See page Sliding roof system does not operate. (Door Lock does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Power Main Relay (I/P J/B No.1) 3. Wire Harness – BE–60 – Sliding roof system does not operate. (Door Lock is normal) 1. 2. 3. 4. Ignition Switch Sliding Roof Control Relay and Switch Sliding Roof Motor and Limit Switch Wire Harness BE–14 BE–74 BE–74 – Sliding roof system operates abnormally. 1. Sliding Roof Control Relay and Switch 2. Sliding Roof Motor and Limit Switch 3. Wire Harness BE–74 BE–74 – Sliding roof system stops operation half way. (Stones of foreign material trapped in motor assembly) 1. Sliding Roof Control Relay and Switch 2. Sliding Roof Motor and Limit Switch 3. Wire Harness BE–74 BE–74 – ”Key–off Sliding Roof” operation does not operate. 1. 2. 3. 4. 5. – – BE–14 BE–14 – DOME Fuse (E/G Room J/B No.2) GAUGE Fuse (I/P J/B No.1) Ignition Switch Integration Relay (I/P J/B No.1) Wire Harness Author: Date: 2229 BE–10 BODY ELECTRICAL – BODY ELECTRICAL SYSTEM POWER SEAT CONTROL SYSTEM Symptom Suspect Area See page Power seat does not operate. (Door lock system does not operate) 1. POWER M–Fuse (I/P J/B No.1) 2. Wire Harness – – Power seat does not operate. (Door lock system is normal) 1. Power Seat Swtich (D,P) 2. Wire Harness BE–78 – ”Slide operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Slide Motor (D, P) BE–78 – BE–78 ”Lifter Operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Lifter Motor (D, P) BE–78 – BE–78 ”Reclining Operation” does not operate. 1. Power Seat Switch (D, P) 2. Wire Harness 3. Reclining Motor (D, P) BE–78 – BE–78 (D): Driver’s seat (P): Passenger’s seat POWER MIRROR CONTROL SYSTEM Symptom Suspect Area Mirror does not operate. 1. 2. 3. 4. Mirror operates abnormally. 1. Mirror Switch 2. Mirror Motor 3. Wire Harness See page CIG Fuse (I/P J/B No.1) Mirror Switch Mirror Motor Wire Harness – BE–83 BE–83 – BE–83 BE–83 – Author: Date: 2230 BE–11 BODY ELECTRICAL – POWER SOURCE POWER SOURCE BE0A0–03 LOCATION Engine Room Relay Block No.1 Engine Room Junction Block No.2 Engine Room Relay Block No.2 Instrument Panel Junction Block No.1 Turn Signal Flasher Z19043 Author: Date: 2231 BE–12 BODY ELECTRICAL – POWER OUTLET POWER OUTLET BE0A1–03 LOCATION Power Outlet Instrument Panel J/B No.1
PWR OUTLET Fuse N20688 Author: Date: 2232 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–13 IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A2–03 LOCATION Key Unlock Warning Switch Instrument Panel J/B No.1
Integration Relay Ignition Switch N20687 Author: Date: 2233 BE–14 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE0A3–02 INSPECTION 1. ACC ON LOCK 4 3 2 1 8 7 6 5 START N14824 INSPECT IGNITION SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK – ACC 2–3 Continuity ON 2–3–4 6–7 Continuity START 1–2–4 6–7–8 Continuity No continuity If continuity is not as specified, replace the switch. 2. OFF ON 2 1 INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY Switch position Tester connection OFF (Key removed) – ON (Key set) 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. N20125 3. 10 6 5 1 (a) (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE A) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzer sounds. N20126 (d) 10 6 5 (e) 1 Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. N20127 Author: Date: 2234 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–15 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20128 4. 10 6 5 1 (a) (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE B) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzerr sounds. N20129 (d) 10 6 5 (e) 1 Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. N20130 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20131 5. 10 6 5 (a) 1 (b) (c) Key unlock warning system: INSPECT INTEGRATION RELAY (TYPE C) OPERATION Connect the positive (+) lead from the battery to terminal 1. Connect the negative (–) lead from the battery to terminals 5, 6 and 10. Check the buzzerr sounds. N20132 Author: Date: 2235 BE–16 BODY ELECTRICAL (d) (e) 10 6 5 – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Disconnect the negative (–) lead from the battery to terminal 6. Check that the buzzerr stops sounding. 1 N20133 (f) 10 6 5 Connect the negative (–) lead from the battery to terminal 6. (g) Disconnect the negative (–) lead from the battery to terminal 5. (h) Check that the buzzerr stops sounding. If operation is not as specified, replace the relay. 1 N20134 6. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE A) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Tester connection Condition Specified condition 2 – Ground 4 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity 2 – Ground 4 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF No continuity 6 – Ground Driver’s door courtesy switch ON Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage Author: Date: 2236 BODY ELECTRICAL (b) Wire harness side: – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH BE–17 Disconnect the connector from the integration relay and inspect the connector on the wire harness side. 1 23 4 N20136 Tester connection Condition Specified condition 1 – Ground Light control switch OFF No continuity 1 – Ground Light control switch HEAD or TAIL Continuity 4 – Ground Light control switch OFF or TAIL No continuity 4 – Ground Light control switch HEAD Continuity 2 – Ground 3 – Ground Constant Battery positive voltage If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 7. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE B) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Tester connection Condition Specified condition 2 – Ground All door courtesy switches OFF (Except Driver’s Door/ Door closed) No continuity 2 – Ground One of the door courtesy switches ON (Except Driver’s Door/ Door opened) Continuity 4 – Ground Door courtesy switches except that of the driver’s door OFF (Door closed) No continuity 4 – Ground One of the door courtesy switches except that of the driver’s door ON (Door opened) Continuity Author: Date: 2237 BE–18 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF (Door closed) No continuity 6 – Ground Driver’s door courtesy switch ON (Door opened) Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage 11 – Ground Ignition switch LOCK No voltage 11 – Ground Ignition switch ACC or ON Battery positive voltage (b) Wire harness side: 1 – 2 3 4 5 6 Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Connector ”A” Wire harness side: 1 2 3 eh–25–1 h–4–1 4 Connector ”B” N20137 Tester connection Condition Specified condition A3 – Ground Constant Continuity A5 – Ground Driver’s door unlock detection switch OFF (Door locked) No continuity A5 – Ground Driver’s door unlock detection switch ON (Door unlocked) Continuity A6 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity Author: Date: 2238 BODY ELECTRICAL – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH A6 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity A7 – Ground Passenger’s door unlock detection switch OFF (Door locked) No continuity A7 – Ground Passenger’s door unlock detection switch ON (Door unlocked) Continuity A9 – Ground Rear door unlock detection switch OFF (Door locked) No continuity A9 – Ground Rear door unlock detection switch ON (Door unlocked) Continuity Constant Continuity A16 – Ground Door lock manual switch OFF or UNLOCK No continuity A16 – Ground Door lock manual switch LOCK Continuity A17 – Ground Door lock manual switch OFF or LOCK No continuity A17 – Ground Door lock manual switch UNLOCK Continuity A18 – Ground Driver’s and passenger’s door key lock and unlock switch OFF or UNLOCK No continuity A18 – Ground Driver’s or passenger’s door key lock and unlock switch LOCK Continuity A19 – Ground Driver’s door key lock and unlock switch OFF or LOCK No continuity A19 – Ground Driver’s door key lock and unlock switch UNLOCK Continuity A20 – Ground Passenger’s door key lock and unlock switch OFF or LOCK No continuity A20 – Ground Passenger’s door key lock and unlock switch UNLOCK Continuity A1 – Ground Constant Battery positive voltage B1 – Ground Light control switch OFF No voltage B1 – Ground Light control switch TAIL or HEAD Battery positive voltage B4 – Ground Light control switch OFF or TAIL No voltage B4 – Ground Light control switch HEAD Battery positive voltage B2 – Ground B3 – Ground Constant Battery positive voltage A11 – A12 A12 – A25 BE–19 If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. 8. (a) Junction block side: 12 11 10 9 8 7 6 5 4 INSPECT INTEGRATION RELAY (TYPE C) CIRCUIT Remove the relay from the junction block No.1 and inspect the connector on the junction block side. 3 2 1 N20135 Author: Date: 2239 BE–20 BODY ELECTRICAL Tester connection – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Condition Specified condition 2 – Ground All door courtesy switches OFF (Except Driver’s Door/ Door closed) No continuity 2 – Ground One of the door courtesy switches ON (Except Driver’s Door/ Door opened) Continuity 4 – Ground Door courtesy switches except that of the driver’s door OFF (Door closed) No continuity 4 – Ground One of the door courtesy switches except that of the driver’s door ON (Door opened) Continuity 5 – Ground Key unlock warning switch OFF No continuity 5 – Ground Key unlock warning switch ON Continuity 6 – Ground Driver’s door courtesy switch OFF (Door closed) No continuity 6 – Ground Driver’s door courtesy switch ON (Door opened) Continuity 8 – Ground Buckle switch OFF (Seat belt unfastened) No continuity 8 – Ground Buckle switch ON (Seat belt fastened) Continuity 10 – Ground Constant Continuity 1 – Ground Constant Battery positive voltage 7 – Ground 9 – Ground Ignition switch LOCK or ACC No voltage 7 – Ground 9 – Ground Ignition switch ON Battery positive voltage 11 – Ground Ignition switch LOCK No voltage 11 – Ground Ignition switch ACC or ON Battery positive voltage (b) Wire harness side: Disconnect the connector from the integration relay and inspect the connectors on the wire harness side. 1 2 3 4 5 6 7 8 9 10 11 12 13 Connector ”A” Wire harness side: 1 2 3 4 Connector ”B” N20138 Author: Date: 2240 BODY ELECTRICAL Tester connection – IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH Condition Specified condition A1 – Ground Door lock manual switch OFF or UNLOCK No continuity A1 – Ground Door lock manual switch LOCK Continuity A2 – Ground Door lock manual switch OFF or LOCK No continuity A2 – Ground Door lock manual switch UNLOCK Continuity A3 – Ground Driver’s and passenger’s door key lock and unlock switch OFF or UNLOCK No continuity A3 – Ground Driver’s or passenger’s door key lock and unlock switch LOCK Continuity A4 – Ground Driver’s door key lock and unlock switch OFF or LOCK No continuity A4 – Ground Driver’s door key lock and unlock switch UNLOCK Continuity A5 – Ground Passenger’s door key lock and unlock switch OFF or LOCK No continuity A5 – Ground Passenger’s door key lock and unlock switch UNLOCK Continuity Constant Continuity A8 – Ground Passenger’s door courtesy switch OFF (Door closed) No continuity A8 – Ground Passenger’s door courtesy switch ON (Door opened) Continuity A9 – Ground Driver’s door unlock detection switch OFF (Door closed) No continuity A9 – Ground Driver’s door unlock detection switch ON (Door opened) Continuity A10 – Ground Passenger’s door unlock detection switch OFF (Door closed) No continuity A10 – Ground Passenger’s door unlock detection switch ON (Door opened) Continuity A11 – Ground Rear door unlock detection switch OFF (Door closed) No continuity A11 – Ground Rear door unlock detection switch ON (Door opened) Continuity A12 – Ground Constant Continuity A13 – Ground Constant Battery positive voltage B1 – Ground Light control switch OFF No voltage B1 – Ground Light control switch TAIL or HEAD Battery positive voltage B4 – Ground Light control switch OFF or TAIL No voltage B4 – Ground Light control switch HEAD Battery positive voltage B2 – Ground B3 – Ground Constant Battery positive voltage A6 – A7 BE–21 If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2241 BE–22 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM BE0A4–02 LOCATION E/G Room J/B No.2
HEAD LH Fuse (USA)
HEAD RH Fuse (USA)
HEAD LH (UPR) Fuse (CANADA)
HEAD RH (UPR) Fuse (CANADA)
DOME Fuse
ECU–B Fuse
Headlight Control Relay Daytime Resister E/G Room R/B No.2 (CANADA)
HEAD LH (LWR) Fuse
HEAD RH (LWR) Fuse
DRL No.2 Fuse
Daytime Running Light Relay No.4 Automatic Light Control Sensor Headlight Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
Taillight Control Relay
Integration Relay Ignition Switch Combination Switch
Light Control Switch
Headlight Dimmer Switch Daytime Running Light Relay Door Courtesy Switch Light Failure Sensor Taillight I08436 Author: Date: 2242 BE–23 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A5–02 COMPONENTS Combination Switch
Light Control Switch
Headlight Dimmer Switch Switch Body Spiral Cable Combination Switch
Wiper and Washer Switch N18012 Author: Date: 2243 BE–24 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE10D–01 INSPECTION 1. Hi beam HEAD TAIL OFF Flash INSPECT LIGHT CONTROL SWITCH CONTINUITY Switch position Tester connection Specified condition OFF – TAIL 14 – 16 Continuity HEAD 13 – 14 – 16 Continuity No continuity If continuity is not as specified, replace the switch. 2. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY 8 7 Switch position Tester connection Specified condition Low beam 16 – 17 Continuity High beam 7 – 16 Continuity Flash 7 – 8 – 16 Continuity If continuity is not as specified, replace the switch. 17 16 14 13 N20149 3. 1 2 4 2 1 4 3 3 INSPECT HEADLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–4 Continuity If continuity is not as specified, replace the relay. Z08521 4. 2 1 3 5 5 2 1 3 INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 5. 2 4 1 3 2 4 1 INSPECT HEADLIGHT DIMMER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 – 4, 2 – 4 Continuity Apply B+ between terminals 2 and 4. 3–4 Continuity If continuity is not as specified, replace the relay. 3 Z08523 Author: Date: 2244 BE–25 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM 6. INSPECT DAYTIME RUNNING LIGHT RELAY (MAIN) CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. Wire harness side: I08219 Tester connection Condition Specified condition 2 – Ground Light control switch position OFF or TAIL No continuity 2 – Ground Light control switch position HEAD Continuity 3 – Ground Headlight dimmer switch position Low beam No continuity 3 – Ground Headlight dimmer switch position High beam of Flash Continuity 4 – Ground Brake fluid level warning position OFF No continuity 4 – Ground Brake fluid level warning position ON Continuity 12 – Ground Constant Continuity 14 – Ground Parking brake switch position OFF (Parking brake lever released) No continuity 14 – Ground Parking brake switch position ON (Parking brake lever pulled up) Continuity 17 – Ground Light control switch position OFF or HEAD No voltage 17 – Ground Light control switch position TAIL Continuity 20 – Ground Constant Continuity 21 – Ground Constant Continuity 13 – Ground Engine Stop No voltage 13 – Ground Engine Running Battery positive voltage 16 – Ground Constant Battery positive voltage 18 – Ground Ground terminal 19 Battery positive voltage 19 – Ground Constant Battery positive voltage 22 – Ground Constant Battery positive voltage 23 – Ground Ignition switch position LOCK or ACC No voltage 23 – Ground Ignition switch position ON or START Battery positive voltage If circuit is as specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2245 BE–26 BODY ELECTRICAL 7. 2 3 1 4 2 1 3 4 – HEADLIGHT AND TAILLIGHT SYSTEM INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY Condition Tester connection Specified condition Constant 3–4 Continuity Apply B+ between terminals 3 and 4. 1–2 Continuity If continuity is not as specified, replace the relay. Z08559 8. 2 1 INSPECT DAYTIME RUNNING LIGHT RESISTER CONTINUITY Condition Tester connection Specified condition Constant 1–2 Approx. 250mΩ If continuity is not as specified, replace the resistor. 9. INSPECT LIGHT AUTO TURN OFF SYSTEM (See Integration relay circuit on page BE–14) N20139 10. (a) (b) (c) (d) (e) INSPECT AUTOMATIC LIGHT CONTROL Turn the ignition switch ON. Turn the light control switch to OFF. Parking brake lever released. Gradually cover the top of the sensor. Verify that the lights should turn ON the accessory lights and the headlights. 11. (a) (b) INSPECT AUTOMATIC LIGHT CONTROL Gradually expose the sensor. Verify that the lights should turn OFF the headlights and the accessory lights. INSPECT LIGHT–OFF CONDITION Turn the ignition switch ON. Gradually cover the top of the sensor. Lights auto ON: INSPECT LIGHTS–ON CONDITION Open the driver’s door while the ignition switch is OFF. Turn the light control switch to OFF leaving the door open and cover the top of the sensor, and verify that the lights go on when the ignition switch is turned ON. I08422 12. (a) (b) I08423 13. (a) (b) Author: Date: 2246 BE–27 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM 14. INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Connector disconnected: Disconnect the connector from the sensor and inspect the connector on the wire harness side, as shown in the table. Wire harness side: 1234 I01254 Tester connection Condition Specified condition 3 – Ground Constant Constant 1 – Ground Ignition switch LOCK or ACC No voltage 1 – Ground Ignition switch ON Battery positive voltage 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON 5.2 – 9.0 v If circuit is as specified, perform the inspection on the following page. If the circuit is not as specified, inspect the circuit connected to other parts. 15. 4 3 1 2 I01255 INSPECT AUTOMATIC LIGHT CONTROL SENSOR CIRCUIT Connector disconnected: Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side, as shown. HINT:
Ignition switch ON.
Light control switch OFF.
Vehicle’s surroundings are bright. Tester connection Condition Specified condition 3 – Ground Constant Continuity 1 – Ground Ignition switch LOCK or ACC No voltage 1 – Ground Ignition switch ON 9.5 V or more Vehicle under the direct sun light. (Sensor is not covered) Taillight and Headlight are ON. If circuit is as specified, try replacing the sensor with a new one. If the circuit is not as specified, inspect the circuit connected to other parts. Author: Date: 2247 BE–28 BODY ELECTRICAL – HEADLIGHT AND TAILLIGHT SYSTEM BE0A7–02 ADJUSTMENT 1. ADJUST HEADLIGHT AIMING For Adjustment in Vertical Direction For Adjustment in Horizontal Direction N20156 2. ADJUST SPIRAL CABLE (See page SR–16) Author: Date: 2248 BE–29 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A8–03 LOCATION E/G Room J/B No.2
HORN Fuse Hazard Warning Switch Ignition Switch Turn Signal Light Instrument Panel J/B No.1
TURN Fuse Turn Signal Flasher Combination Switch
Turn Signal Switch Turn Signal Light Z19045 Author: Date: 2249 BE–30 BODY ELECTRICAL – TURN SIGNAL AND HAZARD WARNING SYSTEM BE0A9–02 INSPECTION Right 1. Left INSPECT TURN SIGNAL SWITCH CONTINUITY Switch position Tester connection Left turn 1–2 Neutral – Right turn 2–3 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 3 2 1 N20150 2. (a) 3 2 (b) 1 Turn Signal Light Bulbs (21 W) 4 3 BE1843 INSPECT TURN SIGNAL FLASHER OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3. Connect the 2 turn signal light bulbs in parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT: The turn signal lights should flash 60 to 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashes will be more than 140 per minute. If operation is not as specified, replace the flasher. 3. INSPECT HAZARD WARNING SWITCH CONTINUITY Switch position Tester connection Switch OFF 7 – 10 Continuity Switch ON 5–6–9 7–8 Continuity Illumination circuit 2–3 Continuity 2 1 10 9 8 7 6 5 Specified condition If continuity is not as specified, replace the switch. N20140 Author: Date: 2250 BE–31 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM BE0AA–03 LOCATION E/G Room J/B No.2
DOME Fuse Instrument Panel J/B No.1
Integration Relay Map Light Dome Light Door Courtesy Switch Door Courtesy Switch Luggage Compartment Door Courtesy Switch Z19046 Author: Date: 2251 BE–32 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM BE0AB–03 INSPECTION w/ Sliding roof: 2 1 1. INSPECT MAP LIGHT SWITCH CONTINUITY Switch position Tester connection OFF – ON 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the light assembly or bulb. w/o Sliding roof: 1 2 N21873 2. (a) (b) 2 Ohmmeter INSPECT DOME LAMP SWITCH Disconnect the connector from the dome lamp. Turn the dome lamp switch ON, check that continuity exists between terminal 2 and body ground. N20157 (c) Turn the dome lamp switch DOOR, check that there is continuity exists between terminal 1 and 2. If operation is not as specified, replace the switch. 2 Ohmmeter 1 N20158 3. (a) ON Ohmmeter OFF INSPECT DOOR COURTESY SWITCH CONTINUITY Check that continuity exists between terminal and the switch body with the switch ON (switch pin released: opened door). (b) Check that no continuity exists between terminal and the switch body with the switch OFF (switch pin pushed in: closed doors). If operation is not as specified, replace the switch. N20159 Author: Date: 2252 BE–33 BODY ELECTRICAL – INTERIOR LIGHT SYSTEM 4. ON OFF I01447 INSPECT LUGGAGE COMPARTMENT DOOR COURTESY SWITCH CONTINUITY (a) Check that continuity exists between terminal and switch body with the switch ON (switch pin released: opened door). (b) Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. 5. INSPECT ILLUMINATED ENTRY SYSTEM (See Integration relay circuit on page BE–14) Author: Date: 2253 BE–34 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BACK–UP LIGHT SYSTEM BE0AC–02 LOCATION Instrument Panel J/B No.1
GAUGE Fuse Ignition Switch Back–up Light 1MZ–FE engine: 5S–FE engine: Back–up Light Switch Back–up Light Switch PNP Switch Z19047 Author: Date: 2254 BE–35 BODY ELECTRICAL – BACK–UP LIGHT SYSTEM BE0AD–02 INSPECTION INSPECT BACK–UP LIGHT SWITCH CONTINUITY Tester connection Free – Push 1–2 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. Push Free Condition N14065 Author: Date: 2255 BE–36 BODY ELECTRICAL – STOP LIGHT SYSTEM STOP LIGHT SYSTEM BE0AE–02 LOCATION Stop Light Switch Instrument Panel J/B No.1
STOP Fuse Hi–Mounted Stop Light Stop Light Light Failure Sensor Z19048 Author: Date: 2256 BE–37 BODY ELECTRICAL – STOP LIGHT SYSTEM BE0AF–02 INSPECTION w/o Cruise control: Free 1. Pushed in 2 1 w/ Cruise control: Free Switch position Tester connection Specified condition Switch pin free 1–2 Continuity Switch pin pushed in 1–2 No continuity If continuity is not as specified, replace the switch. 2. w/ Cruise control: INSPECT STOP LIGHT SWITCH CONTINUITY Pushed in 1 2 w/o Cruise control: INSPECT STOP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition Switch pin free 1–2 Continuity Switch pin pushed in 1–2 No continuity Switch pin free 3–4 No continuity Switch pin pushed in 3–4 Continuity If continuity is not as specified, replace the switch. 3 4 N18026 3. 1 INSPECT HI–MOUNTED STOP LIGHT ASSEMBLY CONTINUITY Using the ohmmeter, check that continuity exists between terminals. If continuity is not as specified, replace the bulb or light assembly. 2 N20208 Author: Date: 2257 BE–38 BODY ELECTRICAL STOP LIGHT SYSTEM 4. INSPECT LIGHT FAILURE RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown. Wire harness side: 5 4 – 3 2 1 12 11 10 9 8 7 6 e–12–2–B N20209 Tester connection Condition Specified condition 1 – Ground Constant Continuity* 2 – Ground Constant Continuity* 9 – Ground Constant Continuity* 11 – Ground Constant Continuity 3 – Ground Light control switch OFF No voltage 3 – Ground Light control switch TAIL or HEAD Battery positive voltage 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON Battery positive voltage 7 – Ground Stop light switch OFF No voltage 7 – Ground Stop light switch ON Battery positive voltage 8 – Ground Ignition switch LOCK or ACC No voltage 8 – Ground Ignition switch ON Battery positive voltage *: There is resistance because this circuit is grounded through the bulb. If the circuit is as specified, replace the relay. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2258 BE–39 BODY ELECTRICAL – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM BE0AG–03 LOCATION Wiper Motor Washer Tank Washer Motor Wiper and Washer Switch Instrument Panel J/B No.1
WIPER Fuse Z19049 Author: Date: 2259 BE–40 BODY ELECTRICAL – WIPER AND WASHER SYSTEM BE0AH–03 w/o Timer OFF INT LO HI INSPECTION 1. INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY Switch position Tester connection OFF 7 – 16 Continuity INT 7 – 16 Continuity LO 7 – 17 Continuity HI 8 – 17 Continuity Washer ON 2 – 11 Continuity Washer ON w/ Timer OFF INT LO HI Specified condition If continuity is not as specified, replace the switch. Washer ON 8 7 17 2 11 16 N20218 2. (a) (b) (c) 2 7 (d) 16 INSPECT INTERMITTENT OPERATION Turn the wiper switch to INT position. Turn the intermittent time control switch to FAST position. Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2, check that the meter needle indicates battery positive voltage. N20210 (e) 7 2 After connecting terminal 16 to terminal 17, connect it to terminal 2, check the voltage rises from 0 volts to battery positive voltage within the time, as shown in the table. 17 INT time control switch position 16 Voltage Approx. 2 sec. Battery positive voltage FAST N20211 0V 10.7 ± 5 sec. Battery positive voltage SLOW 0V 3.3 ± 1 sec. Non variable type Battery positive voltage 0V If operation is not as specified, replace the wiper and washer switch. Author: Date: 2260 BE–41 BODY ELECTRICAL 3. (a) 2 7 (b) (c) 16 – WIPER AND WASHER SYSTEM INSPECT WASHER LINKED OPERATION Connect the positive (+) lead from the battery to terminal 16 and the negative (–) lead to terminal 2. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (–) lead to terminal 2. Push in the washer switch, and check that the voltage changes as shown in the chart. Washer Switch ON N20210 OFF Less than 1 sec. Approx. 3 sec. Battery positive Voltage 0V N11301 If operation is not as specified, replace the wiper and washer switch. 4. Low speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and the negative (–) lead to terminal 4, check that the motor operates at low speed. If operation is not as specified, replace the motor. 5 4 N20151 Author: Date: 2261 BE–42 BODY ELECTRICAL – WIPER AND WASHER SYSTEM 5. High speed: INSPECT FRONT WIPER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 4, check that the motor operates at high speed. If operation is not as specified, replace the motor. 3 4 N20152 6. (a) Stopping in stop position: INSPECT FRONT WIPER MOTOR OPERATION Operate the motor at low speed and stop the motor operation anywhere except in the stop position by disconnecting positive (+) lead from terminal 5. 5 4 N20153 Author: Date: 2262 BE–43 BODY ELECTRICAL – WIPER AND WASHER SYSTEM (b) (c) 3 Connect terminals 3 and 5. Connect the positive (+) lead from the battery to terminal 2 and negative (–) lead to terminal 4, check that the motor stops running in the stop position after the motor operates again. If operation is not as specified, replace the motor. 2 5 4 N20154 7. INSPECT WASHER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. 2 1 2 1 N20155 Author: Date: 2263 BE–44 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE0AI–03 LOCATION Brake Fluid Level Warning Switch E/G Room J/B No.2
ECU–B Fuse
DOME Fuse Washer Fluid Level Warning Switch Combination Meter
Bulb Check Relay ECM ABS ECU Light Control Rheostat Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
IGN Fuse
Integration Relay Z19050 Author: Date: 2264 BE–45 BODY ELECTRICAL PKB Switch – COMBINATION METER Door Courtesy Switch Seat Belt Buckle Switch Door Courtesy Switch Fuel Sender Gauge
Fuel Level Warning Switch Light Failure Sensor 5S–FE engine: 1MZ–FE engine: Low Oil Pressure Warning Switch Engine Coolant Temperature Gauge Engine Coolant Temperature Gauge Low Oil Pressure Warning Switch Park/Neutral Position Switch Park/Neutral Position Switch Z19055 Author: Date: 2265 BE–46 BODY ELECTRICAL – COMBINATION METER BE0AJ–03 CIRCUIT Connector ”A” 1 2 3 4 5 6 Connector ”B” 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 Connector ”C” 9 10 11 12 13 14 15 16 J–13–1–A C7 E T 7 8 9 10 11 1213 J–16–1 B3 C5 A2 A1 C8 F 1 2 3 4 5 6 Connector ”C” Connector ”B” J–13–1 Connector ”A” B15 C6 S B14 ODOMETER Fuel Level Warning Seat Belt Warning ABS Warning Low Oil Pressure Warning Cruise Control Indicator Malfunction Indicator O/D OFF Indicator Light Failure Warning Brake Warning SLIP Indicator TRAC Indicator Washer Level Warning Discharge Warning A13 B2 C1 B1 C9 A6 A11 A7 A10 A8 A9 Bulb Check Relay Right Turn Indicator Left Turn Indicator Security Indicator L 2 D N R P Illumination C13 B8 B11 B12 Hi–Beam Indicator Open Door Warning SRS Warning B6 A4 C4 B5 C10 C2 A12 A3 B7 C3 A5 C11 B4 No. A B16 B C12 B9 B10 B13 C F : Fuel Gauge E : Engine Coolant Temperature Gauge T : Tachometer S : Speedometer 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 Wire Harness Side Engine coolant temperature sender gauge Ground Light failure sensor Integration relay Traction ECU Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) O/D OFF switch (A/T) IGN fuse Turn signal switch ST relay Fuel sender gauge Generator Oil pressure switch Fuel sender gauge Parking brake switch and brake fluid level warning switch Headlight dimmer switch Headlight dimmer switch Door courtesy switch DOME fuse ECU–B fuse Airbag sensor assembly ECM No.1 Vehicle speed sensor Ground Turn signal switch ECM Traction ECU ABS ECU Ground No.1 Vehicle speed sensor GAUGE fuse Igniter Security ECU Cruise control ECU Washer fluid level warning switch Light control rheostat TAIL fuse N20107 N20108 Z18937 Author: Date: 2266 BE–47 BODY ELECTRICAL – COMBINATION METER BE0AK–03 INSPECTION 1. INSPECT SPEEDOMETER ON–VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. USA (mph) CANADA (km/h) Standard indication Allowable range Standard indication Allowable range 20 18 – 24 20 40 38 – 44 40 38 – 46 60 56 – 66 60 57.5 – 67 80 78 – 88 80 77 – 88 100 98 – 110 100 96 – 109 120 118 – 132 120 115 – 130 140 134 – 151.5 160 153 – 173 2. (a) 3 (b) 1 (c) (d) 2 N02332 17 – 24 INSPECT VEHICLE SPEED SENSOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2. Connect the positive (+) lead from the tester to terminal 3 and the negative (–) lead to terminal 2. Rotate the shaft. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. 3. INSPECT TACHOMETER ON–VEHICLE (a) Connect a tune–up test tachometer, and start the engine. NOTICE:
Reversing the connection of the tachometer will damage the transistors and diodes inside.
When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks. Author: Date: 2267 BE–48 BODY ELECTRICAL (b) Ignition Switch – COMBINATION METER Compare the tester with tachometer indications. DC 13.5 V 25°C at (77 °F) Standard indication Allowable range 700 630 – 770 1,000 900 – 1,100 2,000 1,850 – 2,150 3,000 2,800 – 3,200 4,000 3,800 – 4,200 5,000 4,800 – 5,200 6,000 5,750 – 6,250 7,000 6,700 – 7,300 4. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 and 3 on the wire harness side connector through a 3.4–W test bulb. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. Fuel Gauge Battery N20160 Ignition Switch (d) Fuel Gauge Battery 1 2 4 BE1206 Ie–5–1–A 3 5 Z05727 HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 5. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. A B C Tester connection Resistance (Ω) A–B Approx. 126.2 A–C Approx. 280.5 B–C Approx. 154.3 If resistance value is not as specified, replace the receiver gauge. N20212 Author: Date: 2268 BE–49 BODY ELECTRICAL – COMBINATION METER 6. INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3 for each float position. F 1/2 E 3 1 2 N20161 Float position mm (in.) Resistance (Ω) F: Approx. –91.1 (–3.587) Approx. 3.0 1/2: Approx. –34.2 (–1.346) Approx. 31.7 E: Approx. 30.8 (1.213) Approx. 110.0 If resistance value is not as specified, replace the sender gauge. 7. (a) (b) INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 1 and 3 on the wire harness side connector. (c) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. Warning Light Ignition Switch Battery 2 1 4 3 5 Z05730 BE1217 Ie–5–1–A 3 1 8. (a) INSPECT FUEL LEVEL WARNING SWITCH Apply battery positive voltage between terminals 1 and 3 through a 3.4–W test bulb, check that the bulb lights up. HINT: It takes a short time for the bulb to light up. N20213 1 3 (b) Submerge the switch in fuel, check that the bulb goes out. If operation is not as specified, replace the sender gauge. N20214 9. Engine coolant temperature gauge Ignition Switch Battery (a) (b) Sender Gauge INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. N20215 Author: Date: 2269 BE–50 BODY ELECTRICAL Battery COMBINATION METER (c) Ground terminal on the wire harness side connector through a 3.4–W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. Engine coolant temperature gauge Ignition Switch – Test Bulb (3.4 W) Wire Harness Side Z15788 10. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. C B A N20216 Tester connection Resistance (Ω) * A–B Approx. 175.7 A–C Approx. 54.0 B–C Approx. 229.7 *: This circuit includes the diode. HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. If resistance value is not as specified, replace the receiver gauge. 11. INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Measure the resistance between the terminal and gauge body. Temperature °C (°F) Resistance (Ω) 50 (122.0) 274 120 (248.0) 26.4 If resistance value is not as specified, replace the engine coolant temperature sender gauge. N21646 12. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery 1 Z14205 Author: Date: 2270 BE–51 BODY ELECTRICAL 13. (a) (b) (c) N06640 – COMBINATION METER INSPECT LOW OIL PRESSURE SWITCH Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2, 3.55 psi). If operation is not as specified, replace the switch. 14. (a) Warning Light Ignition Switch Battery BE1217 INSPECT BRAKE SYSTEM WARNING LIGHT Disconnect the connector from the brake fluid warning switch. (b) Release the parking brake pedal. (c) Connect the terminals on the wire harness side of the level warning switch connector. (d) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. 15. (a) (b) (c) OFF ON 2 1 N02346 INSPECT BRAKE FLUID LEVEL WARNING SWITCH Remove the reservoir tank cap and strainer. Disconnect the connector. Check that no continuity exists between the terminals with the switch OFF (float up). (d) Use syphon, etc. to take fluid out of the reservoir tank. (e) Check that continuity exists between the terminals with the switch ON (float down). (f) Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. 16. INSPECT PARKING BRAKE SWITCH (a) Check that continuity exists between the terminal and switch body with the switch ON (switch pin released). (b) Check that no continuity exists between the terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. N01212 17. (a) INSPECT WASHER FLUID LEVEL WARNING LIGHT Disconnect the connectors from the level warning switch and parking brake switch. (b) Connect terminals on the wire harness side connector of the level warning switch connector. (c) Remove the GAUGE fuse and turn the ignition switch ON, and check that the warning light comes on. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery BE1217 Author: Date: 2271 BE–52 BODY ELECTRICAL Ohmmeter OFF ON – COMBINATION METER 18. (a) INSPECT WASHER FLUID LEVEL WARNING SWITCH Check that no continuity exists between terminals with the switch OFF (float up). (b) Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. N20217 19. INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch and ground terminal 1 on the wire harness side, and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. Warning Light Ignition Switch Battery 1 Z05732 20. (a) Warning Light Ignition Switch Battery BE0044 INSPECT SEAT BELT WARNING LIGHT Remove the integration relay from the instrument panel junction block. (b) Ground terminal 2 on the integration relay with the connectors still connected. (c) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 21. 1 2 OFF ON w/o Power seat: INSPECT BUCKLE SWITCH CONTINUITY (a) Check that continuity exists between the terminals on the switch side connector with the switch ON (belt fastened). (b) Check that no continuity exists between the terminals on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. Z16167 OFF 1 2 ON N02354 22. w/ Power seat: INSPECT BUCKLE SWITCH CONTINUITY (a) Check that continuity exists between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). (b) Check that no continuity exists between terminals 1 and 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. Author: Date: 2272 BE–53 BODY ELECTRICAL 23. Type A: 1 7 (a) 9 10 (b) (c) (d) Type B and C: 1 (e) 7 9 – COMBINATION METER INSPECT INTEGRATION RELAY OF SEAT BELT WARNING SYSTEM OPERATION Connect the positive (+) lead from the battery to terminals 1 and 7. Connect the terminal 7 to terminal 9 through the 3.4–W test bulb. Connect the negative (–) lead from the battery to terminal 10. Check that the bulb lights and the buzzer sounds for 4 – 8 seconds. Return to step (a) and operate the chime again. 10 N20219 (f) Type A: 1 7 Connect the negative (–) lead from the battery to terminal 8. Check that the buzzer stops sounding. (g) HINT: Check the buzzer within a period of 4 to 8 seconds. If operation is not as specified, replace the relay. 24. INSPECT INTEGRATION RELAY CIRCUIT See page BE–14 8 9 10 Type B and C: 1 7 8 9 10 N20220 Author: Date: 2273 BE–54 BODY ELECTRICAL 25. (a) (b) (c) – COMBINATION METER INSPECT LIGHT CONTROL RHEOSTAT Connect the positive (+) lead from the battery to terminal 1 and negative lead (–) to terminal 3. Connect the positive (+) lead from the voltmeter to terminal 2 and negative lead to terminal 3. Turn the rheostat knob and check that the voltage changes. 270° 2 3 1 N08958 (a) B A C (b) B A C 26. (a) INSPECT BULB CHECK RELAY OPERATION Connect the positive (+) lead from the battery to terminal C through a 1.4–W test bulb and the negative (–) lead to terminal B, check that the test bulb does not light up. (b) Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Z09972 Author: Date: 2274 BE–55 BODY ELECTRICAL – DEFOGGER SYSTEM DEFOGGER SYSTEM BE0AL–03 LOCATION Defogger Switch Instrument Panel J/B No.1
DEFOG M–Fuse
HTR Fuse
MIR–HTR Fuse
Defogger Relay Mirror Defogger Defogger Wire Z19051 Author: Date: 2275 BE–56 BODY ELECTRICAL – DEFOGGER SYSTEM BE0AM–03 INSPECTION Switch side: 2 1. INSPECT DEFOGGER SWITCH CONTINUITY Check that is continuity exists between terminals 2 and 6. If continuity is not as specified, check the bulb. 1 6 5 4 3 N20315 2. (a) 5 ON 4 3 N20314 INSPECT DEFOGGER TIMER OPERATION Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 3. (b) Connect the positive (+) lead from the battery to terminal 5 through a 3.4–W tester bulb. (c) Push the defogger switch ON, check that the indicator light and test bulb light up for 12 to 18 minutes, then the indicator light and test bulb light goes out. If operation is not as specified, replace the switch. 3. INSPECT DEFOGGER TIMER CIRCUIT Disconnect the connector from the switch and inspect the connector on the wire harness side, as shown in the table. Wire harness side: 1 2 3 4 5 6 S–6–1 Z08467 Tester connection Condition Specified condition 3 – Ground Constant Continuity 4 – Ground Ignition switch LOCK or ACC No voltage 4 – Ground Ignition switch ON Battery positive voltage 5 – Ground Ignition switch LOCK or ACC No voltage 5 – Ground Ignition switch ON Battery positive voltage Connect terminals 3 and 5. Defogger system operation is normal – If the circuit is not as specified, replace the switch. 4. 1 2 3 5 1 5 2 3 INSPECT DEFOGGER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 Author: Date: 2276 BE–57 BODY ELECTRICAL 5. (a) 6 4 – DEFOGGER SYSTEM w/ Heater: INSPECT MIRROR DEFOGGER Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 6. Check that the mirror becomes warm. (b) HINT: It takes short time for the mirror to become warm. N21371 Tester Probe Heat Wire Tin Foil BE4029 At Center 6. INSPECT DEFOGGER WIRE NOTICE:
When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires.
Do not use detergents or glass cleaners with abrasive ingredients.
When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown. (a) Turn the ignition switch ON. (b) Turn the defogger switch ON. (c) Inspect the voltage at the center of each heat wire, as shown. Voltage Criteria Approx. 5V Okay (No break in wire) Approx.10V or 0V Broken wire BE0123 Several 0 Volt Volts Broken Wire BE0124 HINT: If there is approximately 10 V, the wire is broken between the center of the wire and the positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. (d) Place the voltmeter positive (+) lead against the defogger positive (+) terminal. (e) Place the voltmeter negative (–) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (–) terminal end. (f) The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. Author: Date: 2277 BE–58 BODY ELECTRICAL 7. (a) Repair Point (b) Broken Wire (c) Masking Tape – DEFOGGER SYSTEM IF NECESSARY, REPAIR DEFOGGER WIRE Clean the broken wire tips with grease, wax and silicone remover. Place the masking tape along both sides of the wire to be repaired. Thoroughly mix the repair agent (Dupont paste No. 4817). BE0150 (d) (e) (f) (g) Thoroughly mix the repair agent (Dupont paste No. 4817 or equivalent). Using a fine tip brush, apply a small amount to the wire. After a few minutes, remove the masking tape. Do not repair the defogger wire for at least 24 hours. BE0151 Author: Date: 2278 BE–59 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM BE0AN–03 LOCATION Ignition Switch Instrument Panel J/B No.1
POWER M–Fuse
GAUGE Fuse
Power Main Relay
Integration Relay Door Courtesy Switch Power Window Switch Power Window Switch Power Window Switch Power Window Master Switch Power Window Regulator Assembly
Power Window Motor Door Courtesy Switch Power Window Regulator Assembly
Power Window Motor Power Window Regulator Assembly
Power Window Motor Z19052 Author: Date: 2279 BE–60 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM BE0AO–02 INSPECTION 1. (a) 6 5 4 3 2 1 141312 1110 9 8 7 INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Inspect the front driver’s switch. Window unlock: Switch position Tester connection Specified condition UP 3–8–9 4–5–6 Continuity OFF 3–4–5 4–5–6 Continuity DOWN 6–8–9 3–4–5 Continuity Window lock: Switch position Tester connection UP 3–8–9 4–5–6 Continuity OFF 3–4–5 4–5–6 Continuity DOWN 6–8–9 3–4–5 Continuity N20559 (b) Specified condition Inspect the front passenger’s switch. Window unlock: Switch position Tester connection Specified condition UP 8 – 9 – 11 4 – 5 – 13 Continuity OFF 4 – 5 – 11 4 – 5 – 13 Continuity DOWN 8 – 9 – 13 4 – 5 – 11 Continuity Window lock: (c) Switch position Tester connection Specified condition UP 8 – 9 – 11 Continuity OFF 11 – 13 Continuity DOWN 8 – 9 – 13 Continuity Inspect the rear left switch. Window unlock: Switch position Tester connection UP 8 – 9 – 10 4 – 5 – 12 Continuity OFF 4 – 5 – 10 4 – 5 – 12 Continuity DOWN 8 – 9 – 12 4 – 5 – 10 Continuity Author: MH Specified condition Date: 3/7/02 2280 BE–61 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM Window lock: (d) Switch position Tester connection UP 8 – 9 – 10 Continuity Specified condition OFF 10 – 12 Continuity DOWN 8 – 9 – 12 Continuity Inspect the rear right switch. Window unlock: Switch position Tester connection Specified condition UP 7–8–9 4 – 5 – 14 Continuity OFF 4–5–7 4 – 5 – 14 Continuity DOWN 8 – 9 – 14 4–5–7 Continuity Window lock: Switch position Tester connection Specified condition UP 7–8–9 Continuity OFF 7 – 14 Continuity DOWN 8 – 9 – 14 Continuity If continuity is not as specified, replace the master switch. 2. Unlock (a) (b) 4 8 INSPECT POWER WINDOW MASTER SWITCH ILLUMINATION Set the window lock switch to the unlock position. Connect the positive (+) lead from the battery to terminal 8 and the negative (–) lead to terminal 4, and check that all the illuminations light up. N02358 (c) Set the window lock switch to the lock position, check that all the passenger’s power window switch illuminations go out. If operation is not as specified, replace the master switch. Lock 4 8 N02359 Author: Date: 2281 BE–62 BODY ELECTRICAL 3 3. 6 (a) (b) (c) Z05738 (d) 3 (e) 6 – POWER WINDOW CONTROL SYSTEM Using an ammeter: INSPECT ONE–TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 3 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 6 on the wire harness side connector. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Z05739 4. 8 (a) (b) (c) Z05740 8 (d) (e) Using an ammeter with a current – measuring probe: INSPECT ONE–TOUCH POWER WINDOW SYSTEM/ CURRENT OF CIRCUIT Remove the master switch with connector connected. Attach a current–measuring probe to terminal 8 of the wire harness. Turn the ignition switch ON and set the power window switch in the down position. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Z05741 Author: MH Date: 3/7/02 2282 BE–63 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM 5. INSPECT POWER WINDOW MASTER SWITCH CIRCUIT Disconnect the connector from the master switch and inspect the connector on the wire harness side, as shown in the following page. Wire harness side: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 e–14–1–A Z05742 Tester connection Condition Specified condition 4 – Ground Constant Continuity 8 – Ground Ignition switch position LOCK or ACC *No voltage 8 – Ground Ignition switch position ON Battery positive voltage *Exceptions: During 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or a passenger’s door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, inspect the circuits connected to other parts. 6. 5 4321 Front passenger’s door: INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 – 2, 3 – 4 Continuity OFF 1 – 2, 3 – 5 Continuity DOWN 1 – 4, 3 – 5 Continuity If continuity is not as specified, replace the switch. N20560 7. 5 432 1 Rear door: INSPECT POWER WINDOW SWITCH CONTINUITY Switch position Tester connection Specified condition UP 1 – 3, 4 – 5 Continuity OFF 1 – 2, 4 – 5 Continuity DOWN 1 – 2, 3 – 5 Continuity If continuity is not as specified, replace the switch. N20561 8. 1 2 3 5 5 1 2 3 INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N14863 Author: Date: 2283 BE–64 BODY ELECTRICAL 9. TMMK made: (a) 2 – POWER WINDOW CONTROL SYSTEM Left side door: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. 1 TMC made: N20555 (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. TMMK made: 2 1 TMC made: N20556 Author: MH Date: 3/7/02 2284 BE–65 BODY ELECTRICAL 10. TMMK made: (a) 2 – POWER WINDOW CONTROL SYSTEM Right side door: INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the motor turns clockwise. 1 TMC made: N20557 (b) Reverse the polarity, and check that the motor turns counterclockwise. If operation is not as specified, replace the motor. TMMK made: 2 1 TMC made: N20558 Author: Date: 2285 BE–66 BODY ELECTRICAL 11. 1 2 (a) (b) (c) I21314 (d) (e) – POWER WINDOW CONTROL SYSTEM Driver’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the master switch. Connect the positive (+) lead from the ammeter to terminal 2 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector, and raise the window to the fully position. Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, and check that the window begins to descend. If operation is not as specified, replace the motor. 2 1 I21315 12. 2 1 (a) (b) (c) I21312 (d) (e) Passenger ’s door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION Disconnect the connector from the power window switch. Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. Disconnect the leads from the terminals. Author: MH Date: 3/7/02 2286 BE–67 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, and check that the window begins to descend. If operation is not as specified, replace the motor. 2 1 I21313 13. 2 1 I12561 2 1 Rear Door: INSPECT POWER WINDOW MOTOR PTC THERMISTOR OPERATION (a) Disconnect the connector from the power window switch. (b) Connect the positive (+) lead from the ammeter to terminal 1 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 2 on the wire harness side connector, and raise the window to the fully position. (d) Continue to apply voltage and check that the current changes to less than 1 A within 4 to 90 seconds. (e) Disconnect the leads from the terminals. (f) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, and check that the window begins to descend. If operation is not as specified, replace the motor. I12560 14. Type B: (b) Close (c) Open A3 N20564 Key–off power window signal: INSPECT INTEGRATION RELAY (TYPE B) OPERATION HINT: When the relay circuit is as specified, inspect the key–off power window signal. (a) Connect the positive (+) lead from the voltmeter to terminal A3 and the negative (–) lead to body ground. (b) Close the door with ignition switch turned to LOCK or ACC, and check that the meter needle indicates battery positive voltage. (c) Open the door and check that the meter needle indicates 0 V. Author: Date: 2287 BE–68 BODY ELECTRICAL – POWER WINDOW CONTROL SYSTEM (d) Turn the ignition switch ON and check that the meter needle indicates battery positive voltage again. If operation is not as specified, replace the relay. Type B: A3 N20565 Type C: 15. (b) Close (c) Open A12 N20566 Key–off power window signal: INSPECT INTEGRATION RELAY (TYPE C) OPERATION HINT: When the relay circuit is as specified, inspect the key–off power window signal. (a) Connect the positive (+) lead from the voltmeter to terminal A12 and the negative (–) lead to body ground. (b) Close the door with ignition switch turned to LOCK or ACC, and check that the meter needle indicates battery positive voltage. (c) Open the door and check that the meter needle indicates 0 V. (d) Turn the ignition switch ON and check that the meter needle indicates battery positive voltage again. If operation is not as specified, replace the relay. 16. INSPECT INTEGRATION RELAY CIRCUIT (See page XX–XXX) Type C: A12 N20567 Author: MH Date: 3/7/02 2288 BE–69 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE0AP–02 LOCATION Instrument Panel J/B No.1
POWER M–Fuse
CIG Fuse
DOOR Fuse
Integration Relay Door Key Lock and Unlock Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Power Window Master Switch
Door Lock Control Switch Door Lock Assembly
Door Lock Motor
Door Unlock Detection Switch Door Lock Control Switch Z19053 Author: Date: 2289 BE–70 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM BE0AQ–02 INSPECTION 1. N21181 Master switch: INSPECT DRIVER’S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection LOCK 2–4 OFF – UNLOCK 4–7 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER’S DOOR LOCK CONTROL SWITCH CONTINUITY Switch position Tester connection LOCK 3–6 OFF – UNLOCK 3–5 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N20568 3. OFF UNLOCK LOCK 1 2 3 w/ Theft deterrent system: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 2–1 OFF – UNLOCK 3–1 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N20569 4. Lock Unlock w/o Theft deterrent system: INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection LOCK 2–1 OFF – UNLOCK 3–1 Specified condition Continuity No continuity Continuity If continuity is not as specified, replace the switch. N21580 4 5. 1 Lock Unlock INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY Switch position Tester connection OFF (Door Lock set to LOCK) – ON (Door Lock set to UNLOCK) 1–4 Specified condition No continuity Continuity If continuity is not as specified, replace the switch. N20673 Author: Date: 2290 BE–71 BODY ELECTRICAL 3 2 3 – POWER DOOR LOCK CONTROL SYSTEM 6. (a) INSPECT MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2, and check that the door lock link moves to UNLOCK position. (b) Remove the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. 2 N20570 7. Front door Rear door (a) (b) Using an ammeter: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 3. Connect the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to battery negative (–) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. N20571 Front door (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. Rear door N20572 Front door 8. Rear door (a) (b) Using an ammeter with a current–measuring probe: INSPECT PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2. Attach a current–measuring probe to either the positive (+) lead or the negative (–) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. N20573 Front door (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. Rear door N20572 Author: Date: 2291 BE–72 BODY ELECTRICAL Type B: 9. Lock A25 A12 N20574 Type B: Unlock A25 A12 – POWER DOOR LOCK CONTROL SYSTEM Door lock signal: INSPECT INTEGRATION RELAY (Type B) OPERATION HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the positive (+) lead from the voltmeter to terminal A12 and the negative (–) lead to terminal A25. (b) Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. (c) Reverse the polarity of the voltmeter leads. (d) Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. N20575 Type C: 10. Lock A7 A6 N20576 Type C: Unlock A7 A6 Door lock signal: INSPECT INTEGRATION RELAY (Type C) OPERATION HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the positive (+) lead from the voltmeter to terminal A6 and the negative (–) lead to terminal A7. (b) Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. (c) Reverse the polarity of the voltmeter leads. (d) Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. 11. INSPECT INTEGRATION RELAY CIRCUIT (See page BE–14) N20577 Author: Date: 2292 BE–73 BODY ELECTRICAL – SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM BE0AR–02 LOCATION E/G Room J/B No.2
DOME Fuse Ignition Switch Instrument Panel J/B No.1
POWER Fuse
GAUGE Fuse
Power Main Relay
Integration Relay Sliding Control Relay and Switch Sliding Roof Motor
Limit Switch Z19490 Author: Date: 2293 BE–74 BODY ELECTRICAL – SLIDING ROOF SYSTEM BE0AS–02 INSPECTION Wire harness side: 1. 1 2 INSPECT SLIDING ROOF CONTROL RELAY AND SWITCH CIRCUIT Disconnect the connector from the relay and switch and inspect the connector on the wire harness side, as shown in the table. 3 4 5 6 7 8 s–8–1 N21643 TMMK made: Tester connection Condition Specified condition 1–5 Constant Continuity 2 – Ground Constant Continuity 3 – Ground Limit switch No.1 is OFF (Sliding roof is in a closed position) No continuity 3 – Ground Limit switch No.1 is ON (Sliding roof is in an open position) Continuity 7 – Ground Limit switch No.2 is OFF (Sliding roof is in a tilt up position) No continuity 7 – Ground Limit switch No.2 is ON (Sliding roof is in the open position) Continuity 8 – Ground Limit switch No.3 is OFF (Sliding roof is in a closed position) No continuity 8 – Ground Limit switch No.3 is ON (Sliding roof is in an open position) Continuity 4 – Ground Ignition switch is in a LOCK or ACC position * No voltage 4 – Ground Ignition switch is in an ON position Battery positive voltage TMC made: Tester connection Condition Specified condition 1–5 Constant Continuity 2 – Ground Constant Continuity 3 – Ground No.1 limit switch OFF (Sliding roof closed) No continuity 3 – Ground No.1 limit switch ON (Sliding roof opened) Continuity 7 – Ground No.2 limit switch OFF (Sliding roof tilted up open approx. 200 mm (7.87 in.) No continuity 7 – Ground No.2 limit switch ON (Except for conditions mentioned above) Continuity 4 – Ground Ignition switch LOCK or ACC * No voltage 4 – Ground Ignition switch ON Battery positive voltage *: Exceptions: For 60 seconds after the ignition switch is turned ON to OFF (ACC) or until driver or passenger door is opened after the ignition switch is turned ON to OFF (ACC). If the circuit is not as specified, replace the relay and switch. Author: Date: 2294 BE–75 BODY ELECTRICAL Webasto type: 2 1 2. (a) – SLIDING ROOF SYSTEM INSPECT SLIDING ROOF MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise (moves to the close and up side). DENSO type: 1 2 N21182 (b) Webasto type: 2 1 Reverse the polarity, check that the motor turns clockwise (moves to the open and down side). If operation is not as specified, replace the motor. DENSO type: 1 2 N21183 3. (a) INSPECT CIRCUIT BREAKER OPERATION With the sliding roof in the fully opened position, hold the sliding roof switch in ”OPEN” position and check that is a circuit breaker operation noise is heard within 10 to 60 seconds. Within 10 to 60 seconds N21644 Author: Date: 2295 BE–76 BODY ELECTRICAL – SLIDING ROOF SYSTEM (b) With the sliding roof in fully opened position, hold the sliding roof switch in ”TILT UP” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. within 60 seconds N21645 4. No.3 Limit Switch ON OFF Switch position Tester connection No.1 Limit Switch No.1 limit switch OFF (SW pin released) 3–5 No continuity No.2 Limit Switch No.1 limit switch ON (SW pin pushed in) 3–5 Continuity No.2 limit switch OFF (SW pin released) 3–6 No continuity No.2 limit switch ON (SW pin pushed in) 3–6 Continuity No.3 limit switch OFF (SW pin released) 3–4 No continuity No.3 limit switch ON (SW pin pushed in) 3–4 Continuity N21872 5. ON OFF TMMK made: INSPECT SLIDING ROOF LIMIT SWITCH CIRCUIT No.1 Limit Switch No.2 Limit Switch 4 1 5 2 6 3 N21180 Specified condition TMC made: INSPECT SLIDING ROOF LIMIT SWITCH CIRCUIT Switch position Tester connection Specified condition No.1 limit switch OFF (SW pin released) 4–5 No continuity No.1 limit switch ON (SW pin pushed in) 4–5 Continuity No.2 limit switch OFF (SW pin released) 4–6 No continuity No.2 limit switch ON (SW pin pushed in) 4–6 Continuity If continuity is not as specified, replace the switch. 6. INSPECT KEY–OFF SLIDING ROOF OPERATION (See integration relay circuit on page BE–14) Author: Date: 2296 BE–77 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM BE0AT–02 LOCATION Instrument Panel J/B No.1
CIG Fuse Lifter Motor Reclining Motor Power Seat Switch Lifter Motor Sliding Motor Power Seat Switch Z19504 Author: Date: 2297 BE–78 BODY ELECTRICAL – POWER SEAT CONTROL SYSTEM BE0AU–02 INSPECTION Lifter Up 1. (a) Down Reclining Forward Rear (b) Front Rear Slide (c) 5 4 3 21 121110 9 8 7 6 I01932 TMC made: INSPECT DRIVER’S SEAT SWITCH CONTINUITY Inspect the slide switch. Switch position Tester connection FRONT 4 – 6, 8 – 11 Continuity Specified condition OFF 4 – 6, 6 – 8 Continuity BACK 6 – 8, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 11, 3 – 6 Continuity OFF 3 – 6, 2 – 6 Continuity DOWN 2 – 6, 3 – 11 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 1 – 11, 5 – 6 Continuity OFF 1 – 6, 5 – 6 Continuity REAR 1 – 6, 5 – 11 Continuity If continuity is not as specified, replace the switch. 2. TMMK made: INSPECT DRIVER’S SEAT SWITCH CONTINUITY (a) Inspect the slide switch. (b) (c) Switch position Tester connection Specified condition FRONT 2 – 11, 4 – 7 Continuity OFF 4 – 11, 4 – 7 Continuity BACK 2 – 7, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 5, 4 – 8 Continuity OFF 4 – 5, 4 – 8 Continuity DOWN 2 – 8, 4 – 5 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 2 – 12, 4 – 6 Continuity OFF 4 – 12, 4 – 6 Continuity REAR 2 – 6, 4 – 12 Continuity If continuity is not as specified, replace the switch. Author: Date: 2298 BE–79 BODY ELECTRICAL 3. Lifter Up (a) Down Reclining Forward Front Rear (b) Rear Slide (c) 5 4 3 21 121110 9 8 7 6 I01932 – POWER SEAT CONTROL SYSTEM TMC made: INSPECT PASSENGER’S SEAT CONTINUITY Inspect the slide switch. Switch position Tester connection Specified condition FRONT 4 – 6, 8 – 11 Continuity OFF 4 – 6, 6 – 8 Continuity BACK 6 – 8, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 6, 3 – 11 Continuity OFF 3 – 6, 2 – 6 Continuity DOWN 3 – 6, 2 – 11 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 5 – 6, 1 – 11 Continuity OFF 1 – 6, 5 – 6 Continuity REAR 1 – 6, 5 – 11 Continuity If continuity is not as specified, replace the switch. 4. TMMK made: INSPECT PASSENGER’S SEAT CONTINUITY (a) Inspect the slide switch. (b) (c) Switch position Tester connection Specified condition FRONT 2 – 11, 4 – 7 Continuity OFF 4 – 11, 4 – 7 Continuity BACK 2 – 7, 4 – 11 Continuity Inspect the lifter switch. Switch position Tester connection Specified condition UP 2 – 8, 4 – 5 Continuity OFF 4 – 5, 4 – 8 Continuity DOWN 2 – 5, 4 – 8 Continuity Inspect the reclining switch. Switch position Tester connection Specified condition FORWARD 2 – 12, 4 – 6 Continuity OFF 4 – 12, 4 – 6 Continuity REAR 2 – 6, 4 – 12 Continuity If continuity is not as specified, replace the switch. (a) 5. (a) INSPECT SLIDE MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 2 1 N21865 Author: Date: 2299 BE–80 BODY ELECTRICAL 2 6. 1 (a) (b) – POWER SEAT CONTROL SYSTEM INSPECT SLIDE MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to the battery negative (–) terminal, then move the seat cushion to the front position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. N21866 2 (c) (d) Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to move backwards. If operation is not as specified, replace the seat adjuster. 1 N21867 (a) 7. (a) INSPECT LIFTER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 1 1 2 N21865 2 8. (a) 1 (b) INSPECT LIFTER PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to the battery negative (–) terminal, then move the seat cushion to the highest position. Continue to apply voltage, check that the current changes to less than 1 ampere within 4 to 90 seconds. N21868 2 (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to fall down. If operation is not as specified, replace the seat adjuster. 1 N21869 Author: Date: 2300 BE–81 BODY ELECTRICAL (a) 1 POWER SEAT CONTROL SYSTEM 9. (a) INSPECT RECLINING MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clockwise. If operation is not as specified, replace the seat adjuster. (b) 2 – 1 2 N21865 2 10. 1 (a) (b) INSPECT RECLINING MOTOR PTC THERMISTOR OPERATION Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative (–) lead to the battery negative (–) terminal, then recline the seat back to the most forward position. Continue to apply voltage, check that the current change to less than 1 ampere within 4 to 90 seconds. N21870 2 (c) (d) Disconnect the leads from the terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the seat back starts to fall backward. If operation is not as specified, replace the seat adjuster. 1 N21871 Author: Date: 2301 BE–82 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM BE0AV–03 LOCATION Mirror Control Switch Instrument Panel J/B No.1
CIG Fuse LH Mirror
Mirror Motor RH Mirror
Mirror Motor Z19488 Author: Date: 2302 BE–83 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM BE0AW–03 INSPECTION R L 1. MIRROR OFF RIGHT SIDE LEFT SIDE UP LEFT OFF Switch position Tester connection Specified condition OFF – UP 1 – 9, 6 – 10 Continuity DOWN 1 – 10, 6 – 9 Continuity LEFT 5 – 9, 6 – 10 Continuity RIGHT 5 – 10, 6 – 9 Continuity No continuity If continuity is not as specified, replace the switch. 2. Master switch right side: INSPECT MIRROR CONTROL SWITCH CONTINUITY RIGHT DOWN 4 3 10 9 8 Master switch left side: INSPECT MIRROR CONTROL SWITCH CONTINUITY 2 1 7 6 5 BE2357 h–10–2 Z16591 Switch position Tester connection Specified condition OFF – UP 6 – 10, 7 – 9 Continuity DOWN 6 – 9, 7 – 10 Continuity LEFT 6 – 10, 8 – 9 Continuity RIGHT 6 – 9, 8 – 10 Continuity No continuity If continuity is not as specified, replace the switch. 3. (a) TMMK made (w/o Heater) 1 (b) 2 TMC made (w/o Heater) 3 2 TMMK made (w/ Heater) 3 2 (c) INSPECT MIRROR MOTOR TMMK made (w/o Heater): Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the mirror turns to left side. TMC made (w/o Heater): Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns to left side. TMMK made (w/ Heater): Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns to left side. N21184 Author: Date: 2303 BE–84 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM (d) Reverse the polarity and check that the mirror turns to right side. (e) TMMK made (w/o Heater): Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMC made (w/o Heater): Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMMK made (w/ Heater): Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the mirror turns upward. TMMK made (w/o Heater) TMC made (w/o Heater) – TMMK made (w/ Heater) N21185 TMMK made (w/o Heater) (f) (g) TMC made (w/o Heater) TMMK made (w/ Heater) N21186 Author: Date: 2304 BE–85 BODY ELECTRICAL – POWER MIRROR CONTROL SYSTEM (h) TMMK made (w/o Heater) TMC made (w/o Heater) Reverse the polarity, check that the mirror turns downward. If operation is not as specified, replace the mirror assembly. TMMK made (w/ Heater) N21187 Author: Date: 2305 BE–86 BODY ELECTRICAL – AUDIO SYSTEM AUDIO SYSTEM BE0AX–03 DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: 30 kHz Frequency Designation 3 MHz 300 kHz LF Modulation method 300 MHz VHF HF MF AM Radio wave 30 MHz FM Amplitude modulation Frequency modulation LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. SERVICE AREA There are great differences in the size of the service area for AM and FM monaural. Sometimes FM stereo broadcasts cannot be received even through AM comes in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference (”noise”) easily. FM (Stereo) FM (Monaural) AM BE2818 3. RECEPTION PROBLEMS Besides the problem of static, there are also the problems called ”fading”, ”multipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading
Ionosphere Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same transmitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. BE2819 Author: Date: 2306 BE–87 BODY ELECTRICAL Multipath – AUDIO SYSTEM
Multipath One type of interference caused by bouncing of radio waves off obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is received directly.
Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mountains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstructions. This is called ”fade out”. BE2820 Fade Out BE2821 4. NOISE PROBLEMS (a) Questionnaire for noise: It is very important for noise troubleshooting to have good understanding of the claims from the customers, so that make the best use of following quenstionnaire and diagnose the problem accurately. AM FM Noise occurs at a specific place. Strong possibility of foreign noise. Noise occurs when listening to faint broadcasting. There is a case that the same program is broadcasted from each local station and that may be the case you are listening to different station if the program is the same. Noise occurs only at night. Strong possibility of the beat from a distant broadcasting. Noise occurs while driving and at a specific place. Strong possibility of multipath noise and fading noise caused by the changes of FM waves. HINT: In the case that the noise occurrence condition does not meet any of the above quenstionnaire, check based on the ”Trouble Phenomenon”. Refer to previous page for multipath and fading. Author: Date: 2307 BE–88 BODY ELECTRICAL Noise Glass Printed Antenna Noise Matlers that require attention when checking:
Noise coming into the radio usually has no harm for practical use as the noise protection is taken and it is hardly thinkable for an extremely loud noise to come in. When extremely loud noise comes into the radio, check if the grounding is normal where the antenna is installed.
Check if all the regular noise prevention parts are properly installed and if there is any installation of non–authorized parts and non–authorized wiring.
If you leave the radio out of tune (not tuning), it is easy to diagnose the phenomenon as noise occurs frequently. (c) Antenna and noise: Electronic signal received by the antenna will reach to the radio transmitting through the core wire of the coaxial cable. Any noise wave other than radio wave is mixed into this core wire, that naturally causes noise in the radio and poor sound quality. In order to prevent these noises from mixing into the radio, the core wire inside the coaxial cable is covered with a mesh wire called shield wire. This shield wire shelters the noise and transmits it to the ground, thus preventing noise from mixing in. If this shield wire has grounding failure, that causes noise. (d) Choke coil and noise: The choke coil is connected in the rear window defogger circuit. This is conneted so to prevent noise from mixing into the radio by making the noise current included in the power source of the rear window defogger flow to the ground. Signal Radio Noise N21545 to Radio Battery Choke Coil AUDIO SYSTEM (b) Noise Noise – Noise N21546 Author: Date: 2308 BE–89 BODY ELECTRICAL Plug (Main) Antenna Terminal (Main) (1) (2) (3) (4) Plug (Sub) Antenna Terminal (Sub) I00399 5. – AUDIO SYSTEM Glass printed antenna: GROUNDING FOR THE ANTENNA CORD AND CHOKE COIL HINT: During troubleshooting, in case that the antenna code continuity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustration. Terminal connection Normal condition (1) ↔ (2) Continuity (3) ↔ (4) Continuity Ground point: Antenna Cord Center Brace Pillar (RH) Choke Coil N21548 I00402 I00403 Pillar (LH) I00407 Author: Date: 2309 BE–90 BODY ELECTRICAL 6. Antenna Terminal Plug (1) (2) I00400 – AUDIO SYSTEM Fixed mast antenna: GROUNDING FOR THE ANTENNA CORD AND CHOKE COIL HINT: During troubleshooting, in case that the antenna code continuity check, grounding check and grounding check of the choke coil are needed, please check refering to the following illustrations. Terminal connection Normal condition (1) ↔ (2) Continuity Ground point: Antenna Cord Center Brace Luggage Room (RH side) Noise Filter I00427 I00428 I00429 Pillar (LH) I00408 Author: Date: 2310 BE–91 BODY ELECTRICAL – AUDIO SYSTEM BE0AY–05 TROUBLESHOOTING NOTICE: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement part (spare part). HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and connectors, etc.). Always inspect the trouble taking the following items into consideration.  Open or short circuit of the wire harness  Connector or terminal connection fault Problem Radio Tape Player CD Player Noise No. Radio not operating when power switch turned ’ON’. 1 Display indicates when power switch turned ’ON’, but no sound (including ’noise’) is produced. 2 Noise present, but AM – FM not operating. 3 Any speaker does not work. 4 Either AM or FM does not work, reception poor (volume faint), Fewer station presets. 5 Poor reception. 6 Sound quality poor. 7 Preset memory disappears. 8 Cassette tape cannot be inserted. 9 Cassette tape is inserted, but no power. 10 Power coming in, but tape player not operating. 11 Either speaker does not work. 12 Sound quality poor. (volume faint) 13 Tape jammed, malfunction with tape speed or auto–reverse. 14 Cassette tape will not be ejected. 15 CD cannot be inserted. 16 CD inserted, but no power. 17 Power coming in, but CD player not operating. 18 Sound jumps. 19 Sound quality poor (Volume faint). 20 Either speaker does not work. 21 CD will not be ejected. 22 Noise occurs. 23 Noise produced by vibration or shock while driving. 24 Noise produced when engine starts. 25 The term ”AM” includes LW, MW and SW, and the term ”FM” includes UKW. Author: Date: 2311 BE–92 BODY ELECTRICAL 1 Radio – AUDIO SYSTEM RADIO NOT OPERATING WHEN POWER SWITCH TURNED ’ON’
Radio–CD Plater Unit (Built–in Power Amplifier)
Radio–Tape Plater Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio assembly faulty. No NG Replace fuse. Check that RAD No.1 fuse is OK? OK No ACC wire harness faulty. Is ACC applied to radio? Yes NG Replace fuse. Check that RAD No.2 fuse is OK? OK No Is +B applied to radio? Yes Check that GND (wire harness side) to radio is OK? +B wire harness faulty. NG GND faulty. OK Radio assembly faulty. Author: Date: 2312 BE–93 BODY ELECTRICAL – AUDIO SYSTEM
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Yes Does tape or CD player operate normally? Radio assembly faulty. No NG Replace fuse. Check that RAD No.1 fuse is OK? OK Is ACC applied to power amplifier? No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK Is ACC applied to radio assembly? No Power amplifier or wire harness faulty. Yes No Is +B applied to radio assembly? Power amplifier or wire harness faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG GND faulty. OK Radio assembly faulty. I03349 Author: Date: 2313 BE–94 BODY ELECTRICAL 2 – AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED ’ON’, BUT NO SOUND (INCLUDING ’NOISE’) IS PRODUCED Radio
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to radio? No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to radio? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio is OK? NG GND faulty. OK Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Yes Speaker faulty. No Radio faulty. I03350 Author: Date: 2314 BE–95 BODY ELECTRICAL – AUDIO SYSTEM
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to power amplifier. No ACC wire harness faulty. Yes Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier. No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK No Is ACC applied to radio assembly? Power amplifier faulty. Yes Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG GND faulty. OK Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Yes Temporarily install another speaker. Functions OK? Speaker faulty. No No Hiss noise from speaker? Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. V08239 Author: Date: 2315 BE–96 BODY ELECTRICAL 3 Radio – AUDIO SYSTEM NOISE PRESENT, BUT AM–FM NOT OPERATING Yes Does tape player operate normally? Radio assembly faulty. No Yes Separate amplifier? No Hiss noise from speaker? Power amplifier faulty. Yes No Radio assembly faulty. 4 Radio ANY SPEAKER DOSE NOT WORK
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Does tape or CD player operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker? Yes Radio assembly Recheck system after repair. No Does continuity exist in speaker wire harness? Yes Temporarily install another speaker. Functions OK? No Yes Speaker wire harness faulty. Speaker faulty. No Power amplifier faulty. Recheck system after repair. I03351 Author: Date: 2316 BE–97 BODY ELECTRICAL 5 Radio – AUDIO SYSTEM EITHER AM OR FM DOES NOT WORK, RECEPTION POOR (VOLUME FAINT), FEWER STATION PRESETS
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Problem with radio wave signals or location? Yes Poor signals, poor location. No Are both AM or FM defective? No Radio assembly faulty. Yes Is power for the antenna being output from the radio assembly? No Yes Go to No.15 Does tape player operate normally? Yes Radio assembly faulty. No Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Problem with radio wave signals or location? Yes Poor signals, poor location. No Are both AM and FM defective? No Radio assembly faulty. Yes Is power for the antenna being output from the radio assembly? No Yes Go to No.15 Does tape player operate normally? Yes Radio assembly faulty. No Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Hiss noise from speaker? No Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. V08242 I03352 Author: Date: 2317 BE–98 BODY ELECTRICAL 6 Radio – AUDIO SYSTEM POOR RECEPTION Is the condition bad in comparison with other vehicle? Yes An electric wave environment. No Yes Is there any additional installation parts? (Sun shade film, telephone antenna etc.). Does the condition get better if removing them? Yes No No Check if there is any scratch and breaking in a wire on the glass antenna and the defogger pattern. (See page BE–115) Influence of additional installation parts. Yes Repair No Is the contact of the plug jack of the radio OK? No Check for contact. Yes No Does the condition get better by using the outer antenna? (Such as pillar antenna) Check the radio. Yes No Is the contact of the antenna terminal on the glass surface and the defogger terminal? Measure for contact. Yes No Is the continuity of the antenna cord OK? Exchange the antenna cord. Yes NG Check the grounding of the antenna, antenna cord, choke coil and noise filter. Grounding failure. OK Yes Does the condition get better by exchanging the choke coil? Exchange the choke coil. No Yes Does the condition get better by exchanging the antenna cord? Exchange the antenna cord. No Exchange the glass. I01472 Author: Date: 2318 BE–99 BODY ELECTRICAL 7 Radio – AUDIO SYSTEM SOUND QUALITY POOR
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) No Is sound quality always bad? Yes Is sound quality bad in certain area only. Poor signals, poor location. No Yes Radio assembly faulty. Yes Does tape player operate normally? Radio assembly faulty. No No Installed properly. Is speaker properly installed? Yes Yes Speaker faulty. Temporarily install another speaker. Functions OK? No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power amplifier)
Radio–Tape CD Unit (Separate Power Amplifier) Is sound quality always bad? No Yes Is sound quality bad only in certain areas? Poor signals, poor location. No Yes Does tape player operate normally? Yes No Radio assembly or power amplifier faulty. Does tape player operate normally? Radio assembly faulty. Yes Radio assembly faulty. No Is speaker properly installed? No Installe properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly or power amplifier faulty. Recheck system after repair. I03353 Author: Date: 2319 BE–100 BODY ELECTRICAL 8 – AUDIO SYSTEM PRESET MEMORY DISAPPEARS Radio
Radio–Tape Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Built–in Power Amplifier) Can cassette tape be inserted in tape player? Yes Radio assembly faulty. No Replace fuse. NG Check that RAD No.1 fuse is OK? OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio? NG GND faulty. OK Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier) Can cassette tape be inserted in tape player? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier? NG GND faulty. OK Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly? NG Power amplifier faulty. OK Radio assembly faulty. I03354 Author: Date: 2320 BE–101 BODY ELECTRICAL 9 Tape Player – AUDIO SYSTEM CASSETTE TAPE CANNOT BE INSERTED
Radio–Tape Player Unit (Built–in Power Amplifier) Is there a foreign object inside tape player? Yes Remove foreign object. No Does auto search button of radio operate normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Check that GND (wire harness side) to radio assembly? NG GND faulty. OK Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Is there a foreign object inside tape player? Yes Remove foreign object. No Yes Does auto search button radio operate normally? Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Check that GND (wire harness side) to power amplifier is OK? NG GND faulty. OK Is +B applied to radio assembly? No Power amplifier faulty. Yes Check that GND (wire harness side) to radio assembly is OK? NG Power amplifier faulty. OK Radio assembly faulty. V08246 Author: Date: 2321 BE–102 BODY ELECTRICAL 10 Tape Player – AUDIO SYSTEM CASSETTE TAPE IS INSERTED, BUT NO POWER
Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is ACC applied to radio assembly? No ACC wire harness faulty. Yes Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does radio operate normal? Yes Radio assembly faulty. No Check that RAD No.2 fuse is OK? NG Replace fuse. OK Is ACC applied to power amplifier? No ACC wire harness faulty. Yes Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Is ACC applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. V08247 Author: Date: 2322 BE–103 BODY ELECTRICAL 11 Tape Player – AUDIO SYSTEM POWER COMING IN, BUT TAPE PLAYER NOT OPERATING
Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Does radio operate normally? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Function OK if different cassette tape inserted? Yes Cassette tape faulty. No Does radio operate normally? Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Hissing sound from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. V08248 Author: Date: 2323 BE–104 BODY ELECTRICAL 12 Tape Player – AUDIO SYSTEM EITHER SPEAKER DOES NOT WORK
Radio–Tape Player Unit (Built–in Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Is hiss noise produces by non–functioning speaker. Yes Radio assembly faulty. No Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does radio operate normally? Yes Radio assembly faulty. No Is hiss noise produced by non–functioning speaker. Yes No Does continuity exist in speaker wire harness? No Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Radio assembly or power amplifier faulty. V08249 Author: Date: 2324 BE–105 BODY ELECTRICAL 13 Tape Player – AUDIO SYSTEM SOUND QUALITY POOR (VOLUME FAINT)
Radio–Tape Player Unit (Built–in Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Yes Operates normally after cleaning the heads? Head dirty. No Does radio operate normally? Yes Radio assembly faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Function OK? Yes Speaker faulty. No Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Functions OK if different cassette tape inserted? Yes Cassette tape faulty. No Yes Operates normally after cleaning the heads? Head dirty. No Does radio operate normally? Yes Radio assembly faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly faulty or power amplifier faulty. V08250 Author: Date: 2325 BE–106 BODY ELECTRICAL 14 Tape Player – AUDIO SYSTEM TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR AUTO–REVERSE Function OK if different tape (less than 120 mints.) inserted? Yes Cassette tape faulty. No Yes Is there a foreign object inside tape player? Remove foreign object. No Operates normally after cleaning the heads? Yes Head dirty. No Radio assembly faulty. 15 Tape Player CASSETTE TAPE WILL NOT BE EJECTED
Radio–Tape Player Unit (Built–in Power Amplifier) No Does tape player operate normally? Cassette tape jammed. Yes Is auto search button of radio operating normally? Yes Radio assembly faulty. No NG Check that RAD No.1 fuse is OK? Replace fuse. OK Is +B applied to radio assembly? No +B wire harness faulty. Yes Radio assembly faulty.
Radio–Tape Player Unit (Separate Power Amplifier)
Radio–Tape Player–CD Player Unit (Separate Power Amplifier) Does tape player operate normally? No Cassette tape jammed. Yes Is auto search button of radio operating normally? Yes Radio assembly faulty. No Check that RAD No.1 fuse is OK? NG Replace fuse. OK Is +B applied to power amplifier? No +B wire harness faulty. Yes Is +B applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. V08251 Author: Date: 2326 BE–107 BODY ELECTRICAL 16 CD Player – AUDIO SYSTEM CD CANNOT BE INSERTED
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Is CD already inserted? Eject CD. No Yes Is auto search button of radio operating normally? No Is +B applied to CD player? Radio assembly faulty. Yes NG Check that GND wire harness side to CD player is OK? No OK CD player faulty. NG Check that RAD No.1 fuse is OK? Replace fuse. OK No Is +B applied to power amplifier? +B wire harness faulty. Yes NG Check that GND (wire harness side) to radio assembly is OK? OK Radio assembly faulty. 17 CD Player CD INSERTED, BUT NO POWER
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Does radio operate normally? Yes Is ACC applied to CD player? No Radio assembly faulty. Yes No Check that RAD No.1 and No.2 fuse is OK? CD player faulty. NG Replace fuse. OK Is ACC and +B, +B2 applied to power amplifier? No ACC and +B, +B2 wire harness faulty. I03355 Yes Is ACC and +B, +B2 applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. I03355 Author: Date: 2327 BE–108 BODY ELECTRICAL 18 CD Player – AUDIO SYSTEM POWER COMING IN, BUT CD PLAYER NOT OPERATING
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) No Is CD inserted with correct side up? Insert correctly. Yes Yes Function OK if different CD inserted? CD faulty. No Yes Does radio operate normally? Is temperature inside cabin hot? Protective circuit in operation. No No Has sudden temperature change occurred inside cabin? Yes Yes Formation of condensation due to temp. changes. No CD player faulty. Does continuity exist in speaker wire harness? No Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Hissing sound from speaker? Yes No Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. I03356 Author: Date: 2328 BE–109 BODY ELECTRICAL 19 CD Player – AUDIO SYSTEM SOUND JUMPS
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Does sound jump only during strong vibration? Jumping caused by vibration. No Is CD player properly installed? No Installed properly. Yes Functions OK if different CD inserted? Yes CD faulty. No Has sudden temperature change occurred inside cabin? Yes No Formation of condensation due to temp. changes. CD player faulty. 20 CD Player SOUND QUALITY POOR (VOLUME FAINT)
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Functions OK if different CD inserted? CD faulty. No Does radio operate normally? Yes CD player faulty. No Is speaker properly installed? No Installed properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. No Radio assembly or CD player or Power amplifier faulty. I03357 Author: Date: 2329 BE–110 BODY ELECTRICAL 21 CD Player – AUDIO SYSTEM EITHER SPEAKER DOES NOT WORK
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Yes Does radio operate normally? CD player. No Yes Is hiss noise produced by non–functioning speaker? Radio assembly faulty. Recheck system after repair. No No Does continuity exist in speaker wire harness? Speaker wire harness faulty. Yes Yes Temporarily install another speaker. Function OK. Speaker faulty. No Power amplifier faulty. Recheck system after repair. 22 CD Player CD WILL NOT BE EJECTED
Radio–CD Player Unit (Built–in Power Amplifier)
Radio–CD Player Unit (Separate Power Amplifier)
Radio–Tape Player – CD Player (Separate Power Amplifier) Is auto search button of radio operating normally? Yes Is +B applied to CD player? No Radio assembly faulty. Yes No Check that RAD No.1 fuse is OK? CD player faulty. NG Replace fuse. OK Is +B and +B2 applied to power amplifier? No +B wire harness faulty. Yes Is +B and +B2 applied to radio assembly? No Power amplifier faulty. Yes Radio assembly faulty. I03358 Author: Date: 2330 BE–111 BODY ELECTRICAL 23 Noise – AUDIO SYSTEM NOISE OCCURS No Does the noise occur only in the radio? It occurs in the cassette CD. (Go to step 13 or 20) Yes Yes Does the noise occur in a particular place? An electric environment. No Yes Is there any additional installation part around the glass printed antenna? (Sunshade film, telephone antenna, etc.) Does the noise stop by removing it? Yes No No Influence of the film of the noise radiation of additional installation part. Does the noise occur even pulling out the antenna cord from the radio? Yes Check the radio. No Yes Does the noise occur even pulling out the antenna terminal on the glass surface? Mixing into the antenna cable. No Yes Is there any adhesive stuck on the bases of the antenna terminal, defogger terminal and bus bar? Failure of glass installation. Must plane the butyl rubber. No Yes Does the noise occur even pulling out the defogger terminal? Interfering noise from the defogger line and choke coil. Does the condition get better by exchanging the choke coil? No Exchange the choke coil. Check the grounding of the antenna, antenna cord, choke coil and noise filter. NG OK Grounding failure. Yes Does the condition get better by exchanging the antenna cord? Exchange the antenna cord. No Radiates directly to the antenna from the generation source. I01473 Author: Date: 2331 BE–112 BODY ELECTRICAL 24 Noise – AUDIO SYSTEM NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING Is speaker properly installed? No Installed properly. Yes No Is speaker properly installed? Yes With vehicle stationary lightly tap each system. Is noise produced? Yes Each system faulty. No Noise produced by static electricity accumulated in the vehicle body. I01474 Author: Date: 2332 BE–113 BODY ELECTRICAL 25 Noise – AUDIO SYSTEM NOISE PRODUCED WHEN ENGINE STARTS Whistling noise which becomes high–pitched when accelerator strongly depressed, disappears shortly after engine stops. Yes Generator noise. No Whining noise occurs when A/C is operating. Yes A/C noise. No Scratching noise occurs during sudden acceleration, driving on rough roads or when ignition switch is turned on. Yes Fuel gauge noise. No Clicking sound heard when horn button is pressed, then released. Whirring/ grating sound when pressed continuously. Yes Horn noise. No Murmuring sound stops when engine stops. Yes Ignition noise. No Tick–tock noise occurs in co–ordination with blinking of flasher. Yes Turn signal noise. No Noise occurs during window washer operation. Yes Washer noise. No Yes Scratching noise occurs while engine is running and continues for a while even after engine stops. Engine coolant temp. gauge noise. No Scraping noise in time with wiper beat. Yes Wiper noise. No Other type of noise. I01475 Author: Date: 2333 BE–114 BODY ELECTRICAL – AUDIO SYSTEM BE0AZ–05 LOCATION Tweeter Speaker Tweeter Speaker AMP Instrument Panel J/B No.1
RADIO Fuse
DOME Fuse Glass Printed Antenna (MAIN) Front Speaker Diversity Only (SUB) Rear Speaker Z19489 Author: Date: 2334 BE–115 BODY ELECTRICAL – AUDIO SYSTEM BE0B0–06 INSPECTION 1. GLASS PRINTED ANTENNA INSPECTION PROCEDURE NOTICE:
When cleaning the glass, use soft dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires.
Do not use detergents or glass cleaners with abrasive ingredients. NOTICE: In order not to damage the glass printed antenna, wrap up the tip of the tester stick with aluminum foil as shown in the illustration and check by holding the aluminum foil with a finger. Tester Probe Aluminum Foil BE4029 By placing and moving the tester stick along the glass printed antenna, check if continuity exists. I00430 HINT: Matching module is built in the bus bar of the glass printed antenna (main terminal side) of CAMRY and no continuity exists between the terminal and the antenna. Therefore, for the continuity checking of the glass printed antenna on the main antenna side of CAMRY, place one probe of the tester on the position beside the bus bar (position shown in the illustration) and check by making the other probe of the tester move along. Matching module I00459 2. (a) Repair Point (b) Broken Wire (c) GLASS PRINTED ANTENNA REPAIR PROCEDURE Clean the broken wire tips with grease, wax and silicone remover. Place the masking tape along both sides of the wire for repair. Thoroughly mix the repair agent (Dupont paste No. 4817). Masking Tape BE0150 Author: Date: 2335 BE–116 BODY ELECTRICAL (d) (e) – AUDIO SYSTEM Using a fine tip brush, apply a small amount of the agent to the wire. After a few minutes, remove the masking tape. BE0151 Author: Date: 2336 BE–117 BODY ELECTRICAL – CLOCK CLOCK BE0B1–02 TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Clock will not operate 1 Clock loses or gains time 2 ± 1.5 seconds / day Ground E Connector (Clock Side) Power Source (Illumination) ILL B Power Source (System Operation) ACC Power Source (Display Operation) 4 3 2 1 (Wire Harness Side) 1 2 3 4 Z04388 BE1847 e–4–2–D e–4–1–D 1 CLOCK WILL NOT OPERATE (a) Check that the battery positive voltage is 10 – 16 V. (Wire Harness Side) (Clock Side) If voltage is not as specified, replace the battery. (b) Check that the DOME fuse is not blown. If the fuse is blown, replace the fuse and check for short circuit. (c) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. B+ GND e–4–2–D e–4–1–D Is there battery positive voltage between terminal B+ and body ground? No Open or short circuit in wire harness between terminal GND and body ground. No Open circuit in wire harness between terminal GND and body ground. Yes Does continuity exist between terminal GND and body ground. Yes Replace clock. V04421 Author: Date: 2337 BE–118 BODY ELECTRICAL 2 – CLOCK CLOCK LOSES OR GAINS TIME (Clock Side) (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Inspect the error of the clock. Allowable error (per day): ± 1.5 seconds (Wire Harness Side) If the error exceeds the allowable error, replace the clock. (c) Check that the clock adjusting button is caught in position, and does not return. If the button is not returned, repair or replace the clock. (d) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. e–4–2–D e–4–1–D B+ GND Is there 10 – 16 V between terminal B+ and body ground? Below 10 V Locate cause and repair, or recharge battery. Yes Adjust or replace clock. V04422 Author: Date: 2338 BE–119 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM BE0B2–06 REGISTRATION PROCEDURE 1. KEY REGISTRATION IN AUTOMATIC REGISTRATION MODE (a) Registration of a new transponder key. HINT:
This must be done when you have installed a new ECM.
The new ECM is in the automatic key code registration mode. The already fixed number of key codes for this ECM can be registered. On this type of vehicle, up to 4 key codes can be registered.
In the automatic registration mode, the last key registered becomes sub–key. START Security indicator blinks until the first key is inserted. The indicator lights up after the key registration. Insert the key in the key cylinder. Security Indicator ON Under registration Security OFF Indicator Registration completion Remove the key. Yes Security Indicator ON (After the last key (sub–key) has been registered, the indicator goes off.) Will you register the next key? No END Author: Date: 2339 BE–120 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM HINT:


When a key is not inserted in the key cylinder in the automatic registration mode, the security indicator always lights on. When the immobiliser system operations normally and the key is pull out, the security indicator blinks. When key code registration could not be performed in the automatic registration mode, code 2–1 is output from the security indicator and when inserting the already registered key, code 2–2 is output. Blinks 1.2 Sec. 0.8 Sec. (b) Code 2–1 0.25 Sec. 1 Sec. 0.25 Sec. 0.5 Sec. Code2–2 0.25 Sec. 1 Sec. 0.25 Sec.0.5 Sec. Automatic registration mode completion If completing the mode forcibly when more than 1 key code have been registered in the automatic registration mode, perform the following procedures. After 1 more key code have been registered with master key, perform step (1) or (2) without pulling the key out or inserting the already registered key. (1) Depress and release brake pedal 5 times or more within 15sec. (2) With the TOYOTA hand–held tester, require automatic registration mode completion. Author: Date: 2340 BE–121 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 2. REGISTRATION OF ADDITIONAL MASTER KEY There are 2 ways for registration of additional master key, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. HINT:
It is possible to register up to 7 master key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 5 times. Depress and release the brake pedal 6 times, and remove the master key. Within 15 sec. Within 20 sec. Within 10 sec. Insert key to be registered in key cylinder. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec. additional master key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2341 BE–122 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select master key registration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec., additional master key is registered. (Security indicator OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2342 BE–123 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 3. REGISTRATION ADDITIONAL OF SUB–KEY There are 2 ways for registration of additional sub–key, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. HINT:
It is possible top register up to 3 sub–key codes including the already registered key code.
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: Insert already registered master key in the key cylinder Depress and release the acceleration pedal 4 times. Depress and release the brake pedal 5 times, and remove the master key. Within 15 sec. Within 20 sec. Within 10 sec. Insert key to be registered in key cylinder. Within 10 sec. Depress and release the acceleration pedal 1 time. (Security indicator blinks) Within 10 sec. After 60 sec. additional sub–key is registered. (Security indicator is OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2343 BE–124 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: Insert already registered master key in the key cylinder. Within 120 sec. Listing TOYOTA hand–held tester select sub–key registration. Within 20 sec. Remove the master key. Within 10 sec. Insert key to be registered in key cylinder. (Security indicator blinks) Within 10 sec. Within 10 sec. After 60 sec., additional master key is registered. (Security indicator OFF) Yes Will you register the next key? No The registration mode completes when pulling out the key within 10sec. and the brake pedal is depressed or after indicator is off 10 sec. pass. Author: Date: 2344 BE–125 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM 4. ERASURE OF TRANSPONDER KEY CODE There are 2 ways for erasure of transponder key code, one is depressing brake pedal and acceleration pedal and the other is using TOYOTA hand–held tester. NOTICE: All other master and sub–key codes are deleted leaving the master key code to use the operation. When using the key which was used before deleting, it is necessary to register the code again. HINT:
When any operation time described below is over, registration mode completes.
When the next procedure is performed while the timer is working, the timer completes counting time, then next timer starts. (1) Depressing brake pedal and acceleration pedal: 1. Insert master key in the key cylinder. Within 15 sec. 2. Depress and release the acceleration pedal 6 times. Within 20 sec. 3. Depress and release the brake pedal 7 times. (Security indicator blinks) Within 10 sec. 4. Remove the master key. (Security indicator blinks) END (Key code erasured) HINT: When the key cannot be pulled out in the step 4, key code deletion is canceled. (Security indicator is OFF) Author: Date: 2345 BE–126 BODY ELECTRICAL (2) – ENGINE IMMOBILISER SYSTEM Using TOYOTA hand–held tester: 1. Insert master key in the key cylinder. Within 120 sec. 2. Require key code deletion from hand–held tester. (Security indicator blinks) Within 10 sec. 3. Remove the master key. END (Key code erasured) HINT: When the key cannot be pulled out in the step 3, key code deletion is canceled. (Security indicator is OFF) Author: Date: 2346 BE–127 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B3–06 LOCATION Engine Room J/B No.2
EFI Fuse Transponder Key Amplifier Transponder Key Coil ECM Instrument Panel J/B
IGN Fuse I02682 Author: Date: 2347 BE–128 BODY ELECTRICAL – ENGINE IMMOBILISER SYSTEM BE0B4–05 INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminal 1 and 2. If continuity is not as specified, replace the coil. I03099 Author: Date: 2348 BO–1 BODY – CLIP CLIP REPLACEMENT BO0LJ–01 The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Pliers Clip Remover Screwdriver Scraper V00005 Author: Date: 2349 BO–2 BODY Shape (Example) – CLIP Removal/Installation Removal Removal Installation Installation V00012 Author: Date: 2350 BO–3 BODY – SRS AIRBAG SRS AIRBAG BO0KU–01 PRECAUTION The CAMRY is equipped with SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag, side airbag and seat belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. Author: Date: 2351 BO–4 BODY – FRONT BUMPER FRONT BUMPER BO0KV–01 COMPONENTS Turn Signal Light Assembly Clip Turn Signal Light Assembly Upper Reinforcement Sub–Assembly Fender Liner No.2 Reinforcement 5.5 (55, 49 in.·lbf) 34 (350, 25) Front Bumper Reinforcement Emblem, Radiator Grill 34 (350, 25) Clip Fender Liner Energy Absorber Mounting Plate Front Bumper Energy Absorber Bumper Cover Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque H01708 Author: Date: 2352 BO–5 BODY – FRONT BUMPER BO0KW–01 REMOVAL 1. REMOVE THESE PARTS: (a) Engine under cover (b) Fender liner (c) Turn signal light assembly HINT: Remove the light assembly as shown. H01709 2. (a) REMOVE BUMPER COVER Remove the 2 bolts and 3 clips. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) (b) (c) Remove the bolt holding the bumper end to the fender. Pull the bumper cover forward to remove the bumper cover from the clip under the turn signal light area. Pull the bumper cover forward to remove it. H01710 (d) H01711 H01712 HINT: At the time of installation, please refer to the refer to the following item. Align the holes of the bumper cover with the 2 bumper stays of the reinforcement. 3. REMOVE THESE PARTS: (a) Front bumper energy absorber (b) Front bumper reinforcement Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) (c) Front bumper upper reinforcement subassembly Author: Date: 2353 BO–6 BODY – FRONT BUMPER BO0KX–01 INSTALLATION Installation is in the reverse order of removal (See page BO–5). Author: Date: 2354 BO–7 BODY – REAR BUMPER REAR BUMPER BO0KY–01 COMPONENTS Left Side Luggage Trim Right Side Luggage Trim Rear Bumper Reinforcement Rear Bumper Energy Absorber 34 (350, 25) Rear Bumper Side Retainer 5.0 (50, 43 in.·lbf) 5.0 (50, 43 in.·lbf) Quarter Air Duct Rear Bumper Side Retainer Rear Bumper Cover N·m (kgf·cm, ft·lbf) : Specified Torque H01713 Author: Date: 2355 BO–8 BODY – REAR BUMPER BO0KZ–01 REMOVAL 1. (a) (b) 2. (a) REMOVE THESE PARTS: Right side luggage trim Left side luggage trim REMOVE REAR BUMPER COVER Remove the 7 clips, 2 bolts and 6 nuts from the bumper cover. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) H01714 H01715 (b) Pull the bumper cover rearward to remove it. HINT: With a plastic hammer, tap the ends of the bumper end bolts. (c) Using a screwdriver, slide the rear bumper side retainers from the bumper ends. (d) Remove the 2 gaskets from the side retainers. HINT: Use 2 new gaskets. 3. REMOVE THESE PARTS: (a) Rear bumper energy absorber (b) Rear bumper reinforcement Torque: 34 N·m (350 kgf·cm, 25 ft·lbf) Author: Date: 2356 BO–9 BODY – REAR BUMPER BO0L0–01 INSTALLATION Installation is in the reverse order of removal (See page BO–8). Author: Date: 2357 BO–10 BODY – HOOD HOOD BO0L1–01 ADJUSTMENT Centering Bolt Bolt with Washer HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock can not be adjusted with it on. Substitute a bolt and washer for the centering bolt. BO5235 1. ADJUST HOOD IN FORWARD/REARWARD AND LEFT/RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. Torque: 26 N·m (260 kgf·cm, 19 ft·lbf) N20963 2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTIONS Adjust the hood by turning the cushions. N20964 3. (a) N20965 ADJUST HOOD LOCK Replace each centering bolt with a regular bolt and washer. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) HINT: Remove the anti–theft bolt cover, then remove the lower hood lock bolt. You may have to remove the front bumper to access this bolt. (b) Adjust the lock by loosening the bolts. Author: Date: 2358 BO–11 BODY – FRONT DOOR FRONT DOOR BO0L2–01 COMPONENTS Front Door Upper Moulding Outside Rear View Mirror Front Door Belt Moulding Door Lock Cylinder Outside Handle 5.5 (55, 49 in.·lbf) Door Glass Door Frame
5.0 (50, 43 in.·lbf) Door Glass Run Door Lock 5.5 (55, 49 in.·lbf) Service Hole Cover 8.0 (80, 69 in.·lbf) Door Hinge 31 (310, 22) 23 (230, 17) 26 (260, 19) Door Lock Striker Window Regulator 8.0 (80, 71 in.·lbf) 30 (300, 22) X6 7.5 (75, 66 in.·lbf) Door Check Regulator Motor X3 31 (310, 22) Door Hinge Speaker 26 (260, 19) Rear Lower Frame Front Lower Frame Front Window Upper Garnish Power Window Switch Inside Handle 3.5 (35, 31 in.·lbf) Inside Handle Bezel Door Trim Driver’s Side: Regulator Motor N·m (kgf·cm, ft·lbf) : Specified torque
Precoated part P t d H01975 t Author: Date: 2359 BO–12 BODY – FRONT DOOR BO0L3–01 DISASSEMBLY 1. H01738 w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. HINT: At the time of assembly, please refer to the following item. With the door window fully closed, install the plate and the regulator handle with the snap ring. 2. (a) N20968 4 Clips N21003 REMOVE INSIDE HANDLE BEZEL Using a screwdriver, pry open the screw cover and remove the screw. HINT: Tape the screwdriver tip before use. (b) Using a screwdriver, pry out the bezel. HINT: Tape the screwdriver tip before use. 3. REMOVE FRONT WINDOW UPPER GARNISH 4. REMOVE DOOR TRIM (a) Using a screwdriver, remove the screw caps. HINT: Tape the screwdriver tip before use. (b) Remove the 2 clips, 2 screws and 2 bolts. (c) Insert a screwdriver between the door and door trim to pry out. (d) Pull the trim upward to remove it, then remove the power window switch and disconnect the harness connector. 5. REMOVE THESE PARTS: (a) Outside rear view mirror Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) (b) Speaker 6. (a) REMOVE DOOR INSIDE HANDLE Remove the screw and pull the handle forward. Torque: 3.5 N·m (35 kgf·cm, 31 in.·lbf) (b) Remove the link from the clamp. (c) Remove the inside handle from the ends of the 2 links. 7. REMOVE SERVICE HOLE COVER Remove the grommet, then remove the service hole cover. (c) (a) (b) N20969 Author: Date: 2360 BO–13 BODY 8. (a) (a) (b) (b) N20970 – FRONT DOOR REMOVE DOOR GLASS Open the door glass until the bolt appears in the service hole. Remove the 2 bolts and the door glass. (b) HINT: Pull the glass upward. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) 9. REMOVE GLASS RUN HINT: Pull the glass run upward. 10. REMOVE FRONT AND REAR SIDE FRAMES Remove the 2 bolts, 2 nuts and the side frames. HINT: Remove the side frames through the service hole. 11. REMOVE FRONT DOOR BELT MOULDING Pry the rearward end of the front door belt moulding from the door and remove the moulding. Clip N21004 12. REMOVE FRONT DOOR UPPER MOULDING (a) Using a drill, cut the flange portion of the 7 rivets. HINT: At the time of assembly, please refer to the following item. Use 7 new rivets. (b) Pry out the 2 clips and remove the moulding. : 7 rivets : clip : clip : clip H01729 Author: Date: 2361 BO–14 BODY – FRONT DOOR 13. REMOVE WINDOW REGULATOR ASSEMBLY Remove the bolts and window regulator. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator rollers. 14. w/ Power Window: REMOVE MOTOR FROM WINDOW REGULATOR Remove the 3 screws and motor. w/ Power Window: w/o Power Window: H01730 15. (a) (b) (c) (d) REMOVE DOOR LOCK Remove the 2 clips. Disconnect the 2 links from the door lock and remove the links. Disconnect the 2 links from the outside handle and the lock cylinder. Remove the 3 screws and door lock. N20971 HINT: At the time of reassembly, please refer to the following item. Apply adhesive to 3 screws. Part No. 08833–00070, THREE BOND 1324 or equivalent Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) (e) w/ Power Door Lock: Disconnect the connector. (f) Remove the door lock through the service hole. HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding surface of the door lock. 16. REMOVE OUTSIDE HANDLE Torque: 7.0 N·m (70 kgf·cm, 61 in.·lbf) w/o Power Door Lock w/ Power Door Lock H01732 Author: Date: 2362 BO–15 BODY – FRONT DOOR BO0L4–01 ADJUSTMENT 1. ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. SST 09812–00020 Torque: 31 N·m (310 kgf·cm, 22 ft·lbf) SST N20966 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS To adjust, loosen the door side hinge. HINT: Substitute the bolt and washer for the centering bolt. Torque: 26 N·m (260 kgf·cm, 19 ft·lbf) N20967 3. (a) (b) (c) ADJUST DOOR LOCK STRIKER Check that door fits and the door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Using a plastic hammer, tap the striker to adjust it. Torque: 23 N·m (230 kgf·cm, 17 ft·lbf) BO2556 Author: Date: 2363 BO–16 BODY – FRONT DOOR BO0L5–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–12). Author: Date: 2364 BO–17 BODY – REAR DOOR REAR DOOR BO0L6–01 COMPONENTS Rear Door Upper Moulding w/o Power Door Lock: Door Belt Moulding Door Lock Door Glass Outside handle 7.0 (70, 61 in.·lbf) Door Glass Run Door Lock Door Lock Control Link Child Protector Lock Lever Cover 5.0 (50, 43 in.·lbf) Door Lock Remote Control Link 8.0 (80, 71 in.·lbf) Door Hinge 26 (260, 19) 8.0 (80, 71 in.·lbf) Door Lock Striker Door Check 30 (300, 22) 23 (230, 17) Window Regulator Motor Rear Side Frame 5.5 (55, 49 in.·lbf) Window Regulator 5.5 (55, 49 in.·lbf) Door Hinge Cover Power Window Switch Service Hole Cover Inside Handle Door Trim 3.5 (35, 31 in.·lbf) Rear Door Weatherstrip 26 (260, 19) w/o Power Window: Plate Snap Ring Regulator Handle Inside Handle Bezel N·m (kgf·cm, ft·lbf) : Specified torque H01733 Author: Date: 2365 BO–18 BODY – REAR DOOR BO0L8–01 DISASSEMBLY 1. H01738 w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. HINT: At the time of reassembly, please refer to the following item. With the door window fully closed, install the plate and the regulator handle with the snap ring. 2. w/ Power Window: REMOVE POWER WINDOW SWITCH Using a screwdriver, pry out the switch, then disconnect the connector. HINT: Tape the screwdriver tip before use. 3. (a) N20968 6 Clips N21007 REMOVE INSIDE HANDLE BEZEL Using a screwdriver, pry open the screw cover and remove the screw. HINT: Tape the screwdriver tip before use. (b) Using a screwdriver, pry out the bezel. HINT: Tape the screwdriver tip before using. Use the screwdriver to release the bezel from the top and bottom protrusions on the handle assembly as shown. 4. REMOVE DOOR TRIM HINT: Tape a screwdriver tip before use. (a) Using the screwdriver, remove the 2 screw caps. (b) Remove the inside cover. (c) Remove the 2 screws and clip. (d) Insert the screwdriver between the door and door trim to pry out. (e) Pull the trim upward to remove it, then disconnect the connector. 5. REMOVE DOOR INSIDE HANDLE (a) Remove the screw and pull the handle forward. Torque: 3.5 N·m (35 kgf·cm, 31 in.·lbf) (b) Remove the link from the clamp. (c) Remove the inside handle from the ends of the 2 links. 6. REMOVE SERVICE HOLE COVER Remove the grommet, then remove the service hole cover. N20969 Author: Date: 2366 BO–19 BODY 7. (a) (b) (b) (b) (c) (a) N20974 – REAR DOOR REMOVE DOOR GLASS AND RUN Remove the bolt and nut holding the rear side frame to the door. Remove the 2 bolts holding the door glass to the window regulator. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) Remove the rear side frame and the rear section of the door glass run. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) HINT: Pull the door glass run upward. (d) Remove the door glass. (e) Remove the entire door glass run. HINT: Pull the door glass run upward. Clip 8. REMOVE REAR DOOR BELT MOULDING Pry the rearward end of the rear door belt moulding from the door and remove the moulding. N21008 : 7 rivets : clips : clips : clips 9. REMOVE REAR DOOR UPPER MOULDING (a) Using a drill, cut the flange portion of the 5 rivets. HINT: Use 5 new rivets. (b) Insert a screwdriver between the door and the rear door upper moulding and pry it off. H01743 Author: Date: 2367 BO–20 BODY – REAR DOOR 10. REMOVE WINDOW REGULATOR ASSEMBLY Remove the bolts and window regulator assembly. Torque: 5.5 N·m (55 kgf·cm,49 in.·lbf) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the window regulator rollers. 11. w/ Power Window: REMOVE MOTOR FROM WINDOW REGULATOR Remove the 3 screws and motor. w/ Power Window: w/o Power Window: 12. H01744 REMOVE REAR DOOR LOCK CHILD PROTECTION COVER Using a screwdriver, pry out the cover. HINT: Tape the screwdriver tip before use. 13. (a) (b) (c) (d) (b) (b) (a ) N20975 HINT: At the time of reassembly, please refer to the following item. Apply adhesive to the 3 screws. Part No. 08833–00070, THREE BOND 1324 or equivalent (e) w/o Power Door Lock REMOVE DOOR LOCK Remove the clip. Disconnect the 2 links from the door lock and remove the 2 links. Disconnect the link from the outside handle. Remove the 3 screws. Torque: 5.0 N·m (50 kgf·cm, 43 in.·lbf) w/ Power Door Lock: Disconnect the connector. Remove the door lock through the service hole. (f) HINT: At the time of reassembly, please refer to the following item. Apply MP grease to the sliding surface of the door lock. 14. REMOVE OUTSIDE HANDLE Torque: 7.0 N·m (70 kgf·cm, 61 in.·lbf) w/ Power Door LockH01746 Author: Date: 2368 BO–21 BODY – REAR DOOR BO0L7–01 ADJUSTMENT 3 Clips 1. 2 Clips N21006 ADJUST DOOR IN FORWARD/REARWARD AND VERTICAL DIRECTION Remove the front part of the rear seat side garnish. Remove the rear part of the front door inside scuff plate. Remove the center pillar lower garnish. (a) (b) (c) HINT: Pull both sides of the top and bottom part of the garnish outward, then pull out to remove the garnish. (d) Loosen the body side hinge nuts to adjust. Torque: 26 N·m (260 kgf·cm, 19 ft·lbf) (e) Install center pillar lower garnish. (f) Install front door inside scuff plate. (g) Install rear seat side garnish. N20972 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute a bolt with washer for the centering bolt. Torque: 26 N·m (260 kgf·cm, 19 ft·lbf) N20973 3. (a) (b) (c) ADJUST DOOR LOCK STRIKER Check that the door fit and door lock linkages are adjusted correctly. Loosen the striker mounting screws to adjust. Torque: 23 N·m (230 kgf·cm, 17 ft·lbf) Using a plastic hammer, tap the striker to adjust it. BO2556 Author: Date: 2369 BO–22 BODY – REAR DOOR BO0L9–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–18). Author: Date: 2370 BO–23 BODY – OUTSIDE REAR VIEW MIRROR OUTSIDE REAR VIEW MIRROR BO0LA–01 COMPONENTS Outside Rear View Mirror Cover 5.5 (55, 49 in.·lbf) Door Trim N·m (kgf·cm, ft·lbf) : Specified Torque H01758 Author: Date: 2371 BO–24 BODY – OUTSIDE REAR VIEW MIRROR BO0LB–01 DISASSEMBLY IMI: 1. (a) Mirror Mirror Shell (b) Gasket UTA: Mirror w/case Wire Retainer (c) (d) TOKAIRIKA: Mirror w/case IDENTIFY OUTSIDE REAR VIEW MIRROR w/ Power Rear View Mirror: UTA: The mirror moves smoothly when pressing the end of the mirror inward. w/ Power Rear View Mirror: IMI: The mirror stutters when pressing the end of the mirror inward. w/ Power Rear View Mirror: TOKAIRIKA: Equipped only on vehicles manufactured by TMC. w/o Power Rear View Mirror: Mirrors manufactured by IMI Clip X4 H01759 2. Gasket Mirror w/case Mirror Housing Wire Retainer H01760 UTA: DISASSEMBLE OUTSIDE REAR VIEW MIRROR (a) Disconnect the battery. (b) Press the inboard end of the mirror inward to access the rear of the mirror w/case assembly. (c) Unlatch both ends of the wire retainer, then remove the mirror parts from the mirror housing. NOTICE: Be careful not to damage the wires on heated mirrors. Disconnect the wires from the back side of the heater. 3. IMI: DISASSEMBLE OUTSIDE REAR VIEW MIRROR (a) w/Heated Mirrors: Disconnect the battery. (b) Protect the door surface. (c) Pivot the mirror housing to the forward position. Pivot Mirror Housing Forward H01761 (d) Mirror Glass Terminals Mirror Case Scraper Insert a scraper between the mirror and the case to remove the mirror. NOTICE: Be careful not to damage the wires on heated mirrors. Disconnect the wires from the back side of the heater. H01762 Author: Date: 2372 BO–25 BODY Shop Towel Mirror Housing H01763 – OUTSIDE REAR VIEW MIRROR 4. TOKAIRIKA: DISASSEMBLE OUTSIDE REAR VIEW MIRROR (a) Disconnect the battery. (b) Slide a shop towel between the mirror and the mirror housing as shown. (c) Pull the ends of the shop towel upward to disconnect the mirror from the housing. (d) Pull the mirror upward and disconnect it. NOTICE: Be careful not to damage the wires on heated mirrors. Disconnect the wires from the back side of the heater. Author: Date: 2373 BO–26 BODY – OUTSIDE REAR VIEW MIRROR BO0LC–01 Gasket 1. Mirror w/case Mirror Housing REASSEMBLY Wire Retainer H01764 UTA: ASSEMBLE OUTSIDE REAR VIEW MIRROR (a) w/Heated Mirrors: Connect the heater wires. (b) Install the wire retainer onto the mirror w/case assembly, then press the mirror firmly into place to engage the 6 lugs of the wire retainer. NOTICE: Pull the mirror edges to confirm the wire retainer lugs completely engage with the mirror housing. (c) Reconnect the battery, then operate the mirror to its full stop position. 2. 50–60 mm H01765 Glass Case Edge Claw B H01766 Claw A H01767 IMI: ASSEMBLE OUTSIDE REAR VIEW MIRROR (a) From a distance of 50–60 mm, use a heat gun or hair dryer to heat the edge of the mirror case until the mirror case becomes soft. CAUTION: Use extreme caution when using a heat gun or hair dryer. Holding it too close can melt the mirror case. (b) w/ Heated Mirrors: Connect the heater wires. (c) Before the the case cools down, position and snap the new mirror glass into the case. NOTICE: Verify the glass case edge completely surrounds the mirror glass. (d) Allow the case to cool down before moving the mirror back to its operating position. (e) Recheck the fit between the glass and the case. (f) Reconnect the battery, then operate the mirror to its full stop position. 3. TOKAIRIKA: ASSEMBLE OUTSIDE REAR VIEW MIRROR (a) w/ Heated Mirrors: Connect the heater wires. (b) Connect the claws (A) and install the mirror into the mirror housing. (c) Push the mirror inward to connect the claws (B) onto the mirror housing. (d) Reconnect the battery, then operate the mirror to its full stop position. Author: Date: 2374 BO–27 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE LUGGAGE COMPARTMENT DOOR AND HINGE BO0LD–01 COMPONENTS Torsion Bar Luggage Compartment Door Hinge Luggage Compartment Door Hinge 8.0 (80, 71 in.·lbf) 8.0 (80, 71 in.·lbf) Luggage Compartment Door Luggage Compartment Door Trim Right Side Luggage Trim Lock Cylinder Left Side Luggage Trim 5.5 (55, 49 in.·lbf) Right Hand Back Up Light Door Lock 5.5 (55, 49 in.·lbf) Luggage Compartment Floor Mat Left Hand Back Up Light Door Lock Striker Package Tray Trim Finish Side Trim High Mounted Stop Light Rear Seatback Finish Side Trim Rear Luggage Trim Room Partition Trim Rear Seat Cushion N·m (kgf·cm, ft·lbf) : Specified torque H01747 Author: Date: 2375 BO–28 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LE–01 REMOVAL 1. 2. (a) (b) (c) 3. (a) (b) (c) (d) (e) 4. (a) 2 1 1 (b) REMOVE LUGGAGE COMPARTMENT DOOR TRIM REMOVE LUGGAGE COMPARTMENT DOOR Disconnect the connector. Using a clip remover, disconnect the clamps. Remove the 4 bolts and door. Torque: 8.0 N·m (80 kgf·cm, 71 in.·lbf) REMOVE THESE PARTS: Luggage compartment floor mat LH and RH rear floor finish side plates Inner cover trims Rear seat Room partition trims REMOVE HIGH–MOUNTED STOP LIGHT Push on the both side of the cover to release the claws by your hand and remove the cover as shown in the illustration. Remove the 2 bolts and stop light, then disconnect the connector. N22588 5. REMOVE ROOF SIDE INNER GARNISH (a) Remove the clip. (b) Using a screwdriver, pry loose and remove the garnish. HINT: Tape the screwdriver tip before use. 6. REMOVE PACKAGE TRAY TRIM : 4 Clips N21430 7. (a) REMOVE TORSION BAR Remove the torsion bar from the center bracket. N22591 Author: Date: 2376 BO–29 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE (b) Install SST to the torsion bar on the hinge side. SST 09804–24010 (c) Push down on SST, and pull the luggage compartment door hinge from the torsion bar. (d) Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST. Remove the torsion bar. Repeat for the other side. SST BO4010 SST BO4011 (e) (f) SST BO4012 Author: Date: 2377 BO–30 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LF–01 DISASSEMBLY 1. (a) (b) 2. (a) (b) REMOVE DOOR LOCK Disconnect the control link. Remove the 2 bolts and lock. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) REMOVE REAR COMBINATION LIGHT Disconnect the connector. Remove the 10 nuts and rear combination lights. Author: Date: 2378 BO–31 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LG–01 ADJUSTMENT 1. (a) (b) (c) N22589 2. (a) (b) (c) (d) ADJUST LUGGAGE COMPARTMENT DOOR Remove the 11 clips and luggage compartment door trim. For forward/rearward and left/right adjustments loosen the bolts. Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf) For vertical adjustment of the front end of the door, increase or decrease the number of washers between the hinge and the door. ADJUST DOOR LOCK STRIKER Remove the LH and RH rear floor finish side plates. Remove the rear floor finish plate. Loosen the 2 lock striker set bolts. Torque: 5.5 N·m (56 kgf·cm, 49 in.·lbf) Using a hammer and a brass bar, tap the striker to adjust it. N22590 Author: Date: 2379 BO–32 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LH–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–30). Author: Date: 2380 BO–33 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO0LI–01 INSTALLATION 1. INSTALL TORSION BAR (a) Insert the torsion bar into the bracket. HINT: The center bracket opening is the nominal position of the torsion bar. If needed, move the torsion bar to the upper or lower hole to provide the correct luggage door lift. H01754 (b) (c) Install the SST onto the torsion bar of the hinge side. SST 09804–24010 Slowly lift the torsion bar with the SST and place it in the torsion bar bracket. H01755 (d) (e) (f) (g) 2. Slowly push the SST down and install the torsion bar to the hinge. Slowly lift the SST and install the torsion bar. Install the torsion bar to the center bracket. Repeat for the other side. INSTALL PACKAGE TRAY TRIM 3. 4. 5. (a) (b) (c) (d) (e) 6. (a) (b) (c) 7. INSTALL ROOF SIDE INNER GARNISH INSTALL HIGH MOUNTED STOP LIGHT INSTALL THESE PARTS: Room partition trims Rear seat Inner cover trims LH and RH rear floor finish side plates Luggage compartment floor mat INSTALL LUGGAGE COMPARTMENT DOOR Install the door with 4 bolts. Install clamps. Connect the connector. INSTALL LUGGAGE COMPARTMENT DOOR TRIM H01756 : 4 clips N21430 Author: Date: 2381 BO–34 BODY Full Open 1/2 Open Pop–Up H01757 – LUGGAGE COMPARTMENT DOOR AND HINGE 8. CHECK LUGGAGE DOOR LIFT
Pop–up distance: 35 – 100 mm
Pop– up to 1/2 open: Door should remain in any position.
Past 1/2 open: Door should open fully by itself.
Full open position: Door should not easily fall closed If adjustment is necessary, refer to step 2 –(a) above. Author: Date: 2382 BO–35 BODY – FRONT WIPER AND WASHER FRONT WIPER AND WASHER BO0LK–01 COMPONENTS Cowl Louver RH 24 (245, 18) Wiper Motor Wiper Arms Cowl Louver LH Weatherstrip Wiper Link Wiper Motor Assembly 5.5 (55, 49 in.·lbf) Window Washer Nozzle N·m (kgf·cm, ft·lbf) : Specified torque N21119 Author: Date: 2383 BO–36 BODY – FRONT WIPER AND WASHER BO0LL–01 REMOVAL N20998 1. REMOVE WIPER ARMS 2. REMOVE WEATHERSTRIP AND COWL LOUVERS 3. REMOVE WIPER MOTOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 5 bolts and wiper motor assembly. 4. REMOVE WIPER MOTOR Remove the 2 bolts, then separate the motor crank arm from the wiper links at the ball and socket joint. 5. REMOVE WINDOW WASHER NOZZLE (a) Remove the hoses from the nozzles. (b) Using a screwdriver, remove the nozzle. HINT: Tape the screwdriver tip before use. BO4391 Author: Date: 2384 BO–37 BODY – FRONT WIPER AND WASHER BO0LM–01 ADJUSTMENT B B D 1. (a) C C B INSPECT WASHER NOZZLE While operating the washer, check that the washer fluid hits the windshield and the upsurge area within the shaded areas. B U.S. mm (in.) E A U.S. F A B H01773 ”a” 280 (11) 600 (23.6) ”B” 150 (5.9) 150 (5.9) ”C” 50 (2.0) 250 (9.8) 50 (2.0) Max ”E” 180 (7.1) 360 (14) ”F” 395 (15.5) 114 (4.5) ”b” D F C Canada ”A” ”D” B Canada mm (in.), Approx. A G E (b) H H01774 (c) 90 (3.5) ”H” 474 (18.7) ”I” 350 (13.8) Canadian models: Adust the nozzle so the outboard points ”a” and ”b” are within the wipe pattern. Check if the lower point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass the wiper blades wipe). 2. ADJUST WASHER NOZZLE Using a tool like that shown in the illustration, rotate the nozzle to adjust the fluid direction against the windshield. 2 – 2.5 mm (0.079 – 0.098 in.) 0.7 – 0.75 mm (0. 028 – 0.030 in.) ”G” BE3367 Author: Date: 2385 BO–38 BODY – FRONT WIPER AND WASHER BO0LN–01 INSTALLATION 1. 2. 3. (a) (b) INSTALL WINDOW WASHER NOZZLE INSTALL WIPER LINK TO MOTOR INSTALL THESE PARTS: Wiper motor assembly Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) Cowl louvers and weatherstrip N20998 4. (a) ”A” ”A” Cowl Louver Edge H01772 INSTALL WIPER ARMS Operate the wipers once and turn the wiper switch OFF, then install the wiper arms. HINT: If the driver’s side wiper arm mount has a blue dot on it, use an ITT wiper arm. If there is no mark, use a ND wiper arm. (b) Adjust the installation position of the wiper arms as shown (blade tip to cowl louver edge). ”A” Approx. 35 mm (1.4 in.) (c) Tighten the wiper arm nut. Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) Author: Date: 2386 BO–39 BODY – BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING BO0M8–01 COMPONENTS Front Door Outside Moulding Rear Quarter Outside Moulding Front Fender Outside Moulding Front Quarter Outside Moulding Rear Door Outside Moulding N22598 Author: Date: 2387 BO–40 BODY – BODY OUTSIDE MOULDING BO0M9–01 REMOVAL CAUTION:
Store in a cool place, avoiding direct sunlight, high temperature and dust.
The moulding is made of polyvinyl chloride. Do not allow this material to come in contact with thinner or other solvents, open flame or boiling water.
The storage time for the moulding and adhesive is limited to about 9 months. 1. REMOVE ENDS OF MOULDING Using a scraper, pry the moulding loose about 30 mm (1.18 in.) form each end. HINT: Tape the scraper tip before using. H01782 2. REMOVE MOULDING AND ADHESIVE (a) Pull off the moulding by cutting the adhesive with a knife. (b) Scrape off adhesive from the body with sandpaper cutter. NOTICE:
Remember that 30 – 80 mm (1.18 – 3.15 in.) of the ends of the moulding are glued tightly with a strong adhesive.
Do not reuse moulding. H01783 Author: Date: 2388 BO–41 BODY – BODY OUTSIDE MOULDING BO0MA–01 INSTALLATION 1. (a) HEAT BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface to 40 – 60 °C (104 – 140 °F). NOTICE: Do not heat body excessively. (b) Remove the adhesive tape from the body. (c) Wipe off stains with cleaner. BO6675 N19058 2. CLEAN MOULDING If reusing the moulding: (a) Using a heat light, heat the moulding to 20 – 30 °C (68 – 86 °F). NOTICE: Do not heat moulding excessively. (b) Remove the adhesive tape from the moulding. (c) Wipe off stains with cleaner. (d) Apply a new adhesive tape to moulding as shown in the illustration. Adhesive Tape Adhesive Tape H01884 3. (a) N22643 INSTALL MOULDING Using a heat light, heat the body and moulding. Body: 40 – 60 °C (104 – 140 °F) Moulding: 20 – 30 °C (68 – 86 °F) NOTICE: Do not heat moulding excessively. (b) Lift moulding release sheet from face of moulding. NOTICE: When the moulding release sheet is removed, make sure that no dirt or dust can get onto the uncoated area. (c) Align the bosses with their corresponding holes in the body, and press firmly on the moulding. Refer to the illustration for the front fender moulding application procedures. NOTICE: Do not apply excessive force onto the moulding, but steady pressure with your thumbs. Author: Date: 2389 BO–42 BODY – WINDSHIELD WINDSHIELD BO0LO–01 COMPONENTS Inside Rear View Mirror Map Light Assembly Sun Visor Front Pillar Garnish Weatherstrip Sun Visor Windshield Glass Holder Windshield Upper Moulding Stopper Weatherstrip Dam Windshield Outside Moulding Wiper Arm Cowl Louver RH 24 (245, 18) Windshield Outside Cowl Louver LH Moulding Front Pillar Garnish Weatherstrip Hood N·m (kgf·cm, ft·lbf) : Specified torque N20947 Author: Date: 2390 BO–43 BODY – WINDSHIELD BO0LP–01 REMOVAL N20982 1. REMOVE THESE PARTS: (a) Inner rear view mirror (b) Sun visors and holders (c) Map light assembly (d) Front pillar garnishes (e) Hood (f) Wiper arms (g) Cowl louvers (h) Weatherstrips 2. REMOVE WEATHERSTRIP Remove the weatherstrip by pulling. HINT: Remove only the front half of weatherstrip. 3. REMOVE WINDSHIELD OUTSIDE MOULDING (a) Using a drill of less than ø 5.0 mm (0.20 in.), drill out the rivet heads and remove the moulding. (b) Using a vacuum cleaner, remove the drill rivet and their dust from the inside of the door. CAUTION: The cut rivet and rivet cutter will be not, avoid touching them. NOTICE: Do not jiggle the rivet cutter while cutting.You may enlarge the rivet hole or damage the rivet cutter. HINT: Do not drill the body. Sealant may cause the moulding to stick to the glass. If necessary, separate from the glass using a knife. 4. REMOVE WINDSHIELD UPPER MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. N20983 5. (a) REMOVE WINDSHIELD GLASS Push piano wire through between the body and glass from the interior. Tie both wire ends to a wooden block or a similar object. (b) HINT: Apply adhesive tape to the outer surface to prevent scratching. BO5232 Author: Date: 2391 BO–44 BODY – WINDSHIELD NOTICE: When separating the glass, be careful not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. (c) Cut the adhesive by pulling the piano wire around it. (d) Remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when removing the glass. 6. REMOVE RETAINERS BO1689 Author: Date: 2392 BO–45 BODY – WINDSHIELD BO0LQ–01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. (b) Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) (b) REPLACE STOPPER Remove the damaged stopper. Cut off the old adhesive around the stopper installation area. NOTICE: Be careful not to damage the body. (c) Clean the installation area. (d) Install a new stopper onto the body. N21015 3. (a) CLEAN REMOVED GLASS Using a scraper, remove the adhesive sticking to the glass. (b) Clean the glass with cleaner. NOTICE: Do not touch the glass after cleaning it. BO5231 4. (a) (b) (c) (d) POSITION GLASS Place glass in the correct position. Check that all contacting parts of the glass rim are perfectly even and do not make contact with the fasteners. Place reference marks between the glass and body. Remove the glass. BO2820 5. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface black–colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. BO4421 Author: Date: 2393 BO–46 BODY – WINDSHIELD 6. INSTALL DAM Install the dam with double–stick tape as shown in the illustration. NOTICE: Do not touch the glass face after cleaning it. A: 7 mm (0.276 in.) A N21016 7. Primer ”M” COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M. NOTICE: Let the primer coating dry for 3 minutes or more. Do not coat Primer M to the adhesive. Do not keep any of the opened Primer M for later use. Primer ”M” N00141 8. COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or a sponge, coat the edge of the glass and the contact surface with Primer G. (b) Before the primer dries, wipe it off with a clean shop rag. NOTICE: Let the primer coating dry for 3 minutes or more. Do not keep any of the opened Primer G for later use. Primer G N21017 9. (a) 12.5 mm or more (0.492 in.) APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Fill the cartridge with adhesive. Part No. 08850 – 00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the chart below. 8.0 mm or more (0.315 in.) N21018 Temperature (b) (c) Tackfree time 35 °C (95 °F) 15 minute 20 °C (68 °F) 100 minute 5 °C (41 °F) 8 hour Load the cartridge into the sealer gun. Coat the glass with adhesive as shown. Author: Date: 2394 BO–47 BODY – WINDSHIELD 10. INSTALL GLASS HINT: Confirm that the dam is attached the body panel as shown in the illustration. Adhesive N21019 (a) (b) Position the glass so that the reference marks are lined up, and press in gently along the rim. Using a spatula, apply adhesive on the glass rim. BO2821 (c) Use a scraper to remove any excess or protruding adhesive. NOTICE: Take care not to drive the vehicle during the time described in the chart below. BO3986 (d) 11. (a) (b) 12. Temperature Minimum time prior to drive the vehicle 35 °C (95 °F) 1.5 hour 20 °C (68 °F) 5 hour 5 °C (41 °F) 24 hour Hold the windshield glass in place securely with a protective tape or equivalent until the adhesive hardened. INSPECT FOR LEAKS AND REPAIR Do a leak test after the hardening time has elapsed. Seal any leak with sealant. Part No. 08833 – 00030 or equivalent APPLY ADHESIVE AT MOULDING INSTALLATION AREA Part No. 08833 – 00030 or equivalent Adhesive Adhesive BO3671 Author: Date: 2395 BO–48 BODY – WINDSHIELD 13. INSTALL WINDSHIELD UPPER MOULDING Place the moulding onto the body and tap it in by hand. N22592 14. (a) (b) INSTALL WINDSHIELD OUTSIDE MOULDING Install the pawl of the outside moulding to the upper moulding to set the moulding to the body. Using an air riveter with nose piece, install the new 3 rivets and outside moulding. N20984 20 mm (0.79 in.) N15432 CAUTION: To avoid personal injury and short of the wiring when installing ø 5.0 mm (0.20 in.) rivets keep your hands out of the 20 mm (0.79 in.) radius that the caulked ø 5.0 mm (0.20 in.) rivet will cover. HINT: Install the rivet firmly pressed at a right angle (90°) against the installation hole. 15. INSTALL THESE PARTS: (a) Cowl louvers (b) Weatherstrips (c) Wiper arms Torque: 24 N·m (245 kgf·cm, 18 ft·lbf) (d) Front pillar garnishes (e) Map light assembly (f) Sun visors and holders (g) Inner rear view mirror Author: Date: 2396 BO–49 BODY – BACK WINDOW GLASS BACK WINDOW GLASS BO0LR–01 COMPONENTS Back Window Moulding Back Window Glass
Dam Roof Side Inner Garnish Rear Seatback 19 (185, 13) Rear Side Seat Back LH Rear Side Seat Back RH 19 (185, 13) High–Mounted Stop Light 19 (185, 13) Rear Seat Cushion Rear Seat Outer Belt Rear Seat Center Belt Package Tray Trim Rear Seat Outer Belt 42 (420, 31)
Non–reusable part N·m (kgf·cm, ft·lbf) : Specified torque Room Partition Trim N20948 Author: Date: 2397 BO–50 BODY – BACK WINDOW GLASS BO0LS–01 REMOVAL 3 Clips 1 Clip 1. 2. (a) (b) REMOVE REAR SEAT CUSHION AND SEATBACKS REMOVE ROOF SIDE INNER GARNISHES Remove the clips. Pull the garnish to remove it. 3. (a) REMOVE HIGH–MOUNTED STOP LIGHT Push on the both side of the cover to release the claws by your hand and remove the cover as shown in the illustration. Remove the 2 bolts and stop light, then disconnect the connector. N21020 (b) N22588 4 Clips 4. (a) (b) (c) REMOVE PACKAGE TRAY TRIM Remove the bolts holding the rear seat belt lower side to the body. Remove the seat belts with seat belt hole covers from the package trim. Remove the trim by pulling forward. N21021 5. REMOVE ROOM PARTITION TRIMS Remove the 6 clips and room partition trims. 6. REMOVE THESE PARTS (a) Assist grips. (b) Rear side of roof headlining. 7. DISCONNECT DEFOGGER WIRE CONNECTORS N21121 8. REMOVE BACK WINDOW MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. 9. REMOVE BACK WINDOW GLASS Remove the glass in the same way as windshield. (See page BO–43) N20985 Author: Date: 2398 BO–51 BODY – BACK WINDOW GLASS BO0LT–01 INSTALLATION HINT: Refer to the installation of windshield, install back window glass by the following operations. (See page BO–45) 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY 2. CLEAN REMOVED GLASS N21122 3. REPLACE STOPPERS 4. POSITION GLASS 5. CLEAN CONTACT SURFACE OF GLASS 6. INSTALL DAM Install the dam with double–stick tape as show in the illustration. NOTICE: Do not touch the glass face after cleaning it. 7. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” 8. COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” 9. APPLY ADHESIVE AT MOULDING INSTALLATION AREA Adhesive Adhesive BO3671 N20986 10. INSTALL BACK WINDOW MOULDING Place the moulding onto the body and tap it by hand. 11. APPLY ADHESIVE 12. INSTALL GLASS 13. INSPECT FOR LEAKS AND REPAIR 14. CONNECT DEFOGGER CONNECTORS 15. INSTALL THESE PARTS: (a) Rear side of roof headlining (b) Assist grips (c) Package tray trim Author: Date: 2399 BO–52 BODY (d) (e) (f) (g) (h) – BACK WINDOW GLASS Room partition trims Seat belt lower side bolts Torque: 42 N·m (420 kgf·cm, 31 ft·lbf) High–mounted stop light Roof side inner garnish Rear seatbacks and seat cushion Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Author: Date: 2400 BO–53 BODY – SLIDING ROOF (TMC Made) SLIDING ROOF (TMC Made) BO0M1–01 ON–VEHICLE INSPECTION N10192 INSPECT SLIDING ROOF GLASS ALIGNMENT (a) Start the engine and check the operation time of the sliding roof. Operation time: Approx. 6 secs. (b) Check for abnormal noise or binding during operation. (c) With the sliding roof fully closed, check for water leakage. (d) Check for a difference in level between the sliding roof weatherstrip and roof panel. Except rear end: 0 ± 1.5 mm (0 ± 0.059 in.) Rear end: 0 + 1.5 mm (0 + 0.059 in.) 0 – 1.0 mm (0 – 0.039 in.) Author: Date: 2401 BO–54 BODY – SLIDING ROOF (TMC Made) BO0M2–01 COMPONENTS Side Garnish Sliding Roof Glass Rear Roof Drip Channel Roof Window Deflector Panel Side Garnish Drive Cable Guide Block Guide Block Sliding Roof Housing Drive Gear Guide Rail Stopper Sunshade Trim Sliding Roof Panel Stopper Roof Rail Rear Frame N·m (kgf·cm, ft·lbf) : Specified torque 5.5 (55, 49 in.·lbf) N22654 Author: Date: 2402 BO–55 BODY – SLIDING ROOF (TMC Made) BO0M3–01 REMOVAL 1. REMOVE ROOF HEADLINING (See page BO–83) 2. REMOVE SIDE GARNISH Using a screwdriver, remove the garnishes. HINT: Tape the screwdriver tip before use. 3. REMOVE SLIDING ROOF GLASS ASSEMBLY (a) Using a torx wrench, remove the 4 screws. (b) Pull the glass upward to remove it. 4. REMOVE DRIVE GEAR NOTICE: Remove the drive gear with the sliding roof is full closed. (a) Disconnect the connector. (b) Remove the 3 bolts and drive gear. N21524 (c) (d) Remove the screw and cam plate cover. Turn the drive gear to align the point marks as shown in the illustration. (e) Install the cam plate cover and screw. NOTICE: At the time of installation, please refer to the following item. If the sliding roof position and drive gear full close position is not matched, the sliding roof does not operate normally. Point Marks N21527 Author: Date: 2403 BO–56 BODY 5. (a) (b) (c) – SLIDING ROOF (TMC Made) REMOVE SLIDING ROOF HOUSING Disconnect the 4 drain hoses from the housing. Remove the 8 bolts and 4 brackets. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) Remove the 6 nuts, then remove the housing as shown on the following page. N21529 Author: Date: 2404 BO–57 BODY – SLIDING ROOF (TMC Made) BO0M4–01 DISASSEMBLY 1. REMOVE SLIDING ROOF PANEL STOPPER Remove the 2 screws and 2 stoppers. 2. REMOVE SUNSHADE TRIM N21523 3. REMOVE REAR ROOF DRIP CHANNEL Remove the rear roof drip channel as shown in the illustration. N21421 4. REMOVE REAR FRAME Remove the 4 screws and rear frame. N21424 5. (a) (b) REMOVE DRIVE CABLE Remove the screw and guide rail stopper. Slide the drive cable rearward, then remove it. N21526 HINT: At the time of reassembly, please refer to the following items.
Adjust the drive cable to a closed and tilted down position.
Slide the cable forward or backward to align the 2 marks as shown.
Slide the cable to the forefront with your hand. 6. REMOVE ROOF WINDOW DEFLECTOR PANEL N21525 Author: Date: 2405 BO–58 BODY – SLIDING ROOF (TMC Made) 7. REMOVE GUIDE BLOCK Remove the 2 screws and guide block. N21420 8. REMOVE SLIDING ROOF HOUSING Remove the 6 screws and sliding roof housing. N21522 Author: Date: 2406 BO–59 BODY – SLIDING ROOF (TMC Made) BO0M5–01 ADJUSTMENT 1. REMOVE SIDE GARNISH Before making adjustments, using a screwdriver, remove the side garnishes. HINT:
Tape the screwdriver tip before use.
After adjustment, reinstall the side garnishes. N21422 2. (a) (b) TO ADJUST FORWARD OR REARWARD Using a torx wrench, loosening the sliding roof glass installation screws. Adjust the sliding roof glass forward and rearward. Z04207 3. TO ADJUST CLEARANCE (Difference in left and right clearance) (a) When the front or rear alignment is not correct, remove the drive gear and sliding roof glass, then adjust the drive rail. NOTICE: Remove the drive gear with sliding roof is full closed. BO3396 (b) (c) Adjust by slide the cable forward or rearward to align the 2 marks as shown. Install the drive gear and sliding roof glass. N21525 Author: Date: 2407 BO–60 BODY – SLIDING ROOF (TMC Made) BO0M6–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–57). Author: Date: 2408 BO–61 BODY – SLIDING ROOF (TMC Made) BO0M7–01 INSTALLATION Installation is in the reverse order of removal (See page BO–55). Author: Date: 2409 BO–62 BODY – SLIDING ROOF (TMMK Made) SLIDING ROOF (TMMK Made) BO0LU–01 ON–VEHICLE INSPECTION H01814 Glass Panel Level Difference ± 1.5 mm Roof Panel Weatherstrip H01815 INSPECT SLIDING ROOF GLASS ALIGNMENT (a) Start the engine and check the operation time of the sliding roof. Operation time: Approximately 6 sec. (b) Check for abnormal noise or binding during operation. (c) Check for water leakage with the sliding roof fully closed. (d) Check the alignment between the sliding roof weatherstrip and the roof panel. All sides: 0 ± 1.5 mm (0 ± 0.059 in.) HINT: At the time of installation, please refer to the following item. To align the glass to the roof surface, loosen the 4 screws, then adjust and retighten. If the sliding roof does not operate: (e) Remove the map light assembly. (f) Manually operate the sliding roof by inserting a hex wrench into the motor to turn the drive shaft. H01816 Author: Date: 2410 BO–63 BODY – SLIDING ROOF (TMMK Made) BO0LV–01 COMPONENTS Sliding Roof Sliding Roof Glass Sunroof Opening Trim Headliner Assembly Room Light Map Light Assembly H01812 Author: Date: 2411 BO–64 BODY – SLIDING ROOF (TMMK Made) Wind deflector Roof Drip Channel Deflector Spring RH Lift Arm and Cable Assembly RH Roof Drip Channel Guide LH Roof Drip Channel Guide Sunshade Trim LH Lift Arm and Cable Assembly Drain Cap Drive Rail Assembly 5.5 (55, 49 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H01813 Author: Date: 2412 BO–65 BODY – SLIDING ROOF (TMMK Made) BO0LW–01 REMOVAL 1. H01824 REMOVE ROOF HEADLINING (See page BO–83) REMOVE SIDE GARNISHES 2. HINT: At the time of installation, please refer to the following item. Soak the garnishes in water to soften them before assembly. 3. REMOVE GLASS PANEL ASSEMBLY (a) Remove the 4 glass panel adjustment screws. HINT: At the time of installation, please refer to the following item. Adjust the height of the glass panel, then tighten the 4 screws. (b) Pull the glass upward to remove it. 4. (a) (b) (c) REMOVE SLIDING ROOF ASSEMBLY Remove the 4 drain hoses from the sliding roof assembly. Remove the 8 bolts and 4 brackets. Torque: 5.5 N·m (55 kgf·cm, 49 in.·lbf) Remove the 6 nuts and the sliding roof assembly. H01825 Author: Date: 2413 BO–66 BODY – SLIDING ROOF (TMMK Made) BO0LX–01 DISASSEMBLY 1. REMOVE SLIDING ROOF HOUSING DRAIN CAP Pull the drain cap rearward to remove it. HINT: At the time of reassembly, please refer to the following item. Apply seal packing to the drain cap. Seal packing: Part No.1 08826 – 00090 or equivalent 2. REMOVE REAR ROOF DRIP CHANNEL Unclip the roof drip channel from the roof drip channel guide. HINT: At the time of reassembly, please refer to the following item. Aligh the rear roof drip channel to the roof drip channel guide hook. 3. REMOVE SUNSHADE TRIM H01826 4. (a) REMOVE LH AND RH ROOF DRIP CHANNEL GUIDE Using a screwdriver, remove the guide from the lift arm assembly. HINT: Tape the screwdriver tip before using. (b) Slide the guide out of the side rail. H01827 5. (a) H01828 REMOVE DRIVE GEAR ASSEMBLY Use a hex wrench to align the gear pointer with the housing pointer. Disconnect the harness connector. Remove the 3 screws and the drive gear assembly. (b) (c) HINT: At the time of reassembly, please refer to the following item. Aligh the drive gear assembly during reassembly. (See page BO–68). H01829 Author: Date: 2414 BO–67 BODY 6. (a) H01830 – SLIDING ROOF (TMMK Made) REMOVE LH AND RH SIDING ROOF LIFT ARM AND CABLE ASSEMBLIES Using a drill, cut the flange portion of the stop pin (rivet) from each side rail. HINT: At the time of reassembly, please refer to the following item. Use two new rivets. (b) Slide the LH sliding roof lift arm and drive cable from its side rail. (c) Slide the RH sliding roof lift arm and drive cable from its side rail. 7. REMOVE WIND DEFLECTOR (a) Remove the 2 screws from the front rail assembly. HINT: At the time of reassembly, please refer to the following item. Insert the strap into the front rail assembly as shown. H01831 H01832 (b) Using a drill, cut the flange portion of the 4 rivets. NOTICE: Be careful not to damage the side rail (rivet) holes when drilling. HINT: At the time of reassembly, please refer to the following item. Use 4 new special sealing type rivets. Part No. 09884–26003 (c) Remove the deflector and spring assembly. (d) Remove the spring from the deflector. Author: Date: 2415 BO–68 BODY – SLIDING ROOF (TMMK Made) BO0LY–01 ADJUSTMENT Motor Housing Pointer (Grey) Gear Pointer (Brown) 1. ALIGN THE MOTOR TO ”O” POSITION NOTICE: The ”O” position is the same as the sliding roof ”flush ” position (sliding roof closed). Use the vehicle sliding roof switch or a hex wrench to align the gear pointer with the motor housing pointer as shown. H01817 NOTICE: Use only the sliding roof switch to electrically operate the motor or sliding roof. Do not use any other electrical source to power the motor. If the sliding roof switch (under vehicle power) is not available, use a hex wrench to align the motor pointers. 2. REMOVE DRIVE GEAR ASSEMBLY H01818 3. REMOVE GLASS PANEL (a) Remove the 4 glass panels adjustment screws. HINT: At the time of installation, please refer to the following item. Adjust the height of the glass panel, then tighten the 4 screws. (b) Pull the glass upward to remove it. H01819 Parts shown disassembled for clarity 4. ALIGN SLIDING ROOF COMPONENTS (a) Verify the hook appears as shown. (b) Align the cable arm hole with the lift arm hole. HINT: Using a screwdriver, move the LH and RH cable assemblies forward and backward to align the holes in the cable arm and lifter arm. (c) Temporarily insert a 3 mm (0.12 in.) pin through the alignment holes in the cable arm and lifter arm. HINT: Verify the cam block alignment hole is aligned with the lift arm alignment hole. Misalignment at this point will result in a malfunction of the sliding roof mechanism. 5. REINSTALL DRIVE GEAR ASSEMBLY HINT: Before reinstalling the drive gear assembly, double check the alignment of the gear pointers. H01820 Author: Date: 2416 BO–69 BODY 6. (a) OK NG H01821 – SLIDING ROOF (TMMK Made) VERIFY CORRECT INSTALLATION TIMING Cycle the unit once (vent position closed, slide open, slide completely closed). HINT: After cycling the unit closed from the slide open position, verify the alignment holes in the cable arm and cam block are aligned and the motor pointers are in the ”O” position. The timing of the sliding roof is okay if the holes are within 1/2 a diameter of each other as shown when closed from the ”side open” position. NOTICE: The holes will normally not align when moving the sliding roof from the vent open position to the closed position. (b) Lift Arm Assembly Guide Pin Slide Rail H01822 There should be a slight interference between the guide pin and the curved ”lead–in” of the side rail. Confirm by cycling the unit. A clicking sound from the hook indicates the adjustment is incorrect. If the guide pin has been disturbed, readjust as follows: (1) Loosen the screw and adjust the pin so there is a slight interference. (2) Tighten the screw and cycle the unit. (3) Confirm the hook smoothly engages the wind deflector spring. (4) Repeat if necessary. 7. REINSTALL GLASS PANEL Hook H01823 Author: Date: 2417 BO–70 BODY – SLIDING ROOF (TMMK Made) BO0LZ–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–66). Author: Date: 2418 BO–71 BODY – SLIDING ROOF (TMMK Made) BO0M0–01 INSTALLATION Installation is in the reverse order of removal (See page BO–65). NOTICE: Check and adjust the sliding roof after installation (See page BO–62). Author: Date: 2419 BO–72 BODY – INSTRUMENT PANEL INSTRUMENT PANEL BO0MB–01 COMPONENTS N Instrument Panel Reinforcement G G N N N G Instrument Panel Brace Mount H Q Q No.2 Instrumental Panel Brace N N B O No.1 Instrument Panel Brace N N N Front Pillar Garnish N Front Passenger Airbag Assembly Front Pillar Garnish D No.2 Instrumental Panel Bracket No.1 Instrumental Panel Bracket D 20 (200, 14) No.2 Side Defroster Nozzle Cowl Side Trim Front Door Opening Cover Front Door Inside Scuff Plate Glove Compartment Door Finish Plate Instrument Panel C Hazard Warning Switch Lower Finish Remote Control Mirror Hole Base Plate Upper Column Cover A F F J F F Glove Compartment A No.2 Lower Panel Cluster Finish Panel Radio Assembly Combination Switch Lower Column Cover D Front Door Opening Cover Cowl Side Trim D Center Cluster Finish Panel 35 (360, 26) D D No.1 Lower Panel F A A Steering Wheel D Lower Panel Insert Combination Meter Coin Box Front Console Box Center Console Front Door Upper Panel Inside Scuff Plate N·m (kgf·cm, ft·lbf) : Specified torque Author: A/C Control Assembly Steering Wheel Pad F F B B Rear Console Box N20950 Date: 2420 BO–73 BODY – INSTRUMENT PANEL Instrument Panel Wire Harness No.1 Defroster Nozzle Garnish A Defroster Nozzle Assembly A RH Side Defroster Duct Nozzle No.1 Side Defroster Duct Nozzle No.2 Heater Duct to K Register A A A A No.3 Instrument Panel Register Assembly K A A K K A No.1 Heater Duct to Register A A K K A Instrument Panel Center Bracket No.2 Instrument Panel Register Assembly No.1 Instrument Panel Regigter Assembly Glove Box Light Assembly Instrument Panel N20951 Author: Date: 2421 BO–74 BODY – INSTRUMENT PANEL HINT: Screw shapes and size are indicated in the table below. The code (”A”–”P”) correspond to those indicated on the previous page. mm (in.) Code Shape Size Code ø = 5.2 (0.21) A B L = 16 (0.63) D ø = 6.0 (0.24) ø = 8.0 (0.31) E ø = 5.0 (0.20) L = 20 (0.79) ø = 5.2 (0.21) F L = 20 (0.79) ø = 6.0 (0.24) L = 20 (0.79) L = 20 (0.79) ø = 5.0 (0.20) L = 18 (0.79) ø = 5.0 (0.20) L L = 14 (0.55) L = 12 (0.47) 6 x 1.00 8 x 1.25 ø = 8.0 (0.31) Size ø = 6.0 (0.24) C I K L = 18 (0.17) Shape ø = 6.0 (0.24) H ø = 6.0 (0.24) M ø = 6.0 (0.24) Code L = 10 (0.39) L = 22 (0.87) J Size L = 16 (0.63) L = 20 (0.79) G Shape N O 6 x 1.00 P H01983 Author: Date: 2422 BO–75 BODY – INSTRUMENT PANEL BO0MC–01 REMOVAL 1. REMOVE THESE PARTS: HINT: Tape a screwdriver tip before use. (a) Front door inside scuff plates (b) Cowl side trims (c) Front pillar garnishes (d) Front door opening covers (e) Lower finish plate 2. REMOVE STEERING WHEEL (See page SR–11) 3. REMOVE STEERING COLUMN COVERS (a) Remove the steering tilt handle. (b) Remove the 3 screws, then the upper and lower column covers. 4. REMOVE COMBINATION SWITCH 5. (a) (b) (c) REMOVE No.1 LOWER PANEL Remove the 2 screws and hood lock release lever. Press on the sides of the coin box while pulling the coin box outward, and remove the coin box. Remove the screw, bolt and the No.1 lower panel. N20987 6. (a) (b) 7. REMOVE LOWER PANEL INSERT Remove the 2 screws holding the DLC3 to the LH lower panel. Remove the 4 bolts, and the panel. REMOVE No.2 LOWER COVER N21123 Author: Date: 2423 BO–76 BODY – INSTRUMENT PANEL 8. (a) N20988 7 Clips N21023 REMOVE GLOVE COMPARTMENT ASSEMBLY Using a screwdriver, remove the glove compartment door finish plate to the glove compartment box inside. NOTICE: When handling the airbag connector, be careful not to damage the airbag wire harness. HINT: Tape the screwdriver tip before use. (b) Pull up and disconnect the airbag connector. (c) Remove the 4 screws, bolt and glove compartment assembly. 9. REMOVE CENTER CONSOLE UPPER PANEL Using a screwdriver, remove the panel, then disconnect the connector. HINT: Tape the screwdriver tip before use. 10. REMOVE REAR CONSOLE BOX Remove the 2 bolts, 2 screws and the console box. 11. REMOVE CENTER CLUSTER FINISH PANEL Using a screwdriver, remove the panel, then disconnect the connector. HINT: Tape the screwdriver tip before using. 12. REMOVE FRONT CONSOLE BOX Remove the 2 screws and the front console box. 13. REMOVE RADIO ASSEMBLY 14. REMOVE A/C CONTROL ASSEMBLY (See page AC–82) 15. REMOVE HAZARD WARNING SWITCH 16. REMOVE CLUSTER FINISH PANEL (a) Remove the 2 screws. (b) Using a screwdriver, remove the panel. HINT: Tape the screwdriver tip before use. 17. REMOVE COMBINATION METER 18. REMOVE REMOTE CONTROL MIRROR HOLE BASE 6 Clips N21024 Author: Date: 2424 BO–77 BODY – INSTRUMENT PANEL 19. W03509 REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (See page RS–28) Remove the 2 bolts, 4 nuts and the front passenger airbag assembly. Torque: Bolt: 20 N·m (200 kgf·cm, 14 ft·lbf) CAUTION:
Store the front passenger airbag door facing upward (never downward).
Never disassemble the front passenger airbag assembly. NOTICE: The 2 bolts to the instrument panel have been anti–rust treated. After removing the front passenger airbag assembly, always replace the bolts and nuts with new ones. 20. REMOVE No.1 AND No.2 INSTRUMENT PANEL BRACKETS Remove the 4 bolts and the No.1 and No.2 panel brackets. 21. REMOVE NO.2 SIDE DEFROSTER NOZZLE N20991 22. (a) (b) (c) REMOVE INSTRUMENT PANEL ASSEMBLY Disconnect the connectors from the LH and RH connector holders. Remove the bolts holding the ground wire to the body. Remove the connector holder from the body. N20992 (d) (e) Disconnect the connectors. Remove the bolt holding the ground wire to the No.2 instrument panel brace. N20993 Author: Date: 2425 BO–78 BODY – INSTRUMENT PANEL (f) Remove the bolt, nut, screw and the instrument panel assembly. 23. (a) (b) REMOVE INSTRUMENT PANEL BRACES Remove the wire brackets and connector. Remove the bolt and connector from the No.1 instrument panel brace. w/ Wireless Control: Remove the nut and the wireless control unit from the No.1 instrument panel brace. Remove the nut holding the radio antenna to the No.2 instrument panel brace. Remove a nut and brace mount bracket. Remove the 6 nuts, 2 bolts and No.1 and No.2 instrument panel braces. N20994 (c) (d) N20995 (e) (f) 24. (a) (b) (c) (d) (e) N20996 (f) REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the connectors from the steering column tube. Remove the 4 wire brackets and connectors. Remove the 2 nuts and bolt holding the No.1 Junction Box (J/B) to the reinforcement. Remove the 4 nuts and the steering column from the reinforcement. Remove the brake pedal spring from the reinforcement and brake pedal. Remove the 4 nuts, 3 bolts and the reinforcement. N20997 Author: Date: 2426 BO–79 BODY – INSTRUMENT PANEL BO0MD–01 DISASSEMBLY 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) REMOVE THESE PARTS: No.1 defroster nozzle garnish No.1 defroster nozzle RH side defroster duct nozzle No.1 side defroster duct nozzle No.1 heater duct to register No.2 heater duct to register No.2 register assembly No.3 register assembly No.1 register assembly 2. REMOVE INSTRUMENT PANEL WIRE HARNESS Remove the 2 brackets, 8 clips and wire harness. 3. REMOVE INSTRUMENT PANEL CENTER BRACKET 4. REMOVE THESE PARTS: (a) Clock unit (b) Glove box light assembly N21124 Author: Date: 2427 BO–80 BODY – INSTRUMENT PANEL BO0ME–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–79). Author: Date: 2428 BO–81 BODY – INSTRUMENT PANEL BO0MF–01 INSTALLATION Reassembly is in the reverse order of removal (See page BO–75). Author: Date: 2429 BO–82 BODY – ROOF HEADLINING ROOF HEADLINING BO0MG–01 COMPONENTS Assist Grip Roof Headlining Sun Visor Map Light Assembly Assist Grip Holder Cover Room Light Holder Sun Visor Center Pillar Garnish Front Pillar Garnish Roof Side Inner Garnish Rear Side Seat Back RH 42 (420, 31) Lower Center Pillar Garnish Front Door Scuff Plate Rear Seat Side Garnish Rear Seatback Rear Side Seat Back LH 18 (185, 13) 42 (420, 31) 18 (185, 13) Rear Seat Cushion Center Pillar Garnish 42 (420, 31) 18 (185, 13) 42 (420, 31) Roof Seat Side Garnish Front Pillar Garnish Rear Seat Side Garnish 42 (420, 31) Lower Center Pillar Garnish N·m (kgf·cm, ft·lbf) : Specified torque Front Door Scuff Plate N22600 Author: Date: 2430 BO–83 BODY – ROOF HEADLINING BO0MH–01 REMOVAL : 4 Clips 1. (a) (b) (c) (d) (e) (f) (g) (h) (i) 2. REMOVE THESE PARTS: Rear seat cushion Rear seatback and rear side seatbacks Front door scuff plates Front seat belt shoulder anchor bolts Sun visor and holders Assist grips Front pillar garnishes Rear door scuff plates Lower center pillar garnishes REMOVE ROOF SIDE INNER GARNISH (See page BO–28) 3. (a) (b) REMOVE FRONT PILLAR GARNISH Pry out clips by your hand. Pull the garnish upward to remove it. 4. (a) (b) REMOVE CENTER PILLAR GARNISH Remove the clip. Pry off the garnish. N21457 : Clip : 2 Clips N21458 5. REMOVE ROOM LIGHT (a) Using a screwdriver, remove the room light cover. HINT: Tape the screwdriver tip before use. (b) Remove the 4 screws, then disconnect the connector. 6. REMOVE MAP LIGHT ASSEMBLY N21415 Author: Date: 2431 BO–84 BODY 7. (a) (b) (c) 2 Clips – ROOF HEADLINING REMOVE ROOF HEADLINING Remove the 2 clips from the roof panel rear end. Remove the headlining. Bring out the headlining. N22971 Author: Date: 2432 BO–85 BODY – ROOF HEADLINING BO0MI–01 INSTALLATION Installation is in the reverse order of removal (See page BO–83). Author: Date: 2433 BO–85 BODY – ROOF HEADLINING BO0MI–01 INSTALLATION Installation is in the reverse order of removal (See page BO–83). Author: Date: 2433 BO–86 BODY – FRONT SEAT (Power Seat for TMC Made) FRONT SEAT (Power Seat for TMC Made) BO0MJ–01 COMPONENTS Headrest Seatback Frame Headrest Support
Hog Ring Hinge Cover 18 (185, 13) Seatback Cover 6.0 (61, 53 in.·lbf) w/ Side Airbag Assembly Side Airbag Assembly Seatback Pad 15 (150, 11) Seat Cushion Cover Seat Cushion Pad Lumber Support Adjuster Seat Cushion Frame 37 (375, 27)
Hog Ring Power Seat Adjuster 37 (375, 27) Seat Track Cover Front Vertical Motor Power Seat Switch Seat Cushion Shield Switch Knob Rear Vertical Motor Reclining Motor Lower Seat Cushion Shield N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part H01977 Author: Date: 2434 BO–87 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MK–01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. (c) Disconnect the connector. (d) Remove the front seat. NOTICE: Be careful not to damage the body. Author: Date: 2435 BO–88 BODY – FRONT SEAT (Power Seat for TMC Made) BO0ML–01 DISASSEMBLY 1. (a) (b) (c) (d) (e) 2. (a) (b) REMOVE THESE PARTS: Headrest Switch knobs Seat cushion shield Lower seat cushion shield Power seat switch REMOVE SEATBACK ASSEMBLY Remove the 3 clips of the side airbag wire harness from the seat cushion frame. Remove the 4 bolts and seatback assembly. 3. (a) (b) (c) (d) H01870 REMOVE SEATBACK COVER Remove the hog rings and hooks. Remove the hook as shown in the illustration. Remove the headrest supports. Remove the hog rings and seatback frame from seatback cover with pad. (e) Remove the hog rings and seatback cover from seatback pad. 4. REMOVE SIDE AIRBAG ASSEMBLY Remove the 1 clip of side airbag wire harness, 2 nuts and side airbag assembly from the seatback frame. CAUTION:
Do not store the side airbag assembly with the airbag deployment direction facing down.
Never disassemble the side airbag assembly. 5. REMOVE LUMBER SUPPORT ADJUSTER Remove the 2 screws and lumber support adjuster. 6. REMOVE SEAT CUSHION ASSEMBLY Remove the 4 bolts and seat cushion assembly. 7. REMOVE SEAT CUSHION COVER (a) Remove the 2 clips, hook and seat cushion frame from seat cushion cover with pad. (b) Remove the hog rings and seat cushion cover from the seat cushion pad. Author: Date: 2436 BO–89 BODY – FRONT SEAT (Power Seat for TMC Made) 8. REMOVE REAR VERTICAL MOTOR Remove the 2 screws and front vertical motor. H01978 9. (a) (b) REMOVE SLIDE MOTOR Remove the 2 screws. Disconnect the No.1 drive cable, then remove the slide motor. 10. (a) (b) REMOVE RECLINING MOTOR Remove the 2 screws. Disconnect the No.2 drive cable, then remove the reclining motor. H01979 H01980 Author: Date: 2437 BO–90 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MM–01 REASSEMBLY 1. INSTALL RECLINING MOTOR Connect the No.2 drive cable, then install the reclining motor with 2 screws. H01980 2. INSTALL SLIDE MOTOR Connect the No.1 drive cable, then install the slide motor with 2 screws. H01979 H01978 3. INSTALL REAR VERTICAL MOTOR Install the front vertical motor with 2 screws. 4. INSTALL LOWER SEAT CUSHION SHIELD 5. INSTALL SEAT CUSHION COVER (a) Install the seat cushion cover with new hog rings to seat cushion pad. (b) Install the seat cushion cover with pad to the seat cushion frame with hook and 2 clips. HINT: Install the hog rings to prevent wrinkles as least as possible. 6. INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly with 4 bolts. 7. INSTALL SIDE AIRBAG ASSEMBLY Install the side airbag assembly with 2 new nuts and 1 clip of side airbag wire harness to the seatback frame. Torque: 6.0 N·m (61 N·m, 53 in.·lbf) NOTICE:
Make sure that the side airbag assembly is installed to the specified torque.
If the side airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the side airbag assembly with a new one. 8. INSTALL SEATBACK COVER (a) Install the seatback cover with new hog rings to the seatback pad. (b) Install the seatback cover with pad to the seatback frame with new hog rings. (c) Install the headrest supports. Author: Date: 2438 BO–91 BODY H01870 – FRONT SEAT (Power Seat for TMC Made) (d) Hang the hook onto the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. 9. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly with 4 bolts. (b) Install the 2 clips of the side airbag wire harness to the seat cushion frame. (c) Install a new hog rings and 7 hooks. HINT: Install the hog rings to prevent wrinkles as least as possible. 10. INSTALL THESE PARTS: (a) Power seat switch (b) Lower Seat cushion shield (c) Seat cushion shield (d) Switch knobs (e) Headrest Author: Date: 2439 BO–92 BODY – FRONT SEAT (Power Seat for TMC Made) BO0MN–01 INSTALLATION Installation is in the reverse order of removal (See page BO–87). Author: Date: 2440 BO–93 BODY – FRONT SEAT (Power Seat for TMMK Made) FRONT SEAT (Power Seat for TMMK Made) BO0MU–01 COMPONENTS Front Seatback Cover Front Seatback Headrest Pad Front Seat Cushion Cover Headrest Support
Hog Ring Front Seatback Hinge Cover
Hog Ring Front Seat Cushion Inner No.1 Shield Seatback Frame Front SeatbackHingeCover Front Seat Adjuster Assembly Front Seat Cushion Pad w/ Lumber Support: Lumber Support Lever Front Seat Cushion Frame Front Power Seat Switch Front Seat Cushion Shield Front Seat Cushion Bracket Switch Knob Seat Cushion Lower Shield w/ Side Airbag Assembly: 6.0 (61, 53 in.·lbf) Side Airbag Assembly N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part H01873 Author: Date: 2441 BO–94 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MV–01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. (c) w/ Side Airbag Assembly: Disconnect the connector. (d) Disconnect the front power seat connector. (e) Remove the front seat. NOTICE: Be careful not to damage the body. Author: Date: 2442 BO–95 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MW–01 DISASSEMBLY 1. (a) (b) (c) (d) (e) (f) (g) 2. (a) (b) (c) (d) REMOVE THESE PARTS: Switch knob Front seat cushion shield Front power seat switch Seat cushion lower shield w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY w/ Side Airbag Assembly: Remove the side airbag wire harness after removing clips. Remove the hog rings. Remove the bolts and front seatback hinge cover. Remove the seatback assembly. 3. (a) H01870 REMOVE SEATBACK COVER w/ Side Airbag Assembly: Remove the hook from the seatback frame. (b) Remove the headrest supports. (c) Remove the seatback frame from the seatback cover with pad. (d) Remove the seatback cover from the seatback pad. 4. w/ Side Airbag Assembly: REMOVE SIDE AIRBAG ASSEMBLY Remove the 2 nuts and side airbag assembly from the seatback frame. CAUTION:
Do not store the side airbag assembly with the airbag deployment direction facing down.
Never disassemble the side airbag assembly. 5. REMOVE SEAT CUSHION ASSEMBLY Remove the 4 bolts and seat cushion assembly from the seat adjuster. 6. REMOVE SEAT CUSHION COVER (a) Remove the seat cushion frame. (b) Remove the seat cushion cover from the seat cushion pad. 7. REMOVE THESE PARTS: (a) Front seat cushion inner No.1 shield (b) Front seat cushion bracket (c) Front seat cushion inner shield Author: Date: 2443 BO–96 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MX–01 REASSEMBLY 1. (a) (b) (c) 2. (a) (b) INSTALL THESE PARTS: Front seat cushion inner shield Front seat cushion bracket Front seat cushion inner No.1 shield INSTALL SEAT CUSHION COVER Install the seat cushion cover to seat cushion pad. Install the seat cushion cover with pad to the seat cushion frame. 3. INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly with 4 bolts to the seat adjuster. HINT: Tighten the 4 bolts temporarily, then from the bolts on the rear side tighten completely. 4. w/ Side Airbag Assembly: INSTALL SIDE AIRBAG ASSEMBLY Install the side airbag assembly with 2 nuts to the seatback frame. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) NOTICE:
Make sure that the side airbag assembly is installed to the specified torque.
If the side airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the side airbag assembly with a new one.
When installing the side airbag assembly, take care is not pinched between other parts. 5. INSTALL SEATBACK COVER (a) Install the seatback cover to the seatback pad. (b) Install the seatback cover with pad to the seatback frame. (c) Install the headrest supports. (d) w/ Side Airbag Assembly: Hang the hook on to the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cove slides, it might cause incorrect deploying. H01870 Author: Date: 2444 BO–97 BODY – FRONT SEAT (Power Seat for TMMK Made) 6. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly with 4 bolts. HINT: Tighten the 4 bolts temporarily, then from the bolt on the front right side tighten completely. (b) Install Front Seatback hinge cover with bolts. (c) Install a new hog rings. HINT: Install the hog rings to prevent wrinkles as least as possible. (d) 7. (a) (b) (c) (d) (e) (f) (g) w/ Side Airbag Assembly: Securely fix the side airbag wire harness to seat cushion by clips. INSTALL THESE PARTS: Front seat inner belt Headrest w/ Lumber Support: Lumber support lever Seat cushion lower shield Front power seat switch Front seat cushion shield Switch knob H01871 Author: Date: 2445 BO–98 BODY – FRONT SEAT (Power Seat for TMMK Made) BO0MY–01 INSTALLATION INSTALL FRONT SEAT (a) Mount the seat to the vehicle. (b) w/ Side Airbag: Connect the connector. (c) Connect the front power seat connector. (d) Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten completely. (e) Slide the seat to the most rear position to install the bolts on the front side. Author: Date: 2446 BO–99 BODY – FRONT SEAT (Manual Seat for TMC Made) FRONT SEAT (Manual Seat for TMC Made) BO0MZ–01 COMPONENTS Headrest Seatback Pad
Hog Ring Headrest Support Seatback Cover Seatback Frame w/ Side Airbag: Seat Cushion Cover 6.0 (61, 53 in.·lbf) Side Airbag Assembly 18 (185, 13) Seat Cushion Pad Seat Cushion Inner Shield
Hog Ring Seat Cushion Frame w/ Lumber Support: Lumper Support Lever Front Seat Inner Upper Track Seat Track Adjusting Handle 18 (185, 13) 18 (185, 13) 37 (375, 27) 18 (185, 13) Seat Track Cover w/o Vertical: Front Seat Inner Upper Track Front Seat Inner Track 18 (185, 13) Release Handle 37 (375, 27) 37 (375, 27) Front Seat Inner Track 37 (375, 27) 37 (375, 27) Front Seat Cushion Shield Vertical Adjuster Knob Front Seat Cushion Lower Shield Release Handle Front Seat Outer Adjuster Front Seat Cushion Shield Front Seat Cushion Lower Shield N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part H01869 Author: Date: 2447 BO–100 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N0–01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track outer cover. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. (c) w/ Side Airbag Assembly: Disconnect the connector. (d) Remove the front seat. NOTICE: Be careful not to damage the body. Author: Date: 2448 BO–101 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N1–01 DISASSEMBLY 1. (a) (b) (c) (d) (e) (f) (g) (h) 2. (a) (b) REMOVE THESE PARTS: Release handle Front seat cushion shield Vertical Seat Adjuster: Vertical adjuster knob Front seat cushion lower shield Seat cushion inner shield w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY w/ Side Airbag Assembly: Remove the side airbag wire harness after removing clips. Remove the bolts and seatback assembly. 3. (a) (b) H01870 REMOVE SEATBACK COVER Remove the hog rings. w/ Side Airbag Assembly: Remove the hook from the seatback frame. (c) Remove the headrest supports. (d) Remove the seatback frame from the seatback cover with pad. (e) Remove the seatback cover from the seatback pad. 4. w/ Side Airbag Assembly: REMOVE SIDE AIRBAG ASSEMBLY Remove the 1 clip of side airbag wire harness, 2 nuts and side airbag assembly from the seatback frame. CAUTION:
Do not store the side airbag assembly with the airbag deployment direction facing down.
Never disassemble the side airbag assembly. 5. REMOVE SEAT CUSHION ASSEMBLY Remove the 4 bolts and seat cushion assembly from the seat adjuster. 6. REMOVE SEAT CUSHION COVER (a) Remove the seat cushion frame. (b) Remove the seat cushion cover from the seat cushion pad. 7. REMOVE SEAT TRACK ADJUSTING HANDLE Remove the seat track handle. 8. REMOVE FRONT SEAT OUTER ADJUSTER Remove the E ring and front seat outer adjuster from the front seat inner truck with upper track. Author: Date: 2449 BO–102 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N2–01 INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF (a) When reclining the seat, inspect that the outer and inner tracks are released at the same time. HINT: When the reclining lock positions slip off, disassemble the seat to adjust the position. (b) When sliding the seat, inspect that the outer and inner tracks are locked at the same time. HINT: When sliding lock positions slip off, loosen the bolts to adjust the position. Author: Date: 2450 BO–103 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N3–01 REASSEMBLY 1. Vertical Seat Adjuster: INSTALL FRONT SEAT OUTER ADJUSTER Install front seat outer adjuster to front seat inner adjuster with E ring, nuts and bolts. 2. w/o Vertical Seat Adjuster: INSTALL FRONT SEAT OUTER AND INNER ADJUSTER Install the adjusters to the seat cushion frame. 3. INSTALL SEAT TRACK ADJUSTING HANDLE Install the seat track adjusting handle. 4. Vertical Seat Adjuster: INSTALL SEAT CUSHION COVER (a) Install the seat cushion cover to seat cushion pad. (b) Install the seat cushion cover with pad to the seat cushion frame. 5. INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly with 4 bolts to the seat adjuster. HINT: Tighten the 4 bolts temporarily, then from the bolts on the rear side tighten completely. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) 6. w/ Side Airbag Assembly: INSTALL SIDE AIRBAG ASSEMBLY Install the side airbag assembly with new 2 nuts to the seatback frame. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) NOTICE:
Make sure that the side airbag assembly is installed to the specified torque.
If the side airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the side airbag assembly with a new one.
When installing the side airbag assembly, take care is not pinched between other parts. 7. INSTALL SEATBACK COVER (a) Install the seatback cover to the seatback pad. (b) Install the seatback cover with pad to the seatback frame. (c) Install the headrest supports. Author: Date: 2451 BO–104 BODY – FRONT SEAT (Manual Seat for TMC Made) (d) H01870 w/ Side Airbag Assembly: Hang the hook on to the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. 8. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly with bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (b) Install new hog rings. HINT: Install the hog rings to prevent wrinkles as least as possible. (c) w/ Side Airbag Assembly: Securely fix the side airbag wire harness to seat cushion and seatback by clips. 9. INSTALL THESE PARTS: (a) Front seat inner belt (b) Headrest (c) Lumber support lever (d) Seat cushion inner shield (e) Front seat cushion shield (f) Vertical Seat Adjuster: Vertical adjuster knob (g) Front seat cushion lower shield (h) Release handle Author: Date: 2452 BO–105 BODY – FRONT SEAT (Manual Seat for TMC Made) BO0N4–01 INSTALLATION INSTALL FRONT SEAT (a) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (b) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front positions slip off. (c) Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten completely. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) (d) Slide the seat to the most rear position to install the bolts on the front side. Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) Author: Date: 2453 BO–106 BODY – FRONT SEAT (Manual Seat for TMMK Made) FRONT SEAT (Manual Seat for TMMK Made) BO0MO–01 COMPONENTS Front Seatback Pad
Hog Ring Headrest Front Seatback Cover Front Seat Cushion Cover Headrest Support
Hog Ring Front Seatback Frame Front Seatback Hinge Cover w/ Lumber Support: Lumber Support Lever Front Seat Cushion Pad Inner Adjuster Sub–Assembly Track Cover Front Seat Cushion Shield Front Seat Cushion Frame Release Handle Seat Track Adjusting Handle w/o Vertical: Outer Adjuster Sub–Assembly Inner Adjuster Sub–Assembly Vertical Adjuster Knob Front Seat Cushion Lower Shield w/ Side Airbag Assembly: Side Airbag Assembly Outer Adjuster Sub–Assembly Front Seat Cushion Shield Front Seat Cushion Lower Shield Release Handle 6.0 (61, 53 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part H01872 Author: Date: 2454 BO–107 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MP–01 REMOVAL REMOVE FRONT SEAT (a) Using a screwdriver, remove the seat track covers. HINT: Tape the screwdriver tip before use. (b) Remove the 4 bolts. (c) w/ Side Airbag Assembly: Disconnect the connector. (d) Remove the front seat. NOTICE: Be careful not to damage the body. Author: Date: 2455 BO–108 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MQ–01 DISASSEMBLY 1. (a) (b) (c) (d) (e) (f) (g) (h) 2. (a) (b) (c) REMOVE THESE PARTS: Release handle Front seat cushion shield Vertical Seat Adjuster: Vertical adjuster knob Front seat cushion lower shield Front seatback hinge cover. w/ Lumber Support: Lumber support lever Headrest Front seat inner belt REMOVE SEATBACK ASSEMBLY w/ Side Airbag Assembly: Remove the side airbag wire harness after removing clips. Remove the hog rings. Remove the bolts and seatback assembly. 3. (a) H01870 REMOVE SEATBACK COVER w/ Side Airbag Assembly: Remove the hook from the seatback frame. (b) Remove the headrest supports. (c) Remove the seatback frame from the seatback cover with pad. (d) Remove the seatback cover from the seatback pad. 4. w/ Side Airbag Assembly: REMOVE SIDE AIRBAG ASSEMBLY Remove the 2 nuts and side airbag assembly from the seatback frame. CAUTION:
Do not store the side airbag assembly with the airbag deployment direction facing down.
Never disassemble the side airbag assembly. 5. REMOVE SEAT CUSHION ASSEMBLY Remove the 4 bolts and seat cushion assembly from the seat adjuster. 6. REMOVE SEAT CUSHION COVER (a) Remove the seat cushion frame. (b) Remove the seat cushion cover from the seat cushion pad. 7. REMOVE RECLINING CONNECTING PIPE Remove the reclining connecting pipe. 8. REMOVE SEAT TRACK ADJUSTING HANDLE Remove the seat track adjusting handle. 9. REMOVE OUTER ADJUSTER SUB–ASSEMBLY Remove the outer adjuster sub–assembly from the inner adjuster sub–assembly. Author: Date: 2456 BO–109 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MR–01 INSPECTION INSPECT RECLINING LOCK POSITION AND SLIDING LOCK POSITION SLIPPING OFF (a) When reclining the seat, inspect that the outer and inner tracks are released at the same time. HINT: When the reclining lock positions slip off, disassemble the seat to adjust the position. (b) When sliding the seat, inspect that the outer and inner tracks are locked at the same time. HINT: When sliding lock positions slip off, loosen the bolts to adjust the position. Author: Date: 2457 BO–110 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MS–01 REASSEMBLY 1. INSTALL OUTER ADJUSTER SUB–ASSEMBLY Install the outer adjuster sub–assembly to the inner adjuster sub–assembly. 2. INSTALL SEAT ADJUSTING HANDLE Install the seat track adjusting handle. 3. INSTALL RECLINING CONNECTING PIPE (a) Adjust the reclining lock positions of the seat adjusters. (b) Slide the seat adjusters to the most front position. (c) Place the adjusters on a spacer to adjust the seat rails in parallel and install the connecting pipe. HINT: When installing the connecting pipe with raising up the adjusters, the lock positions adjusted in 3–(a) step slip off, lock error will occur. 4. INSTALL SEAT CUSHION COVER (a) Install the seat cushion cover to seat cushion pad. (b) Install the seat cushion cover with pad to the seat cushion frame. 5. INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly with 4 bolts to the seat adjuster. HINT: Tighten the 4 bolts temporarily, then from the bolts on the rear side tighten completely. 6. w/ Side Airbag Assembly: INSTALL SIDE AIRBAG ASSEMBLY Install the side airbag assembly with 2 nuts to the seatback frame. Torque: 6.0 N·m (61 kgf·cm, 53 in.·lbf) NOTICE:
Make sure that the side airbag assembly is installed to the specified torque.
If the side airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the side airbag assembly with a new one.
When installing the side airbag assembly, take care is not pinched between other parts. 7. INSTALL SEATBACK COVER (a) Install the seatback cover to the seatback pad. (b) Install the seatback cover with pad to the seatback frame. (c) Install the headrest supports. Author: Date: 2458 BO–111 BODY – FRONT SEAT (Manual Seat for TMMK Made) (d) H01870 w/ Side Airbag Assembly: Hang the hook on to the seatback frame. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. 8. INSTALL SEATBACK ASSEMBLY (a) Install the seatback assembly with 4 bolts. HINT: Tighten the 4 bolts temporarily, then from the bolt on the front right side tighten completely. (b) Install a new hog rings. HINT: Install the hog rings to prevent wrinkles as least as possible. (c) 9. (a) (b) (c) (d) (e) (f) (g) (h) w/ Side Airbag Assembly: Securely fix the side airbag wire harness to seat cushion by clips. INSTALL THESE PARTS: Front seat inner belt Headrest w/ Lumber Support: Lumber support lever Front seatback hinge cover Front seat cushion lower shield Vertical Seat Adjuster: Vertical adjuster knob Front seat cushion shield Release handle H01871 Author: Date: 2459 BO–112 BODY – FRONT SEAT (Manual Seat for TMMK Made) BO0MT–01 INSTALLATION INSTALL FRONT SEAT (a) Slide the front seat to the most front position. NOTICE: Make sure that seat adjuster locks. (b) Without holding the seat track handle, mount the seat to the vehicle. HINT: If holding the seat track handle, the adjusted most front positions slip off. (c) Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten completely. (d) Slide the seat to the most rear position to install the bolts on the front side. Author: Date: 2460 BO–113 BODY – REAR SEAT (TMC Made) REAR SEAT (TMC Made) BO0NA–01 COMPONENTS Headrest Seatback Locking Knob Headrest Support Seatback Lock Knob Gromet Seatback Frame Rear Seatback Lock Control Seatback Pad Seatback Lock control Cable Rear Seatback lock 17.5 (178, 12.5) Control Bezel Seatback Cover Seat Belt Guide RH Rear Side Seatback RH Seatback Hinge 18 (185, 13) 18 (185, 13) Center Seatback Hinge Rear Seat center Armrest 18 (185, 13) 18 (185, 13) Center Armrest Hinge Cover LH Rear Side Seatback LH Seatback Hinge Seat Cushion Cover Seat Cushion Pad N·m (kgf·cm, ft·lbf) : Specified torque H01874 Author: Date: 2461 BO–114 BODY – REAR SEAT (TMC Made) BO0NB–01 REMOVAL 1. REMOVE LH SEATBACK ASSEMBLY (a) Release lock to lean the seat back to front. (b) Remove the clips. (c) Remove the 2 bolts and LH seatback assembly. 2. REMOVE RH SEAT BACK ASSEMBLY (a) Release lock to lean the seatback to front. (b) Remove the clips. (c) Remove the 2 bolts and RH seatback assembly. 3. REMOVE SEAT CUSHION ASSEMBLY (a) Remove the seat cushion assembly. HINT: Remove the rear seat inner with center belt from seat cushion slit to remove the seat cushion. (b) Remove the 2 lock hooks. 4. REMOVE LH AND RH REAR SIDE SEATBACK (a) Remove the bolt and LH rear side seatback. (b) Remove the bolt and RH rear side seatback. 5. REMOVE SEATBACK HINGE (a) Remove the bolts and LH seatback hinge and RH seatback hinge. (b) Remove the 2 bolts and center seatback hinge. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Author: Date: 2462 BO–115 BODY – REAR SEAT (TMC Made) BO0NC–01 DISASSEMBLY 1. REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. 2. REMOVE THESE PARTS: HINT: Remove the clips to turn over the seatback cover before performing the following steps. (a) Headrest (b) Rear seatback lock control Bezel. (c) Rear seatback Board (d) Headrest supports (e) Seatback locking knob (f) Seatback lock knob Gromet (g) Rear seat center armrest 3. REMOVE SEATBACK COVER (a) Remove the hog rings and seatback frame from the seatback cover with pad. (b) Remove the hog rings and seatback cover from the seatback pad. 4. REMOVE SEATBACK LOCK (a) Remove the rear seatback lock control cable. (b) Remove the 2 bolts and rear seatback lock control. Torque: 17.5 N·m (178 kgf·cm, 12.5 ft·lbf) Author: Date: 2463 BO–116 BODY – REAR SEAT (TMC Made) BO0ND–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–115). Author: Date: 2464 BO–117 BODY – REAR SEAT (TMC Made) BO0NE–01 INSTALLATION Installation is in the reverse order of removal (See page BO–114). Author: Date: 2465 BO–118 BODY – REAR SEAT (TMMK Made) REAR SEAT (TMMK Made) BO0N5–01 COMPONENTS Seatback Lock Knob Headrest Rear seatback Board Seatback Lock Knob Cover Rear Seatback Lock Control Headrest Support Rear Seatback frame Rear Seatback Pad 17.5 (178, 12.5) Rear Seatback Cover Rear Seatback Lock Control Cable RH Rear Side Seatback RH Seatback Hinge 18 (185, 13) 18 (185, 13) Center Seatback Hinge Rear Seat center Armrest Center Armrest Hinge Cover w/ CRS: Rear Seatback Control Bezel 18 (185, 13) 18 (185, 13) Headrest LH Side Seatback Headrest Suppot Seatback Pad Seatback Cover LH Seatback Hinge Seat Cushion Cover 7.8 (79, 69 in.·lbf) 42 (428, 31) Child Restraint Seat Cover 18 (185, 13) 13 (130, 9) Child Restraint Seat Seat Cushion Pad Center Seatback Hinge N·m (kgf·cm, ft·lbf) : Specified torque H01875 Author: Date: 2466 BO–119 BODY – REAR SEAT (TMMK Made) BO0N6–01 REMOVAL 1. REMOVE SEAT CUSHION ASSEMBLY (a) Remove the seat cushion assembly. HINT: Remove the rear seat inner with center belt from seat cushion slit to remove the seat cushion. (b) Remove the 2 lock hooks. 2. REMOVE LH SEATBACK ASSEMBLY (a) Release lock to lean the seatback to front. (b) Remove the 2 bolts and LH seatback assembly. 3. w/ CRS: REMOVE CHILD RESTRAINT SEAT (a) Remove child restraint seat cover. (b) Remove the 3 bolts and 2 nuts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) (c) Remove the child restraint seat. 4. w/o CRS: REMOVE RH SEATBACK ASSEMBLY (a) Release lock to lean the seatback to front. (b) Remove the clips. (c) Remove the bolts and RH seatback assembly. 5. w/ CRS: REMOVE RH SEATBACK ASSEMBLY (a) Remove the 3 bolts. Torque: RH bolt: 7.8 N·m (80 kgf·cm, 69 in.·lbf) Center bolt: 42 N·m (428 kgf·cm, 31 ft·lbf) (b) Remove the RH seatback assembly. 6. REMOVE LH AND RH REAR SIDE SEATBACK (a) Remove the bolt and LH rear side seatback. (b) Remove the bolt and RH rear side seatback. 7. REMOVE SEATBACK HINGE (a) Remove the bolt and LH seatback hinge. (b) Remove the 2 bolts and center seatback hinge. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) (c) w/o CRS: Remove the bolt and RH seatback hinge. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Author: Date: 2467 BO–120 BODY – REAR SEAT (TMMK Made) BO0N7–01 DISASSEMBLY 1. REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. 2. REMOVE THESE PARTS: HINT: Remove the clips to turn over the seatback cover before performing the following steps. (a) Headrest (b) Rear seatback control Bezel (c) Headrest supports (d) Seatback lock knob (e) Seatback lock knob cover (f) Rear seat center armrest 3. REMOVE SEATBACK COVER (a) Remove the hog rings and seatback frame from the seatback cover with pad. (b) Remove the hog rings and seatback cover from the satback pad. 4. REMOVE SEATBACK LOCK (a) Remove the rear seatback lock control cable. (b) Remove the 2 bolts and rear seatback lock control. Torque: 17.5 N·m (178 kgf·cm, 12.5 ft·lbf) Author: Date: 2468 BO–121 BODY – REAR SEAT (TMMK Made) BO0N8–01 REASSEMBLY Reassembly is in the reverse order of disasssembly (See page BO–120). Author: Date: 2469 BO–122 BODY – REAR SEAT (TMMK Made) BO0N9–01 INSTALLATION Installation is in the reverse order of removal (See page BO–119). Author: Date: 2470 BO–123 BODY – SEAT BELT SEAT BELT BO0NF–01 COMPONENTS Rear Seat Outer Belt 42 (420, 31) Center Belt 42 (420, 31) 42 (420, 31) Rear Seat Front Seat Outer Belt 42 (420, 31) Front Seat Front Seat Inner Belt 42 (420, 31) 42 (420, 31) Rear Seat Inner Belt 7.8 (79, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque H01877 Author: Date: 2471 BO–124 BODY – SEAT BELT BO0NG–01 INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts or sill–bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. All Seat Belt: RUNNING TEST (IN SAFE AREA) (a) Fasten the front seat belts. (b) BO0632 HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver’s Seat Belt (ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) 15° 45° If a 3. BO0633 Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. (a) (b) (c) (d) If a Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. problem is found, replace the assembly. Front RH Seat Belt and Rear Seat Belt (ALR/ELR): STATIC TEST Make sure that the belt locks when pulled out quickly. Remove the locking retractor assembly. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again Make sure that the belt cannot be extended further. problem is found, replace the assembly. Author: Date: 2472 BO–125 BODY (e) (f) – SEAT BELT Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. Tilt the retractor slowly. Full Belt Length Minus 200 mm (7.87 in.) N10070 (g) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 15° 45° BO0633 Author: Date: 2473 BO–126 BODY – SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER BO0NH–01 REMOVAL NOTICE:
If the wiring connector of the supplemental restraint system is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded.
Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. 1. REMOVE THESE PARTS: (a) Front door scuff plate (b) Center pillar lower garnish 2. REMOVE FRONT SEAT OUTER BELT CAUTION: Never disassemble the front seat outer belt. NOTICE: When removing the front outer seat belt, take care not to pull the seat belt pretensioner wire harness. (a) Remove the bolts and floor anchor. (b) Using a screwdriver, remove the anchor caps. HINT: Tape the screwdriver tip before use. (c) Remove the bolt and shoulder anchor. (d) (e) Disconnect the pretensioner connector as shown in the illustration. Remove the 2 bolts and front seat outer belt. H01346 Author: Date: 2474 BO–127 BODY – SEAT BELT PRETENSIONER BO0NI–01 INSPECTION 1. (a) PRETENSIONER IS NOT ACTIVATED Perform a diagnostic system check. (See page DI–626) H00563 (b) H01878 Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle.
Check for cuts and cracks in, or marked discoloration of the center pillar lower garnish.
Check for cuts and cracks in wire harnesses, and for chipping in connectors.
Check for deformation of the center pillar. CAUTION: For removal and installation of the front seat outer belt, see page BO–123. Be sure to follow the correct procedure. 2. PRETENSIONER IS ACTIVATED (a) Perform a diagnostic system check. (See page DI–626) (b) Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle.
Check for deformation of the center pillar.
Check for damage on the connector and wire harness. Author: Date: 2475 BO–128 BODY – SEAT BELT PRETENSIONER BO0NJ–01 DISPOSAL HINT: When scrapping vehicles equipped with a supplemental restraint system or disposing of a front seat outer belt (with seat belt pretensioner) always first activate the seat belt pretensioner in accordance with the procedure described below. If any abnormality occurs with the seat belt pretensioner operation, contact the SERVICE DEPT. of the DISTRIBUTOR. when disposing of a front seat outer belt (with seat belt pretensioner) deployed in a collision, follow the same procedure given in step 1–(d) in ”DISPOSAL”. SST AB0152 CAUTION:
Never dispose of front seat outer belt which has an undeployed pretensioner.
The seat belt pretensioner produces a sizeable exploding sound when it deploys, so perform the operation out–of–door and where it will not create a nuisance to nearby residents.
When deploying the seat belt pretensioner, always use the specified SST. (SRS Airbag Deployment Tool) Perform the operation in a place away from electrical noise. SST 09082–00700, 09082–00740
When deploying a front seat outer belt (with seat belt pretensioner), perform the operation from at least 10 m (33 ft) away from the front seat outer belt.
Use gloves and safety glasses when handling a front seat outer belt with operated pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with operated pretensioner. Author: Date: 2476 BO–129 BODY 1. Battery – SEAT BELT PRETENSIONER SEAT BELT PRETENSIONER DEPLOYMENT WHEN SCRAPPING VEHICLE HINT: Have a battery ready as the power source to deploy the airbag. SST AB0158 (a) Check functioning of SST CAUTION: When deploying the seat belt pretensioner, always use the specified SST: SRS Airbag Deployment Tool. SST 09082–00700, 09082–00740 SST AB0152 (1) Battery Connect the SST to battery. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which will be connected with the seat belt pretensioner. SST AB0158 (2) SST H01580 Check functioning of SST Press the SST activation switch, and check the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. (b) Install the SST. (1) Remove the front door scuff plate. (2) Remove the center pillar lower garnish. (3) Disconnect the pretensioner connector as shown in the illustration. (4) Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. SST 09082–00700, 09082–00740 H01346 Author: Date: 2477 BO–130 BODY – SEAT BELT PRETENSIONER (5) SST Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082–00700, 09082–00740 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of secondary lock of the twin lock. SST H01880 (6) 10 m (33 ft) or more R13455 Move the SST to at least 10mm (33 ft) from the front of the vehicle. Close all the doors and windows of the vehicle. (7) NOTICE: Take care not to damage the SST wire harness. (8) Connect the SST red clip the battery positive (–) terminal and the black clip to the negative (+) terminal. (c) Deploy the airbag. (1) Confirm that no one is inside the vehicle or within 10 m (33 ft) area around of the vehicle. (2) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch light up. (d) Disposal of front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat outer belt with deployed seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with deployed seat belt pretensioner. When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with operated front seat outer belt still installed. Author: Date: 2478 BO–131 BODY – SEAT BELT PRETENSIONER 2. DEPLOYMENT WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTICE:
When disposing of the front seat outer belt (with seat belt pretensioner) only, never use the customer’s vehicle to deploy the seat belt pretensioner.
Be sure to following the procedure given below when deploying the seat belt pretensioner. HINT: Have a battery ready as the power source when deploying the seat belt pretensioner. (a) Remove the front seat outer belt (See page BO–123) HINT: Cut the belt near the seat belt retractor. (b) Check functioning of SST. (See step 1–(a)) SST 09082–00700, 09082–00740 Battery SST AB0158 (c) SST Install the SST. (1) Connect the 2 SST, then connect them to the seat belt pretensioner. SST 09082–00700, 09082–00740 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. SST H01880 (2) SST Locate the front seat outer belt on the ground and cover it by the disc wheel with tire. NOTICE: Place the front seat outer belt shown in the illustration. (3) Move the SST to as least 10 m (33 ft) from the disc wheel. NOTICE: Take care not to damage the SST wire harness. SST H01881 Author: Date: 2479 BO–132 BODY (d) – SEAT BELT PRETENSIONER Deploy the seat belt pretensioner. (1) Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (–) terminal. (2) Check that no one is within 10 m (33 ft) area around of the disc wheel. (3) Press the SST activation switch and activate the seat belt pretensioner. HINT: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up. 10 m (33 ft) or more R05181 (e) H01882 Disposal of front seat outer belt (with seat belt pretensioner). CAUTION:
The front seat outer belt is very hot when the seat belt pretensioner is deployed, so leave it alone for at least 30 minutes after deployment.
Use gloves and safety glasses when handling a front seat outer belt with deployed seat belt pretensioner.
Always wash your hands with water after completing the operation.
Do not apply water, etc. to a front seat outer belt with deployed seat belt pretensioner. (1) Remove the disc wheel and SST. (2) Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of in it the same way as other general parts. Author: Date: 2480 BO–133 BODY – SEAT BELT PRETENSIONER BO0NK–01 REPLACEMENT REPLACE REQUIREMENTS In the following cases, replace the seat belt pretensioner.
If the seat belt pretensioner has been activated.
If the seat belt pretensioner has been found to be faulty in troubleshooting.
If the front seat outer belt has been found to be faulty during the check in items 1–(b) or 2–(b).
If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner, see page BO–126 and BO–134. Be sure to follow the correct procedure. Author: Date: 2481 BO–134 BODY – SEAT BELT PRETENSIONER BO0NL–01 INSTALLATION NOTICE: Never use seat belt pretensioner from another vehicle. When replace parts, replace them with new parts. 1. INSTALL FRONT SEAT OUTER BELT (a) Install the front seat belt parts by following the reverse order of removal and torque the following bolts. (1) Front seat outer belt retractor Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) (2) Seat belt shoulder anchor Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) (3) Seat belt floor anchor Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) NOTICE:
Make sure that the front seat outer belt is installed with the specified torque.
If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one.
When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts. (b) (c) 2. (a) (b) Connect the pretensioner connector as shown in the illustration. w/ Seat Belt Warning: Connect the retractor switch connector. INSTALL THESE PARTS: Center pillar lower garnish Front door scuff plate H01352 Author: Date: 2482 BE–1 BODY ELECTRICAL – TROUBLESHOOTING TROUBLESHOOTING BE16T–01 PROBLEM SYMPTOMS TABLE COMBINATION METER METER, GAUGES AND ILLUMINATION: Symptom Suspect Area See page Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–4 – Fuel Gauge does not operate or abnormal operation. 1. 2. 3. 4. 5. 6. 7. 8. Fuel Receiver Gauge Fuel Temperature Sensor (For Delivery Pipe) Fuel Temperature Sensor (For Fuel Tank) Fuel Pressure Sensor (For Delivery Pipe) Fuel Pressure Sensor (For Fuel Pipe) ECM Meter Circuit Plate Wire Harness BE–5 SF–36 SF–40 SF–42 SF–45 – BE–4 – Engine Coolant Temperature Gauge does not operate or abnormal operation 1. 2. 3. 4. Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness BE–5 BE–5 BE–4 – All illumination lights do not light up. 1. TAIL Fuse (I/P J/B No.1) 2. Light Control Rheostat 3. Wire Harness Only one illumination light does not light up. 1. Bulb 2. Wire Harness – BE–54* – – – COMBINATION METER WARNING LIGHTS: Symptom Suspect Area See page Warning lights do not light up. (Except Discharge, Open Door and SRS) 1. GAUGE Fuse (I/P J/B No.1) 2. Meter Circuit Plate 3. Wire Harness – BE–4 – Low Oil Pressure warning light does not light up. 1. 2. 3. 4. Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness – BE–5 BE–4 – Fuel Level warning light does not light up. 1. 2. 3. 4. 5. 6. 7. 8. Bulb Fuel Temperature Sensor (For Delivery Pipe) Fuel Temperature Sensor (For Fuel Tank) Fuel Pressure Sensor (For Delivery Pipe) Fuel Pressure Sensor (For Fuel Pipe) ECM Meter Circuit Plate Wire Harness – SF–36 SF–40 SF–42 SF–45 – BE–4 – *: See Pub. No. RM654U Author: Date: 533 BE–2 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE0AI–04 LOCATION Brake Fluid Level Warning Switch E/G Room J/B No.2
ECU–B Fuse
DOME Fuse Washer Fluid Level Warning Switch Combination Meter
Bulb Check Relay ECM ABS ECU Light Control Rheostat Instrument Panel J/B No.1
GAUGE Fuse
TAIL Fuse
IGN Fuse
Integration Relay I08447 Author: Date: 534 BE–3 BODY ELECTRICAL – COMBINATION METER Door Courtesy Switch PKB Switch Seat Belt Buckle Switch Door Courtesy Switch Light Failure Sensor Low Oil Pressure Warning Switch Engine Coolant Temperature Sender Gauge Park/Neutral Position Switch I08448 Author: Date: 535 BE–4 BODY ELECTRICAL – COMBINATION METER BE0AJ–04 CIRCUIT Connector ”A” 1 2 3 4 5 6 Connector ”B” 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 9 10 11 12 13 14 15 16 J–13–1–A C7 E T 1 2 3 4 5 6 7 8 9 10 11 1213 J–16–1 B3 C5 A2 A1 C8 F Connector ”C” Connector ”C” Connector ”B” J–13–1 Connector ”A” B15 C6 S B14 ODOMETER Fuel Level Warning Seat Belt Warning ABS Warning Low Oil Pressure Warning Cruise Control Indicator Malfunction Indicator O/D OFF Indicator Light Failure Warning Brake Warning SLIP Indicator TRAC Indicator Washer Level Warning Discharge Warning A13 B2 C1 B1 C9 A6 A11 A7 A10 A8 A9 Bulb Check Relay Right Turn Indicator Left Turn Indicator Security Indicator L 2 D N R P Illumination C13 B8 B11 B12 Hi–Beam Indicator Open Door Warning SRS Warning B6 A4 C4 B5 C10 C2 A12 A3 B7 C3 A5 C11 B4 No. A B16 B C12 B9 B10 B13 C F : Fuel Gauge E : Engine Coolant Temperature Sender Gauge T : Tachometer S : Speedometer N20107 N20108 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 Wire Harness Side Engine coolant temperature sender gauge Ground Light failure sensor Integration relay Traction ECU Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) Park/neutral position switch (A/T) O/D OFF switch (A/T) IGN fuse Turn signal switch ST relay ECM Generator Oil pressure switch ECM Parking brake switch and brake fluid level warning switch Headlight dimmer switch Headlight dimmer switch Door courtesy switch DOME fuse ECU–B fuse Airbag sensor assembly ECM No.1 Vehicle speed sensor Ground Turn signal switch ECM Traction ECU ABS ECU Ground No.1 Vehicle speed sensor GAUGE fuse Igniter Security ECU Cruise control ECU Washer fluid level warning switch Light control rheostat TAIL fuse Z18937 BE–5 BODY ELECTRICAL – COMBINATION METER BE16U–01 INSPECTION Ignition Switch Fuel Gauge 1. (a) (b) INSPECT FUEL RECEIVER GAUGE OPERATION Disconnect the connector from the ECM. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 on the wire harness side connector through a 3.4–W test bulb. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. ECM Battery I12031 Fuel Gauge (d) Ignition Switch Wire Harness Side Battery I12029 HINT: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. 2. INSPECT FUEL RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. A B C N20212 Ignition Switch Wire Harness Side Battery I12030 Resistance (Ω) A–B Approx. 270.1 A–C Approx. 141.3 B–C Approx. 128.8 If resistance value is not as specified, replace the receiver gauge. 3. INSPECT FUEL SENDER GAUGE RESISTANCE (See page SF–36) 4. (a) (b) (c) Warning Light Tester connection INSPECT FUEL LEVEL WARNING LIGHT Disconnect the connector from the sender gauge. Connect terminals 8 on the wire harness side connector. Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. 5. INSPECT FUEL LEVEL WARNING SWITCH (See page SF–40) BE–6 BODY ELECTRICAL 6. Engine coolant temperature gauge (a) (b) Ignition Switch Sender Gauge Battery – COMBINATION METER INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION Disconnect the connector from the sender gauge. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. N20215 (c) Ground terminal on the wire harness side connector through a 3.4–W test bulb. (d) Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. Engine coolant temperature gauge Ignition Switch Battery Test Bulb (3.4 W) Wire Harness Side Z15788 7. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. C B A N20216 Tester connection Resistance (Ω) * A–B Approx. 175.7 A–C Approx. 54.0 B–C Approx. 229.7 *: This circuit includes the diode. HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. If resistance value is not as specified, replace the receiver gauge. BE–7 BODY ELECTRICAL – COMBINATION METER 8. 35.63 ± 0.1 Ω 35.63 ± Slide rheostat 0.1 Ω INSPECT ENGINE COOLANT TEMPERATURE SENDER GAUGE RESISTANCE Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate ”0” using the slide rheostat, then read the rheostat indication. Temperature °C (°F) Resistance (Ω) 50 (122.0) 160 – 240 120 (248.0) 17.1 – 21.2 If resistance value is not as specified, replace the engine coolant temperature sender gauge. I07709 9. (a) INSPECT LOW OIL PRESSURE WARNING LIGHT Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. (b) Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Warning Light Ignition Switch Battery 1 Z14205 10. (a) (b) (c) N06640 INSPECT LOW OIL PRESSURE SWITCH Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2, 3.55 psi). If operation is not as specified, replace the switch. BO–1 BODY – CLIP CLIP BO2DL–01 REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/Installation Pliers Clip Remover Screwdriver Scraper V00005 Author: Date: 540 BO–2 BODY Shape (Example) – CLIP Removal/Installation Removal Removal Installation Installation V00012 Author: Date: 541 BO–3 BODY – SRS AIRBAG SRS AIRBAG BO2DM–01 PRECAUTION The CAMRY CNG is equipped with SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and seat belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section (See Pub. No. RM654U). Author: Date: 542 BO–4 BODY – REAR BUMPER REAR BUMPER BO2DN–01 COMPONENTS Luggage Compartment Trim Front Cover Inner Luggage Compartment Trim Cover Inner Luggage Compartment Trim Cover Spare Wheel Cover Rear Bumper Reinforcement Rear Bumper Energy Absorber 4.9 (50, 43 in.·lbf) 4.9 (50, 43 in.·lbf) 34 (350, 25) Rear Bumper Side Retainer 4.9 (50, 43 in.·lbf) Quarter Air Duct 4.9 (50, 43 in.·lbf) Rear Bumper Side Retainer Rear Bumper Cover 4.9 (50, 43 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified Torque H09249 Author: Date: 543 BO–5 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE LUGGAGE COMPARTMENT DOOR AND HINGE BO2DO–02 COMPONENTS Luggage Compartment Door Hinge Luggage Compartment Door 5.4 (55, 49 in.·lbf) Luggage Compartment Door Hinge 7.8 (80, 69 in.·lbf) 7.8 (80, 69 in.·lbf) Door Lock Cylinder Reat Combination Light Luggage Compartment Door Cover x11 Door Lock 22 (224, 16) Door Lock Striker 5.4 (55, 49 in.·lbf) 22 (224, 16) 22 (224, 16) Door Support Spare Wheel Cover Spare Wheel Carrier Spare Wheel Carrier Spacer Inner Luggage Compartment Trim Cover Luggage Compartment Trim Front Cover Spare Wheel Rear Floor Finish Side Plate Rear Floor Finish Plate High–mounted Stop Light Rear Floor Finish Side Plate Rear Seat Outer Belt Inner Lower Luggage Compartment Trim Cover 41 (420, 31) Rear Seat Outer Belt Rear Seatback 18 (185, 13) 41 (420, 31) Roof Side Inner Garnish Package Tray Trim Rear Seat Cushion Roof Side Inner Garnish N·m (kgf·cm, ft·lbf) : Specified Torque No. 1 Upper Back Panel Hole Cover Author: Date: H09250 544 BO–6 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO2DP–01 REMOVAL 1. REMOVE LUGGAGE COMPARTMENT DOOR COVER Remove the 11 clips and luggage compartment door cover. 2. REMOVE LUGGAGE COMPARTMENT DOOR (a) Disconnect the connectors. (b) Using a clip remover, disconnect the clamps. (c) Remove the 4 bolts and door. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) 3. REMOVE LUGGAGE COMPARTMENT TRIM FRONT COVER Using a clip remover, remove the 6 clips and luggage compartment trim front cover. 4. REMOVE SPARE WHEEL COVER H09251 5. H09252 REMOVE INNER LUGGAGE COMPARTMENT TRIM COVER (a) Using a clip remover, remove the 2 clips and inner luggage compartment trim cover. (b) Employ the same manner described above to the other side. 6. REMOVE REAR FLOOR FINISH SIDE PLATES Using a clip remover, remove the 6 clips and 2 rear floor finish side plates. 7. REMOVE INNER LOWER LUGGAGE COMPARTMENT TRIM COVER (a) Remove the spare wheel carrier, spare wheel carrier spacer and spare wheel. (b) Using a clip remover, remove the 3 clips and inner lower luggage compartment trim cover. HINT: Tape the screwdriver tip before use. BO–7 BODY 2 Clips H09253 3 Clips Clip – LUGGAGE COMPARTMENT DOOR AND HINGE 8. REMOVE REAR FLOOR FINISH PLATE (a) Using a clip remover, remove the 2 clips. HINT: Tape the screwdriver tip before use. (b) Insert a screwdriver between the rear floor finish plate and body to pry out the rear floor finish plate. HINT: Tape the screwdriver tip before use. 9. REMOVE REAR SEAT CUSHION AND SEATBACK (See page BO–22) 10. REMOVE ROOF SIDE INNER GARNISH (a) Using a clip remover, remove the clip. (b) Insert a screwdriver between the roof side inner garnish and body to pry it out. HINT: Tape the screwdriver tip before use. (c) Employ the same manner described above to the other side. H09254 2 1 1 H09255 1 2 H07599 11. REMOVE HIGH–MOUNTED STOP LIGHT Remove the high–mounted stop light as shown in the illustration, then disconnect the connector. 12. REMOVE PACKAGE TRAY TRIM (a) Remove the bolts and rear seat outer belt floor anchors. Torque: 41 N·m (420 kgf·cm, 31 ft·lbf) (b) Using a screwdriver, remove the seat belt bezels from the package tray trim. HINT: Tape the screwdriver tip before use. (c) Using a hexagon wrench, remove the 2 hexagon screws. (d) Remove the package tray trim, then disconnect the connectors. HINT: Remove the package tray trim through out the rear seat outer belt floor anchors from the hole in the package tray trim. 13. REMOVE NO. 1 UPPER BACK PANEL HOLE COVER Remove the 2 clips and No. 1 upper back panel hole cover. 14. REMOVE LUGGAGE COMPARTMENT DOOR SUPPORTS Remove the 4 bolts and luggage compartment door support. Torque: 22 N·m (224 kgf·cm, 16 ft·lbf) 15. REMOVE LUGGAGE COMPARTMENT DOOR HINGES Remove the pins and luggage compartment door hinges. BO–8 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO2DQ–01 DISASSEMBLY 1. (a) (b) REMOVE DOOR LOCK Disconnect the control link. Remove the 2 bolts and door lock. Torque: 5.4 N·m (55 kgf·cm, 49 in.·lbf) 2. REMOVE REAR COMBINATION LIGHTS (a) Disconnect the connectors. (b) Remove the 6 nuts and rear combination lights. 3. REMOVE DOOR LOCK CYLINDER Remove the 2 bolts and door lock cylinder. Torque: 5.4 N·m (55 kgf·cm, 49 in.·lbf) BO–9 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO2DR–01 ADJUSTMENT 1. (a) ADJUST LUGGAGE COMPARTMENT DOOR Remove the 11 clips and luggage compartment door cover. (b) Loosen the bolts to adjust the lggage compartment door in forward/rearward and left/right directions. Tighten the loosened bolts again. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) Increase or decrease the number of washers between the hinge and door panel to adjust vertical direction. (c) (d) H09256 2. (a) (b) (c) (d) (e) N21779 ADJUST DOOR LOCK STRIKER Remove the rear floor finish side plates. Remove the rear floor finish plate. Loosen the 2 lock striker set bolts. Using a hammer and brass bar, tap the striker to adjust it. Tighten the loosened bolts again. Torque: 5.4 N·m (55 kgf·cm, 49 in.·lbf) BO–10 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO2DS–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–8). BO–11 BODY – LUGGAGE COMPARTMENT DOOR AND HINGE BO2DT–01 INSTALLATION Installation is in the reverse order of removal (See page BO–6). BO–12 BODY – LUGGAGE COMPARTMENT DOOR SUPPORT LUGGAGE COMPARTMENT DOOR SUPPORT BO2DU–01 REPLACEMENT 1. H09251 REMOVE LUGGAGE COMPARTMENT TRIM FRONT COVER Using a clip remover, remove the 6 clips and luggage compartment trim front cover. HINT: Tape the screwdriver tip before use. 2. REMOVE LUGGAGE COMPARTMENT DOOR SUPPORT (a) Remove the 2 bolts and luggage compartment door support from the luggage compartment door panel. HINT: While supporting the door with your hand, remove the support. (b) Remove the 2 bolts and support from the body. 3. IF NECESSARY, REPLACE LUGGAGE COMPARTMENT DOOR SUPPORT NOTICE: When handling the luggage compartment door support.
Do not disassemble the luggage compartment door support because the cylinder is filled with pressurized gas.
Hole Here 150 mm (5.91 in.)


H11085
4. (a) If the luggage compartment door support is to be replaced, drill a 2.0 – 3.0 mm (0.079 – 0.118 in.) hole in the bottom of the luggage compartment door support as shown in the illustration to completely release the high–pressure gas before disposing of it. When drilling, chips may fly out so work carefully. The gas is colorless, odorless and non–toxic. When working, handle the luggage compartment door support carefully. Never score or scratch the exposed part of the piston rod, and never allow paint or oil to get on it. Do not turn the piston rod and cylinder with the luggage compartment door support fully extended. INSTALL LUGGAGE COMPARTMENT DOOR SUPPORT Install the bolt and luggage compartment door support to the body. Torque: 22 N·m (224 kgf·cm, 16 ft·lbf) Author: Date: 551 BO–13 BODY (b) 5. – LUGGAGE COMPARTMENT DOOR SUPPORT Install the 2 bolts and luggage compartment door support to the luggage compartment door panel. Torque: 22 N·m (224 kgf·cm, 16 ft·lbf) INSTALL LUGGAGE COMPARTMENT TRIM FRONT COVER Author: Date: 552 BO–14 BODY – BACK WINDOW GLASS BACK WINDOW GLASS BO2E2–01 COMPONENTS
Stopper
Back Window Outside Moulding Back Window Glass Roof Side Inner Garnish Roof Side Inner Garnish Rear Seatback 18 (185, 13) RH Rear Seat Outer Belt High–mounted Stop Light LH Rear Seat Outer Belt Rear Seat Cushion 41 (420, 30) Package Tray Trim N·m (kgf·cm, ft·lbf) : Specified Torque
Non–reusable part H09257 Author: Date: 553 BO–15 BODY – BACK WINDOW GLASS BO2E3–01 REMOVAL 1. REMOVE REAR SEAT CUSHION AND SEATBACK (See page BO–22) 2. (a) (b) REMOVE ROOF SIDE INNER GARNISH Using a clip remover, remove the clip. Insert a screwdriver between the roof side inner garnish and body to pry it out. HINT: Tape the screwdriver tip before use. (c) Employ the same manner described above to the other side. 3 Clips Clip H09254 3. REMOVE HIGH–MOUNTED STOP LIGHT Remove the high–mounted stop light as shown in the illustration, then disconnect the connector. 4. REMOVE PACKAGE TRAY TRIM (a) Remove the bolts and rear seat belt floor anchors. 2 1 1 H09255 (b) 1 2 H07599 N20985 Using a screwdriver, remove the seat belt bezels from the package tray trim. HINT: Tape the screwdriver tip before use. (c) Using a hexagon wrench, remove the 2 hexagon screws. (d) Remove the package tray trim, then disconnect the connectors. HINT: Remove the package tray trim through out the rear seat outer belt floor anchors from the hole in the package tray trim. 5. REMOVE BACK WINDOW OUTSIDE MOULDING (a) Using a knife, cut off the moulding as shown in the illustration. NOTICE: Do not damage the body with the knife. (b) Remove the remaining moulding. BO–16 BODY Protective Tape H09266 Protective Tape H09258 – BACK WINDOW GLASS 6. REMOVE BACK WINDOW GLASS (a) Disconnect the connector. (b) Push piano wire through from the interior. (c) Tie both wire ends to wooden blocks or similar objects. HINT: Apply protective tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and exterior. (d) Cut the adhesive by pulling the piano wire with leaving the adhesive where the stoppers are. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. (e) Remove the glass. BO–17 BODY – BACK WINDOW GLASS BO2E4–01 INSTALLATION Adhesive BO4420 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. (b) Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. (a) (b) CLEAN REMOVED GLASS Remove the damaged stoppers. Using a scraper, remove the adhesive sticking to the glass. (c) Clean the glass with cleaner. NOTICE:
Be careful not to damage the glass.
Do not touch the glass face after cleaning it. BO5231 3. INSTALL NEW STOPPERS Attach new stoppers to the ceramic notch areas on the glass to set stoppers. H09259 A H09260 4. INSTALL NEW BACK WINDOW OUTSIDE MOULDING Install a new back window outside moulding to the glass as shown in the illustration. HINT:
Install the back window outside moulding from the center of glass at the lower side of vehicle mark A indicates the ceramic notch for moulding installation.
When installing the back window outside moulding, do not stretch it. 5. (a) (b) (c) (d) H09261 POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are perfectly even. Place reference marks on the glass and body. Remove the glass. BO–18 BODY – BACK WINDOW GLASS 6. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black–colored area around the entire glass rim. NOTICE: Do not touch the glass surface after cleaning it. BO4421 7. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat Primer M to the exposed part of body on the vehicle side. NOTICE:
Let the coated primer dry for 3 minutes or more.
Do not coat Primer M to the adhesive.
Do not keep any of the opened Primer M for later use. Primer M Primer M Adhesive H02865 8. a a b b b b a–a b–b Primer G H09262 COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the contact surface with Primer G as shown in the illustration. (b) When the primer is coated wrongly to the area other than the specified, wipe it off with a clean shop rag before primer dries. NOTICE:
Let the primer coating dry for 3 minutes or more.
Do not keep any of the opened Primer G for later use. BO–19 BODY 9. (a) a a b b b–b a–a A B BACK WINDOW GLASS APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850–00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time described in the table below. b b – Temperature Tackfree time 35 °C (95 °F) 15 minutes 20 °C (68 °F) 100 minutes 5 °C (41 °F) 8 hour (b) (c) Load the cartridge into the sealer gun. Apply adhesive to the glass as shown in the illustration. A: 12.0 mm (0.472 in.) B: 8.0 mm (0.315 in.) 10. (a) INSTALL GLASS Position the glass so that the reference marks are lined up, and press in gently along the rim. A B : Adhesive H09263 H09264 HINT: Confirm that the moulding is attached to the body panel as shown in the illustration. (b) Hold the back window glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTICE: Take care not to drive the vehicle during the time described in the table below. H09265 11. (a) (b) Temperature Minimum time prior to driving the vehicle 35 °C (95 °F) 1.5 hours 20 °C (68 °F) 5 hours 5 °C (41 °F) 24 hours INSPECT FOR LEAK AND REPAIR Conduct a leak test after the hardening time has elapsed. Seal any leak with sealant. Part No. 08833–00030 or equivalent 12. INSTALL REAR SIDE OF ROOF HEADLINING Install the rear side of roof headlining with the 2 clips. 13. INSTALL ASSIST GRIPS BO–20 BODY – BACK WINDOW GLASS 14. INSTALL PACKAGE TRAY TRIM (a) Connect the connectors. (b) Install the package tray trim with the 2 screws. HINT: Before installing the package tray trim pass the rear seat outer belt floor anchor through the hole in the package tray trim. 15. INSTALL HIGH–MOUNTED STOP LIGHT 16. (a) (b) 17. 3 Clips Clip H09254 INSTALL ROOF SIDE INNER GARNISH Install the roof side inner garnish with clip. Employ the same manner described above to the other side. INSTALL REAR SEAT CUSHION AND SEATBACK (See page BO–25) BO–21 BODY – REAR SEAT REAR SEAT BO2DV–02 COMPONENTS Headrest Headrest Headrest Support Headrest Support Rear Seatback Pad Rear Seatback Cover 18 (185, 13) Rear Seat Cushion Cover
Hog Ring
Hog Ring 18 (185, 13) Rear Seat Cushion Cover Hook Hook Rear Seat Cushion Cover N·m (kgf·cm, ft·lbf) : Specified torque H09268 Author: Date: 560 BO–22 BODY – REAR SEAT BO2DW–01 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY Pull up the front part of seat cushion assembly to remove the rear seat cushion assembly. HINT: When removing the rear seat cushion assembly, pass the rear seat inner with center belt through the hole on the seatback. 2. REMOVE REAR SEATBACK ASSEMBLY (a) Remove the 3 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) HINT: At the time of reassembly, please refer to the following item. When installing hog rings, take care to prevent wrinkles as little as possible. (b) Pull up the seatback assembly to remove it. BO–23 BODY – REAR SEAT BO2DX–01 DISASSEMBLY 1. REMOVE HEADRESTS AND HEADREST SUPPORTS 2. REMOVE SEATBACK COVER Remove the hog rings and seatback cover from the seatback pad. 3. REMOVE SEAT CUSHION COVER Remove the hog rings and seat cushion cover from the seat cushion pad. BO–24 BODY – REAR SEAT BO2DY–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BO–23). BO–25 BODY – REAR SEAT BO2DZ–02 INSTALLATION Installation is in the reverse order of removal (See page BO–22). BO–26 BODY – SEAT BELT SEAT BELT BO2E0–01 COMPONENTS 41 (420, 31) 41 (420, 30) Anchor Cover Cap 41 (420, 30) Front Seat Outer Belt Rear Seat Outer Belt 41 (420, 31) 41 (420, 30) 41 (420, 30) Front Seat 7.8 (80, 69 in.·lbf) 41 (420, 30) RH Rear Seat Inner with Center Belt 41 (420, 30) LH Rear Seat Inner with Center Belt N·m (kgf·cm, ft·lbf) : Specified torque H09269 Author: Date: 565 BO–27 BODY – SEAT BELT BO2E1–01 INSPECTION CAUTION: Replace the seat belt assembly (Outer belt, inner belt, bolts, nuts or sill–bar) if it has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. All seat belt: RUNNING TEST IN SAFE AREA (a) Fasten the front seat belts. (b) BO0632 HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver’s seat belt (ELR): STATIC TEST (a) Make sure that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) 15° 45° If a 3. BO0633 Drive the car at 10 m/h (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. (a) (b) (c) (d) If a Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. problem is found, replace the assembly. Except driver’s seat belt (ALR/ELR): STATIC TEST Make sure that the belt locks when pulled out quickly. Remove the locking retractor assembly. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. Make sure that the belt cannot be extended further. problem is found, replace the assembly. BO–28 BODY (e) Full Belt Length Minus 200 mm (7.87 in.) (f) – SEAT BELT Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. Tilt the belt slowly. N10070 (g) Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. 15° 45° BO0633 4. (a) (b) (c) BO5906 Manual type: TESTING Adjust the belt to the proper length. Apply a firm load to the belt. Make sure that the belt is not extended. MA–1 MAINTENANCE – OUTSIDE VEHICLE OUTSIDE VEHICLE MA001–10 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, adjust. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them. 4. TIRE ROTATION Check the owner’s manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. If necessary, replace. 6. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 7. DOORS AND ENGINE HOOD (a) Check that all doors and the tailgate operate smoothly, and that all latches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released. Author: Date: 44 MA–2 MAINTENANCE – INSIDE VEHICLE INSIDE VEHICLE MA002–11 GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner’s responsibility. They can be done by the owner or they can have them done at a service shop. These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. Items and procedures for general maintenance are as follows. 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that it is working. 5. WINDSHIELD GLASS Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater or air conditioner. 8. REAR VIEW MIRROR Check that it is mounted securely. 9. SUN VISORS Check that they move freely and are mounted securely. 10. STEERING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noises. 11. SEATS (a) Check that the seat adjusters operate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the head restraints move up and down smoothly and that the locks hold securely in any latch position. (d) For fold–down seat backs, check that the latches lock securely. 12. SEAT BELTS (a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. Author: Date: 45 MA–3 MAINTENANCE – INSIDE VEHICLE 13. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 14. CLUTCH PEDAL (See page CL–2) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper freeplay. 15. BRAKE PEDAL (See page BR–5) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper reserve distance and freeplay. (c) Check the brake booster function. 16. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 17. PARKING BRAKE (See page BR–8) (a) Check that the lever has the proper travel. (b) On a safe incline, check that the vehicle is held securely with only the parking brake applied. 18. AUTOMATIC TRANSMISSION ”PARK” MECHANISM (a) Check the lock release button of the selector lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is held securely with the selector lever in ”P” position and all brakes released. Author: Date: 46 MA–4 MAINTENANCE – UNDER HOOD UNDER HOOD MA003–09 GENERAL MAINTENANCE 1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner’s manual supplement in which the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic maintenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless otherwise noted.
Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL Check that the coolant level is between the ”FULL” and ”LOW” lines on the see–through reservoir. 4. RADIATOR AND HOSES (a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. (b) Check the hoses for cracks, kinks, rot or loose connections. 5. BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. 6. BRAKE AND CLUTCH FLUID LEVELS (a) Check that the brake and clutch fluid levels are near the upper level line on the see–through reservoirs. (b) Check that the clutch fluid level is with is ± 5 mm (0.20 in.). of the reservoir hem. 7. ENGINE DRIVE BELTS Check drive belt for fraying, cracks, wear or oiliness. 8. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. 9. POWER STEERING FLUID LEVEL
Check the level.
The level should be in the ”HOT” or ”COLD” range depending on the fluid temperature. 10. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) With the engine idling and the parking brake applied, shift the selector into all positions from ”P” to ”L”, and then shift into ”P” position. (c) Pull out the dipstick and wipe off the fluid with a clean rag. Re–insert the dipstick and check that the fluid level is in the HOT range. (d) Do this check with the fluid at normal driving temperature (70 – 80°C, 158 – 176°F). HINT: Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at high speeds, in hot weather, in heavy traffic or pulling a trailer. 11. EXHAUST SYSTEM If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. Author: Date: 47 MA–5 MAINTENANCE – ENGINE ENGINE MA00L–01 INSPECTION 1. 2. 3. REPLACE TIMING BELT 5S–FE: (See page EM–17) 1MZ–FE: (See page EM–15) INSPECT DRIVE BELTS 5S–FE: (See page CH–1) 1MZ–FE: (See page CH–1) REPLACE SPARK PLUGS 5S–FE: (See page IG–1) 1MZ–FE: (See page IG–1) 4. (a) Outside Inside P00495 INSPECT AIR FILTER Visually check that the air filter is not excessively dirty or oily. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. 5. REPLACE AIR FILTER Replace the air filter with a new one. 6. REPLACE ENGINE OIL AND OIL FILTER 5S–FE: (See page LU–2) 1MZ–FE: (See page LU–3) 7. REPLACE ENGINE COOLANT 5S–FE: (See page CO–2) 1MZ–FE: (See page CO–2) 8. 1MZ–FE: INSPECT CHARCOAL CANISTER (See page EC–6) 9. REPLACE GASKET IN FUEL TANK CAP 5S–FE: (See page EC–6) 1MZ–FE: (See page EC–6) 10. INSPECT FUEL LINES AND CONNECTIONS 5S–FE: (See page EC–6) 1MZ–FE: (See page EC–6) 11. INSPECT EXHAUST PIPES AND MOUNTINGS 5S–FE: (See page EC–15) 1MZ–FE: (See page EC–17) 12. ADJUST VALVE CLEARANCE 5S–FE: (See page EM–4) 1MZ–FE: (See page EM–4) Author: Date: 48 MA–6 MAINTENANCE – BRAKE BRAKE MA00M–01 INSPECTION MA0055 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or left before checking the front brake. (a) Check all brake lines and hoses for:
Damage
Wear
Deformation
Cracks
Corrosion
Leaks
Bends
Twists (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. 2. INSPECT FRONT BRAKE PADS AND DISCS (See page BR–22) 3. INSPECT REAR BRAKE PADS AND DISCS (See page BR–37) 4. INSPECT BRAKE LININGS AND DRUMS (See page BR–34) Author: Date: 49 MA–7 MAINTENANCE – CHASSIS CHASSIS MA00N–01 INSPECTION 1. (a) (b) INSPECT STEERING LINKAGE Check the steering wheel freeplay. (See page SR–8) Check the steering linkage for looseness or damage. Check that:
Tie rod ends do not have excessive play.
Dust seals and boots are not damaged.
Boot clamps are not loose. 2. INSPECT SRS AIRBAG (See page RS–2) 3. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 4. INSPECT DRIVE SHAFT BOOTS Check the drive shaft boots for clamp looseness, leakage or damage. 5. (a) N01022 INSPECT BALL JOINTS AND DUST COVERS Inspect the ball joints for excessive looseness.
Jack up the front of the vehicle and place wooden blocks with a height of 180 – 200 mm (7.09 – 7.87 in.) under the front tires.
Lower the jack until there is about half a load on the front coil spring. Place stands under the vehicle for safety.
Check that the front wheels are pointing straight ahead, and block them with chocks.
Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is play, replace the ball joint. (b) Check the dust cover for damage. 6. CHECK TRANSAXLE OIL (FLUID) (a) Visually check the transaxle for oil (fluid) leakage. If leakage is found, check for the cause and repair. 7. (a) (b) REPLACE TRANSAXLE OIL (FLUID) M/T: Replace the transaxle oil. S51: (See page MX–4) E153: (See page MX–4) A/T: Replace the transaxle fluid. A140E: (See page DI–389) A541E: (See page DI–438) Author: Date: 50 MA–8 MAINTENANCE – BODY BODY MA00O–01 INSPECTION 1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten these parts:
Front seat mount bolts Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) MA0676 B00995
Front suspension member–to–body mounting bolts Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) N21126
Rear suspension member–to–body mounting nuts Torque: 51 N·m (520 kgf·cm, 38 ft·lbf) Check that the brakes work properly and do not drag. N21125 2. (a) (b) FINAL INSPECTION Check the operation of the body parts:
Hood: Auxiliary catch operates properly Hood locks securely when closed
Front and rear doors: Door lock operates properly Doors close properly
Luggage compartment door and back door: Door lock operates properly
Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding–down rear seat backs lock securely Road test:
Check the engine and chassis for abnormal noises.
Check that the vehicle does not wander or pull to one side. Author: Date: 51 MA–9 MAINTENANCE –

(c) Be




BODY Check that the brakes work properly and do not drag. Do setting of the parking brake shoes and drum. sure to deliver a clean car. Especially check: Steering wheel Shift lever knob All switch knobs Door handles Seats Author: Date: 52 MA–1 MAINTENANCE – ENGINE ENGINE MA00L–02 INSPECTION 1. 2. 3. REPLACE TIMING BELT (See Pub. No. RM654U, page EM–17) INSPECT DRIVE BELTS (See Pub. No. RM654U, page CH–1) REPLACE SPARK PLUGS (See page IG–1) 4. (a) Outside Inside P00495 INSPECT AIR CLEANER FILTER Visually check that the air filter is not excessively dirty or oily. (b) Clean the air cleaner filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air cleaner filter. 5. REPLACE AIR CLEANER FILTER Replace the air filter with a new one. 6. REPLACE ENGINE OIL AND OIL FILTER (See Pub. No. RM654U, page LU–2) 7. REPLACE ENGINE COOLANT (See Pub. No. RM654U, page CO–2) 8. INSPECT FUEL PRESSURE REGULATOR RESERVOIR (See page SF–6) 9. INSPECT FUEL FILTER (See page SF–3) 10. REPLACE FUEL FILTER (See page SF–5) 11. INSPECT FUEL LINES AND CONNECTIONS Visually check for loose connections, sharp bends or damage. 12. INSPECT FUEL TANK BAND (See page SF–18) 13. INSPECT FUEL TANK (a) Check for fuel leaks (See page SF–1). (b) Check the fuel tank mounting (See page SF–18). 14. REPLACE FUEL TANK (See page SF–18) 15. INSPECT EXHAUST PIPES AND MOUNTINGS (See Pub. No. RM654U, page EC–15) 16. ADJUST VALVE CLEARANCE (See page EM–4) Author: Date: 42 CO–1 COOLING (5S–FE) – COOLANT COOLANT CO066–03 INSPECTION HINT: Check the coolant level when the engine is cold. 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add ”Toyota Long Life Coolant” or equivalent up to the ”FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. Author: Date: 1575 CO–2 COOLING (5S–FE) – COOLANT CO067–03 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Radiator Drain Plug Engine Drain Plug Z18990 Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug (on the left rear of the cylinder block), and drain the coolant. (c) Close the drain plugs. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) for engine 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant.
Use of improper coolants may damage engine cooling system.
Use ”Toyota Long Life Coolant” or equivalent and mix it with plan water according to the manufacturer’s directions.
Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 % (freezing protection down to –50°C (–58°F)) of ethylene–glycol is recommended but not more than 70 %. NOTICE:
Do not use an alcohol type coolant or plain water alone.
The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: (b) (c) (d) 3. w/ Oil cooler 6.9 litters (7.3 US qts, 6.1 lmp. qts) w/o Oil cooler 6.2 litters (6.5 US qts, 5.4 lmp. qts) Install the radiator cap. Start the engine, and bleed the cooling system. Refill the radiator reservoir with coolant until it reaches the ”FULL” line. CHECK FOR COOLANT LEAKS Author: Date: 1576 CO–3 COOLING (5S–FE) – WATER PUMP WATER PUMP CO068–03 COMPONENTS 64 (650, 47) 64 (650, 47) Engine Moving Control Rod 52 (530, 38) Ground Strap Connector No.2 RH Engine Mounting Bracket Generator Drive Belt w/ Oil Cooler A/C Compressor Connector A/C Compressor Cylinder Block Insulator PS Pump Drive Belt RH Front Fender Apron Seal N·m (kgf·cm, ft·lbf) : Specified torque S05543 Author: Date: 1577 CO–4 COOLING (5S–FE) – WATER PUMP Generator Wire Generator Connector * Gasket Generator Wire Clamp No.2 Timing Belt Cover Wire Clamp Timing Belt No.1 Timing Belt Cover Timing Belt Guide High–Tension Cord Crankshaft Pulley Spark Plug * Gasket 18 (180,13) Wire Clamp 108 (1,100, 80) Wire Clamp
O–Ring Wire Clamp No.1 Idler Pulley 42 (425,31) Tension Spring
O–Ring No.2 Idler Pulley
Gasket 42 (425,31) Generator Drive Belt Adjusting Bar Water Pump and Water Pump Cover Assembly Wire Clamp Lower Radiator Hose Crankshaft Position Sensor Connector Water Pump Cover
Gasket Water Pump N·m (kgf·cm, ft·lbf) : Specified torque * Replace only if damaged
Non–reusable part S05939 Author: Date: 1578 CO–5 COOLING (5S–FE) – WATER PUMP CO069–04 REMOVAL 1. 2. 3. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–17) DISCONNECT LOWER RADIATOR HOSE FROM WATER OUTLET 4. REMOVE TIMING BELT TENSION SPRING Loosen the No.1 idler pulley bolt, and remove the tension spring. 5. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 6. w/ Oil Cooler: REMOVE A/C COMPRESSOR (See page EM–69) 7. (a) (b) (c) REMOVE GENERATOR DRIVE BELT ADJUSTING BAR Disconnect the engine wire clamp from the adjusting bar. Disconnect the crankshaft position sensor connector from the bracket on the adjusting bar. Remove the bolt and adjusting bar. S05599 8. (a) REMOVE WATER PUMP AND WATER PUMP COVER ASSEMBLY Remove the 2 nuts holding the water pump to the water bypass pipe. S05924 (b) Remove the 3 bolts in the sequence shown. 1 3 2 S05963 Author: Date: 1579 CO–6 COOLING (5S–FE) Disconnect – WATER PUMP (c) Disconnect the water pump cover from the water bypass pipe, and remove the water pump and water pump cover assembly. (d) Remove the gasket and 2 O–rings from the water pump and water bypass pipe. 9. REMOVE WATER PUMP FROM WATER PUMP COVER Remove the 3 bolts, water pump and gasket. S05965 Author: Date: 1580 CO–7 COOLING (5S–FE) – WATER PUMP CO06A–03 INSPECTION Turn Air Hole S01486 1. INSPECT WATER PUMP (a) Visually check the air hole for coolant leakage. If leakage is found, replace the water pump. If engine coolant has leaked onto the timing belt, replace the timing belt. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT TIMING BELT COMPONENTS (See page EM–22) Author: Date: 1581 CO–8 COOLING (5S–FE) – WATER PUMP CO06B–03 INSTALLATION 1. INSTALL WATER PUMP TO WATER PUMP COVER Install a new gasket and the water pump with the 3 bolts. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) N00918 2. Connect (a) (b) (c) (d) INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY Install new O–ring and gasket to water pump cover. Install a new O–ring to the water bypass pipe. Apply soapy water to the O–ring on the water bypass pipe. Connect the water pump cover to the water bypass pipe. Do not install the nuts yet. S06015 (e) Install the water pump with the 3 bolts. Tighten the bolts in the sequence shown. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) (f) Install the 2 nuts holding the water pump cover to the water bypass pipe. Torque: 9.3 N·m (95 kgf·cm, 82 in.·lbf) 3. (a) INSTALL GENERATOR DRIVE BELT ADJUSTING BAR Install the adjusting bar with the bolt. Torque: 22 N·m (224 kgf·cm, 16 ft·lbf) Install the engine wire clamp to the adjusting bar. Install the crankshaft position sensor connector to the bracket on the adjusting bar. w/ Oil Cooler: INSTALL A/C COMPRESSOR (See page EM–75) INSTALL NO.2 IDLER PULLEY (See page EM–23) 3 1 2 Z19283 S05924 (b) (c) 4. S05599 5. Author: Date: 1582 CO–9 COOLING (5S–FE) 6. 7. 8. 9. 10. – WATER PUMP INSTALL TIMING BELT TENSION SPRING (See page EM–23) CONNECT LOWER RADIATOR HOSE TO WATER INLET INSTALL TIMING BELT (See page EM–23) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author: Date: 1583 CO–10 COOLING (5S–FE) – THERMOSTAT THERMOSTAT CO06C–03 COMPONENTS w/ Oil Cooler Oil Filter Thermostat
Gasket Water Inlet
Non–reusable part S05299 Author: Date: 1584 CO–11 COOLING (5S–FE) – THERMOSTAT CO06D–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. w/ Oil Cooler: REMOVE OIL FILTER (See page LU–2) 3. (a) (b) (c) REMOVE WATER INLET AND THERMOSTAT Remove the 2 nuts, and disconnect the water inlet from the water pump cover. Remove the thermostat. Remove the gasket from the thermostat. S05322 Author: Date: 1585 CO–12 COOLING (5S–FE) – THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. CO06E–03 P13560 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified, replace the thermostat. P00436 (c) Check the valve lift. Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. Valve Lift P24125 Author: Date: 1586 CO–13 COOLING (5S–FE) – THERMOSTAT CO0SN–01 5° 5° INSTALLATION Protrusion 1. (a) (b) Jiggle Valve P13611 PLACE THERMOSTAT IN WATER INLET Install a new gasket to the thermostat. Align the jiggle valve of the thermostat with the protrusion of the water inlet, and insert the thermostat in the water inlet. HINT: The jiggle valve may be set within 5° of either side of the prescribed position. 2. INSTALL WATER INLET AND THERMOSTAT Install the water inlet and thermostat with the 2 nuts. Torque: 8.8 N·m (90 kgf·cm, 78 in.·lbf) 3. w/ Oil Cooler: INSTALL OIL FILTER (See page LU–2) 4. FILL WITH ENGINE COOLANT 5. START ENGINE AND CHECK FOR COOLANT LEAKS 6. CHECK ENGINE OIL LEVEL S05322 Author: Date: 1587 CO–14 COOLING (5S–FE) – RADIATOR RADIATOR CO06G–03 ON–VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core.) Author: Date: 1588 CO–15 COOLING (5S–FE) – RADIATOR CO06H–04 ON–VEHICLE INSPECTION 1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Radiator Cap Tester 30° or More Radiator Cap Z00570 Radiator Cap Tester B06362 2. INSPECT RADIATOR CAP NOTICE:
If the radiator cap has contaminations, always rinse it with water.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
When performing steps (a) and (b) below, keep the tester at an angle of over 30° above the horizontal. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester, and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 74 – 103 kPa (0.75 – 1.05 kgf/cm2, 10.7 – 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2, 8.5 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator with coolant, and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. REINSTALL RADIATOR CAP Author: Date: 1589 CO–16 COOLING (5S–FE) – RADIATOR CO06I–03 COMPONENTS Upper Radiator Support No.2 Electric Cooling Fan Connector Radiator Reservoir Hose Upper Radiator Support Radiator Assembly Lower Radiator Support No.1 Electric Cooling Fan Connector ECT Switch Connector for Electric Cooling Fan Lower Radiator Hose Upper Radiator Hose Oil Cooler Hose for A/T S05951 Author: Date: 1590 CO–17 COOLING (5S–FE) – RADIATOR No.2 Electric Cooling Fan ECT Switch Connector for Electric Cooling Fan Lower Radiator Hose No.1 Electric Cooling Fan Wire Clamp Radiator Oil Cooler Hose for A/T S05948 Radiator Cap Upper Tank
O–Ring A/T
O–Ring Plate Washer Nut Core Pipe Oil Cooler
O–Ring
O–Ring Nut Plate Washer
O–Ring ECT Switch for Electric Cooling Fan Lower Tank Drain Plug
O–Ring
Non–reusable part S05240 Author: Date: 1591 CO–18 COOLING (5S–FE) – RADIATOR CO06J–04 REMOVAL 1. 2. (a) (b) (c) (d) (e) (f) (g) DRAIN ENGINE COOLANT REMOVE RADIATOR ASSEMBLY Disconnect the No.1 electric cooling fan connector. Disconnect the No.2 electric cooling fan connector. Disconnect the ECT switch connector for the electric cooling fan. Disconnect the upper radiator hose from the radiator. Disconnect the lower radiator hose from the water inlet. Disconnect the radiator reservoir hose from the radiator. A/T: Disconnect the 2 oil cooler hoses from the oil cooler pipes. (h) (i) (j) (k) (l) S05955 Remove the 2 bolts and 2 upper radiator supports. Remove the radiator assembly. Remove the 2 lower radiator supports. Remove the lower radiator hose from the radiator. A/T: Remove the 2 oil cooler hoses from the radiator. 3. REMOVE NO.1 ELECTRIC COOLING FAN FROM RADIATOR (a) Disconnect the ECT switch connector for the cooling fan. (b) Disconnect the ECT switch wire clamp for the cooling fan from the bracket of the radiator. (c) Remove the 2 bolts and cooling fan. 4. REMOVE NO.2 ELECTRIC COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Author: Date: 1592 CO–19 COOLING (5S–FE) – RADIATOR CO06K–03 DISASSEMBLY 1. (a) (b) 2. (a) (b) 3. Part ”A” Dimension ”B” SST Claw Stopper Bolt Overhaul Handle CO1205 Lock Plate Stopper Bolt ASSEMBLE SST SST 09230–01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Dimension: 0.2 – 0.3 mm (0.008 – 0.012 in) NOTICE: If this adjustment is not done the claw may be damaged. 4. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230–01010 Tank SST REMOVE ECT SWITCH Remove the ECT switch. Remove the O–ring. REMOVE DRAIN PLUG Remove the drain plug. Remove the O–ring. S04699 5. REMOVE TANKS AND O–RINGS Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft–faced hammer, and remove the tank and the O–ring. Tap S04703 6. (a) (b) (c) A/T: REMOVE OIL COOLER FROM LOWER TANK Loosen the nut, and remove the cooler pipe. Remove the 2 nuts and plate washers. Remove the oil cooler and 2 O–rings. S04705 Author: Date: 1593 CO–20 COOLING (5S–FE) – RADIATOR CO06L–04 REASSEMBLY Pipe 1. 18° Downward (a) (b) (c) S05307 Lock Plate Lock Plate Core CO1267  Normal X Twisted A/T: INSTALL OIL COOLER TO LOWER TANK Install 2 new O–rings to the oil cooler. Install the oil cooler to the lower tank with the 2 plate washers and nuts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) Install the cooler pipe in the direction indicated in the illustration. Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf) 2. INSPECT LOCK PLATE FOR DAMAGE HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 3. INSTALL NEW O–RINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new O–ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. O–Ring X Twisted CO0317 CORRECT WRONG Tap Tank (b) (c) Install the tank without damaging the O–ring. Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. Lock Plate S04698 Author: Date: 1594 CO–21 COOLING (5S–FE) 4. Part ”A” (a) (b) Dimension ”B” SST Punch Assembly Stopper Bolt Overhaul Handle 7 3 1 2 4 6 8 SST RADIATOR ASSEMBLE SST SST 09230–01010, 09231–14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension ”B” is as shown in the illustration. Dimension: 8.4 mm (0.331 in) CO1206 5. (a) 5 – CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 09230–01010 Tank Lock Plate Stopper Bolt Z18947 (2) (3) HINT:
Do not stake the areas protruding around the pipes, brackets or tank ribs.
The points shown in the illustration and oil cooler near here (A/T) cannot be staked with the SST. Use pliers or similar object and be careful not to damage the core plates. (3) (3) (1) (1) (2) (2) (2) (2) (2) (2) S05241 Z18946 Author: Date: 1595 CO–22 COOLING (5S–FE) – RADIATOR (b) H S04700 Check the lock plate height (H) after completing the caulking. Plate height: 7.40 – 7.80 mm (0.2913 – 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL ECT SWITCH (a) Install a new O–ring to the ECT switch. (b) Install the ECT switch. 7. INSTALL DRAIN PLUG (a) Install a new O–ring to the drain plug. (b) Install the drain plug. 8. (a) SST (b) (c) INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230–01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) Submerge the radiator in water. S04704 Tank Lock Plate O–Ring (d) Inspect for leaks. HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear. S01713 Author: Date: 1596 CO–23 COOLING (5S–FE) – RADIATOR CO06M–03 INSTALLATION 1. (a) (b) (c) (d) 2. (a) (b) 3. (a) (b) (c) (d) (e) (f) (g) (h) (i) S05955 (j) (k) (l) 4. 5. INSTALL NO.1 ELECTRIC COOLING FAN TO RADIATOR Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Connect the ECT switch connector for the cooling fan. Install the ECT switch wire clamp for the cooling fan to the bracket of the radiator. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) INSTALL NO.2 ELECTRIC COOLING FAN TO RADIATOR Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) INSTALL RADIATOR ASSEMBLY Install the lower radiator hose to the radiator. A/T: Install the 2 oil cooler hoses to the radiator. Install the 2 lower radiator supports to the radiator. Attach the 2 lower radiator supports on the radiator to the body brackets. Install the 2 upper radiator supports with the 2 bolts. Torque: 12.8 N·m (130 kgf·cm, 9 ft·lbf) Connect the upper radiator hose to the radiator. Connect the lower radiator hose to the water inlet. Connect the radiator reservoir hose to the radiator. A/T: Connect the 2 oil cooler hoses to the oil cooler pipes. Connect the No.1 electric cooling fan connector. Connect the No.2 electric cooling fan connector. Connect the ECT switch connector for the electric cooling fan. FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author: Date: 1597 CO–24 COOLING (5S–FE) – ELECTRIC COOLING FAN ELECTRIC COOLING FAN CO06N–03 ON–VEHICLE INSPECTION 1. S05959 ECT Switch Connector S05953 No.1 Ammeter CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 83°C (181°F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch. (c) Disconnect the ECT switch connector. (d) Check that the cooling fan rotates. If not, check the fan main relay, cooling fan relay, cooling fan, fuses, and check for short circuit between the cooling fan relay and ECT switch. (e) Reconnect the ECT switch connector. 2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 93°C (199°F)) (a) Start the engine, and raise coolant temperature to above 93°C (199°F). (b) Check that the cooling fan rotates. If not, replace the ECT switch. 3. (a) (b) (c) (+) (–) (d) No.2 INSPECT COOLING FANS Disconnect the cooling fan connector. Connect battery and ammeter to the connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 4.9 – 8.5 A Reconnect the cooling fan connector. Battery (–) Ammeter (+) Battery Z19282 Author: Date: 1598 CO–25 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06O–03 COMPONENTS No.1 Cooling Fan No.1 Electric Cooling Fan Connector No.1 Electric Cooling Fan Connector Holder ECT Switch Connector ECT Switch Wire Upper Radiator Hose S05950 No.1 Cooling Fan Fan Motor Connector Holder Fan Fan Shroud S05238 Author: Date: 1599 CO–26 COOLING (5S–FE) – ELECTRIC COOLING FAN No.2 Cooling Fan No.2 Electric Cooling Fan Connector No.2 Electric Cooling Fan S05949 No.2 Cooling Fan Connector Holder Fan Fan Motor Cover Fan Motor Fan Shroud S05239 Author: Date: 1600 CO–27 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06P–03 REMOVAL 1. (a) (b) REMOVE NO.1 COOLING FAN Drain the engine coolant. Disconnect the upper radiator hose from the radiator. (c) Remove the No.1 cooling fan. (1) Disconnect the cooling fan connector. (2) Disconnect the ECT switch connector. (3) Remove the 2 bolts, and disconnect the cooling fan from the radiator. (4) Disconnect the connector holder and wire for the ECT switch from the fan shroud, and remove the cooling fan. 2. (a) (b) REMOVE NO.2 COOLING FAN Disconnect the cooling fan connector. Remove the 2 bolts and cooling fan. S05956 S05957 Author: Date: 1601 CO–28 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06Q–03 DISASSEMBLY S05234 1. REMOVE FAN Remove the nut and fan. 2. No.2 Cooling Fan: REMOVE FAN MOTOR COVER Remove the 2 screws and motor cover. 3. REMOVE FAN MOTOR (a) Disconnect the wire and connector holder from the fan shroud. (b) Remove the 3 screws and fan motor. Author: Date: 1602 CO–29 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06R–04 REASSEMBLY No.1 Cooling Fan 1. (a) (b) 2. INSTALL FAN MOTOR Install the fan motor with the 3 screws. Install the wire and connector holder to the fan shroud. No.2 Cooling Fan: INSTALL FAN MOTOR COVER Install the motor cover with the 2 screws. 3. INSTALL FAN Install the fan with the nut. No.2 Cooling Fan Z19069 Author: Date: 1603 CO–30 COOLING (5S–FE) – ELECTRIC COOLING FAN CO06S–03 INSTALLATION 1. (a) Attach S06016 (b) (c) (d) 2. (a) (b) (c) INSTALL NO.1 COOLING FAN Install the No.1 cooling fan. (1) Attach the lower side of the cooling fan to the bracket of the radiator. (2) Install the cooling fan with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) (3) Install the wire and connector holder for the ECT switch to the fan shroud. (4) Connect the cooling fan connector. (5) Connect the ECT switch connector. Connect the upper radiator hose to the radiator Fill with engine coolant Start the engine and check for coolant leaks INSTALL NO.2 COOLING FAN Attach the lower side of the cooling fan to the bracket of the radiator. Install the cooling fan with the 2 bolts. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) Connect the cooling fan connector. Attach S06017 Author: Date: 1604 CO–31 COOLING (5S–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO06T–03 INSPECTION ECT Switch Connector ECT Switch O–Ring 1. DRAIN ENGINE COOLANT 2. (a) (b) (c) REMOVE ECT SWITCH Disconnect the connector. Remove the ECT switch. Remove the O–ring from the ECT switch. S05245 3. (a) Ohmmeter P05962 INSPECT ECT SWITCH Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 93°C (199°F). If there is continuity, replace the switch. (b) Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is below 83°C (181°F). If there is no continuity, replace the switch. 4. REINSTALL ECT SWITCH (a) Install a new O–ring to the ECT switch. (b) Install the ECT switch. (c) Connect the connector. 5. REFILL WITH ENGINE COOLANT 6. START ENGINE AND CHECK FOR COOLANT LEAKS Author: Date: 1605 CO–32 COOLING (5S–FE) – ENGINE MAIN RELAY ENGINE MAIN RELAY CO06U–03 INSPECTION Engine Main Relay 1. 2. REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE MAIN) S05391 Ohmmeter 3. (a) Ohmmeter Continuity 2 Ohmmeter 1 5 3 4 Continuity Ohmmeter No Continuity B02803 (b) Ohmmeter No Continuity 2 1 5 4 3 INSPECT ENGINE MAIN RELAY Inspect the relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. Continuity Battery B02804 Inspect the relay operation. (1) Apply battery positive voltage across terminals 3 and 5. (2) Using an ohmmeter, check that there is no continuity between terminals 2 and 4. If there is continuity, replace the relay. (3) Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 4. REINSTALL ENGINE MAIN RELAY 5. REINSTALL RELAY BOX COVER Author: Date: 1606 CO–33 COOLING (5S–FE) – COOLING FAN RELAY COOLING FAN RELAY CO06V–03 INSPECTION No.1 Cooling Fan Relay 1. (a) (b) INSPECT NO.1 COOLING FAN RELAY Remove the relay box cover. Remove the No.1 cooling fan relay. (Marking: FAN NO.1) S05390 Ohmmeter Ohmmeter 1 Continuity 4 3 (c) Inspect the No.1 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. 2 Continuity B02801 (d) Ohmmeter 1 No Continuity Battery 3 4 2 Inspect the No.1 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (e) Reinstall the No.1 cooling fan relay (f) Reinstall the relay box cover. B02802 No.2 Cooling Fan Relay 2. (a) (b) INSPECT NO.2 COOLING FAN RELAY Remove the relay box cover. Remove the No.2 cooling fan relay. (Marking: FAN NO.2) S05387 Ohmmeter (c) Continuity 4 2 Ohmmeter 1 5 Ohmmeter 3 Continuity No Continuity S04972 Inspect the No.2 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. Author: Date: 1607 CO–34 COOLING (5S–FE) – COOLING FAN RELAY (d) 4 2 Ohmmeter 5 1 Battery Ohmmeter 3 No Continuity Continuity S04971 No.3 Cooling Fan Relay Inspect the No.2 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4 If there is continuity, replace the relay. (3) Check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (e) Reinstall the No.2 cooling fan relay. (f) Reinstall the relay box cover. 3. (a) (b) INSPECT NO.3 COOLING FAN RELAY Remove the relay box cover. Remove the No.3 cooling fan relay. (Marking: FAN NO.3) S05388 (c) Continuity Ohmmeter Ohmmeter 2 1 5 3 Inspect the No.3 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04970 (d) 2 Ohmmeter 1 5 3 Battery Continuity Inspect the No.3 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (e) Reinstall the No.3 cooling fan relay. (f) Reinstall the relay box cover. S04969 Author: Date: 1608 CO–1 COOLING (1MZ–FE) – COOLANT COOLANT CO03B–04 INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ’’Toyota Long Life Coolant” or Equivalent up to the ”FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. (c) Reinstall the radiator cap. Author: Date: 1609 CO–2 COOLING (1MZ–FE) – COOLANT CO03C–04 REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Drain Plug Drain Plug Z18835 Loosen the radiator drain plug and engine drain plugs, and drain the coolant. (c) Close the drain plugs. Torque: RH engine drain plug on EGR cooler: 7 N·m (70 kgf·cm, 61 in.·lbf) LH engine drain plug on union: 13 N·m (130 kgf·cm, 9 ft·lbf) 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant.
Use of improper coolants may damage engine cooling system.
Use ”Toyota Long life Coolant” or equivalent and mix it with plan water according to the manufacturer’s directions.
Using of coolant which includes more than 50 % (freezing protection down to –35°C (–31°F) or 60 % (freezing protection down to –50°C (–58°F)) of ethylene–glycol is recommended but not more than 70 %. NOTICE:
Do not use an alcohol type coolant or plain water alone.
The coolant should be mixed with plain water (preferably demineralized water or distilled water). Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts) (b) Install the radiator cap. (c) Start the engine, and bleed the cooling system. (d) If necessary, refill coolant into the reservoir up to the ”FULL” line. 3. CHECK ENGINE COOLANT FOR LEAKS 4. CHECK ENGINE COOLANT SPECIFIC GRAVITY CORRECTLY Author: Date: 1610 CO–3 COOLING (1MZ–FE) – WATER PUMP WATER PUMP CO03D–04 COMPONENTS RH Fender Apron Seal 64 (650, 47) 32 (320, 23) Generator Drive Belt Engine Moving Control Rod 64 (650, 47) RH Engine Mounting Stay No.2 RH Engine Mounting Bracket PS Pump Drive Belt No.2 RH Engine Mounting Stay (M/T) Ground Strap Engine Coolant Reservoir Hose N·m (kgf·cm, ft·lbf) : Specified torque A06654 Author: Date: 1611 CO–4 COOLING (1MZ–FE) – WATER PUMP Timing Belt Gasket No.2 Timing Belt Cover RH Engine Mounting Bracket 28 (290, 21) Timing Belt Guide No.2 Generator Bracket No.1 Timing Belt Cover Gasket Crankshaft Pulley 215 (2,200, 159) Engine Wire Protector No.2 Idler Pulley RH Camshaft Timing Pulley 125 (1,300, 94) *88 (900, 65) 43 (440, 32) LH Camshaft Timing Pulley 125 (1,300, 94) Dust Boot Timing Belt Tensioner N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part *For use with SST 27 (280, 20) B06388 Author: Date: 1612 CO–5 COOLING (1MZ–FE) – WATER PUMP Gasket No.3 Timing Belt Cover Collar Bushing x6 8.5 (85, 74 in.·lbf) Engine Wire
Gasket Water Pump 8 (80, 69 in.·lbf) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B04403 Author: Date: 1613 CO–6 COOLING (1MZ–FE) – WATER PUMP CO03E–03 REMOVAL 1. 2. 3. 4. 5. DRAIN ENGINE COOLANT REMOVE TIMING BELT (See page EM–15) REMOVE CAMSHAFT TIMING PULLEYS (See page EM–15) REMOVE NO.2 IDLER PULLEY (See page EM–15) REMOVE NO.3 TIMING BELT COVER (See page EM–32) 6. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. P12942 Author: Date: 1614 CO–7 COOLING (1MZ–FE) – WATER PUMP CO03F–03 INSPECTION P12487 1. INSPECT WATER PUMP (a) Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. (b) Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT TIMING BELT COMPONENTS (See page EM–19) Author: Date: 1615 CO–8 COOLING (1MZ–FE) – WATER PUMP CO0SO–01 INSTALLATION P12942 1. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) NOTICE: Do not get oil on the gasket. 2. INSTALL NO.3 TIMING BELT COVER (See page EM–57) 3. INSTALL NO.2 IDLER PULLEY (See page EM–21) 4. INSTALL CAMSHAFT TIMING PULLEYS (See page EM–21) 5. INSTALL TIMING BELT (See page EM–21) 6. FILL WITH ENGINE COOLANT 7. START ENGINE AND CHECK FOR LEAKS 8. RECHECK ENGINE COOLANT LEVEL Author: Date: 1616 CO–9 COOLING (1MZ–FE) – THERMOSTAT THERMOSTAT CO03H–03 COMPONENTS MAF Meter Connector EGR Vacuum Hose EVAP Hose Air Cleaner Cap Assembly No.2 ECT Switch Connector Air Filter Engine Wire Protector Thermostat
Gasket Water Inlet
O–Ring Water Inlet Pipe 8 (80, 69 in.·lbf) 19.5 (200, 14) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part B06397 Author: Date: 1617 CO–10 COOLING (1MZ–FE) – THERMOSTAT CO03I–03 REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR FILTER 3. DISCONNECT NO.2 ECT SWITCH CONNECTOR 4. DISCONNECT ENGINE WIRE PROTECTOR FROM WATER INLET AND RH CYLINDER HEAD Remove the 2 nuts, and disconnect the engine wire protector from the water inlet and cylinder head. S04581 5. (b) DISCONNECT WATER INLET PIPE FROM WATER INLET AND LH CYLINDER HEAD Remove the bolt, and disconnect the inlet pipe from the water inlet. Remove the O–ring from the inlet pipe. 6. (a) (b) REMOVE WATER INLET AND THERMOSTAT Remove the 3 nuts, water inlet and thermostat. Remove the gasket from the thermostat. (a) S04502 S04503 Author: Date: 1618 CO–11 COOLING (1MZ–FE) – THERMOSTAT CO03J–03 INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. P13255 (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified, replace the thermostat. CO0601 (c) Check the valve lift. Valve lift: 10.0 mm (0.394 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. (d) Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. 10 mm Z10579 Author: Date: 1619 CO–12 COOLING (1MZ–FE) – THERMOSTAT CO03K–03 INSTALLATION 15° 15° Jiggle Valve Stud Bolt S04532 1. (a) PLACE THERMOSTAT IN WATER PUMP Install a new gasket on to the thermostat. (b) Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 8 N·m (80 kgf·cm, 69 in.·lbf) 3. INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe. (b) Apply soapy water to the O–ring. (c) Connect the water inlet pipe to the water inlet. (d) Install the bolt holding the water inlet pipe to the cylinder head. Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf) 4. INSTALL ENGINE WIRE PROTECTOR 5. CONNECT NO.2 ECT SWITCH CONNECTOR 6. REINSTALL AIR FILTER AND AIR CLEANER CAP ASSEMBLY 7. FILL WITH ENGINE COOLANT 8. START ENGINE AND CHECK FOR LEAKS 9. RECHECK ENGINE COOLANT LEVEL Author: Date: 1620 CO–13 COOLING (1MZ–FE) – RADIATOR RADIATOR CO03L–03 ON–VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core) Author: Date: 1621 CO–14 COOLING (1MZ–FE) – RADIATOR CO03M–03 ON–VEHICLE INSPECTION 1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blow out under pressure. 2. INSPECT RADIATOR CAP NOTICE:
If the radiator cap has contaminations, always rinse it with water.
When performing steps (a) and (b) below, keep the radiator cap tester at an angle of over 30° above the horizontal.
Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. (a) Radiator Cap Tester 30° or More Radiator Cap Z00570 Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push/(3 seconds or more) NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap. (b) Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 83 – 113 kPa (0.85 – 1.15 kgf/cm2, 12.1 – 16.4 psi) Minimum opening pressure: 69 kPa (0.7 kgf/cm2, 10.0 psi) HINT: Use the tester’s maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. Author: Date: 1622 CO–15 COOLING (1MZ–FE) – RADIATOR 3. (a) Radiator Cap Tester P13014 INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 127 kPa (1.3 kgf/cm2, 18.5 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. 4. REINSTALL RADIATOR CAP Author: Date: 1623 CO–16 COOLING (1MZ–FE) – RADIATOR CO03N–03 COMPONENTS A/T Oil Cooler Hose No.2 Cooling Fan Radiator No.1 Cooling Fan
O–Ring No.1 ECT Switch No.2 Cooling Fan Connector Upper Radiator Support No.1 ECT Switch Wire Lower Radiator Hose Upper Radiator Hose Upper Radiator Support No.1 Cooling Fan Connector Radiator Assembly Lower Radiator Support No.1 ECT Switch Wire Connector Drain Plug
O–Ring Lower Radiator Support Relay Block (for Daytime Running Light System) Lower Radiator Hose A/T Oil Cooler Hose
Non–reusable part B06399 Author: Date: 1624 CO–17 COOLING (1MZ–FE) – RADIATOR Upper Tank
O–Ring A/T Oil Cooler Inlet Pipe Cushion Core Plate Washer
O–Ring Nut
O–Ring Lower Tank
Non–reusable part S04606 Author: Date: 1625 CO–18 COOLING (1MZ–FE) – RADIATOR CO03O–03 REMOVAL HINT:


1. 2. 3. 4. 5. 6. 7. 8. (a) (b) (c) At the time of installation, please refer to the following items. Start the engine, and check for coolant and A/T fluid leaks. Check the A/T fluid level. (See page DI–438) DRAIN ENGINE COOLANT CANADA: DISCONNECT RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) FROM BATTERY HOLD–DOWN CLAMP DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR DISCONNECT LOWER RADIATOR HOSE FROM WATER INLET PIPE DISCONNECT A/T OIL COOLER HOSES FROM OIL COOLER PIPES DISCONNECT NO.1 AND NO.2 COOLING FAN CONNECTORS DISCONNECT NO.1 ECT SWITCH WIRE CONNECTOR REMOVE RADIATOR AND COOLING FANS ASSEMBLY Remove the 2 bolts and 2 upper supports. Torque: 12.8 N·m (130 kgf·cm, 9 ft·lbf) Lift out the radiator, and remove the radiator and cooling fans assembly. Remove the 2 lower supports. S04725 9. Lower Hose 10. REMOVE A/T OIL COOLER HOSES FROM RADIATOR REMOVE LOWER RADIATOR HOSE FROM RADIATOR Oil Cooler Hose B05937 Author: Date: 1626 CO–19 COOLING (1MZ–FE) 11. – RADIATOR REMOVE NO.1 ECT SWITCH S04588 No.1 12. REMOVE NO.1 COOLING FAN FROM RADIATOR Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) 13. REMOVE NO.2 COOLING FAN FROM RADIATOR Remove the 3 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) No.2 B05938 Author: Date: 1627 CO–20 COOLING (1MZ–FE) – RADIATOR CO03P–03 Part ”A” Dimension ”B” Claw SST Stopper Bolt Overhaul Handle CO1205 1. 2. REMOVE CUSHION FROM RADIATOR ASSEMBLE SST SST 09230–01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram is 0.2 – 0.5 mm (0.008 – 0.020 in.). NOTICE: If this adjustment is not done, the claw may be damaged. 3. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230–01010 Tank Lock Plate SST Stopper Bolt DISASSEMBLY S04737 4. (a) (b) Tap REMOVE TANKS AND O–RINGS Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft–faced hammer and remove the tank. Remove the O–ring. S04738 5. A/T (a) (b) (c) A/T: REMOVE OIL COOLER FROM LOWER TANK Remove the pipe. Remove the nuts and plate washers. Remove the oil cooler and O–rings. Z18546 Author: Date: 1628 CO–21 COOLING (1MZ–FE) – RADIATOR CO03Q–03 A/T (2) REASSEMBLY (1) 1. (6) (a) (b) (c) (d) (5) (4) (3) Z18506 (e) Lock Plate Lock Plate Core CO1267 2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT:
If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.
Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented, Therefore, repair or replace if necessary. NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. 3. (a)  Normal X Twisted O–Ring A/T: INSTALL OIL COOLER TO LOWER TANK Clean the O–ring contact surface of the lower tank and oil cooler. Install a new O–rings (1) to the oil cooler (2). Install the oil cooler with the O–rings to the lower tank (3). Install the plate washers (4), and nuts (5). Torque the nuts. Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf) Install the pipe (6). Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf) INSTALL NEW O–RINGS AND TANKS After checking that there are no foreign objects in the lock plate groove, install the new O–ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. X Twisted CO0317 Author: Date: 1629 CO–22 COOLING (1MZ–FE) CORRECT – RADIATOR (b) (c) Install the tank without damaging the O–ring. Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. 4. ASSEMBLE SST SST 09230–01010, 09231–14010 Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram. Dimension ”B”: 8.4 mm (0.34 in.) Tank WRONG Lock Plate Tap S04736 Part ”A” (a) Dimension ”B” Punch Assembly SST (b) Stopper Bolt Overhaul Handle CO1206 5. (a) 3 5 7 2 1 8 4 6 CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 09230–01010 SST St opper Bolt Tank Lock Plate S04739 HINT: Rib
Do not stake the areas protruding around the pipes, brackets or tank ribs. Bracket S04734 Author: Date: 1630 CO–23 COOLING (1MZ–FE)
– RADIATOR The points shown in the rib sides and oil cooler near here cannot be staked with SST. Use pliers or similar object and be careful not to damage the core plates. S04726 (b) Check the lock plate height (H) after completing the caulking. Plate height (H): 7.4 – 7.8 mm (0.2959 – 0.3119 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 6. INSTALL CUSHION H S04735 Author: Date: 1631 CO–24 COOLING (1MZ–FE) – RADIATOR CO03R–01 INSTALLATION Installation is in the reverse order of removal. (See page CO–18) Author: Date: 1632 CO–25 COOLING (1MZ–FE) – ELECTRIC COOLING FAN ELECTRIC COOLING FAN CO03S–03 ON–VEHICLE INSPECTION 1. B05939 CHECK COOLING FAN OPERATION WITH LOW TEMPERATURE (Below 88°C (190°F)) (a) Turn the ignition switch ON. (b) Check that the cooling fan stops. If not, check the cooling fan relay and ECT switch, and check for a separated connector or severed wire between the cooling fan relay and ECT switch. (c) Disconnect the No.1 ECT switch connector. Disconnect S04727 (d) Check that the cooling fan rotates. If not, check the fuses, engine main relay, cooling fan relay, cooling fan, and check for a short circuit between the cooling fan relay and ECT switch. (e) Reconnect the No.1 ECT switch connector. B05940 2. CHECK COOLING FAN OPERATION WITH HIGH TEMPERATURE (Above 98°C (208°F)) (a) Start the engine, and raise coolant temperature to above 98°C (208°F). (b) Check that the cooling fan rotates. If not, replace the No.1 ECT switch. 3. (a) (b) Ammeter (c) (d) Battery INSPECT NO.1 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.3 – 11.3 A at 20°C (68°F) Reconnect the cooling fan connector. B05941 Author: Date: 1633 CO–26 COOLING (1MZ–FE) Ammeter 4. (a) (b) (c) (d) – ELECTRIC COOLING FAN INSPECT NO.2 COOLING FAN Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 8.3 – 11.3 A at 20°C (68°F) Reconnect the cooling fan connector. Battery B05942 Author: Date: 1634 CO–27 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03T–03 COMPONENTS No.1 Fan Fan Motor
Clip Fan Shroud No.1 Cooling Fan Connector No.1 Cooling Fan No.1 ECT Switch Connector No.1 ECT Switch Wire Relay Block (for Daytime Running Light System)
Non–reusable part B06400 Author: Date: 1635 CO–28 COOLING (1MZ–FE) – ELECTRIC COOLING FAN No.2 Fan Fan Motor
Clip Fan Shroud No.2 Cooling Fan Connector No.2 Cooling Fan Upper Radiator Hose
Non–reusable part B06402 Author: Date: 1636 CO–29 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03U–03 REMOVAL 1. (a) (b) (c) (d) REMOVE NO.1 COOLING FAN Canada: Disconnect the relay block (for daytime running light system) from the battery hold–down clamp. Disconnect the cooling fan connector. Disconnect the No.1 ECT switch wire connector. Disconnect the No.1 ECT switch wire clamps. (e) Remove the 2 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) 2. (a) (b) (c) REMOVE NO.2 COOLING FAN Drain the engine coolant. Disconnect the upper radiator hose from the radiator. Disconnect the cooling fan connector. (d) Remove the 3 bolts and cooling fan. Torque: 5.0 N·m (50 kgf·cm, 44 in.·lbf) B05943 B05944 Author: Date: 1637 CO–30 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03V–03 DISASSEMBLY Protrusion B05945 1. REMOVE NO.1 COOLING FAN (a) Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: At the time of installation, please refer to the following items. Install a new clip from the side opposite the protrusion on the fan. (b) Disconnect the lead wire from the fan shroud. (c) Remove the 3 screws and fan motor. S04584 S04587 Protrusion B05946 2. REMOVE NO.2 COOLING FAN (a) Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: At the time of installation, please refer to the following items. Install a new clip from the side opposite the protrusion on the fan. Author: Date: 1638 CO–31 COOLING (1MZ–FE) – ELECTRIC COOLING FAN (b) Disconnect the lead wire from the fan shroud. (c) Remove the 3 screws and fan motor. S04585 S04586 Author: Date: 1639 CO–32 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03W–01 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page CO–30) Author: Date: 1640 CO–33 COOLING (1MZ–FE) – ELECTRIC COOLING FAN CO03X–01 INSTALLATION Installation is in the reverse order of removal. (See page CO–29) Author: Date: 1641 CO–34 COOLING (1MZ–FE) – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH CO03Y–04 INSPECTION 1. DRAIN ENGINE COOLANT 2. (a) INSPECT NO.1 ECT SWITCH Remove the No.1 ECT switch. No.1 ECT Switch S04602 (b) Ohmmeter P01924 Inspect the No.1 ECT switch. (1) Using an ohmmeter, check that there is no continuity between the terminals when the coolant temperature is above 98°C (208°F). If there is continuity, replace the switch. (2) Check that there is continuity, between the terminals when the coolant temperature is below 88°C (190°F). If there is no continuity, replace the switch. (c) Reinstall the No.1 ECT switch. 3. INSPECT NO.2 ECT SWITCH (a) Remove the No.2 ECT switch. No.2 ECT Switch S04601 (b) Ohmmeter P06722 Inspect the No.2 ECT switch. (1) Using an ohmmeter, check that there is continuity between terminals when the coolant temperature is above 94°C (201°F). If there is no continuity, replace the switch. (2) Check that there is no continuity between the terminals when the coolant temperature is below 83°C (181°F). If there is continuity, replace the switch. (c) Reinstall the No.2 ECT switch. Author: Date: 1642 CO–35 COOLING (1MZ–FE) 4. 5. – ENGINE COOLANT TEMPERATURE (ECT) SWITCH REFILL ENGINE COOLANT START ENGINE AND CHECK FOR COOLANT LEAKS Author: Date: 1643 CO–36 COOLING (1MZ–FE) – ENGINE MAIN RELAY ENGINE MAIN RELAY CO03Z–03 INSPECTION Engine Main Relay 1. 2. REMOVE RELAY BOX COVER REMOVE ENGINE MAIN RELAY (Marking: ENGINE MAIN) S05391 3. (a) Ohmmeter Continuity 2 1 Ohmmeter Ohmmeter 5 4 3 No Continuity Continuity S04974 Ohmmeter No Continuity 2 1 Ohmmeter 5 4 3 Continuity Battery S04973 INSPECT RELAY CONTINUITY Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals 2 and 4. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals 1 and 2. If there is continuity, replace the relay. 4. (a) (b) INSPECT RELAY OPERATION Apply battery positive voltage across terminals 3 and 5. Using an ohmmeter, check that there is no continuity between terminals 2 and 4. If there is continuity, replace the relay. (c) Check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. 5. REINSTALL ENGINE MAIN RELAY 6. REINSTALL RELAY BOX COVER Author: Date: 1644 CO–37 COOLING (1MZ–FE) – COOLING FAN RELAY COOLING FAN RELAY CO040–03 INSPECTION No.1 Cooling Fan Relay 1. 2. (a) REMOVE RELAY BOX COVER INSPECT NO.1 COOLING FAN RELAY Remove the No.1 cooling fan relay. (Marking: FAN NO.1) S05390 Ohmmeter Continuity Continuity 1 4 Ohmmeter 3 2 (b) Inspect the No.1 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. S04975 (c) Inspect the No.1 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (d) Reinstall the No.1 cooling fan relay. Ohmmeter No Continuity 1 4 3 2 Battery S04976 No.2 Cooling Fan Relay 3. (a) INSPECT NO.2 COOLING FAN RELAY Remove the No.2 cooling fan relay. (Marking: FAN NO.2) S05387 (b) Ohmmeter 4 Ohmmeter 2 1 5 Ohmmeter 3 Continuity No Continuity S04972 Inspect the No.2 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. (2) Check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. (3) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. Author: Date: 1645 CO–38 COOLING (1MZ–FE) – COOLING FAN RELAY (c) 4 2 Ohmmeter 5 1 Battery Ohmmeter 3 No Continuity Inspect the No.2 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If there is continuity, replace the relay. (d) Reinstall the No.2 cooling fan relay. Continuity S04971 No.3 Cooling Fan Relay 4. (a) INSPECT NO.3 COOLING FAN RELAY Remove the No.3 cooling fan relay. (Marking: FAN NO.3) S05388 (b) Continuity Ohmmeter Ohmmeter 2 1 5 3 Inspect the No.3 cooling fan relay continuity. (1) Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is mo continuity, replace the relay. (2) Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. No Continuity S04970 (c) 2 Ohmmeter 1 5 3 Battery Continuity Inspect the No.3 cooling fan relay operation. (1) Apply battery positive voltage across terminals 1 and 2. (2) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay. (d) Reinstall the No.3 cooling fan relay. 5. REINSTALL RELAY BOX COVER S04969 Author: Date: 1646 AX–1 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX034–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. Author: Date: 1894 AX–2 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE SYSTEM AX035–01 OPERATION 2nd Brake (B2) Planetary Gear Unit 1st & Reverse Brake (B3) 2nd Coast brake (B1) O/D Direct Forward One – Way clutch O/D Brake (B0) Clutch (C1) Clutch (C0) Direct Clutch (C2) No.2 (F ) 2 One Way Clutch Counter O/D One – Way Rear No.1 (F1) Drive Gear Clutch (F0) Front Planetary Intermediate Planetary Gear O/D Planetary Gear Gear Shaft Shift lever position P Gear position C0 C1 C2 Parking
R Reverse
N Neutral
1st

2nd

3rd




D O/D 2 L B0 B1 B2
1st

2nd

*3rd

1st

*2nd

B3 Input Shaft F0 F1 F2


























: Operating *: Down–shift only in the 3rd gear for the 2 position and 2nd gear for the L position no up–shift. D00989 Author: Date: 1895 AX–3 AUTOMATIC TRANSAXLE (A140E) – VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR AX036–01 ON–VEHICLE REPAIR 1. 2. 3. (a) REMOVE AIR CLEANER ASSEMBLY DISCONNECT VEHICLE SPEED SENSOR CONNECTOR REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Q00207 (b) Vehicle Speed Sensor (c) 4. (a) Drive Gear O–Ring Clip Q04678 (b) (c) 5. 6. Remove the clip and speedometer driven gear from vehicle speed sensor. Remove the O–ring from vehicle speed sensor. INSTALL VEHICLE SPEED SENSOR ASSEMBLY Coat a new O–ring with ATF and install it to the vehicle speed sensor. Install the speedometer driven gear to the vehicle speed sensor and clip. Install the vehicle speed sensor assembly and torque the bolts. Torque: 16 N·m (160 kgf·cm, 12 ft·lbf) CONNECT VEHICLE SPEED SENSOR CONNECTOR INSTALL AIR CLEANER ASSEMBLY Author: Date: 1896 AX–4 AUTOMATIC TRANSAXLE (A140E) – PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AX037–01 ON–VEHICLE REPAIR 1. (a) (b) 2. 3. (a) (b) 4. (a) (b) Q10050 (c) (d) 5. 6. (a) (b) REMOVE CONTROL SHAFT LEVER Remove the nut and control cable. Remove the nut, washer and control shaft lever. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR REMOVE PARK/NEUTRAL POSITION SWITCH Pry off the lock washer and remove the nut. Remove the 2 bolts and park/neutral position switch. INSTALL PARK/NEUTRAL POSITION SWITCH Install the park/neutral position switch with 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install a new lock plate and the nut. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) Bend claws on the lock plate to fix the nut. Adjust the park/neutral position switch. (See page DI–389) CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR INSTALL CONTROL SHAFT LEVER Install the control shaft lever, washer and nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Install the control cable and nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Author: Date: 1897 AX–5 AUTOMATIC TRANSAXLE (A140E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX038–01 ON–VEHICLE REPAIR 1. DRAIN TRANSAXLE FLUID 2. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the oil pan bolts, and carefully remove the oil pan assembly. Discard the gasket. Q00073 3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear AT0103 36 (1.417) mm (in.) 4. (a) (b) REMOVE MANUAL VALVE BODY DETENT SPRING AND MANUAL VALVE BODY Remove the detent spring on the manual valve body. Remove the manual valve body. 14 (0.551) AT2711 Z10944 mm (in.) 20 (0.787) 45 (1.772) AT3336 50 (1.969) 5. REMOVE OIL STRAINER AND OIL PIPE BRACKET (a) Remove the 3 bolts and the oil strainer. (b) Remove the 2 bolts and oil pipe bracket. NOTICE: Be careful as oil will come out of the strainer when it is removed. Z10940 Author: Date: 1898 AX–6 AUTOMATIC TRANSAXLE (A140E) 6. AT0493 – VALVE BODY ASSEMBLY DISCONNECT SOLENOID CONNECTORS Z10941 7. REMOVE OIL PIPES Pry up the both pipe ends with a large screwdriver and remove the 4 pipes. NOTICE: Be careful not to bend or damage the pipe. AT7868 8. REMOVE VALVE BODY Remove the 12 bolts. AT0399 9. (a) (b) 10. REMOVE THROTTLE CABLE Disconnect the throttle cable. Remove the valve body. REMOVE 2ND BRAKE APPLY GASKET 11. (a) (b) (c) REMOVE SHIFT SOLENOID VALVE NO.1 AND NO.2 Remove the 2 bolts and shift solenoid valve No.1. Remove the bolt and shift solenoid valve No.2. Remove the 2 O–rings from the shift solenoid valve No.1 and No.2. OR0038 mm (in.) 16 (0.63) Shift Solenoid Valve No.1 16 (0.63) AT3008 Shift Solenoid Valve No.2 Z19291 Author: Date: 1899 AX–7 AUTOMATIC TRANSAXLE (A140E) 12. (a) (b) (c) (d) 13. – VALVE BODY ASSEMBLY INSTALL SHIFT SOLENOID VALVE NO.1 AND NO.2 Coat 2 new O–rings with ATF. Install the 2 O–rings to the shift solenoid valve No.1 and No.2. Install the shift valve No.1 with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install the shift valve No.2 with the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL NEW 2ND BRAKE APPLY GASKET 14. (a) INSTALL VALVE BODY While holding the cam down by your hand, slip the cable end into the slot. NOTICE: Do not entangle the solenoid wire. OR0038 C B A B A B D C AT0492 Z10942 (b) Install the valve body with the 12 bolts. HINT: Temporarily install the 12 bolts first, then tighten the 12 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Bolt length: Bolt A: 20 mm (0.79 in.) Bolt B: 25 mm (0.98 in.) Bolt C: 36 mm (1.42 in.) Bolt D: 50 mm (1.97 in.) 15. INSTALL OIL PIPES Using a plastic hammer, install the 4 pipes into the positions indicated in the illustration. NOTICE: Be careful not to bend or damage the pipes. AT7870 Shift Solenoid Valve No.1 Shift Solenoid Valve No.2 16. CONNECT SOLENOID CONNECTORS Connect the black wire harness to shift solenoid valve No.2 and white wire harness to shift solenoid valve No.1. White AT0493 Black Z10941 Author: Date: 1900 AX–8 AUTOMATIC TRANSAXLE (A140E) mm (in.) 20 (0.78) 45 (1.772) AT3336 36 (1.417) 17. (a) (b) 50 (1.969) VALVE BODY ASSEMBLY INSTALL OIL STRAINER AND OIL PIPE BRACKET Install the 2 bolts and oil pipe bracket. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Install the 3 bolts and oil strainer. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Z10940 mm (in.) 18. (a) (b) (c) 14 (0.551) AT2711 – Z10944 (d) (e) INSTALL MANUAL VALVE BODY DETENT SPRING AND MANUAL VALVE BODY Align the manual valve with the pin on the manual shaft lever. Lower the manual valve body into place. Temporarily install the 4 bolts first. Then, tighten them with a torque wrench. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Place the detent spring on the manual valve body and temporarily install the 2 bolts first. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) Check that the manual valve lever is touching the center of the detent spring tip roller. 19. INSTALL MAGNETS IN OIL PAN NOTICE: Make sure that the magnets do not interfere with the oil pipes. Magnets AT2368 Z10945 20. INSTALL OIL PAN AND GASKET Install a new gasket and oil pan with the 15 bolts. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) 21. FILL FLUID AND CHECK FLUID LEVEL (See page DI–389) Q00073 Author: Date: 1901 AX–9 AUTOMATIC TRANSAXLE (A140E) – THROTTLE CABLE THROTTLE CABLE AX039–01 ON–VEHICLE REPAIR 1. (a) (b) 3. DISCONNECT THROTTLE CABLE Disconnect the cable from the throttle linkage. Disconnect the cable from the cable clamps in the engine compartment. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) REMOVE VALVE BODY (See page AX–5) 4. (a) (b) REMOVE THROTTLE CABLE Remove the retaining bolt and plate. Pull out the cable from the transaxle case. 5. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR PAINT MARK ON INNER CABLE 2. Q10052 0.8 – 1.5 mm(0.031 – 0.059 in.) 200 mm (7.87 in.) Q10339 HINT: New cable does not have a staked cable stopper. (a) Bend the cable to ensure a radius of about 200 mm (7.87 in.). (b) Pull the inner cable lightly until a slight resistance is felt, and hold it there. (c) Stake the stopper, 0.8 – 1.5 mm (0.031 – 0.059 in.) from the end of the outer cable. (d) Install a new O–ring to the throttle cable. (e) Push in the throttle cable and install the retaining bolt. 6. INSTALL VALVE BODY (See page AX–5) 7. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–4) 8. CONNECT THROTTLE CABLE 9. FILL FLUID AND CHECK FLUID LEVEL (See page DI–389) 10. ADJUST THROTTLE CABLE (See page DI–389) Author: Date: 1902 AX–10 AUTOMATIC TRANSAXLE (A140E) – SHIFT SOLENOID VALVE SL SHIFT SOLENOID VALVE SL AX03A–01 ON–VEHICLE REPAIR 1. 2. Q10051 3. (a) (b) 4. (a) (b) 5. 6. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–4) DISCONNECT SHIFT SOLENOID VALVE SL CONNECTOR REMOVE SHIFT SOLENOID VALVE SL Remove the 2 bolts and shift solenoid valve SL. Remove the 2 O–rings from the shift solenoid valve SL. INSTALL SHIFT SOLENOID VALVE SL Coat 2 new O–rings with ATF and install them to the shift solenoid valve SL. Install the shift solenoid valve SL and 2 bolts. CONNECT SHIFT SOLENOID VALVE SL CONNECTOR INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–4) Author: Date: 1903 AX–11 AUTOMATIC TRANSAXLE (A140E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX03B–01 ON–VEHICLE REPAIR SST 1. REMOVE LH AND RH DRIVE SHAFTS (See page SA–17) 2. REMOVE SIDE GEAR SHAFT OIL SEAL Using SST, drive out the oil seals on both sides. SST 09308–00010 Q00394 3. (a) SST (b) 4. Q00247 5. INSTALL SIDE GEAR SHAFT OIL SEAL Using SST, drive in a new oil seal. SST 09350–32014 (09351–32130, 09351–32150) Oil seal depth: LH: 2.7 ± 0.5 mm (0.106 ± 0.020 in.) RH: 0 ± 0.5 mm (0 ± 0.020 in.) Coat the lip of oil seal with MP grease. INSTALL LH AND RH DRIVE SHAFTS (See page SA–24) CHECK TRANSAXLE FLUID LEVEL (See page DI–389) Author: Date: 1904 AX–12 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made) SHIFT LOCK SYSTEM (TMC Made) AX03C–01 LOCATION Shift Lock Override Cover Shift Lock Override Button Stop Light Switch Key Interlock Solenoid Shift Lock Control Unit Assembly D00760 Author: Date: 1905 AX–13 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMC Made) AX03D–01 INSPECTION 5 (IG) 1 (ACC) 4 (KLS+) 3 (E) 2 (STP) Wire Harness Side D00758 Terminal 1 – 3 (ACC – E) 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connector. Measuring Condition Voltage (V) Ignition switch ACC 10 – 14 Ignition switch ON 10 – 14 2 – 3 (STP – E) Depressing brake pedal 10 – 14 4 – 3 (KLS+ – E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 – 11 6 – 9.5 5 – 3 (IG – E) 2. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 12.5 – 16.5 Ω If resistance value is not as specified, replace the solenoid. 1 (KLS+) 2 (E) Q09456 (c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. 1 (KLS+) 2 (E) Q09457 Author: Date: 1906 AX–14 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) SHIFT LOCK SYSTEM (TMMK Made) AX03E–01 LOCATION Shift Lock Override Cover Shift Lock Override Button Stop Light Switch Key Interlock Solenoid Shift Lock Control ECU Shift Lock Solenoid Shift Lock Control Switch D00759 Author: Date: 1907 AX–15 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) AX03F–01 3 (IG) 6 (STP) INSPECTION 1 (ACC) Back Side A 4 (KLS+) –) 5 (SLS 4 (P2) 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure voltage at each terminal. HINT: Do not disconnect the ECU connector. 1 (P) B 3 (P1) 2 (SLS+) Front Side Q09459 Terminal A, 1 – A, 5 (ACC – E) Measuring Condition Voltage (V) Ignition switch ACC 10 – 14 Ignition switch ON 10 – 14 A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14 A, 4 – A, 5 (KLS+ – E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 – 11 6 – 9.5 (1) Ignition switch ON and P position (2) Depress brake pedal (3) Except P position 0 8 – 13.5 0 B, 3 – B, 1 (P1 – P) (1) Ignition switch ON, P position and depressing brake pedal (2) Shift except P position under conditions above 0 9 – 13.5 B, 4 – B, 1 (P2 – P) (1) Ignition switch ACC, P position (2) Shift except P position under conditions above 9 – 13.5 0 A, 3 – A, 5 (IG – E) B, 2 – B, 5 (SLS+ – SLS–) 2. (a) (b) INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 29 – 35 Ω If resistance value is not as specified, replace the solenoid. 5 (SLS–) 2 (SLS+) Q09460 (c) Apply battery positive voltage between terminals. Check that operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. 5 (SLS–) 2 (SLS+) Q09461 Author: Date: 1908 AX–16 AUTOMATIC TRANSAXLE (A140E) – SHIFT LOCK SYSTEM (TMMK Made) 3. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 12.5 – 16.5 Ω If resistance value is not as specified, replace the solenoid. 1 (KLS+) 2 (E) Q09456 (c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. 1 (KLS+) 2 (E) Q09457 3 (P1) 4 (P2) 1 (P) Q09464 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each terminal. Shift position Tester connection Specified value P position (Release button is not pushed) 1 – 3 (P – P1) Continuity P position (Release button is pushed) 1 – 3 (P – P1) 1 – 4 (P – P2) Continuity R, N, D, 2, L position 1 – 4 (P – P2) Continuity If continuity is not as specified, replace the switch. Author: Date: 1909 AX–17 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03G–01 COMPONENTS 14 (145, 10) Air Cleaner Assembly Engine Hood 14 (145, 10) Starter Hold Down Clamp Cruise Control Actuator RH Drive Shaft Torque Converter Clutch 66 (670, 48) 42 (430, 31) 39 (400, 29)
Snap Ring
Manifold Stay Stiffener Plate 32 (330, 24) Battery 27 (280, 20) TMMK x6 42 (430, 31) 39 (400, 29) 39 (400, 29) TMC 42 (430, 31) Stiffener Plate Battery Tray LH Drive Shaft 66 (670, 48)
Snap Ring Clip 42 (430, 31) Shift Control Cable Exhaust Manifold Stay 15 (150, 11) 66 (670, 48) Plug for Line Pressure Test 19 (195, 14) No.1 Exhaust Pipe Support Bracket Rear End Plate 25 (250, 18) Oil Pan Insulator N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Q10053 Author: Date: 1910 AX–18 AUTOMATIC TRANSAXLE (A140E) RH Fender Apron seal – AUTOMATIC TRANSAXLE UNIT RR Engine Mounting Stabilizer Bar TMC Made : 80 (820, 59) TMMK Made : Green Color Bolt : 66 (670, 48) Silver Color Bolt : 44 (450, 32) 19 (195, 14) RH Rear Lower Brace 10 (100, 7) LH Engine Mounting 64 (650, 47) 39 (400, 29) Steering Return Pipe FR Engine Mounting Stabilizer Bar Link RH Front Lower Brace 181 (1,850, 134) LH Rear Lower Brace 66 (670, 48) 32 (330, 24) Front Suspension Member TMC Made : 80 (820, 59) TMMK Made : Green Color Bolt : 66 (670, 48) Silver Color Bolt : 44 (450, 32) 36 (370, 27) 181 (1,850, 134) LH Front Lower Brace 36 (370, 27)
Front Exhaust Pipe

Gasket
62 (630, 46)
127 (1,300, 94) 80 (820, 59) 181 (1,850, 134) 56 (570, 41)
Gasket
Exhaust Pipe No.1 Support Bracket LH Fender Apron Seal Tie Rod End 33 (330, 24) Exhaust Pipe Clamp 49 (500, 36)
Cotter Pin LH Fender Liner 33 (330, 24) 294 (3,000, 217) Lock Nut Cap Center Engine Under Cover LH Fender Liner Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Q10054 Author: Date: 1911 AX–19 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03H–01 REMOVAL 1. 2. 3. REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY DISCONNECT THROTTLE CABLE 4. w/ CRUISE CONTROL: REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector. Remove the 3 bolts and disconnect cruise control actuator with the bracket. (a) (b) Q10055 5. 6. 7. 8. 9. Q00211 DISCONNECT OIL COOLER HOSE DISCONNECT VEHICLE SPEED SENSOR CONNECTOR DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR DISCONNECT SHIFT SOLENOID VALVE NO.1 AND NO.2 CONNECTOR DISCONNECT SHIFT SOLENOID VALVE SL CONNECTOR 10. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque: TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK made: Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (450 kgf·cm, 32 ft·lbf) 11. 12. (a) (b) DISCONNECT 2 GROUND CABLES REMOVE STARTER Disconnect the connector and remove the nut. Remove the 2 bolts, shift cable clamp and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) REMOVE 3 TRANSAXLE–TO–ENGINE BOLTS Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) Q10056 13. Q10057 Author: Date: 1912 AX–20 AUTOMATIC TRANSAXLE (A140E) Q10058 – AUTOMATIC TRANSAXLE UNIT 14. REMOVE EXHAUST MANIFOLD STAY Remove the 2 bolts and exhaust manifold stay. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 15. REMOVE TRANSAXLE–TO–ENGINE BOLT Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 16. REMOVE ENGINE HOOD (a) Disconnect the washer pipe. (b) Remove the 4 bolts and engine hood. Torque: 14 N·m (145 kgf·cm, 10 ft·lbf) 17. RAISE AND SUPPORT VEHICLE SECURELY 18. REMOVE FRONT WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) 19. REMOVE ENGINE UNDER COVER AND CENTER ENGINE UNDER COVER 20. (a) (b) DISCONNECT SHIFT CONTROL CABLE Remove the nut and disconnect the shift control cable from the park/neutral position switch. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Remove the clip and disconnect the shift control cable from the bracket. Q10059 21. Q00251 REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET HINT: At the time of installation, please refer to the following item. Replace the used gasket with a new gasket. 22. DRAIN DIFFERENTIAL FLUID 23. REMOVE LH AND RH FENDER APRON SEALS 24. REMOVE LH AND RH DRIVE SHAFTS (See page SA–17) Author: Date: 1913 AX–21 AUTOMATIC TRANSAXLE (A140E) 25. (a) (b) (c) Q10060 – AUTOMATIC TRANSAXLE UNIT REMOVE EXHAUST FRONT PIPE Remove the 2 nuts and exhaust front pipe clamp. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 2 bolts and exhaust pipe No.1 support bracket. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 3 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) HINT: At the time of installation, please refer to the following item. Replace the used nuts with new ones. (d) Remove the 2 bolts, nuts and front exhaust pipe. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) HINT: At the time of installation, please refer to the following item. Replace the used nuts with new ones. (e) Remove the 2 gaskets. HINT: At the time of installation, please refer to the following item. Replace the used gaskets with new ones. 26. REMOVE FRONT SIDE ENGINE MOUNTING INSULATOR BOLT Torque: TMC made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK made: Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (450 kgf·cm, 32 ft·lbf) Q00068 27. (a) (b) REMOVE REAR SIDE ENGINE MOUNTING NUT Remove the 2 grommets. Remove the 3 nuts. Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) 28. (a) (b) REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT Remove the 2 grommets. Remove the 2 nuts. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) Q08532 Q10061 Author: Date: 1914 AX–22 AUTOMATIC TRANSAXLE (A140E) 29. (a) (b) (c) – AUTOMATIC TRANSAXLE UNIT REMOVE STEERING GEAR HOUSING Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings. Torque:19 N·m (195 kgf·cm, 14 ft·lbf) Remove the front stabilizer bar. (See page SA–48) Remove the 2 steering gear housing mounting bolts and nuts. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Q10062 30. TIE STEERING GEAR HOUSING TO REAR ENGINE MOUNTING BRACKET BY CORD OR EQUIVALENT 31. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. Q10063 32. (a) REMOVE FRONT FRAME ASSEMBLY Remove the 2 bolts and steering return pipe mounting brackets. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (b) Remove the screws and turn over the front side of the LH and RH fender liners. (c) Remove the screws and turn over the rear side of LH and RH fender liners. Q06479 Q10041 Q10037 Author: Date: 1915 AX–23 AUTOMATIC TRANSAXLE (A140E) (d) Front (e) 33. – AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts and 4 nuts. Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) Remove the front frame assembly. SUPPORT TRANSAXLE WITH A TRANSMISSION JACK Q10172 Rear Q10064 TMC : Bolt TMMK : Nut Q10065 34. REMOVE FRONT SIDE STIFFENER PLATE TMMK made: Remove the nut, 2 bolts and stiffener plate. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) TMC made: Remove the 3 bolts and stiffener plate. Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) 35. REMOVE REAR END PLATE (a) Remove the 2 bolts and No.1 exhaust pipe support bracket. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) (b) Remove the 2 bolts and rear end plate with oil pan insulator. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Author: Date: 1916 AX–24 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT 36. Q10066 REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLT Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley set bolt by a wrench. Torque: 27 N·m (280 kgf·cm, 20 ft·lbf) HINT: At the time of installation, please refer to the following item. First the install black colored bolt and then the 5 other bolts. 37. REMOVE REAR SIDE STIFFENER PLATE (a) Remove the 2 bolts and manifold stay. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) (b) Remove the 4 bolts and stiffener plate. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 38. REMOVE TRANSAXLE ASSEMBLY Separate the transaxle and engine, and lower the transaxle. Author: Date: 1917 AX–25 AUTOMATIC TRANSAXLE (A140E) – AUTOMATIC TRANSAXLE UNIT AX03I–01 INSTALLATION 1. AT3412 CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using a scale and a straight edge, measure to the distance from the installed surface to the transaxle housing. Correct distance: 13.0 mm (0.512 in.) or more 2. TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX–19). HINT: After installation, check and inspect items as follows.
Fluid level (See page DI–389)
Front wheel alignment (See page SA–4)
Road test of the vehicle
Engine hood (See page BO–10) Author: Date: 1918 AX–26 AUTOMATIC TRANSAXLE (A140E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE TORQUE CONVERTER CLUTCH AND DRIVE PLATE SST AX03J–01 INSPECTION 1. (a) (b) AT0953 INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. SST 09350–32014 (09351–32010) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch. SST 09350–32014 (09351–32020) (c) With the torque converter clutch standing on its side,the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter clutch if the clutch still fails the test. Hold Lock Turn Free AT3306 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure the drive plate runout. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within the specification or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) Q04237 Author: Date: 1919 AX–27 AUTOMATIC TRANSAXLE (A140E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE 3. AT4184 MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 in.) If the runout is not within the specification, try to correct by reorienting the installation of the torque converter clutch. If excessive runout cannot be corrected, replace the torque converter clutch. HINT: Mark the position of the torque converter clutch to ensure the correct installation. (b) Remove the torque converter clutch. Author: Date: 1920 AX–1 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX03L–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. Author: Date: 1921 AX–2 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE SYSTEM AX03M–01 OPERATION 1st and Reverse 2nd Coast Brake 2nd Brake (B2) Brake (B3) (B1) Forward Clutch One–Way Clutch Direct Clutch (C1) No.2 (F2) (C2) Planetary Gear Unit O/D Direct Clutch (C0) O/D Brake (B0) One–Way Clutch No.1 (F1) Rear Planetary Gear O/D One–Way Clutch (F0) Counter Drive Gear O/D Planetary Gear Intermediate Shaft Shift Lever Position Gear Position P Parking R Reverse N Neutral C0 C1 C2 Input Shaft Front Planetary Gear B0 B1 B2 B3 F0 F1 F2 1st D 2nd 3rd O/D 1st 2 2nd *3rd L 1st *2nd *Down–shift only – no up–shift : Operating D01018 Author: Date: 1922 AX–3 AUTOMATIC TRANSAXLE (A541E) – VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR AX03N–01 ON–VEHICLE REPAIR 1. 2. 3. (a) REMOVE AIR CLEANER ASSEMBLY DISCONNECT VEHICLE SPEED SENSOR CONNECTOR REMOVE VEHICLE SPEED SENSOR ASSEMBLY Remove the bolt and vehicle speed sensor assembly. Q05725 (b) Vehicle Speed Sensor (c) 4. (a) Driven Gear O–Ring Clip Q04678 (b) (c) 5. 6. Remove the clip and driven gear from the vehicle speed sensor. Remove the O–ring from the vehicle speed sensor. INSTALL VEHICLE SPEED SENSOR ASSEMBLY Coat a new O–ring with ATF and install it to the vehicle speed sensor. Install the driven gear to the vehicle speed sensor and clip. Install the vehicle speed sensor assembly with the bolt. Torque: 4.9 N·m (50 kgf·cm, 43 in.·lbf) CONNECT VEHICLE SPEED SENSOR CONNECTOR INSTALL AIR CLEANER ASSEMBLY Author: Date: 1923 AX–4 AUTOMATIC TRANSAXLE (A541E) – DIRECT CLUTCH SPEED SENSOR DIRECT CLUTCH SPEED SENSOR AX03O–01 ON–VEHICLE REPAIR 1. 2. (a) DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR REMOVE DIRECT CLUTCH SPEED SENSOR Remove the bolt and direct clutch speed sensor. Q05726 (b) 3. (a) O–Ring (b) Remove the O–ring from direct clutch speed sensor. INSTALL DIRECT CLUTCH SPEED SENSOR Coat a new O–ring with ATF and install it to the direct clutch speed sensor. Install the direct clutch speed sensor with the bolt. Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) Q04733 Author: Date: 1924 AX–5 AUTOMATIC TRANSAXLE (A541E) – PARK/NEUTRAL POSITION (PNP) SWITCH PARK/NEUTRAL POSITION (PNP) SWITCH AX03P–01 ON–VEHICLE REPAIR 1. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 2. (a) (b) REMOVE PARK/NEUTRAL POSITION SWITCH Remove the clip from the shift control cable. Remove the nut and control cable. (c) (d) (e) (f) Remove the nut, washer and transaxle control shaft lever. Using a screwdriver, pry off the lock plate. Remove the nut and lock plate. Remove the 2 bolts and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH Temporarily install the park/neutral position switch with the 2 bolts. Install a new lock plate and nut. Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf) Stake the nut with the lock plate. Q00229 Q06496 Q05727 (a) (b) (c) Q04617 Author: Date: 1925 AX–6 AUTOMATIC TRANSAXLE (A541E) Neutral Basic Line – PARK/NEUTRAL POSITION (PNP) SWITCH (d) Adjust the park/neutral position switch. (See page DI–438) (e) (f) Install the transaxle control shaft lever and washer. Install and torque the nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) (g) Install the control cable and nut. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Install the clip to the shift control cable. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR TEST DRIVE VEHICLE Groove Z10304 Q04687 (h) 4. 5. Q06496 Author: Date: 1926 AX–7 AUTOMATIC TRANSAXLE (A541E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX03Q–02 ON–VEHICLE REPAIR 1. DRAIN ATF Using a hexagon wrench, remove the drain plug and fluid into the suitable container. 2. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove oil pan bolts, and carefully remove the pan assembly. Discard the gasket. AT3785 3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look at the chips and particles in the pan and magnet carefully to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (non–magnetic): bushing wear AT0103 4. REMOVE OIL STRAINER AND APPLY PIPE BRACKET (a) Remove the 3 bolts and oil strainer. NOTICE: Be careful as oil will come out of the strainer when it is removed. (b) Remove the 3 bolts and apply pipe bracket. D01019 Connector 5. REMOVE OIL PIPES Pry up both pipe ends with a large screwdriver and remove the 5 pipes. 6. DISCONNECT SOLENOID CONNECTORS Q05728 Author: Date: 1927 AX–8 AUTOMATIC TRANSAXLE (A541E) 7. (a) (b) (c) – VALVE BODY ASSEMBLY REMOVE DETENT SPRING AND OIL PIPE Remove the 2 bolts and detent spring. Remove the bolt. Pry up the pipe with a screwdriver and remove the pipe. D01020 8. REMOVE MANUAL VALVE BODY Remove the 5 bolts and manual valve body. D01021 9. REMOVE CONNECTOR CLAMP AND PIPE RETAINER Remove the 2 bolts, connector clamp and pipe retainer. D01059 10. REMOVE B3 APPLY PIPE Pry up the pipe with a screwdriver and remove the pipe. D01058 11. (a) REMOVE VALVE BODY Remove the 9 bolts. D01023 Author: Date: 1928 AX–9 AUTOMATIC TRANSAXLE (A541E) (b) 12. – VALVE BODY ASSEMBLY Disconnect the throttle cable from the cam and remove the valve body. REMOVE 2ND BRAKE APPLY GASKET OR0038 13. (a) REMOVE SOLENOID VALVES Remove the 3 bolts, shift solenoid valve No.1 and No.2 with the retainer. NOTICE: When removing solenoid, do not use a screwdriver, etc. to pry up the solenoid. (b) Remove the O–rings from the shift solenoid valve No.1 and No.2. Q05643 (c) (d) Remove the bolt and shift solenoid valve SL. Remove the O–ring from the shift solenoid valve SL. (e) (f) Remove the bolt and shift solenoid valve SLN. Remove the O–ring from the shift solenoid valve SLN. 14. (a) INSTALL SOLENOID VALVES Coat the 2 new O–rings with ATF and install it to the shift solenoid valve SL. Install the shift solenoid valve SL. Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Q05657 Q05402 (b) (c) Q05657 Author: Date: 1929 AX–10 AUTOMATIC TRANSAXLE (A541E) (d) (e) (f) – VALVE BODY ASSEMBLY Coat the 2 new O–rings with ATF and install it to the shift solenoid valve SLN. Install the shift solenoid valve SLN. Install and torque the bolt. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) Q05402 (g) (h) (i) 15. Coat the 2 new O–rings with ATF and install it to the shift solenoid valve No.1 and No.2. Install the No.1 and No.2 solenoids. Install and torque the 3 bolts. Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf) PLACE NEW 2ND BRAKE APPLY GASKET Q05643 16. (a) INSTALL VALVE BODY TO TRANSAXLE CASE While holding the cam down with your hand, slip the cable end into the slot. (b) Lower the valve body into place. NOTICE: Be careful not to entangle the solenoid wire. OR0038 D D A C C B C D01023 (c) Install and tighten the 9 bolts. HINT: Hand tighten the 9 bolts first, then torque with a torque wrench. Bolt length: Bolt A: 30 mm (1.181 in.) Bolt B: 43 mm (1.693 in.) Bolt C: 48 mm (1.890 in.) Bolt D: 52 mm (2.047 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 17. INSTALL B3 APPLY PIPE NOTICE: Be careful not to bend or damage the pipe. D01058 Author: Date: 1930 AX–11 AUTOMATIC TRANSAXLE (A541E) 18. (a) (b) B A – VALVE BODY ASSEMBLY INSTALL CONNECTOR CLAMP AND PIPE RETAINER Install the connector clamp and pipe retainer. Install and torque the 2 bolts. Bolt length: Bolt A: 48 mm (1.890 in.) Bolt B: 39 mm (1.535 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) D01059 19. (a) B B A D01021 30 (1.18) B A mm (in.) Z19257 Connector INSTALL MANUAL VALVE BODY Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Hand tighten the 5 bolts first. Then, tighten them with a torque wrench. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 37 mm (1.457 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) 20. INSTALL DETENT SPRING AND OIL PIPE (a) Place the detent springs on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Bolt length: Bolt A: 14 mm (0.551 in.) Bolt B: 37 mm (1.457 in.) Torque: 11 N·m (110 kgf·cm, 8 ft·lbf) (b) Check that the manual valve lever is touching the center of the detent spring tip roller. (c) Using a plastic hammer, install the pipe into the position. NOTICE: Be careful not to bend or damage the pipe. (d) Install and torque the bolt. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) 21. CONNECT SOLENOID CONNECTORS 22. INSTALL OIL PIPES Using a plastic hammer, install the pipes into the positions. NOTICE: Be careful not to bend or damage the pipes. Q05728 Author: Date: 1931 AX–12 AUTOMATIC TRANSAXLE (A541E) A 23. (a) (b) A B B Z19256 – VALVE BODY ASSEMBLY INSTALL OIL STRAINER AND APPLY PIPE BRACKET Install the oil strainer and apply pipe bracket. Install and torque the 6 bolts. Bolt length: Bolt A: 22 mm (0.866 in.) Bolt B: 53 mm (2.087 in.) Torque: Bolt A: 10 N·m (100 kgf·cm, 7 ft·lbf) Bolt B: 11 N·m (110 kgf·cm, 8 ft·lbf) 24. INSTALL MAGNETS IN PLACE Install the 3 magnets in the indentations of the oil pan, as shown in the illustration. NOTICE: Make sure that the magnet does not interfere with the oil pipes. AT3741 25. (a) (b) 26. 27. INSTALL OIL PAN AND GASKET Install the oil pan and a new gasket. Install and torque the 17 new bolts. Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf) INSTALL AND TORQUE DRAIN PLUG Torque: 49 N·m (500 kgf·cm, 36 ft·lbf) FILL ATF AND CHECK FLUID LEVEL (See page DI–438) AT3785 Author: Date: 1932 AX–13 AUTOMATIC TRANSAXLE (A541E) – THROTTLE CABLE THROTTLE CABLE AX03R–01 ON–VEHICLE REPAIR 1. 2. REMOVE BATTERY w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Remove the 3 bolts and cruise control actuator. Q09982 3. DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. 4. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX–5) 5. REMOVE VALVE BODY (See page AX–7) Q00225 6. (a) (b) REMOVE THROTTLE CABLE Remove the bolt and retaining plate. Pull out the cable from the transaxle case. 7. INSTALL THROTTLE CABLE INTO TRANSAXLE CASE Make sure to push it in all the way. Install the retaining plate and bolt. Install and torque the bolt. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) INSTALL VALVE BODY (See page AX–7) Q00270 (a) (b) (c) 8. Q00270 9. 200 mm (7.87 in.) 0.8 – 1.5 mm (0.031–0.059 in.) Q05731 IF THROTTLE CABLE IS NEW, STAKE STOPPER OR PAINT MARK ON INNER CABLE HINT: New cables do not have a staked cable stopper. (a) Bend the cable so there is a radius of about 200 mm (7.87 in.). (b) Pull the inner cable lightly until slight resistance is felt, and hold it there. (c) Stake the stopper, 0.8–1.5 mm (0.031–0.059 in.) from the end of outer cable. Author: Date: 1933 AX–14 AUTOMATIC TRANSAXLE (A541E) 10. 11. 12. – THROTTLE CABLE CONNECT THROTTLE CABLE TO ENGINE Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) ADJUST THROTTLE CABLE (See page DI–438) INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX–5) Q00225 13. w/ Cruise Control: INSTALL CRUISE CONTROL ACTUATOR Install the cruise control actuator with the 3 bolts. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) 14. INSTALL BATTERY 15. TEST DRIVE VEHICLE Q09982 Author: Date: 1934 AX–15 AUTOMATIC TRANSAXLE (A541E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX03S–01 ON–VEHICLE REPAIR SST 1. REMOVE FRONT DRIVE SHAFT (See page SA–25) 2. REMOVE SIDE GEAR SHAFT OIL SEAL Using SST, pull out the oil seal. SST 09308–00010 Q00394 3. (a) SST (b) INSTALL LEFT SIDE GEAR SHAFT OIL SEAL Using SST and a hammer, drive in a new oil seal. SST 09223–15020, 09351–32014 (09351–32130) Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) Coat the lip of the oil seal with MP grease. Q06348 4. (a) (b) 5. SST 6. Q00238 INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL Using SST, drive in a new oil seal. SST 09316–60010 (09316–00010) Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) Coat the lip of the oil seal with MP grease. INSTALL FRONT DRIVE SHAFT (See page SA–25) CHECK TRANSAXLE FLUID LEVEL (See page DI–438) Author: Date: 1935 AX–16 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMC Made) SHIFT LOCK SYSTEM (TMC Made) AX03T–01 LOCATION Key Interlock Solenoid Shift Lock Override Cover Stop Light Switch Shift Lock Override Button Shift Lock Control Unit Assembly D01026 Author: Date: 1936 AX–17 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMC Made) AX03U–02 INSPECTION 5 (IG) 1 (ACC) 4 (KLS+) 3 (E) 2 (STP) Wire Harness Side Q09455 Terminal 1 – 3 (ACC – E) 1. INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter, measure the voltage at each terminal. HINT: Do not disconnect the shift lock control unit assembly connector. Measuring Condition Voltage (V) Ignition switch ACC 10 – 14 Ignition switch ON 10 – 14 2 – 3 (STP – E) Depressing brake pedal 10 – 14 4 – 3 (KLS+ – E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 – 11 6 – 9.5 5 – 3 (IG – E) 2. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 12.5 – 16.5 Ω If resistance value is not as specified, replace the solenoid. 1 (KLS+) 2 (E) Q09456 (c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operated, replace the solenoid. 1 (KLS+) 2 (E) (–) (+) Q09457 Author: Date: 1937 AX–18 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) SHIFT LOCK SYSTEM (TMMK Made) AX03V–01 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Override Cover Shift Lock Override Button Shift Lock Solenoid Shift Lock Control Switch Shift Lock Control ECU D01027 Author: Date: 1938 AX–19 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) AX03W–01 INSPECTION 3 (IG) 1 (ACC) 6 (STP) Back Side A 1 (P) 5 (E) 4 (KLS+) 4 (P2) 5 (SLS–) 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure voltage at each terminal. HINT: Do not disconnect the ECU connector. B 3 (P1) 2 (SLS+) Front Side Q09459 Terminal A, 1 – A, 5 (ACC – E) Measuring Condition Voltage (V) Ignition switch ACC 10 – 14 Ignition switch ON 10 – 14 A, 6 – A, 5 (STP – E) Depressing brake pedal 10 – 14 A, 4 – A, 5 (KLS+ – E) (1) Ignition switch ACC and P position (2) Ignition switch ACC and except P position (3) Ignition switch ACC and except P position (After approx. 1 second) 0 7.5 – 11 6 – 9.5 (1) Ignition switch ON and P position (2) Depress brake pedal (3) Except P position 0 8 – 13.5 0 B, 3 – B, 1 (P1 – P) (1) Ignition switch ON, P position and depress brake pedal (2) Shift except P position under conditions above 0 9 – 13.5 B, 4 – B, 1 (P2 – P) (1) Ignition switch ACC, P position (2) Shift except P position under conditions above 9 – 13.5 0 A, 3 – A, 5 (IG – E) B, 2 – B, 5 (SLS+ – SLS–) 2. (a) (b) INSPECT SHIFT LOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 29 – 35 Ω If resistance value is not as specified, replace the solenoid. 5 (SLS–) 2 (SLS+) Q09460 (c) Apply battery positive voltage between terminals. Check that operation. If the solenoid does not operated, replace the solenoid noise can be heard from the solenoid. 5 (SLS–) 2 (SLS+) Q09461 Author: Date: 1939 AX–20 AUTOMATIC TRANSAXLE (A541E) – SHIFT LOCK SYSTEM (TMMK Made) 3. (a) (b) INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. Standard resistance: 12.5 – 16.5 Ω If resistance value is not as specified, replace the solenoid. 1 (KLS+) 2 (E) Q09456 (c) Apply battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. If the solenoid does not operated, replace the solenoid. 1 (KLS+) 2 (E) (–) (+) Q09457 3 (P1) 4 (P2) 1 (P) Q09464 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between at each terminal. Shift position Tester connection Specified value P position (Release button is not pushed) 1 – 3 (P – P1) Continuity P position (Release button is pushed) 1 – 3 (P – P1) 1 – 4 (P – P2) Continuity R, N, D, 2, L position 1 – 4 (P – P2) Continuity If continuity is not as specified, replace the switch. Author: Date: 1940 AX–21 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX03X–01 COMPONENTS Engine Hood Air Cleaner Assembly 26 (265, 19) 13 (130, 9) w/ Cruise Control : Cruise Control Actuator Shift Control Cable Clamp RH Drive Shaft Starter
Snap Ring 39 (400, 29)
32 (330, 24) 41 (420, 30) x6 48 (490, 35) 66 (670, 48) Hold–Down Clamp 20 (200, 15) Exhaust Manifold Plate x5 Battery Insulator California: Torque Converter Clutch 34 (350, 25) Hole Cover Exhaust manifold Bracket Battery Exhaust Manifold Plate 20 (200, 14) Shift Control Cable Plug for Line California: Pressure Test Clip Battery Tray
Snap Ring 15 (150, 11) 34 (350, 25) LH Drive Shaft Exhaust manifold Bracket N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part D01057 Author: Date: 1941 AX–22 AUTOMATIC TRANSAXLE (A541E) RH Fender Apron Seal – AUTOMATIC TRANSAXLE UNIT Rear Side Engine Mounting Insulator Stabilizer Bar Link Stabilizer Bar RH Rear Lower Brace 19 (195, 14) 36 (370, 27) 32 (330, 24) 80 (820, 59) Steering Return Pipe 10 (100, 7) 39 (400, 29) 181 (1,850, 134) TMC Made: 80 (820, 59) TMMK Made: Green Color Bolt 66 (670, 48) Silver Color Bolt 44 (450, 32) LH Fender Apron Seal 181 (1,850, 134) LH Rear Lower Brace Front Side Engine Mounting Insulator Tie Rod End RH Front Lower Brace 36 (370, 27) Lock Cap 49 (500, 36) 181 (1,850, 134) TMC Made: 80 (820, 59) TMMK Made: Green Color Bolt 66 (670, 48) Silver Color Bolt 44 (450, 32) RH Fender Liner 48 (490, 35) Grommet 80 (820, 59) LH Front Lower Brace
Cotter Pin 294 (3,000, 217) 127 (1,300, 94) Exhaust Front Pipe Support Bracket
62 (630, 46)
Gasket 21 (210, 15)
Gasket
Gasket
Cotter Pin 56 (570, 41)


62 (630, 46) 33 (330, 24) Center Engine Under Cover Exhaust Front Pipe Support Stay 33 (330, 24) LH Fender Liner Engine Under Cover N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part Q10282 Author: Date: 1942 AX–23 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AX03Y–01 REMOVAL 1. 2. 3. REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY REMOVE THROTTLE CABLE FROM THROTTLE BODY Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) 4. w/ Cruise Control: REMOVE CRUISE CONTROL ACTUATOR Disconnect the connector. Remove the 3 bolts and disconnect cruise control actuator with the bracket. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Q00225 (a) (b) Q09982 5. 6. 7. 8. 9. DISCONNECT GROUND CABLE DISCONNECT VEHICLE SPEED SENSOR CONNECTOR DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR DISCONNECT SOLENOID CONNECTOR Q10287 10. (a) (b) DISCONNECT SHIFT CONTROL CABLE Remove the nut and disconnect the shift control cable from the park/neutral position switch. Torque: 15 N·m (150 kgf·cm, 11 ft·lbf) Remove the clip and disconnect the shift control cable. Q00075 11. REMOVE 2 ENGINE MOUNTING ABSORBER BOLTS Torque: 48 N·m (490 kgf·cm, 35 ft·lbf) Q10028 Author: Date: 1943 AX–24 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT 12. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque: TMC Made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK Made: Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (440 kgf·cm, 32 ft·lbf) 13. (a) (b) REMOVE STARTER AND A/T SHIFT CABLE CLAMP Disconnect the connector and remove the nut. Remove the 2 bolts, starter and A/T shift cable clamp. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) 14. REMOVE EXHAUST MANIFOLD BRACKET MOUNTING BOLT Torque: Except California: 20 N·m (200 kgf·cm, 15 ft·lbf) California: 34 N·m (350 kgf·cm, 25 ft·lbf) 15. REMOVE 5 TRANSAXLE–TO–ENGINE BOLTS AND DISCONNECT GROUND TERMINAL Torque: 66 N·m (670 kgf·cm, 48 ft·lbf) REMOVE ENGINE HOOD Disconnect the washer pipe. Remove the 4 bolts and engine hood. Torque: 26 N·m (265 kgf·cm, 19 ft·lbf) RAISE AND SUPPORT VEHICLE SECURELY REMOVE FRONT WHEELS Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET Q06478 Q10286 Q06530 16. (a) (b) Q10038 17. 18. 19. HINT: At the time of installation, please refer to the following item. Replace the used gasket with a new gasket. 20. DRAIN DIFFERENTIAL FLUID 21. REMOVE LH AND RH ENGINE SIDE COVERS 22. REMOVE LH AND RH FRONT DRIVE SHAFTS (See page SA–25) Author: Date: 1944 AX–25 AUTOMATIC TRANSAXLE (A541E) AUTOMATIC TRANSAXLE UNIT 23. REMOVE ENGINE UNDER FRONT COVER AND NO.4 CENTER ENGINE UNDER COVER 24. (a) REMOVE EXHAUST FRONT PIPE Remove the 2 bolts and exhaust front pipe support stay. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) Remove the 4 nuts. Torque: 62 N·m (630 kgf·cm, 46 ft·lbf) (b) Q10030 – HINT: At the time of installation, please refer to the following item. Replace the used nuts with new once. (c) Remove the 2 bolts and nuts. Torque: 56 N·m (570 kgf·cm, 41 ft·lbf) HINT: At the time of installation, please refer to the following item. Replace the used nuts with new once. (d) Remove the 2 exhaust front pipe clamp bolts and exhaust front pipe. Torque: 33 N·m (330 kgf·cm, 24 ft·lbf) (e) Remove the 3 gaskets. HINT: At the time of installation, please refer to the following item. Replace the used gaskets with new once. (f) Remove the 2 nuts, 2 bolts, exhaust front pipe support bracket and hole cover. Torque: Exhaust front pipe support bracket mounting nut: 21 N·m (210 kgf·cm, 15 ft·lbf) Hole plug mounting bolt: 20 N·m (200 kgf·cm, 15 ft·lbf) Q10341 25. REMOVE FRONT SIDE ENGINE MOUNTING INSULATOR BOLT Torque: TMC Made: 80 N·m (820 kgf·cm, 59 ft·lbf) TMMK Made: Green color bolt: 66 N·m (670 kgf·cm, 48 ft·lbf) Silver color bolt: 44 N·m (440 kgf·cm, 32 ft·lbf) Q00235 Author: Date: 1945 AX–26 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT 26. DISCONNECT 2 OIL COOLER HOSES 27. (a) (b) REMOVE REAR SIDE ENGINE MOUNTING NUT Remove the 2 grommets. Remove the 4 nuts. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) 28. (a) (b) REMOVE LEFT SIDE TRANSAXLE MOUNTING NUT Remove the 2 grommets. Remove the 2 nuts. Torque: 80 N·m (820 kgf·cm, 59 ft·lbf) 29. (a) REMOVE STEERING GEAR HOUSING Remove the 4 bolts, LH and RH stabilizer bar brackets and bushings. Torque: 19 N·m (195 kgf·cm, 14 ft·lbf) Remove the front stabilizer bar. (See page SA–47) Remove the 2 steering gear housing mounting bolts and nuts. Torque: 181 N·m (1,850 kgf·cm, 134 ft·lbf) Q10027 Q10071 Q10034 (b) (c) Q10035 30. SUPPORT STEERING GEAR HOUSING, AS SHOWN Q10040 Author: Date: 1946 AX–27 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT 31. Engine Hanger P19478 ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS (a) Install the No.2 engine hanger in the correct direction. Part No.: No.2 engine hanger: 12282–20020 Bolt: 91642–80825 Torque: 20 N·m (200 kgf·cm, 14 ft·lbf) (b) Attach the engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other part. 32. (a) REMOVE FRONT FRAME ASSEMBLY Remove the 2 bolts and PS reservoir pipe mounting brackets. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) (b) Remove the 4 screws and turn over the front side of the LH and RH fender liners. (c) Remove the 2 screws and turn over the rear side of LH and RH fender liners. Q06479 Q10041 Q10037 Author: Date: 1947 AX–28 AUTOMATIC TRANSAXLE (A541E) (d) Front (e) – AUTOMATIC TRANSAXLE UNIT Remove the 6 bolts and 4 nuts. Torque: 19 mm head bolt: 181 N·m (1,850 kgf·cm, 134 ft·lbf) 14 mm head bolt: 32 N·m (330 kgf·cm, 24 ft·lbf) Nut: 36 N·m (370 kgf·cm, 27 ft·lbf) Remove the front frame assembly. Q10172 Rear Q10064 33. Q04660 SUPPORT TRANSAXLE WITH A TRANSMISSION JACK 34. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS Turn the crankshaft to gain access to each bolt, remove the 6 bolts with holding the crankshaft pulley bolt by a wrench. Torque: 41 N·m (420 kgf·cm, 30 ft·lbf) HINT: At the time of installation, please refer to the following item. First install black colored bolt and then the 5 other bolts. 35. REMOVE EXHAUST MANIFOLD PLATE (a) Remove the bolt, nut and exhaust manifold plate. Torque: Except California: 20 N·m (200 kgf·cm, 15 ft·lbf) California: 34 N·m (350 kgf·cm, 25 ft·lbf) Q10036 36. REMOVE 3 LOWER TRANSAXLE–TO–ENGINE BOLTS Torque: 46 N·m (470 kgf·cm, 34 ft·lbf) 37. REMOVE TRANSAXLE ASSEMBLY Separate the transaxle and engine, and lower the transaxle. Left and lower Z14284 Author: Date: 1948 AX–29 AUTOMATIC TRANSAXLE (A541E) – AUTOMATIC TRANSAXLE UNIT AX03Z–01 INSTALLATION 1. CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using a scale and a straight edge, measure from the installed surface to the transaxle housing. Correct distance: 13.7 mm (0.539 in.) or more AT3412 2. TRANSAXLE INSTALLATION Installation is in the reverse order of removal. (See page AX–23) HINT: After installation, check and inspect items as follows.
Fluid level. (See page DI–438)
Front wheel alignment. (See page SA–4)
Do the road test. (See page DI–438)
Hood. (See page BO–10) Author: Date: 1949 AX–30 AUTOMATIC TRANSAXLE (A541E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX040–01 INSPECTION SST 1. (a) INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. SST 09350–32014 (09351–32020) (b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch. SST 09350–32014 (09351–32010) AT0952 SST AT0953 (c) With the torque converter clutch standing on its side,the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter if the clutch still fails the test. Hold Lock Turn Free AT3306 2. AT2821 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR (a) Set up a dial indicator, and measure the drive plate runout. (b) Check the damage of the ring gear. Maximum runout: 0.20 mm (0.0079 in.) If the runout is not within specification or ring gear is damaged, replace the drive plate. Torque: 83 N·m (850 kgf·cm, 61 ft·lbf) Author: Date: 1950 AX–31 AUTOMATIC TRANSAXLE (A541E) – TORQUE CONVERTER CLUTCH AND DRIVE PLATE 3. AT4184 MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator and measure the torque converter clutch sleeve runout. Maximum runout: 0.30 mm (0.0118 in.) If the runout is not within the specification, try to correct by reorienting the installation of the converter. HINT: Mark the position of the converter to ensure the correct installation. (b) Remove the torque converter clutch. Author: Date: 1951 AC–1 AIR CONDITIONING – AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM AC0LG–02 PRECAUTION 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR WEAR EYE PROTECTION ALWAYS WEAR EYE PROTECTION AC2810 3. AC2811 Wrong LO HI 6. Okey LO BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HI N11084 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so that care to avoid this, necessary care should be taken. 7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATE If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. Author: Date: 2483 AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The CAMRY is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and passenger airbag. Failure to carry out service operations the correct sequence could cause the SRS to unexpectedly deployed during servicing, possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following item carefully, then follow the correct procedure described in the repair manual. Author: Date: 2484 AC–3 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LI–02 ON–VEHICLE INSPECTION Sight Glass N20242 Item 1. INSPECT REFRIGERANT VOLUME Observe the sight glass on the liquid tube. Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ”HI” position
A/C switch ON
Temperature control dial at ”COOL” position
Fully open the doors Symptom Amount of refrigerant Remedy 1 Bubbles present in sight glass Insufficient* (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles present in sight glass None, sufficient or too much Refer item 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately after air conditioning is turned off, refrigerant in sight glass stays clear Too much (1) Discharge refrigerant (2) Evacuate air and charge proper amount or purified refrigerant 6 When air conditioning is turned off, refrigerant foams and then stays clear Correct – *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient. Author: Date: 2485 AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when the these conditions are established. Test conditions:
Temperature at the air inlet with the switch set at RECIRC is 30 – 35 °C (86 – 95 °F)
Engine running at 1500 rpm
Blower speed control switch at ”HI” position
Temperature control dial on ”COOL” position HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. (1) Normally functioning refrigeration system. Gauge reading: Low pressure side: 0.15 – 0.25 MPa (1.5 – 2.5 kgf/cm2) High pressure side: 1.37 – 1.57 MPa (14 – 16 kgf/cm2) I01386 Author: Date: 2486 AC–5 AIR CONDITIONING – (2) AIR CONDITIONING SYSTEM Moisture present in refrigeration system. Condition : Periodically cools and then fails to cool I01387 Symptom seen in refrigeration system Probable cause During operation, pressure on low pressure side sometimes become a vacuum and sometime normal Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts Diagnosis (3)
Drier oversaturated state
Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Remedy (1) Replace receiver (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge proper amount of new refrigerant Insufficient cooling Condition: Insufficient cooling I01388 Symptom seen in refrigeration system
Pressure low on both low and high pressure sides
Bubbles seen in sight glass continuously
Insufficient cooling performance Probable cause Gas leakage at some place in refrigeration system Diagnosis
Insufficient refrigerant in system
Refrigerant leaking Author: Remedy (1) Check for gas leakage with gas leak detector and repair if necessary (2) Charge proper amount of refrigerant (3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak Date: 2487 AC–6 AIR CONDITIONING (4) – AIR CONDITIONING SYSTEM Poor circulation of refrigerant Condition: Insufficient cooling I01389 Symptom seen in refrigeration system
Pressure low in both low and high pressure sides
Frost on tube from receiver to unit Probable cause Diagnosis Refrigerant flow obstructed by dirt in receiver (5) Receiver clogged Remedy Replace receiver Refrigerant does not circulate Condition: Does not cool (Cools from time to time in some cases) I01449 Symptom seen in refrigeration system
Vacuum indicated on low pressure side, very low pressure indicated on high pressure side
Frost or dew seen on piping before and after receiver/ drier or expansion valve Probable cause Diagnosis
Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant does not circulate
Refrigerant flow obstructed by gas leakage from expansion valve Author: Remedy (1) Check expansion valve (2) Clean out dirt in expansion valve by blowing with air (3) Replace receiver (4) Evacuate air and charge new refrigerant to proper amount (5) For gas leakage from expansion valve, replace expansion valve Date: 2488 AC–7 AIR CONDITIONING – (6) AIR CONDITIONING SYSTEM Refrigerant overcharged or insufficient cooling of condenser Condition: Insufficient cooling I01390 Symptom seen in refrigeration system
Pressure too high on both low and high pressure sides
No air bubbles seen through the sight glass even when the engine rpm is lowered Probable cause Diagnosis Remedy
Unable to develop sufficient performance due to excessive refrigeration system
Insufficient cooling of condenser
Excessive refrigerant in cycle → refrigerant over charged
Condenser cooling → condenser fins clogged of condenser fan faulty (1) Clean condenser (2) Check condenser fan motor operation (3) If (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant (7) Air present in refrigeration system Condition: Insufficient cooling NOTE : These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging. I01392 Symptom seen in refrigeration system
Pressure too high on both low and high pressure sides
The low pressure piping hot to touch
Bubbles seen in sight glass Probable cause Air entered in refrigeration system Diagnosis
Air present in refrigeration system
Insufficient vacuum purging Author: Remedy (1) Check compressor oil to see if it is dirty or insufficient (2) Evacuate air and charge new refrigerant Date: 2489 AC–8 AIR CONDITIONING (8) – AIR CONDITIONING SYSTEM Expansion valve improperly Condition: Insufficient cooling I01450 Symptom seen in refrigeration system
Pressure too high on both low and high pressure sides
Frost or large amount of dew on piping on low pressure side Probable cause Diagnosis
Excessive refrigerant in low pressure piping
Expansion valve opened too wide Trouble in expansion valve (9) Remedy Check expansion valve Replace if defective Defective compression compressor Condition : Does not cool I01393 Symptom seen in refrigeration system
Pressure too high on low and high pressure sides
Pressure too low on high pressure side Probable cause Internal leak in compressor Diagnosis
Compression defective
Valve leaking or broken sliding parts Author: Remedy Repair or replace compressor Date: 2490 AC–9 AIR CONDITIONING 3. (a) (b) – AIR CONDITIONING SYSTEM INSPECT IDLE–UP SPEED Warm up engine. Inspect idle–up speed when the these conditions are established.
Warm up engine
Blower speed control switch at ”HI” position
A/C switch ON
Temperature control dial at ”COOL” position Magnetic clutch condition Idle–up speed Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 700 ± 50 rpm If idle speed is not as specified, check ISC valve and air intake system. 4. INSPECT FOR LEAKAGE OF REFRIGERANT (a) Perform in these conditions:
Stop engine.
Secure good ventilation (If not the gas leak detector may react to volatile gases witch are not refrigerant, such as evaporated gasoline and exhaust gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is OFF: approx. 392 – 588 kPa (4 – 6 kgf/ cm2, 57 – 85 psi) (b) Bring the gas leak detector close to the drain hose before performing the test. HINT:
After the blower motor stopped, leave the cooling unit for more than 15 minutes.
Expose the gas leak detector sensor the under the drain hose.
When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. (c) If gas leak is not detected on the drain hose, remove the blower resistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test. (d) Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test. (e) Bring the gas leak detector close to the refrigerant lines and perform the test. Author: Date: 2491 AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LJ–03 EVACUATING Quick Disconnect Adapter 1. Charging Hose 2. 3. (a) (b) Service Valve N13795 CONNECT QUICK DISCONNECT ADAPTER TO CHARGING HOSES REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINES SET ON MANIFOLD GAUGE SET Close both hand valves of manifold gauge set. Connect the quick disconnect adapters to the service valves. 4. (a) EVACUATE AIR FROM REFRIGERATION SYSTEM Connect the vacuum pump adapter to the vacuum pump. (b) Connect the center hose of the manifold gauge set to the vacuum pump adapter. Open both the high and low hand valves and run the vacuum pump. After 10 minutes or more, check that the low pressure gauge indicates 750 mmHg (30 in. Hg) or more. Vacuum Pump Vacuum Pump Adapter N13794 Manifold Gauge Set (c) (d) HINT: If the reading 750 mmHg (30 in. Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump. Check the system for leaks and repair necessary. (e) Close both the high and low hand valves and stop the vacuum pump. (f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. Low Pressure Service Valve High Pressure Service Valve Vacuum Pump Adapter N13791 Author: Date: 2492 AC–11 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC21S–01 CHARGING 1. INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the directions given in the instruction manual. (a) Charge the proper amount of refrigerant into the charging cylinder. (b) Connect the center hose to the charging cylinder. CAUTION: Do not open both high and low hand valves of manifold gauge set. (c) Open the valve of charging cylinder. (d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose. Push Air Low Pressure Service Valve High Pressure Service Valve Charging Cylinder N13793 2. (a) INSPECT REFRIGERATION SYSTEM FOR LEAKS Open the high pressure hand valve and charge refrigerant. (b) When the low pressure gauge indicates 98 kPa (1 kgf/cm2, 14 psi) close the high pressure hand valve. (c) Using a gas leak detector, check the system for leakage. (d) If leak is found, repair the faulty component or connection. CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N13792 Author: Date: 2493 AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3. Low Pressure Service Valve High Pressure Service Valve N13790 CHARGE REFRIGERANT INTO REFRIGERANT SYSTEM If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system. CAUTION:
Never run the engine when charging the system through the high pressure side.
Do not open the low pressure hand valve when the system is being charged with liquid refrigerant. (a) Open the high pressure hand valve fully. (b) Charge specified amount of refrigerant, then close the high pressure hand valve. HINT: A fully charged system is indicated by the sight glass being free of any bubbles. (c) Charge partially refrigeration system with refrigerant. (1) Set vehicle in these conditions:
Running engine at 1,500 rpm
Blower speed control set at ”HI”
Temperature control set at ”MAX. COOL”
Air inlet control set at ”RECIRC”
Fully open doors (Sliding roof: closed) (2) Open the low pressure hand valve. CAUTION: Do not open the high pressure hand valve. (d) Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass. Properly Charged Insufficiently Charged I07055 Author: Date: 2494 AC–13 AIR CONDITIONING – AIR CONDITIONING SYSTEM AC0LL–02 LOCATION 1MZ–FE engine: No. 1 Engine Coolant Temperature (ECT) Switch 1MZ–FE engine: No. 2 Engine Coolant Temperature (ECT) Switch Compressor Engine Room Relay Block No. 1
Magnetic Clutch Relay (Marking: MG CLT)
Heater Main Relay (Marking: HTR)
No. 2 Cooling Fan Relay (Marking: FAN NO.2)
No. 3 Cooling Fan Relay (Marking: FAN NO.3) Condenser Fan
Fan Motor Pressure Switch Receiver Condenser Engine Room Junction Block No. 2
Engine Main Relay (Marking: ENGINE MAIN)
No. 1 Cooling Fan Relay (Marking: FAN NO.1) 5S–FE engine models: Engine Coolant Temperature (ECT) Switch A/C Unit Blower Unit 5S–FE engine: ECM (Built in A/C Amplifier) A/C Control Assembly
A/C Switch
Blower Speed Control Switch
Mode Switch Air Outlet Servomotor Expansion Valve 1MZ–FE: A/C Amplifier Evaporator Heater Radiator Blower Motor Thermistor Author: Blower Resistor Z19146 Date: 2495 AC–14 AIR CONDITIONING – TROUBLESHOOTING TROUBLESHOOTING AC21T–01 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page No blower operation 4. 5. 6. 7. 8. 9. No air temperature control 1. Engine coolant volume 2. A/C control assembly – AC–80 No air inlet control 1. A/C control assembly AC–80 No air outlet control 1. HTR Fuse 2. Air outlet servomotor 3. Mode switch – AC–65 AC–84 No compressor operation 1. Refrigerant volume 2. A.C Fuse 3. HTR Fuse 4. Magnetic clutch relay 5. Magnetic clutch 6. Compressor 7. Pressure switch 8. Heater main relay 9. Blower speed control switch 10.A/C switch 11.*1 ECM *2 A/C amplifier 12.Wire harness AC–3 – – AC–71 AC–39 AC–39 AC–67 AC–70 AC–84 AC–84 DI–218 AC–88 – 1. 2. 3. 4. Refrigerant volume Condenser fan Pressure switch *1 ECM *2 A/C amplifier 5. Thermistor 6. Wire harness AC–3 AC–74 AC–67 DI–218 AC–88 AC–24 – 1. Refrigerant volume 2. Refrigerant pressure 3. Drive belt 4. Compressor lock sensor 5. Magnetic clutch 6. Compressor 7. Pressure switch 8. Thermistor 9. A/C switch 10.*1 ECM *2 A/C amplifier 11.Wire harness AC–3 AC–3 AC–16 AC–16 AC–39 AC–39 AC–67 AC–24 AC–84 DI–218 AC–88 – No compressor operates intermittently No cool air comes out HTR Fuse Heater main relay Blower motor Blower resistor Blower speed control switch Wire harness Author: – AC–70 AC–63 AC–64 AC–84 – Date: 2496 AC–15 AIR CONDITIONING – TROUBLESHOOTING Cool air comes out only at high engine rpm 1. Refrigerant volume 2. Drive belt 3. Magnetic clutch 4. Compressor 5. Condenser 6. Condenser fan 7. Receiver 8. Expansion valve 9. Evaporator 10.Thermistor 11.Refrigerant line 12.Pressure switch 13.*1 ECM *2 A/C amplifier AC–3 AC–16 AC–16 AC–39 AC–52 AC–74 AC–49 AC–59 AC–30 AC–24 AC–21 AC–67 DI–218 AC–88 No engine idle–up when A/C switch ON 1. *1 ECM *2 A/C amplifier 2. Wire harness DI–218 AC–88 – Blinking of A/C indicator 1. *1 ECM *2 A/C amplifier 2. Thermistor 3. Compressor DI–218 AC–88 AC–24 AC–39 1. 2. 3. 4. A/C Fuse Mode switch A/C switch *1 ECM *2 A/C amplifier 5. Wire harness – AC–84 AC–84 DI–218 AC–88 – 1. Engine coolant volume 2. A/C control assembly 3. Heater radiator – AC–80 AC–57 1. 2. 3. 4. 5. 6. 7. 8. – – AC–72 AC–72 AC–72 AC–74 AC–67 AC–92 AC–92 AC–92 – A/C indicator does not lights up when turn mode switch to DEF. position No warm air comes out No condenser fan operation CDS FAN Fuse Engine main relay Cooling fan relay No. 1 Cooling fan relay No. 2 Cooling fan relay No. 3 Condenser fan motor Pressure switch *1 Engine coolant temp. switch *2 No. 1 Engine coolant temp. switch 9. *2No. 2 Engine coolant temp. switch 10.Wire harness *1: 5S–FE Engine Models *2: 1MZ–FE Engine Models Author: Date: 2497 AC–16 AIR CONDITIONING – DRIVE BELT DRIVE BELT AC0LM–02 ON–VEHICLE INSPECTION 1. INSPECT DRIVE BELT’S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. Correct Wrong CH0086 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt: 165 ± 26 lbf Used belt: 110 ± 11 lbf Generator Crankshaft Pulley Compressor DENSO N17028 HINT: Borroughs


”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After installing the drive belt, check that it fits properly in the ribbed grooves. N01881 Author: Date: 2498 AC–17 AIR CONDITIONING – DRIVE BELT AC0LN–02 5S–FE: REMOVAL Pivot Bolt Adjusting Bolt Drive Belt 1MZ–FE: Pivot Bolt Adjusting Lock Bolt Drive Belt Adjusting Lock Bolt REMOVE DRIVE BELT (a) Loosen the pivot bolt and adjusting lock bolt. Torque: 5S–FE: Pivot bolt: 52 N·m (530 kgf·cm, 38 ft·lbf) Adjusting lock bolt: 18 N·m (185 kgf·cm, 13 ft·lbf) 1MZ–FE: Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf) Adjusting lock bolt: 18 N·m (185 kgf·cm, 13 ft·lbf) (b) Loosen the drive belt tension by adjusting bolt and remove the drive belt. Adjusting Bolt Z19189 Author: Date: 2499 AC–18 AIR CONDITIONING – DRIVE BELT AC0LO–01 INSTALLATION Installation is in the reverse order of removal (See page AC–17). Author: Date: 2500 AC–19 AIR CONDITIONING – MANIFOLD GAUGE SET MANIFOLD GAUGE SET AC0LP–02 SET ON 1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. 2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE Low Pressure Charging Hose High Pressure Charging hose N20312 5. CONNECT QUICK DISCONNECT ADAPTERS TO SERVICE VALVES HINT: Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it. Sleeve N04392 Author: Date: 2501 AC–20 AIR CONDITIONING – MANIFOLD GAUGE SET AC0LQ–02 SET OFF 1. 2. N06553 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE Author: Date: 2502 AC–21 AIR CONDITIONING – REFRIGERANT LINE REFRIGERANT LINE AC0LR–01 ON–VEHICLE INSPECTION 1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Author: Date: 2503 AC–22 AIR CONDITIONING – REFRIGERANT LINE AC0LS–02 LOCATION Liquid Tube Suction Tube Piping Clamp 32 (330, 24) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) 5.4 (55, 48 in.·lbf) Liquid Tube 10 (100, 7) 14 (140, 10) 10 (100, 7) Suction Hose Discharge Hose 10 (100, 7) N·m (kgf·cm, ft·lbf) : Specified torque I07049 Author: Date: 2504 AC–23 AIR CONDITIONING – REFRIGERANT LINE AC0LT–03 REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torque. Part tightened N·m kgf·cm ft·lbf Receiver x Liquid tube 5.4 55 48 in.·lbf Condenser x Discharge hose 10 100 7 Condenser x Liquid tube 14 140 10 Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Expansion valve x Evaporator 5.4 55 48 in.·lbf Suction line (Piping joint) 32 330 24 Suction line (Block joint) 10 100 7 4. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount : 800 ± 50g (28.22 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION Author: Date: 2505 AC–24 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT AC21U–01 ON–VEHICLE INSPECTION 1. (a) INSPECT FOR LEAKAGE OF REFRIGERANT Remove glove compartment (See page BO–75). (b) Remove the blower resistor. (1) Disconnect the connector. (2) Remove the 2 screws and blower resistor. (c) Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints or check the evaporator. (d) Install the blower resistor. (e) Install the lower No. 2 finish panel (See page BO–81). N20296 2. (a) (b) INSPECT THERMISTOR RESISTANCE Disconnect the connector. Measure resistance between terminals. Standard resistance: 1,500 Ω at 25°C (77°F) If resistance is not as specified, replace the thermistor. N20294 Author: Date: 2506 AC–25 AIR CONDITIONING – AIR CONDITIONING UNIT AC21V–01 COMPONENTS Instrument Panel Reinforcement No. 1 Brace No. 2 Brace Water Hose Piping Clamp Suction Tube Liquid Tube A/C Unit Piping Clamp
O–ring
O–ring Blower Motor Air Duct (Foot) Air Duct (Rear Foot)
Non–reusable part Connector Bracket Author: Date: I07050 2507 AC–26 AIR CONDITIONING – AIR CONDITIONING UNIT Heater Protector Heater Radiator Pipe
Packing
O–ring
O–ring Heater Radiator Heater Case Grommet Plate
Packing Tube and Accessory x13 5.4 (55, 48) Expansion Valve
O–ring Air Outlet Servomotor
Water Seal
O–ring 5.4 (55, 48) Thermistor Holder Air Duct (Foot) Plate Drain Hose Insulator Evaporator Heater Case N·m (kgf·cm, in:lbf) : Specified torque
Non–reusable part I07051 Author: Date: 2508 AC–27 AIR CONDITIONING – AIR CONDITIONING UNIT AC21W–01 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 3. (a) (b) DISCONNECT WATER HOSE FROM HEATER RADIATOR PIPES Using pliers, grip the claws of the hose clip and slide the hose clip along the hose. Disconnect the water hose. N20288 Heater Radiator Pipe Water Hose Marking Upper 45 ± 10° LH RH Hose Clip Lower N20237 HINT: At the time of installation, please refer to the following items.
Push the water hose onto the heater radiator pipe as far as ridge on the pipe and install the hose clip.
Install the hose clip in a position, as shown in the illustration. 4. REMOVE BLOWER UNIT (See page AC–35) 5. REMOVE INSTRUMENT PANEL AND REINFORCEMENT (See page BO–75) 6. (a) DISCONNECT LIQUID AND SUCTION TUBES Using SST, remove the 2 piping clamps. SST 09870–00015 (Suction tube) 09870–00025 (Liquid tube) I09160 Author: Date: 2509 AC–28 AIR CONDITIONING (1) – AIR CONDITIONING UNIT Inert SST to piping clamp. HINT: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label. SST I03838 Push SST (2) Push down SST and release the clamp lock. NOTICE: Be careful not to deform the tubes, when pushing SST. (3) Pull SST slightly and push the release lever, then remove the piping clamp with SST. (4) Remove the piping clamp from SST. (b) Disconnect the both tubes. Pull SST Release Lever I03839 NOTICE:
Do not use tools like screwdriver to remove the tube.
Cap the open fittings immediately to keep moisture or dirt out of the system. Disconnect the tube using hand Screw Driver Tube I06919 Correct HINT: At the time of installation, please refer to the following item.
Lubricate 4 new O–rings with compressor oil and install the tubes.
After connection, check the fitting for claw of the piping clamp. Wrong Gap I06878 7. (a) (b) (c) (d) REMOVE A/C UNIT Disconnect the connector. Slide the floor carpet backward. Remove the rear heater duct. Remove the 2 nuts and A/C unit. N20281 Author: Date: 2510 AC–29 AIR CONDITIONING – AIR CONDITIONING UNIT AC21X–01 DISASSEMBLY N20287 1. (a) (b) 2. (a) (b) (c) 3. REMOVE AIR OUTLET SERVOMOTOR Release the claw and pull out the plate. Remove the 3 screws and servomotor. REMOVE HEATER RADIATOR Remove the 3 screws and 3 plates. Remove the 2 clips and heater radiator pipes. Pull out the heater radiator. REMOVE THESE FOOT AIR DUCT LH 4. (a) (b) (c) REMOVE EXPANSION VALVE Remove piping clamp. Remove the packings. Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve and evaporator. N20283 Water Seal Insurator x13 Plate Evaporator N20243 5. REMOVE EVAPORATOR (a) Remove the grommet from the evaporator. (b) Using a knife, cut off each packings. HINT: Do not reuse the packing. (c) Remove the 13 screws and separate the heater cases, then remove the evaporator and water seal. (d) Release the 4 claws and remove the plate from the evaporator. 6. PEEL OFF THE WATER SEAL FROM HEATER UNIT 7. REMOVE THERMISTOR Pull out the thermistor with the holders. N20293 Author: Date: 2511 AC–30 AIR CONDITIONING – AIR CONDITIONING UNIT AC21Y–01 INSPECTION 1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. 2. CHECK FITTING FOR CRACKS OR SCRATCHES Repair as necessary. 3. (a) Thermometer Ice INSPECT THERMISTOR RESISTANCE Place the thermistor in cold water, and while changing the temperature of water, measure resistance at the connector and at the same time, measure temperature of water with a thermometer. 10 cm (0.39 in.) Thermistor (Ω) 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 0 32 Ohmmeter I03338 (b) Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. 5 41 10 50 15 59 20 68 25(°C) 77(°F) Z04352 Author: Date: 2512 AC–31 AIR CONDITIONING – AIR CONDITIONING UNIT AC0LX–02 REASSEMBLY 1. INSTALL THERMISTOR TO EVAPORATOR 2. INSTALL EVAPORATOR (a) Install the plate to the evaporator. (b) Install the evaporator on the insulator. (c) Connect the heater case with the 13 screws. NOTICE: The packing for water seal should be replaced, with a new one when the A/C unit is reassembled. (d) Install the 2 new packings. (e) Install the grommet to evaporator. HINT: If evaporator is replaced, add compressor oil to the compressor. Add 40 – 50 cc (1.4 – 1.7 fl.oz.) Compressor oil: ND – OIL 8 or equivalent 3. (a) (b) (c) N21046 Packing Paper INSTALL EXPANSION VALVE Lubricate 2 new O–rings with compressor oil and install the tubes. Install the liquid tube and suction tube on the expansion valve. Using a knife, cut off packing paper of packing while peel off the paper, as shown in the illustration. HINT: Leave the packing paper untaped on the tube side so that the installation bolt hole for remains visible. (d) Apply new packing. N21045 NOTICE: Do not overtape the packing beyond the expansion valve edge. N21044 Author: Date: 2513 AC–32 AIR CONDITIONING – AIR CONDITIONING UNIT (e) N20283 Lubricate 2 new O–rings with compressor oil and install the expansion valve. (f) Install the expansion valve with the tubes to evaporator with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator. (g) Peel off the remaining packing paper and apply the packing to expansion valve. 4. INSTALL HEATER RADIATOR (a) Install the heater radiator to heater case. (b) Install the heater radiator pipe with 2 clips. (c) Install the 3 clamps with the 3 screws. 5. (a) (b) Pin INSTALL MODE SERVOMOTOR Install the servomotor with the 3 screws. Insert the drain of the plate to the pin and install plate. Pin N20245 Author: Date: 2514 AC–33 AIR CONDITIONING – AIR CONDITIONING UNIT AC0LY–01 INSTALLATION Installation is in the reverse order of removal (See page AC–27). Author: Date: 2515 AC–34 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT AC0LZ–02 COMPONENTS Connector Bracket Glove Compartment ECM Air Inlet Damper Control Cable Cowl Side Trim Blower Unit 1MZ–FE engine: A/C Amplifier Foot Air Duct Front Door Inside Scuff Plate No.2 Lower Cover Blower Resistor Connecter Blower Motor Connector Blower Unit Case Blower Resistor Blower Motor Z19018 Author: Date: 2516 AC–35 AIR CONDITIONING – BLOWER UNIT AC0M0–02 REMOVAL 1. REMOVE COWL SIDE TRIM 2. REMOVE FRONT DOOR INSIDE PLATE LH 3. REMOVE NO. 2 LOWER COVER 4. REMOVE GLOVE COMPARTMENT 5. REMOVE ECM (a) Disconnect the connectors. (b) Remove the 2 nuts and ECM. 6. DISCONNECT AIR INLET DAMPER CONTROL CABLE HINT: At the in time of installation, please refer to following item. After connection, inspect the air inlet control lever operation. (See page AC–87). 7. REMOVE A/C AMPLIFIER. (a) Disconnect the connector. (b) Release the 2 claws and pull out the amplifier. 8. REMOVE CONNECTOR BRACKET SET SCREWS 9. REMOVE BLOWER UNIT (a) Disconnect the connector. (b) Disconnect the thermistor connector clamp. (c) Remove the 2 screws, bolt and nut, then remove the blower unit. Author: Date: 2517 AC–36 AIR CONDITIONING – BLOWER UNIT AC0M1–01 DISASSEMBLY 1. REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. 2. REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor. Author: Date: 2518 AC–37 AIR CONDITIONING – BLOWER UNIT AC0M2–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–36). Author: Date: 2519 AC–38 AIR CONDITIONING – BLOWER UNIT AC0M3–01 INSTALLATION Installation is in the reverse order of removal (See page AC–35). Author: Date: 2520 AC–39 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH AC0M4–02 ON–VEHICLE INSPECTION 1. (a) (b) INSPECT COMPRESSOR FOR METALLIC SOUND Start engine. Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound is heard, replace the compressor assembly. 2. INSPECT REFRIGERANT PRESSURE See ”ON–VEHICLE INSPECTION” of AIR CONDITIONING SYSTEM on page AC–3. 3. Ω N01143 INSPECT COMPRESSOR LOCK SENSOR RESISTANCE (a) Disconnect the connector. (b) Measure resistance between terminals 1 and 2. Standard resistance: 65 – 125 Ω at 20 °C (68 °F) If resistance is not as specified, replace the compressor assembly. 4. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 5. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 6. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR ROTOR 7. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 8. INSPECT MAGNETIC CLUTCH OPERATION (a) Disconnect the connector. (b) Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to the body ground. (c) Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. N01150 Author: Date: 2521 AC–39 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH AC0M4–02 ON–VEHICLE INSPECTION 1. (a) (b) INSPECT COMPRESSOR FOR METALLIC SOUND Start engine. Check if there is a metallic sound from the compressor when the A/C switch is on. If metallic sound is heard, replace the compressor assembly. 2. INSPECT REFRIGERANT PRESSURE See ”ON–VEHICLE INSPECTION” of AIR CONDITIONING SYSTEM on page AC–3. 3. Ω N01143 INSPECT COMPRESSOR LOCK SENSOR RESISTANCE (a) Disconnect the connector. (b) Measure resistance between terminals 1 and 2. Standard resistance: 65 – 125 Ω at 20 °C (68 °F) If resistance is not as specified, replace the compressor assembly. 4. INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 5. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 6. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR ROTOR 7. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 8. INSPECT MAGNETIC CLUTCH OPERATION (a) Disconnect the connector. (b) Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to the body ground. (c) Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. N01150 Author: Date: 2521 AC–40 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M5–02 COMPONENTS 5S–FE engine :
O–Ring 10 (100, 7) Suction Hose 10 (100, 7)
O–Ring Discharge Hose 25 (250, 18) Compressor 1MZ–FE engine : 56 (570, 41) Generator Drive Belt
O–Ring 10 (100, 7) Discharge Hose Compressor Bracket Drive Belt 10 (100, 7)
O–Ring Suction Hose 25 (250, 18) 18 (185, 13) Compressor 25 (250, 18) 25 (250, 18) 25 (250, 18) Pressure Plate Rotor Drive Belt Adjusting Bar Bracket Stator Compressor Shim 13.2 (135, 9) N·m (kgf·cm, ft·lbf) : Specified torque
Non–reusable part
Snap Ring I03331 Author: Date: 2522 AC–41 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M6–02 REMOVAL 1. 2. 3. 4. 5. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX.10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REMOVE DRIVE BELT (See page AC–17) 6. N20277 1MZ–FE engine models: REMOVE SUCTION HOSE (a) Remove the suction hose clamping bolt. (b) Disconnect the wire harness clamp. (c) Loosen the nut and bolts and remove the suction hose. NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 7. 1MZ–FE engine models: DISCONNECT DISCHARGE HOSE Remove the bolt and disconnect the hose. NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 8. (a) (b) (c) (d) 1MZ–FE engine models: REMOVE GENERATOR Disconnect the generator connector. Remove the nut, and disconnect the generator wire. Disconnect the wire harness from the clip. Remove the pivot bolt, plate washer, adjusting lock bolt and generator. P19978 Author: Date: 2523 AC–42 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH 9. 5S–FE engine models: DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect both hoses. NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 5S–FE N20261 10. 5S–FE (a) (b) 5S–FE engine models: REMOVE COMPRESSOR Disconnect the connector. Remove the 3 bolts and compressor. N20240 11. 1MZ–FE (a) (b) 1MZ–FE engine models: REMOVE COMPRESSOR Disconnect the connector. Remove the 2 bolts, nut and drive belt adjusting bar bracket. Z19152 (c) 1MZ–FE Remove the 3 bolts and compressor. Z19149 Author: Date: 2524 AC–43 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M7–02 DISASSEMBLY 1. (a) REMOVE PRESSURE PLATE Using SST and a socket wrench, remove the shaft bolt. SST 07112–76060 Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf) (b) Install SST on the pressure plate. SST 07112–66040 (c) Using SST and socket wrench, remove the pressure plate. SST 07112–66040, 07112–76060 (d) Remove the shims from the pressure plate. 2. (a) REMOVE ROTOR Using SST, remove the snap ring. SST 07114–84020 SST AC0943 SST AC0944 SST AC0945 Shim Pressure Plate AC0946 SST AC0947 Author: Date: 2525 AC–44 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that beveled side faces up. Snap Ring R–Shape – Rotor Compressor N20013 (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the rotor. AC1743 3. (a) REMOVE STATOR Disconnect the stator lead wire from the compressor housing. (b) Using SST, remove the snap ring. SST 07114–84020 AC1744 SST AC0950 NOTICE: At the time of reassembly, please refer to the following item. The snap ring should be installed so that its beveled side faces up. R–Shape Snap Ring Stator Compressor N20012 Author: Date: 2526 AC–45 AIR CONDITIONING (c) – COMPRESSOR AND MAGNETIC CLUTCH Remove the stator. Stator AC0951 Author: Date: 2527 AC–46 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M8–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–43). Dial Indicator N04963 AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the pressure plate of the magnetic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor when connecting the negative (–) terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) Author: Date: 2528 AC–47 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC0M9–02 INSTALLATION 1. (a) (b) 2. (a) 5S–FE engine models: INSTALL COMPRESSOR Install the compressor with 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the connector. 1MZ–FE engine models: INSTALL COMPRESSOR Install the compressor with 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) (b) (A) (B) N20259 Install the drive belt adjusting bar bracket with 2 bolts and nut. Torque: Bolt (A): 25 N·m (250 kgf·cm, 18 ft·lbf) Bolt (B): 18 N·m (185 kgf·cm, 13 ft·lbf) Nut: 25 N·m (250 kgf·cm, 18 ft·lbf) (c) Connect the connector. 3. 5S–FE engine models: CONNECT DISCHARGE AND SUCTION HOSE Connect the both hoses with the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Hoses should be connected immediately after the caps have been removed. HINT: Lubricate 2 new O–rings with compressor oil and install the tubes. 4. 1MZ–FE engine models: INSTALL GENERATOR (a) Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet. (b) Connect the generator connector. (c) Connect the generator wire with the nut. Author: Date: 2529 AC–48 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH 5. 1MZ–FE engine models: CONNECT DISCHARGE HOSE Connect the discharge hose with the bolt. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Hoses should be connected immediately after the caps have been removed. HINT: Lubricate a new O–ring with compressor oil and install the tube. 6. INSTALL SUCTION HOSE (a) Install the suction hose and tighten the bolt and nut. Torque: Piping joint: 32 N·m (330 kgf·cm, 24 ft·lbf) Block joint: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT: Lubricate 2 new O–rings with compressor oil and install the hose. (b) Install the suction hose clamping bolt. (c) Connect the wire harness clamp. 7. INSTALL AND CHECK DRIVE BELT (See page AC–18, AC–16) 8. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 9. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) 10. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 11. INSPECT A/C OPERATION Author: Date: 2530 AC–49 AIR CONDITIONING – RECEIVER RECEIVER AC0MA–01 ON–VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage. If there is leakage, check the tightening torque at the joints. Author: Date: 2531 AC–50 AIR CONDITIONING – RECEIVER AC0MB–02 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) 2. REMOVE RADIATOR UPPER SUPPORT SEAL N20279 3. DISCONNECT 2 LIQUID TUBES FROM RECEIVER Remove the 2 bolts and both tubes. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new O–rings with compressor oil and install the tubes. 4. REMOVE RECEIVER (a) Remove the holder bolt and pull out receiver downward. HINT: At the time of installation, please refer to the following item. If receiver was replaced, add compressor oil to compressor. Add 20 cc (0.71 fl.oz.) Compressor oil: ND–OIL 8 or equivalent (b) Remove the 2 bolts and holder. Author: Date: 2532 AC–51 AIR CONDITIONING – RECEIVER AC0MC–01 INSTALLATION Installation is in the reverse order of removal (See page AC–50). Author: Date: 2533 AC–52 AIR CONDITIONING – CONDENSER CONDENSER AC0MD–01 ON–VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. Author: Date: 2534 AC–53 AIR CONDITIONING – CONDENSER AC0ME–02 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) 2. REMOVE UPPER RADIATOR SUPPORTS 3. REMOVE RECEIVER AND HOLDER (See page AC–50) I03836 4. DISCONNECT DISCHARGE HOSE Loosen the nut and disconnect the discharge hose. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate a new O–ring with compressor oil and install the tube. 5. REMOVE LIQUID TUBE Loosen the nut and remove the liquid tube. Torque: 14 N·m (140 kgf·cm, 10 ft·lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate a new O–ring with compressor oil and install the tube. Author: Date: 2535 AC–54 AIR CONDITIONING 6. (a) (b) (c) N20451 – CONDENSER REMOVE CONDENSER Remove the 2 nuts from condenser upper mountings. Push the radiator toward the engine. Push the condenser toward the radiator and pull it upward. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the compressor. Add 40–50 cc (1.4–1.7 fl.oz.) Compressor oil: ND–OIL 8 or equivalent Author: Date: 2536 AC–55 AIR CONDITIONING – CONDENSER AC0MF–01 INSTALLATION Installation is in the reverse order of removal (See page AC–53). Author: Date: 2537 AC–56 AIR CONDITIONING – HEATER RADIATOR HEATER RADIATOR AC21Z–01 REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER HOSES FROM A/C UNIT (See page AC–27) 3. REMOVE NO. 1 LOWER INSTRUMENT PANEL 4. REMOVE LH INSTRUMENT LOWER PANEL 5. (a) REMOVE HEATER RADIATOR Release the 3 claws and pull out the heater protector. (b) Remove the 3 screws 3 plate. (c) Remove the 2 screws and 2 clamps and disconnect the 2 heater radiator pipes. (d) Remove the heater radiator. N20692 I09156 I09155 I09154 Author: Date: 2538 AC–57 AIR CONDITIONING – HEATER RADIATOR AC0MK–01 INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Author: Date: 2539 AC–58 AIR CONDITIONING – HEATER RADIATOR AC0ML–01 INSTALLATION Installation is in the reverse order of removal (See page AC–56). Author: Date: 2540 AC–59 AIR CONDITIONING – EXPANSION VALVE EXPANSION VALVE AC0MM–02 ON–VEHICLE INSPECTION 1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. SET ON MANIFOLD GAUGE SET (See page AC–19) 3. RUN ENGINE Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 – 1.57 MPa (14 – 16 kgf/cm2, 199 – 228 psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm2, 0 psi). HINT: When the low pressure drops to 0 kPa (0 kgf/cm2, 0 psi), check the receiver’s IN and OUT sides is no temperature difference. Author: Date: 2541 AC–60 AIR CONDITIONING – EXPANSION VALVE AC220–01 REMOVAL 1. 2. 3. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM DISCONNECT LIQUID AND SUCTION TUBES FROM A/C UNIT (See page AC–27) REMOVE BLOWER UNIT (See page AC–35) 4. REMOVE EXPANSION VALVE (a) Remove the piping clamp. (b) Ply out the packing. HINT: Do not reuse the packing. (c) Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator. Expansion Valve N20246 Author: Date: 2542 AC–61 AIR CONDITIONING – EXPANSION VALVE AC0MO–02 INSTALLATION 1. INSTALL LIQUID TUBE AND SUCTION TUBE TO EXPANSION VALVE HINT: Lubricate 4 new O–rings with compressor oil and install the tubes. 2. (a) INSTALL NEW PACKING ON EXPANSION VALVE Cut off packing paper and peel off the packing paper, as shown in the illustration. HINT: Leave the packing paper untaped on the tube side so that the installing bolt hole for remains visible. N21046 (b) Apply the packing on the expansion valve. N21045 NOTICE: Do not overtape the packing beyond the expansion valve edge. N21044 Author: Date: 2543 AC–62 AIR CONDITIONING – EXPANSION VALVE 3. (a) N20246 INSTALL EXPANSION VALVE Install the expnaion valve with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) NOTICE: When installing the expansion valve, take care so that the packing is not jammed with the evaporator. HINT: Lubricate 2 new O–rings with compressor oil and install O–rings on the expansion valve. (b) Peel off the remaing packing paper and apply the packing to expansion valve. 4. INSTALL BLOWER UNIT (See page AC–38) 5. INSTALL GLOVE COMPARTMENT (See page BO–81) 6. CONNECT LIQUID TUBE AND SUCTION TUBES TO A/C UNIT (See page AC–33) 7. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) 8. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightning torque at the joints. Author: Date: 2544 AC–63 AIR CONDITIONING – BLOWER MOTOR BLOWER MOTOR AC221–01 INSPECTION 1. REMOVE GLOVE COMPARTMENT (See page BO–75) 2. (a) (b) REMOVE BLOWER MOTOR Disconnect the connector. Remove the 3 screws and blower motor. N20295 2 1 3. INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor. N16762 4. (a) (b) INSTALL BLOWER MOTOR Install the blower motor with the 3 screws. Connect the connector. 5. INSTALL GLOVE COMPARTMENT (See page BO–81) N20295 Author: Date: 2545 AC–64 AIR CONDITIONING – BLOWER RESISTOR BLOWER RESISTOR AC222–01 INSPECTION 1. REMOVE GLOVE COMPARTMENT (See page BO–75) 2. (a) (b) REMOVE BLOWER RESISTOR Disconnect the connector. Remove the 2 screws and blower resistor. 3. INSPECT BLOWER RESISTOR RESISTANCE N20296 2 4 1 Tester connection Condition Specified condition 2–4 Constant Approx. 0.38 Ω 2–3 Constant Approx. 1.12 Ω 1–3 Constant Approx. 1.74 Ω If resistance is not as specified, replace the blower resistor. 3 Z19190 4. (a) (b) INSTALL BLOWER RESISTOR Install the blower resistor with the 2 screws. Connect the connector. 5. INSTALL GLOVE COMPARTMENT (See page BO–81) N20296 Author: Date: 2546 AC–65 AIR CONDITIONING – AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AC223–01 INSPECTION 1. 2. REMOVE NO. 1 LOWER INSTRUMENT PANEL REMOVE LH INSTRUMENT LOWER PANEL (See page BO–75) 3. (a) REMOVE SERVOMOTOR Release the claw and pull out the plate. (b) (c) Disconnect the connector. Remove the 3 screws and servomotor. 4. (a) INSPECT SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 6 and the negative (–) lead to terminal 7. Connect the negative (–) lead from the battery to each terminal and check that the shaft rotates at each position, as shown in the illustration. N20287 N20278 FOOT/DEF. FOOT BI–LEVEL 40° 53° DEF. 36° 36° (b) 0 ± 2.5° FACE 6 5 7 Connected terminal Position 5 DEF. 4 FOOT/DEF. 3 FOOT 2 B/L 1 FACE If operation is not as specified, replace the servomotor. 1 4 3 2 Z19151 Author: Date: 2547 AC–66 AIR CONDITIONING – AIR OUTLET SERVOMOTOR 5. (a) (b) INSTALL SERVOMOTOR Install servomotor with the 3 screws. Connect he connector. (c) Install the plate, then restraint the claw. (d) Insert the drain of plate to the lever pin. 6. 7. INSTALL LH INSTRUMENT LOWER PANEL INSTALL NO. 1 LOWER INSTRUMENT PANEL (See page BO–81) N20278 N20287 Pin Pin N20245 Author: Date: 2548 AC–67 AIR CONDITIONING – PRESSURE SWITCH PRESSURE SWITCH AC0N2–02 ON–VEHICLE INSPECTION 1. 2. 3. SET ON MANIFOLD GAUGE SET (See page AC–19) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 1,500 RPM N20291 4. Magnetic clutch control Low pressure side High pressure side ON (Continuity) 196 kPa 3, 140 kPa (2.0 kgf/cm2, 28 psi) (32.0kgf/cm 2, 455 psi) OFF (No Continuity) Z13470 5. Condenser fan control ON (Continuity) 150 kPa (15.5 kgf/cm2, 220 psi) 1, 226 kPa (12.5 kgf/cm2, 178 psi) Magnetic clutch control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and negative (–) lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. OFF (No Continuity) Z13471 Condenser fan control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 2 and negative (–) lead to terminal 3. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 6. STOP ENGINE AND REMOVE MANIFOLD GAUGE SET 7. CONNECT CONNECTOR TO PRESSURE SWITCH Author: Date: 2549 AC–68 AIR CONDITIONING – PRESSURE SWITCH AC0N3–02 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 800 ± 50 g (28.22 ± 1.76 oz.) N20292 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) HINT:
Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch.
At the time of installation, please refer to the following item. Lubricate a new O–ring with the compressor oil and install the switch. Author: Date: 2550 AC–69 AIR CONDITIONING – PRESSURE SWITCH AC0N4–01 INSTALLATION Installation is in the reverse order of removal (See page AC–68). Author: Date: 2551 AC–70 AIR CONDITIONING – HEATER MAIN RELAY HEATER MAIN RELAY AC224–01 INSPECTION 1. REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 2. INSPECT HEATER MAIN RELAY (Marking: HTR RLY) CONTINUITY Heater Main Relay I09189 3 4 5 3 4 1 1 5 2 Condition Tester connection Specified condition Constant 1–3 2–4 Continuity Apply B+ between terminals 1 and 3. 4–5 Continuity If continuity is not as specified, replace the relay. 2 Z19533 Author: Date: 2552 AC–71 AIR CONDITIONING – MAGNETIC CLUTCH RELAY MAGNETIC CLUTCH RELAY AC225–01 INSPECTION 1. REMOVE MAGNETIC CLUTCH RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 2. INSPECT HEATER MAIN RELAY (Marking: MG CLT RLY) CONTINUITY Magnetic Clutch Relay I09189 3 1 5 3 5 1 2 Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. 2 Z18060 Author: Date: 2553 AC–72 AIR CONDITIONING – COOLING FAN RELAY COOLING FAN RELAY AC226–01 INSPECTION 1. REMOVE NO. 1 COOLING FAN RELAY FROM ENGINE ROOM JUNCTION BLOCK NO. 2 2. REMOVE NO. 2 COOLING FAN RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 3. REMOVE NO. 3 COOLING FAN RELAY FROM ENGINE ROOM RELAY BLOCK NO. 1 4. INSPECT NO. 1 COOLING FAN RELAY (Marking: FAN RLY NO. 1) CONTINUITY No. 1 Cooling Fan Relay S05390 No. 2 Cooling Fan Relay S05387 No. 3 Cooling Fan Relay S05388 1 3 4 3 4 1 2 2 Condition Tester connection Specified condition Constant 1–2 3–4 Continuity Apply B+ between terminals 1 and 2. 3–4 Continuity If continuity is not as specified, replace the relay. Z12319 5. 2 3 4 1 5 INSPECT NO. 2 COOLING FAN RELAY (Marking: FAN RLY NO. 2) CONTINUITY Condition Tester connection Specified condition Constant 1–2 3–4 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. N23635 Author: Date: 2554 AC–73 AIR CONDITIONING 6. 3 1 5 3 5 1 2 – COOLING FAN RELAY INSPECT NO. 3 COOLING FAN RELAY (Marking: FAN RLY NO. 3) CONTINUITY Condition Tester connection Specified condition Constant 1–2 Continuity Apply B+ between terminals 1 and 2. 3–5 Continuity If continuity is not as specified, replace the relay. 2 Z18060 Author: Date: 2555 AC–74 AIR CONDITIONING – CONDENSER FAN CONDENSER FAN AC0N6–02 ON–VEHICLE INSPECTION 1. INSPECT CONDENSER FAN OPERATION Inspect the fan operation, as shown in the chart below. Test conditions:
Ignition switch ON
Blower speed control switch position ”HI”
A/C switch ON Condition Fan operation (Fan speed) Engine coolant temperature 83°C (181°F) or below Not rotate Engine coolant temperature 98°C (208°F) or above Rotate Refrigerant pressure is less than 1,520 kPa (15.5 kgf/cm2, 220 psi) Not rotate (Low Speed) Refrigerant pressure is 1,520 kPa (15.5 kgf/cm2, 220 psi) or above Rotate (High Speed) If operation is not as specified, proceed next inspection. 2 2. (a) (b) 1 (c) A N20290 INSPECT CONDENSER FAN MOTOR OPERATION Disconnect the fan connector. Connect the battery and ammeter to the connector, as shown in the illustation. Check that the fan rotates smoothly, and then check that the reading on the ammeter. Specified amperage: 10.1 ± 1.8 A at 20 °C (68 °F)
If operation is not as specified, replace the fan motor.
If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch. Author: Date: 2556 AC–75 AIR CONDITIONING – CONDENSER FAN AC0N7–02 COMPONENTS Upper Radiator Hose Condenser Fan Connector Condenser Fan Fan Shroud Fan Fan Motor
Non–reusable part
Clip Z19147 Author: Date: 2557 AC–76 AIR CONDITIONING – CONDENSER FAN AC0N8–02 REMOVAL 1. 1MZ–FE engine models only: DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. 1MZ–FE engine models only: DISCONNECT UPPER RADIATOR HOSE 3. REMOVE CONDENSER FAN (a) Disconnect the connector. (b) Remove the 4 bolts and fan. Author: Date: 2558 AC–77 AIR CONDITIONING – CONDENSER FAN AC0N9–02 DISASSEMBLY Protrusion P19301 1. REMOVE FAN Remove the clip and fan. NOTICE: When removing the clip and fan, do not apply too much force to the motor shaft. And do not scratch the motor shaft. HINT: Install a new clip from the side opposite the protrusion on the fan. 2. REMOVE FAN MOTOR (a) Disconnect the lead wire from the fan shroud. (b) Remove the 3 screws and fan motor. Author: Date: 2559 AC–78 AIR CONDITIONING – CONDENSER FAN AC0NA–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–77). Author: Date: 2560 AC–79 AIR CONDITIONING – CONDENSER FAN AC0NB–01 INSTALLATION Installation is in the reverse order of removal (See page AC–76). Author: Date: 2561 AC–80 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY AC0NC–01 ON–VEHICLE INSPECTION INSPECT A/C CONTROL DIAL AND LEVER OPERATION Move the control dial and lever left and right and check for stiffness and binding through the full range of the levers. Author: Date: 2562 AC–81 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0ND–02 COMPONENTS LH Lower Instrument Panel Center Cluster Finish Panel A/C Control Assembly No.1 Lower Finish Panel Glove Compartment Cowl Side Trim Cowl Side Trim Front Door Inside Scuff Plate Front Door Inside Scuff Plate Air Inlet Damper Control Cable Blower Speed Control Switch Air Inlet Control Lever Mode Switch A/C Switch Heater Control Base Defogger Switch Heater Control Name Sheet Heater Control Knob Z19017 Author: Date: 2563 AC–82 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NE–02 REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. REMOVE COWL SIDE TRIM LH AND RH REMOVE FRONT DOOR INSIDE SCUFF PLATE LH AND RH REMOVE NO. 2 LOWER COVER REMOVE GLOVE COMPARTMENT REMOVE NO. 1 LOWER INSTRUMENT PANEL REMOVE LH LOWER INSTRUMENT PANEL REMOVE CENTER CLUSTER FINISH PANEL DISCONNECT A/C CONTROL CABLES Air Mix Damper Control Cable Air Inlet Damper Control Cable N20304 9. REMOVE A/C CONTROL ASSEMBLY Remove the 4 screws and pull out the A/C control assembly, then disconnect the connector. N20289 Author: Date: 2564 AC–83 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NF–02 DISASSEMBLY 1. REMOVE A/C SWITCH AND DEFOGGER SWITCH Using a screwdriver, release the claw and pull out the switch backward. HINT: Tape the screwdriver tip before use. 2. REMOVE HEATER CONTROL KNOBS 3. REMOVE HEATER CONTROL CABLE 4. REMOVE BLOWER SPEED CONTROL SWITCH Remove the 2 screws and pull out the switch. 5. REMOVE MODE SWITCH Remove the 2 screws and pull out the switch. 6. REMOVE HEATER CONTROL NAME SHEET (a) Remove the 2 screws. (b) Using a screwdriver, release the 4 claws and heater control name sheet. HINT: Tape the screwdriver tip before use. Author: Date: 2565 AC–84 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NG–02 2 OFF INSPECTION 1 1. (a) INSPECT A/C INDICATOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1. (b) Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. ON N19466 4 2 1 ON OFF 2. (a) INSPECT DIMMING OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1 while press the switch. (b) Connect the positive (+) lead from battery to terminal 4 and then check that the indicator dims. If operation is not as specified, replace the switch. N19484 3. OFF INSPECT A/C SWITCH CONTINUITY Condition/ Circuit Tester connection Specified condition OFF – No continuity ON 2–5 Continuity Illumination circuit 3–4 Continuity ON
N19467 4. M1 M2 Switch continuity: If continuity is not as specified, replace the switch.
Illumination circuit: If continuity is not as specified, replace the bulb. INSPECT BLOWER SPEED CONTROL SWITCH CONTINUITY Position/ Circuit Tester connection Specified condition OFF – No continuity LO 1–3 Continuity M1 1–3–4 Continuity M2 1–3–8 Continuity HI 1–3–5 Continuity Illumination circuit 6–7 Continuity N19464 If continuity is not as specified, replace the switch. Author: Date: 2566 AC–85 AIR CONDITIONING 5. N20257 – AIR CONDITIONING CONTROL ASSEMBLY INSPECT MODE SWITCH CONTINUITY Switch position Tester connection Specified condition FACE 1–6 Continuity B/L 1–5 Continuity FOOT 1–4 Continuity FOOT/DEF. 1–3 Continuity DEF. 1–2 7–8 Continuity If continuity is not as specified, replace the switch. 6. INSPECT REAR DEFOGGER SWITCH OPERATION (See page BE–56) Author: Date: 2567 AC–86 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NH–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC–83). Author: Date: 2568 AC–87 AIR CONDITIONING – AIR CONDITIONING CONTROL ASSEMBLY AC0NI–02 INSTALLATION Installation is in the reverse order of removal (See page AC–82). 1. AFTER INSTALLATION INSPECT A/C CONTROL LEVER AND DIAL OPERATION Move the control dial and lever left and right and check fro stiffness and binding through the full range of the lever and dial. If there is stiffness or binding, proceed next step. 2. ADJUST A/C CONTROL CABLES (a) Set A/C control assembly in these conditions: (1) Air inlet control lever in ”FRESH” position (2) Temperature control dial in ”MAX. COOL” position. Fresh (b) Adjust air inlet control cable. (1) Pull out the inner of air inlet cable and hit the link of blower unit on the link stopper. (2) Set the cable connector to lever pin and clamp the cable outer. (c) Adjust air mix control cable. Set the cable connector to air mix link pin on left side of A/C unit and clamp the cable outer on. Clamp N21047 Cool Clamp N20239 Author: Date: 2569 AC–88 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER AC0NJ–02 ON–VEHICLE INSPECTION Wire harness side: 1. REMOVE GLOVE COMPARTMENT (See page BO–75) 2. (a) INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart below. Test conditions:
Ignition switch ON
Blower speed switch HI
Temperature control lever Max. Cool Z13472 Tester connection Condition Specified condition 5 – Ground Constant Continuity 9 – 13 Evaporator temperature at 25°C (77°F) Approx. 1.5 kΩ 14 – 13 Constant 65 – 125 Ω at 25°C (77°F) 8 – Ground A/C switch ON Battery positive voltage 8 – Ground A/C switch OFF No voltage 8 – Ground Mode switch DEF. position Battery positive voltage 10 – Ground A/C switch ON Below 4.0 V 10 – Ground A/C switch OFF No voltage If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2570 AC–89 AIR CONDITIONING (b) From back side: Z13473 Tester connection – AIR CONDITIONING AMPLIFIER Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart below. Test conditions:
Running engine at idle speed
Blower speed switch HI
A/C switch ON
Temperature control lever Max Cool
Set on manifold gauge set Condition Specified condition 1 – Ground Magnetic clutch is not engaged Below 1.0 V 1 – Ground Magnetic clutch is engaged No voltage 7 – Ground Magnetic clutch is not engaged Below 1.0 V 7 – Ground Magnetic clutch is engaged Battery positive voltage 2 – Ground Refrigerant pressure 196 – 1,340 kPa Battery positive voltage 2 – Ground Refrigerant pressure less than 196 or more than 3,140 kPa No voltage 12 – Ground Refrigerant pressure 196 – 1,340 kPa Below 1.0 V 12 – Ground Refrigerant pressure less than 196 or more than 3,140 kPa Battery positive voltage 12 – Ground Engine coolant temp. 83°C (181°F) or below Battery positive voltage 12 – Ground Engine coolant temp. 93°C (199°F) or above Below 1.0 V If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Author: Date: 2571 AC–90 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC0NK–02 REMOVAL 1. REMOVE GLOVE COMPARTMENT (See page BO–75) 2. (a) (b) REMOVE A/C AMPLIFIER Disconnect the connector. Release the 2 claws and pull out the amplifier. N20285 Author: Date: 2572 AC–91 AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC0NL–01 INSTALLATION Installation is in the reverse order of removal (See page AC–90). Author: Date: 2573 AC–92 AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH ENGINE COOLANT TEMPERATURE (ECT) SWITCH AC227–01 INSPECTION 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. (a) (b) 5S–FE: REMOVE ECT SWITCHES Disconnect the connector. Remove the ECT switch. ECT Switch P15233 1MZ–FE: No. 2 ECT Switch No. 1 ECT Switch P19584 3. P01924 P01924 5S–FE engine: INSPECT ECT SWITCH CONTINUITY (a) Using an ohmmeter, check that no continuity exists between the terminals when the coolant temperature is above 93°C (199°F). If continuity exists, replace the switch. (b) Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below 83°C (181°F). If no continuity exists, replace the switch. 4. 1MZ–FE engine: INSPECT No. 1 SWITCH CONTINUITY (a) Using an ohmmeter, check that no continuity exists between the terminals when the coolant temperature is above 98°C (208°F). If continuity exists, replace the switch. (b) Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below 88°C (190°F). If no continuity exists, replace the switch. Author: Date: 2574 AC–93 AIR CONDITIONING – ENGINE COOLANT TEMPERATURE (ECT) SWITCH 5. P06722 5S– FE: 1MZ–FE engine: INSPECT No. 2 SWITCH CONTINUITY (a) Using an ohmmeter, check that no continuity exists between the terminal and switch body when the coolant temperature is above 93°C (199°F). If continuity exists, replace the switch. (b) Using an ohmmeter, check that continuity exists between the terminals when the coolant temperature is below 83°C (181°F). If no continuity exists, replace the switch. 6. INSTALL ECT SWITCHES (a) Install the ECT switch. HINT: Lubricate a new O–ring with soapy water and install the switch. (b) Connect the connector. ECT Switch P15233 1MZ–FE: No. 2 ECT Switch No. 1 ECT Switch P19584 Author: Date: 2575 CH–1 CHARGING (5S–FE) – CHARGING SYSTEM CHARGING SYSTEM CH02U–01 ON–VEHICLE INSPECTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running. 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance–Free Battery: If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. Except Maintenance–Free Battery: If under the lower level, add distilled water. 2. Except Maintenance–Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 – 1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery. Except Maintenance–Free Battery Z11577 3. Maintenance–Free Battery Voltmeter Z11556 Maintenance–Free Battery: CHECK BATTERY VOLTAGE (a) After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. (b) Turn the ignition switch OFF and turn off the electrical systems. (c) Measure the battery voltage between the negative (–) and positive (+) terminals of the battery. Standard voltage: 12.5 – 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. Author: Date: 1748 CH–2 CHARGING (5S–FE) CHARGED DARK EYE CHARGING SYSTEM HINT: Check the indicator as shown in the illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, H–fuses, M–fuse and fuses for continuity. Maintenance–Free Battery Type A GREEN EYE – CLEAR EYE or LIGHT YELLOW DISCHARGED ADD WATER Type B Blue OK White Red Charging Insufficient Necessary Water Z18811 5. (a) INSPECT DRIVE BELTS Visually check the drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. Z00015 DENSO Borroughs Z00038 CORRECT WRONG CH0086 (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: w/ A/C New belt Used belt 165 ± 25 lbf 110 ± 10 lbf w/o A/C New belt Used belt 125 ± 25 lbf 95 ± 20 lbf If the belt tension is not as specified, adjust it. HINT:
”New belt” refers to a belt which has been used less than 5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more.
After installing a belt, check that it fits properly in the ribbed grooves.
Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. Author: Date: 1749 CH–3 CHARGING (5S–FE) – CHARGING SYSTEM
After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the generator while the engine is running. 7. CHECK CHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ”ON”. Check that the charge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the charge light circuit. Ammeter Battery Disconnect Wire from Terminal B Voltmeter B Generator Z03473 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: (1) Disconnect the wire from terminal B of the generator, and connect it to the negative (–) tester probe of the ammeter. (2) Connect the positive (+) tester probe of the ammeter to terminal B of the generator. (3) Connect the positive (+) tester probe of the voltmeter to terminal B of the generator. (4) Ground the negative (–) tester probe of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.5 – 15.1 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. Author: Date: 1750 CH–4 CHARGING (5S–FE) Terminal F P14433 – CHARGING SYSTEM If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows:
With terminal F grounded, start the engine and check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard voltage, replace the voltage regulator.
If the voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ”HI”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. Author: Date: 1751 CH–5 CHARGING (5S–FE) – GENERATOR GENERATOR CH02V–03 COMPONENTS Adjusting Lock Bolt Generator Wire Rubber Cap Pivot Bolt Generator Connector Wire Clamp Generator Drive Belt S05342
Front Bearing Rotor Pulley Bearing Cover Bearing Cover Drive End Flame (Starter) Rectifier Holder Generator Washer Bearing Cover
Rear Bearing Seal Plate Brush Holder Terminal Insulator Rubber Insulator Wire Clip Voltage Regulator Brush Holder Cover Rectifier End Flame Rear End Cover Plate Terminal
Non–reusable part S05076 Author: Date: 1752 CH–6 CHARGING (5S–FE) – GENERATOR CH02W–03 REMOVAL 1. (a) (b) (c) DISCONNECT CONNECTOR AND WIRE FROM GENERATOR Disconnect the wire clamp from the wire clip on the rectifier end frame. Disconnect the generator connector. Remove the rubber cap and nut, and disconnect the generator wire. B02375 2. (a) w/ A/C Pivot Bolt Adjusting Bolt Adjusting Lock Bolt (b) (c) w/o A/C (d) REMOVE GENERATOR Loosen the adjusting lock bolt (w/ A/C), adjusting bolt and pivot bolt. Torque: Pivot bolt: 52 N·m (530 kgf·cm, 38 ft·lbf) Adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) 18 N·m (185 kgf·cm, 13 ft·lbf) Remove the drive belt. Remove the adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) and pivot bolt. Remove the generator. Pivot Bolt Adjusting Lock Bolt B02376 B02377 B02693 Author: Date: 1753 CH–7 CHARGING (5S–FE) – GENERATOR CH02X–01 DISASSEMBLY 1. (a) (b) REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the bolt, 3 nuts, plate terminal and end cover. 2. (a) (b) (c) REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator. Remove the seal plate from the rectifier end frame. 3. (a) (b) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. Remove the 4 rubber insulators. 4. (a) REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. Z18635 Z18636 B02378 Turn SST (A) (b) SST (B) P13597 (c) (d) Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (B) SST (C) Insert P10834 Author: Date: 1754 CH–8 CHARGING (5S–FE) – GENERATOR (e) SST (C) SST (A) Turn To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one–half of a turn. (f) Remove the generator from SST (C). P10827 Turn (g) (h) Turn SST (B), and remove SST (A and B). Remove the pulley nut and pulley. 5. (a) REMOVE RECTIFIER END FRAME Remove the 4 nuts and wire clip. (b) Using SST, remove the rectifier end frame. SST 09286–46011 Remove the generator washer from the rotor. REMOVE ROTOR FROM DRIVE END FRAME SST (A) SST (B) P13598 S05070 SST (c) 6. P13490 Author: Date: 1755 CH–9 CHARGING (5S–FE) – GENERATOR CH02Y–01 INSPECTION 1. (a) INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.7 – 3.1 Ω at 20°C (68°F) If there is no continuity, replace the rotor. Ohmmeter Continuity CH0784 (b) Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. Ohmmeter No Continuity CH0783 (c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. CH1023 2. (a) INSPECT STATOR (DRIVE END FRAME) Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. Ohmmeter Continuity P13482 (b) Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Ohmmeter No Continuity P13565 Author: Date: 1756 CH–10 CHARGING (5S–FE) – GENERATOR 3. INSPECT BRUSHES Using vernier calipers, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brush holder assembly. Length P13535 4. (a) Ohmmeter Positive (+) Terminal Rectifier Terminal P13568 Ohmmeter Negative (–) Terminal P13566 INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire. (1) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. (b) Check the negative (–) rectifire. (1) Using an ohmmeter, connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing. (See page CH–11) Author: Date: 1757 CH–11 CHARGING (5S–FE) – GENERATOR CH02Z–01 REPLACEMENT 1. (a) REPLACE FRONT BEARING Remove the 4 screws, bearing retainer and bearing. (b) Using a socket wrench and press, press out the bearing. (c) Using SST and a press, press in a new bearing. SST 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws. Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf) CH0827 Socket Wrench P00100 SST (d) Downward P13479 2. (a) REPLACE REAR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820–00021 NOTICE: Be careful not to damage the fan. SST N00581 (b) (c) Remove the bearing cover (inside). Place the bearing cover (inside) on the rotor. P13567 Author: Date: 1758 CH–12 CHARGING (5S–FE) – GENERATOR (d) Using SST and a press, press in a new bearing. SST 09820–00030 (e) Using SST, push in the bearing cover (outside). SST 09285–76010 SST N00578 SST P00074 Author: Date: 1759 CH–13 CHARGING (5S–FE) – GENERATOR CH030–01 REASSEMBLY Pulley 1. (a) (b) INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. Install the rotor to the rectifier end frame. 2. (a) INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) Install the wire clip and 4 nuts. Torque: Nut A: 4.5 N·m (46 kgf·cm, 40 in.·lbf) Nut B: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 3. (a) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. P01364 Z18637 29 mm Socket Wrench P13487 B A A A Z19213 Turn (b) SST (A) (c) SST (B) P13597 Author: Date: 1760 CH–14 CHARGING (5S–FE) – GENERATOR (d) (e) Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) (g) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). SST (C) P04210 SST (C) Turn SST (A) P04395 Turn SST (A) SST (B) P13598 4. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. NOTICE: Be careful of the rubber insulators installation direction. Inside S05075 (b) Push Install the rectifier holder while pushing it with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) S05074 Author: Date: 1761 CH–15 CHARGING (5S–FE) 5. (a) – GENERATOR INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER Place the seal plate on the rectifier end frame. Z18638 (b) Upward Place the voltage regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder installation direction. (c) Install the 5 screws. Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf) S05461 (d) Place the brush holder cover on the brush holder. 6. (a) INSTALL REAR END COVER Install the end cover and plate terminal with the bolt and 3 nuts. Torque: Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf) Bolt: 3.9 N·m (39 kgf·cm, 35 in.·lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY Z18640 Z18635 7. S05069 Author: Date: 1762 CH–16 CHARGING (5S–FE) – GENERATOR CH031–01 INSTALLATION Installation is in the reverse order of removal. (See page CH–6) Author: Date: 1763 CH–1 CHARGING (1MZ–FE) – CHARGING SYSTEM CHARGING SYSTEM CH01D–01 ON–VEHICLE INSPECTION CAUTION:
Check that the battery cables are connected to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Do not perform tests with a high voltage insulation resistance tester.
Never disconnect the battery while the engine is running. 1. CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. (1) Maintenance–Free Battery: If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. (2) Except Maintenance–Free Battery: If under the lower level, add distilled water. 2. Except Maintenance–Free Battery: CHECK BATTERY SPECIFIC GRAVITY Check the specific gravity of each cell. Standard specific gravity: 1.25 – 1.29 at 20°C (68°F) If the specific gravity is less than specification, charge the battery. Except Maintenance–Free Battery Z11577 3. Maintenance–Free Battery Voltmeter (a) (b) Z11556 Maintenance–Free Battery: CHECK BATTERY VOLTAGE After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. Turn the ignition switch OFF and turn off the electrical systems. (c) Measure the battery voltage between the negative (–) and positive (+) terminals of the battery. Standard voltage: 12.5 – 12.9 V at 20°C (68°F) If the voltage is less than specification, charge the battery. Author: Date: 1764 CH–2 CHARGING (1MZ–FE) DARK EYE CHARGED CHARGING SYSTEM HINT: Check the indicator as shown in the illustration. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. If the terminals are corroded, clean the terminals. (b) Check the fusible link, H–fuses, M–fuse and fuses for continuity. Maintenance–Free Battery Type A GREEN EYE – CLEAR EYE or LIGHT YELLOW DISCHARGED ADD WATER Type B Blue OK White Red Charging Insufficient Necessary Water Z18811 5. (a) INSPECT DRIVE BELTS Visually check the drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are considered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. Z00015 DENSO Borroughs (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: DENSO BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ± 20 lbf If the belt tension is not as specified, adjust it. Z00038 HINT:

CORRECT
WRONG
CH0086 ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After installing a belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. Author: Date: 1765 CH–3 CHARGING (1MZ–FE) – CHARGING SYSTEM
After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the generator while the engine is running. 7. CHECK DISCHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ”ON”. Check that the discharge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the discharge light circuit. Ammeter Disconnect Wire from Terminal B Battery Voltmeter Generator Z03473 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, connect the tester to the charging circuit as per manufacturer’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows:
Disconnect the wire from terminal B of the generator, and connect it to the negative (–) tester probe of the ammeter.
Connect the positive (+) tester probe of the ammeter to terminal B of the generator.
Connect the positive (+) tester probe of the voltmeter to terminal B of the generator.
Ground the negative (–) tester probe of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.5 – 15.1 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. Author: Date: 1766 CH–4 CHARGING (1MZ–FE) Terminal F P14228 – CHARGING SYSTEM If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows:
With terminal F grounded, start the engine and check the voltmeter reading of terminal B.
If the voltmeter reading is more than standard voltage, replace the voltage regulator.
If the voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ”HI”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard amperage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. Author: Date: 1767 CH–5 CHARGING (1MZ–FE) – GENERATOR GENERATOR CH01E–01 COMPONENTS Plate Washer Generator Wire Pivot Bolt Generator Connector Adjusting Bolt Generator Adjusting Lock Bolt Drive Belt S05218 Bearing Cover
Front Bearing Generator Washer Retainer Drive End Flame (Stator) Bearing Cover
Rear Bearing Pulley Plate Terminal Rotor Terminal Insulator Rectifire End Flame Seal Plate Cord Clip Rear End Cover Brush Holder Cover Brush Holder Voltage Regulator Rectifire Holder
Non–reusable part Robber Insulator x 4 S05077 Author: Date: 1768 CH–6 CHARGING (1MZ–FE) – GENERATOR CH01F–01 REMOVAL Pivot Bolt Adjusting Bolt Adjusting Lock Bolt 1. REMOVE DRIVE BELT Loosen the pivot bolt, adjusting lock bolt, and adjusting bolt, and remove the drive belt. Torque: Pivot bolt: 56 N·m (570 kgf·cm, 41 ft·lbf) Lock bolt: 18 N·m (180 kgf·cm, 13 ft·lbf) P14226 2. (a) (b) (c) (d) REMOVE GENERATOR Disconnect the generator connector. Remove the nut, and disconnect the generator wire. Disconnect the wire harness from the clip. Remove the pivot bolt, plate washer, adjusting lock bolt and generator. P14227 Author: Date: 1769 CH–7 CHARGING (1MZ–FE) – GENERATOR CH01G–01 DISASSEMBLY Plate Terminal 1. (a) (b) REMOVE REAR END COVER Remove the nut and terminal insulator. Remove the screw, 3 nuts, plate terminal and end cover. 2. (a) (b) REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the brush holder cover from the brush holder. Remove the 5 screws, brush holder and voltage regulator. 3. (a) (b) (c) REMOVE RECTIFIER HOLDER Remove the 4 screws and rectifier holder. Remove the 4 rubber insulators. Remove the seal plate. 4. (a) REMOVE PULLEY Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the rotor shaft. P14233 P14234 S05072 Turn SST (A) (b) SST (B) P10835 (c) (d) Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). SST (B) SST (C) Insert P10834 Author: Date: 1770 CH–8 CHARGING (1MZ–FE) – GENERATOR (e) SST (C) SST (A) Turn To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one–half of a turn. (f) Remove the generator from SST (C). P10827 Turn (g) (h) Turn SST (B), and remove SST (A and B). Remove the pulley nut and pulley. 5. (a) REMOVE RECTIFIER END FRAME Remove the 4 nuts and cord clip. (b) Using SST, remove the rectifier end frame. SST 09286–46011 Remove the generator washer. REMOVE ROTOR FROM DRIVE END FRAME SST (A) SST (B) P10836 S05073 (c) 6. SST P01762 Author: Date: 1771 CH–9 CHARGING (1MZ–FE) – GENERATOR CH01H–01 INSPECTION 1. (a) INSPECT ROTOR Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.1 – 2.5 Ω at 20°C (68°F) If there is no continuity, replace the rotor. Ohmmeter Continuity CH0784 (b) Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. Ohmmeter No Continuity CH0783 (c) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (d) Using vernier calipers, measure the slip ring diameter. Standard diameter: 14.2 – 14.4 mm (0.559–0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. CH0192 2. (a) INSPECT STATOR (DRIVE END FRAME) Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. Continuity Ohmmeter P00484 (b) Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Continuity Ohmmeter P00482 Author: Date: 1772 CH–10 CHARGING (1MZ–FE) – GENERATOR 3. INSPECT BRUSHES Using a vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly. Length P13535 4. (a) Ohmmeter Positive (+) Terminal Rectifire Terminal P00480 Negative (–) Treminal Ohmmeter P00481 INSPECT RECTIFIERS (RECTIFIRE HOLDER) Check the positive (+) rectifire. (1) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. (b) Check the negative (–) rectifire. (1) Using an ohmmeter, connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (2) Reverse the polarity of the tester probes and repeat step (a). (3) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 5. INSPECT BEARING Check the bearing is not rough or worn. If necessary, replace the bearing. (See page CH–11) Author: Date: 1773 CH–11 CHARGING (1MZ–FE) – GENERATOR CH01I–01 REPLACEMENT 1. (a) REPLACE FRONT BEARING Remove the 4 screws, bearing retainer and bearing. (b) Using a socket wrench and press, press out the bearing. (c) Using SST and a press, press in a new bearing. SST 09950–60010 (09951–00500) Install the bearing retainer with the 4 screws. Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf) P14225 Socket Wrench P00628 SST (d) P00479 2. (a) REPLACE REAR BEARING Using SST, remove the bearing cover (outside) and bearing. SST 09820–00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). SST N00581 (c) Place the bearing cover (inside) on the rotor. P13567 Author: Date: 1774 CH–12 CHARGING (1MZ–FE) – GENERATOR (d) Using SST and a press, press in a new bearing. SST 09820–00030 (e) Using SST, push in the bearing cover (outside). SST 09285–76010 SST N00578 SST P00074 Author: Date: 1775 CH–13 CHARGING (1MZ–FE) – GENERATOR CH01J–01 REASSEMBLY Pulley 1. (a) (b) INSTALL ROTOR TO DRIVE END FRAME Place the rectifier end frame on the pulley. Install the rotor to the rectifier end frame. 2. (a) INSTALL RECTIFIER END FRAME Place the generator washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) Install the cord clip with the 4 nuts. Torque: Nut A: 4.5 N·m (46 kgf·cm, 40 in.·lbf) Nut B: 5.4 N·m (55 kgf·cm, 48 in.·lbf) 3. (a) INSTALL PULLEY Install the pulley to the rotor shaft by tightening the pulley nut by hand. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Check that SST (A) is secured to the pulley shaft. P01364 P00427 29 mm Socket Wrench P01763 A B A A Z19214 Turn (b) SST (A) (c) SST (B) P10835 Author: Date: 1776 CH–14 CHARGING (1MZ–FE) – GENERATOR (d) (e) Mount SST (C) in a vise. Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) (g) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110.5 N·m (1,125 kgf·cm, 81 ft·lbf) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). 4. (a) INSTALL RECTIFIER HOLDER Place the seal plate on the rectifier end frame. (b) Install the 4 rubber insulators on the lead wires. SST (A) SST (C) Insert P10834 SST (C) SST (A) Turn P10829 Turn SST (A) SST (B) P10836 P00428 P00645 Author: Date: 1777 CH–15 CHARGING (1MZ–FE) (c) – GENERATOR Install the rectifier holder with the 4 screws. Torque: 2.9 N·m (30 kgf·cm, 26 in.·lbf) S05072 5. Upward INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the voltage regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder installation direction. (b) Install the 5 screws. Torque: 2.0 N·m (20 kgf·cm, 18 in.·lbf) S05460 (c) Place the brush holder cover on the brush holder. 6. (a) INSTALL REAR END COVER Install the end cover and plate terminal with the 3 nuts and screw. Torque: Screw: 3.9 N·m (39 kgf·cm, 35 in.·lbf) Nut: 4.4 N·m (45 kgf·cm, 39 in.·lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N·m (42 kgf·cm, 36 in.·lbf) CHECK THAT ROTOR ROTATES SMOOTHLY P14235 Plate Terminal P14233 7. S05071 Author: Date: 1778 CH–16 CHARGING (1MZ–FE) – GENERATOR CH01K–01 INSTALLATION Installation is in the reverse order of removal. (See page ST–5) Author: Date: 1779